REINFORCEMENT STRIP

Technical Field

] The present invention concerns a method of manufacturing reinforcement panels for the manufacturing of reinforced concrete structures, as well as the so manufactured reinforcement panel.

Background Art

] It has been known in the construction field the use of prefabricated reinforcement panels, to build walls, floors and other similar reinforced concrete structures. These panels are generally constituted by a plate of expanded material, for example of the type of the polystyrene, tightened in sandwich shape between a couple of sheets of metal net; the sheets of metal net are usually made up of electro-welded steel wires. The reinforcement panels are shaped as modular elements to be assembled in place. In particular, the panels are intended to be integrated in place with concrete casting so as to manufacture supporting structural elements of reinforced concrete.

] Patent EP 0 591 849 discloses for example a panel for building walls or floors made up of a plate of expanded material, provided with sound-proof and thermal insulating characteristics, tightened between two sheets of metal wire that are mutually connected by transverse elements crossing the plate of insulating material. The plate of insulating material has parallel waves on opposite faces and is crossed, on a median plane, by a cavity in which a metal cage is housed with a reinforcement function.

] For the manufacturing of the cited reinforcement panels, usually the plates of expanded material are assembled with the sheets of metal net, on a welding bench, through transverse connection segments constituted by steel wires. Such transverse wires are pushed or guided through the plates of expanded material and are then cut to measure and welded at their ends to the metal nets.

] The assembling operations of the plates of expanded material with the metal net sheets and the welding of the transverse wires to the above mentioned sheets are performed through suitable apparatuses. The apparatuses used for such purpose are generally complicated from both the structural and the functional point of view, and require as well considerable working spaces.

] Is it often complained the fact that the manufacturing of reinforcement panels is laborious and not easy to perform. As a matter of facts, it is to be observed that the plate of expanded material and the sheets of metal net need to be correctly aligned to shape the required sandwich structure. [07] A further drawback complained in the concerned field is that the transport of the traditional reinforcement panels in place, that is in the building zone, is not eased by their size, even in case of a low weight, with evident increase of the building costs.

Disclosure

[08] The task of the present invention is that of solving the cited problems, devising a method that allows to perform in a fast and easy way the manufacturing of reinforcement panels for the construction of structures of reinforced concrete.

[09] Within such task, it is a further scope of the present invention that of providing a reinforcement panel that is easy to manufacture without employing complex apparatuses.

[10] Another scope of the invention is to provide a reinforcement panel that allows to optimize production and building costs.

[1 1] A further scope of the invention is to provide a reinforcement panel of simple constructive and functional conception, provided with surely reliable functioning, versatile use as well as relatively economic costs.

[12] The cited scopes are reached, according to the present invention, by the method of manufacturing a reinforcement panel for reinforced concrete and by the so manufactured reinforcement panel according to claims 1 and 5.

[13] The method of manufacturing reinforcement panels provides to prepare an alveolar structure created through a plurality of ribs obtained from a strip of tape material, reciprocally associated on orthogonal geometrical planes and bilaterally shaping an ordered series of first and second hook means, protruding from the same alveolar structure to engage and hold reinforcement metal wires.

[14] Suitably, said first hook means have a longitudinal extension different from said second hook means.

[15] As an alternative, the method according to the invention provides to prepare an alveolar structure created through a plurality of ribs obtained from a strip of tape material and having, in use, a wavy profile. Such ribs, shaped according to a wavy profile, are reciprocally associated at crests or troughs of the wavy profile so as to shape said alveolar structure carrying on both sides the hook means.

[16] The method provides to connect in reticular shape a series of reinforcement metal wires to the hook means of the alveolar structure.

[17] Preferably, the method provides to insert an insulating material inside the alveoli shaped by the ribs in the alveolar structure.

[18] Preferably, the method provides to insert a dense tangle metal net on both sides of the alveolar structure, constrained to the hook means, so as to cover opposite faces of the alveoli. [19] Advantageously, the method provides to insert suitable pipes using a series of cavities, regularly spaced, prearranged at least along one side of the ribs.

[20] Suitably, the method provides to associate at least one container with the pipes, the container being suitable to house technical equipment elements such as plumbing, etc..

[21] Preferably, the method provides to perform a concrete casting at the opposite faces of the cavities of the alveolar structure.

[22] The reinforcement panel comprises an alveolar structure obtained through a plurality of ribs obtained from a strip of tape material, bilaterally provided with an ordered series of hook means protruding from the same alveolar structure to engage and hold reinforcement metal wires.

[23] The ribs are arranged and reciprocally associated on orthogonal geometrical planes.

[24] Alternatively, the ribs are shaped according to a wavy profile and are reciprocally associated at crests or troughs of the wavy profile.

[25] Preferably, the ribs comprise a series of transverse notches, regularly spaced along one side of the ribs, predisposed to be engaged for coupling with the perpendicular ribs.

[26] Preferably, the ribs comprise a series of cavities of circular shape arranged along at least one side of the ribs, substantially at the notches, open outwards, predisposed to house pipes.

[27] Advantageously, the ribs shaped according to a wavy profile comprise tie-rib members, suitably pierced at regular intervals, predisposed to be interposed between the ribs and predisposed to be used to give the ribs a wavy shape.

[28] Advantageously, the ribs shaped according to a wavy profile comprise union means that shape a couple of elastic fins predisposed to be inserted in corresponding holes of the ribs and of the tie-rib members. Preferably, such holes are arranged, in use, at crests and troughs of the sinusoidal profile of said ribs.

[29] Preferably, the ribs shaped according to a wavy profile comprise connection means having at one end a couple of elastic fins, predisposed to be inserted in corresponding holes of the ribs and of the tie-rib members.

[30] Advantageously, it is possible to use an assembly device for assembling the panel.

[31] Preferably, the assembly device comprises a fixed support plane covered by a plurality of blocks.

[32] Preferably, these blocks are placed one adjacent another so as to shape gaps of a thickness equal to the thickness of the ribs, predisposed to act as a guide for the displacing and the coupling of the ribs on orthogonal planes.

[33] Preferably, the hook means of the ribs are inserted in the holes until reaching the fixed support surface in abutment. [34] Suitably, the blocks are made of non-stick material, to prevent adherence to the insulating material.

[35] In case insulating material is chosen for filling the alveoli, a mobile support plane is advantageously introduced, covered with a plurality of upper blocks, specular to the above mentioned blocks.

[36] Preferably, the mobile support plane is placed above the fixed support plane, facing the fixed support plane.

[37] Preferably, the mobile support plane comprises a perimetral surface that extends starting from a lower edge of the same mobile support plane.

[38] Preferably, the mobile support plane is supported by a framework slidable according to a longitudinal direction so as to be coupled with the fixed support plane to define a region suitable to contain insulating material.

[39] Preferably, the region is defined by the perimetral surface and, interiorly and superiorly, by blocks and by the corresponding upper blocks respectively.

[40] Preferably, the mobile support plane is provided with a plurality of valves for the expulsion of air.

[41] Preferably, the fixed support plane is provided with at least one opening for the insertion of a predetermined quantity of insulating material.

[42] Advantageously, a comb member is used being predisposed to turn the panel, manufactured on the fixed support plane, of an angle of 180°. In this way, it is allowed the insertion on the reinforcement wires on the opposite face of the panel.

[43] Preferably, the comb member is provided with a plurality of teeth fixed to a rod, predisposed to be arranged below and orthogonal to the reinforcement metal wires inserted at the hook means of the ribs arranged in use on horizontal planes.

Description of Drawings

[44] Details of the invention shall be more apparent from the detailed description of a preferred embodiment of the reinforcement panel for reinforced concrete structures, illustrated for indicative purposes in the attached drawings, wherein:

figure 1 shows a perspective view of a reinforcement panel being manufactured according to the method of the present invention;

figure 2 shows a magnified view of a detail of said reinforcement panel;

figures 3 and 4 show subsequent manufacturing steps of said detail of the reinforcement panel;

figures 5, 6 and 7 show different embodiments of the detail of the panel;

figure 8 shows a plurality of said details of the panel being manufactured;

figures 9 and 10 show perspective views of an assembly device for the reinforcement panel; figure 1 1 shows a front view of a detail of the assembly device of the panel according to a different embodiment;

figure 12 shows a perspective view of the assembly device according to the above mentioned embodiment;

figure 13 shows a perspective view from a different point of view of the assembly device according to the above mentioned embodiment;

figure 14 shows a comb member predisposed to be associated with the assembly device; figure 15 shows a longitudinal cross-section view of the comb member;

figure 16 shows a perspective view of a detail of the panel being manufactured according to a different embodiment;

figure 17 shows a magnified view of a detail of the panel according to a further embodiment;

figure 18 shows an exploded view of the above mentioned detail of the panel.

Best Mode

[45] With particular reference to such figures, the reinforcement panel for manufacturing reinforced concrete structures according to the invention has been indicated in its entirety with 1. The reinforcement panel 1 comprises an alveolar structure 10 obtained through a series of ribs 2 reciprocally associated on orthogonal geometrical planes. The ribs 2 are constituted by portions of a shaped strip obtained from a corresponding strip of flexible tape material, for more clarity indicated with 20, further to suitable shaping and cutting operations; the strip is made for example of plastic material. Preferably, the shaping operation is performed through the use of cutting rollers.

[46] In particular, the shaped strip has bilaterally an ordered series of first and second hook means 21 , 22 that are predisposed to engage and hold reinforcement metal wires 3, as it is better specified in the following. The first and second hook means 21 , 22 preferably have a different longitudinal extension along the shaped strip and alternate along the same strip, with the hook-shaped hooking part directed in the same direction on both sides of the strip.

[47] The perpendicular ribs 2 are reciprocally associated at transverse notches 23, regularly spaced along one side of the shaped strip. Along the opposite side of the shaped strip, there are cavities 24 of circular shape and open outwardly, predisposed to house containment pipes 4 of the electric or similar equipment; the cavities 24 are arranged, regularly spaced, substantially at opposite notches 23.

[48] Alternatively, each shaped strip has cavities 24 arranged on both sides of the same shaped strip so as to be able to insert pipes 4 on both faces of the panel 1 , according to a transverse direction and/or according to a longitudinal direction. Each couple of cavities 24 is placed, reciprocally face to face, substantially at the transverse notches 23 (see figure 5 and figure 6).

It is possible to provide for suitable containers 5 to be associated with the pipes 4, predisposed to house equipment components such as for example sockets or switches. In particular, each container 5 is inserted on a respective pipe 4, for example through a snap mechanism, at a groove 5a obtained at the rear side of the container 5, having a shape conjugated with the pipe 4 (see figure 8).

Such container 5 is suitably provided with a removable lid, not shown in figures, that allows, further to the concrete casting on the relative face of the panel, to have access to the components contained inside the same container 5.

Alternatively, it is possible to provide the use of a double series of ribs 2, having respectively the above mentioned first and second hook means 21 , 22. The first ribs 2 having the first hook means 21 are arranged in use on planes parallel to each other, for example vertical; the second ribs 2 having the second hook means 22 are arranged in use on planes parallel and orthogonal to the planes of the first ribs 2, for example horizontal. Such solution offers the advantage to use all the hook means 21 , 22 to engage and hold the reinforcement metal wires 3. In this way, it is possible, if necessary, to decrease the reciprocal distance of the above mentioned hook means 21 , 22 and consequently to thicken the tangle of the metal net shaped by the metal wires 3 associated with the same hook means 21 , 22.

If needed, it is possible to overlap to the hook means 21 , 22 of the ribs 2 respective shaped elements of the same shape of the hook means 21 , 22 not represented, so as to increase the resistance and the endurance of the same hook means 21 , 22. Such shaped elements can be mounted on the relative hook means 21 , 22 through the use of a suitable adhesive or glue agent. The shaped elements can be made up of tape material of the same kind of the ribs 2.

The so manufactured alveolar structure shapes a series of alveoli 25, delimited by the ribs 2 facing on the above mentioned orthogonal planes. The alveoli 25 are predisposed to contain a suitable insulating material, for example foam material. Suitably, the ribs 2 have a series of openings 26, obtained along the median axis of the shaped strip, predisposed to put in contact said alveoli 25; in practice, the openings 26 are obtained respectively in median position between each couple of adjacent hook means 21 , 22, with the exception of the parts where the notches 23 and the cavities 24 are made.

The method of manufacturing reinforcement panel to build reinforced concrete structures according to the present invention is described in the following.

Firstly, at least one strip of tape material 20, for example of plastic material of suitable thickness, is prepared (figure 3); such thickness is preferably not larger than 2 mm. The strip of tape material 20 is then shaped on both sides, for example through the use of cutting rollers, so as to create an ordered series of first and second hook means 21 , 22 of alternatively different longitudinal extension, the first hook means 21 having extension larger than the second hook means 22 (figure 4). The different extension of the hook means 21 , 22 is such to ensure in any case the contact between the wires 3 of the horizontal and of the vertical reinforcement.

Alternatively, a double series of ribs 2 is prepared, having respectively the above mentioned first hook means 21 , of larger extension, and second hook means 22, of smaller extension.

A series of transverse notches 23 regularly spaced is obtained along one side of said shaped strip or said shaped strips of tape material; while along the opposite side, substantially at the notches 23, a series of cavities 24 is obtained (see again figure 4). Otherwise, a plurality of cavities 24 is made on both sides of each shaped strip and each couple of cavities 24 is arranged reciprocally face to face at the notches 23 (see figure 5 and 6).

The shaped strip or the shaped strips of tape material are then cut to measure in a plurality of ribs 2 of predetermined size. Such ribs 2 are placed on orthogonal planes and reciprocally associated through snap connection, at said transverse notches 23, so as to define an alveolar structure 10 carrying the first and second hook means 21 , 22 protruding at both sides, on said orthogonal planes (see figure 1 ).

The alveolar structure 10 shapes a series of alveoli 25 that are predisposed to be suitably filled with a suitable insulating material, for example foam; the openings 26 obtained on the ribs 2 enable the foam to interconnect the different alveoli 25. In practice, the alveolar structure 10 has the shape of a chessboard of alveoli 25, having square profile with sides for example of 20 cm.

Obviously, it is possible to provide that the alveoli 25 are not filled with a specific insulating material, leaving the insulating effect to be performed by the air trapped in place inside the same alveoli 25. In this case the ribs 2 can usefully have no openings 26, so that each alveolus is insulated from the adjacent alveoli (see figure 6). In this case, positioning and hooking recesses or protrusions for the boundary and protection net of the alveoli are suitably made in the shaped profile of the ribs 2, as it is specified in the following.

The alveolar structure is completed by connecting in reticular shape a series of reinforcement metal wires 3 with the first and second hook means 21 , 22. The different extension of the above mentioned hook means 21 , 22 allows to arrange the orthogonal metal wires 3 on planes spaced from one another, so as to prevent interference between the same metal wires 3. In the alveolar structure, suitable pipes 4 can be inserted, for example for the housing of electric equipment elements, using the cavities 24 prepared in the ribs 2. It is to be observed that it is possible to insert pipes 4 extending along a direction longitudinal and/or transverse. It is possible as well to insert on the pipes 4 suitable containers 5 predisposed to house equipment components, such as for example, sockets of switches. It is to be observed that the pipes 4 arranged according to a transverse direction have a length equal to the length of the panel 1 and are predisposed to be placed in connection with corresponding pipes 4 of adjacent panels 1 .

It is to be observed that the ribs 2 of the described alveolar structure 10 have, at opposite longitudinal ends, respectively first hook means 21 of larger extension and second hook means 22 of smaller extension. This allows to join a plurality of alveolar structures 10 arranged on a same plane, so as to obtain reinforcement panels of larger size and with different shape, keeping the alternated sequence of the first and second hook means 21 , 22. The union of the alveolar structures can be easily obtained by approaching the cited hook means 21 , 22 placed at the ends of the ribs 2 or overlapping the fins of the panels to be coupled. If provided, the suitable insulating material is then inserted, for example a foam, inside the alveoli 25.

The so obtained reinforcement panel has the shape of a chessboard, shaped by the crossing of the orthogonal ribs 2 of the alveolar structure 10, with the relative tiles filled with the insulating material; the first and second hook means 21 , 22 carrying the inserted metal wires 3 protrude from the opposite faces of said chessboard.

Once shaped the reinforcement panel, having the required shape and size, the concrete casting is performed at the opposite faces of the same panel, according to the technique known in the field, to create the reinforced concrete structure, for example a wall or a floor. In this way, the metal wires 3 are drown in the concrete. Obviously, there is no limit to the diameter of the wires nor to the thickness of the concrete cover.

In case the introduction of an insulating material is not provided, to prevent the concrete from introducing inside the alveoli 25, is possible to provide the use of a dense tangle net 30, placed on the two sides of the alveolar structure, covering the two opposite faces of the alveoli 25 (see figure 17 and 18). Such boundary and protection net 30 of the alveoli suitably inserts in suitably positioning and hook members shaped by the ribs 2, as it was previously said. It ensures that the alveoli 25 can perform an insulating action.

The described method attains the scope of performing in an easy and fast way the manufacturing of reinforcement panels for building reinforcement concrete structures. To manufacture reinforcement panels, it is not necessary to resort to complex and bulky apparatuses, but it is enough to manufacture in place the described alveolar structures that are then reciprocally coupled in modular manner. The manufacturing of such alveolar structures through suitably shaped ribs is particularly easy and fast as it is obtained by snap coupling, without resorting to union means. Similarly, the hooking to the panel of the metal wires, to shape substantially a metal net on both opposite faces of the panel, is obtained by insertion of the metal wires in suitable hook means, without requiring welding or similar operations.

[69] A feature of the method of manufacturing reinforcement panels for building reinforcement concrete structures according to the present invention, as well as the so manufactured reinforcement panel, is that it can be done in place, that is in the same building location of the reinforced concrete structure. As a matter of facts, it is sufficient to have a suitable quantity of shaped ribs to create the described alveolar structures. This avoids problems of transport of objects of considerable size, since the described ribs can be collected in bundles of reduced overall size.

[70] Advantageously, to ease the mounting in place of the panel 1 , it is possible to provide the use of an assembly device 6, as it is shown in figures 9 - 13.

[71] The assembly device 6 comprises a fixed support plane 7 matching the size of the panel 1 to be mounted, therefore having width and length substantially equal to the panel 1 to be mounted. The fixed support 7 is suitably covered with a plurality of blocks 8 placed adjacent to one another so as to reciprocally define gaps 9 of thickness equal to the thickness of the ribs 2, predisposed to act as a guide for the placing and the coupling of the ribs 2 on orthogonal planes.

[72] More particularly, the hook means 21 , 22 of the ribs 2 are inserted in the above mentioned gaps 9 until abutting the fixed support plane 7. The blocks 8 have a thickness equal to the maximum height of the hook means 21 , 22. The blocks 8 are made of non-stick material to prevent the adherence of the insulating material.

[73] A mobile support plane 7a, covered with a plurality of upper blocks 8a specular to the relative blocks 8, is inserted in case the alveoli 25 are filled with an insulating material. The mobile support plane 7a is arranged above the fixed support plane 7 and faces such fixed support plane 7.

[74] Starting from a lower edge of the mobile support plane 7a a perimetral surface 1 1 extends having a height equal to the thickness of the required insulating material.

[75] The mobile support plane 7a is supported by a framework 70 sliding according to a longitudinal direction so as to be coupled with the fixed support plane 7 to shape a region predisposed to contain the insulating material (see figure 12 and figure 13). In particular, such region is shaped by the perimetral surface 1 1 and, at the bottom and at the top, by the upper blocks 8a and by the corresponding blocks 8 respectively.

[76] The mobile support plane 7a is provided with a plurality of valves for the expulsion of air, not shown in figures. The fixed support plane 7 is provided with at least one opening for the insertion of a predetermined quantity of insulating material, not represented.

It is possible as well to provide for the use of a comb member 12 having a plurality of teeth 12a fixed at a rod 13, predisposed to be placed below and orthogonal to the reinforcement metal wires 3 inserted at the hook means 21 , 22 of the ribs 2 arranged in use on horizontal planes. The comb member 12 is operated in rotation about a longitudinal symmetry axis A to rotate the panel 1 created on the fixed support plane 7 of a angle of 180° and thus to allow the insertion of the reinforcement wires 3 on the opposite face of the panel 1.

The mounting of the panel in place means a considerable reduction of the building costs, both because of the easiness of production of the reinforcement panels, which does not require the use of complex equipment, and because of the low transport costs.

The reinforcement panel described by way of example is susceptible to numerous modifications and variations according to the different needs. It is possible for example to provide that the ribs of the alveolar structure have wavy profile with sinusoidal shape and are integral to one other at the crests and troughs of the sinusoidal profile.

In this case, the wavy ribs, for more clarity again indicated with 2, carry at regular distances union means 14, predisposed to be arranged in use at the crests and troughs of the sinusoidal profile of the ribs 2. The union means 14 are suitably made up of small bars obtained by a rod of extruded material, such as PVC and the like, not shown; the individual small bars 14 are cut from the rod to the required measure depending on the needs. The small bars 14 shape at opposite ends respective hook means 15 that are predisposed to engage and hold the reinforcement metal wires 3. More precisely, these coupling means 15 have a hook-shaped hook part, directed upwards, so as to define in use the hooking seats for an electro-welded metal net.

Centrally, the small bars 14 shape a couple of elastic fins 16 predisposed to snap fit, in the shape of a ratchet, in corresponding holes of the wavy ribs 2. The fins 16 are shaped on the face of the small bars 14 facing downwards, that is not in the same direction of the hook part of the hook means 15. In practice, these holes are arranged in use at the crests and troughs of the sinusoidal profile of the ribs 2.

The ribs 2 take the required wavy shape by means of special tie-rib members 17 consisting for example of strings, perforated at regular intervals, for coupling with the ribs 2 by means of the above mentioned small bars 14. The pitch of the holes made on the strings 17 is suitably smaller than the pitch of the holes made on the ribs 2, in such a way as to give the same ribs 2 the required wavy shape. To this end, the strings 17 are interposed between adjacent ribs 2 and joined to them by means of the transverse small bars 14 that, through elastic fins 16, snap insert into holes obtained at regular distances in the same ribs 2 and strings 17. In substance, at each couple of elastic fins 16 of a small bar 14 the crest of a rib 2 unite with the trough of an adjacent rib 2, through the strings 17 interposed therebetween.

According to a different embodiment, the wavy ribs 2 bilaterally shape an ordered series of hook means 15 that are predisposed to engage and hold reinforcement metal wires 3 (see figure 16). Such hook means 15 preferably have different longitudinal extension along each rib 2 and alternate along each rib 2, with the hook-shaped part directed in the same direction on both sides of the rib 2.

The strings 17 are interposed between the wavy adjacent ribs 2, pierced at regular intervals, so as to join such adjacent ribs 2 by means of connection means 18, consisting for example of elongated metal elements of the type of nails or pins. The pitch of the holes made on the string 17 is suitably smaller than the pitch of the holes made on the ribs 2, in such a way as to give to the same ribs 2 the required wavy shape.

The connection means 18 shape at one end a couple of elastic fins, not shown in figures, predisposed to be snap inserted into the holes obtained into the same ribs 2 and in the strings 17. In substance, at each couple of elastic fins of each connecting means 18, the crest of a rib 2 join with the trough of an adjacent rib 2, through the string 17 interposed therebetween.

The alveolar structure shaped by the wavy ribs 2 shapes a series of alveoli 25 with substantially oval shape. Obviously, also in this case the alveoli 25 are predisposed to contain a suitable insulating material, for example foam, introduced through the suitable openings 26 of the wavy ribs 2. Alternatively, the alveolar structure may have closed alveoli, with the wavy ribs 2 devoid of communication openings; in this second case it is suitable to use a dense tangle net, placed on the two sides of the alveolar structure and constrained to the hook means 15 of the small bars 14, or, alternatively the hook means 15 shaped bilaterally by the ribs 2, to cover the opposite faces of the alveoli 25.

Preferably, the wavy ribs 2 end at opposite ends with stretches of length large enough to allow the union, in overlapping manner, to corresponding wavy ribs 2 of an adjacent alveolar structure, so as to obtain reinforcement panels of larger dimensions.

In practice, the embodiment of the invention, the materials used, as well as the shape and dimensions, may vary depending on the requirements.

Should the technical characteristics mentioned in each claim be followed by reference signs, such reference signs were included strictly with the aim of enhancing the understanding the claims and hence they shall not be deemed restrictive in any manner whatsoever on the scope of each element identified for exemplifying purposes by such reference signs.