MULTI-LAYER CONSTRUCTION ELEMENT, METHOD FOR PRODUCTION THEREOF AND PROCESS LINE FOR PRODUCTION OF THE MULTI-LAYER CONSTRUCTION ELEMENT

Abstract

The invention relates to construction and is intended to create a multilayer structural element that is simple and convenient for combining in a structure and provides minimum shrinkage with the possibility for use in building load-bearing walls, interior partitions, floors and ceilings, as well as for manufacturing prefabricated walls having all process openings by means of bonding and ties during manufacturing; a high-capacity production line for producing a multilayer structural element using equipment consuming low levels of energy; and to enable the supply of vertically oriented exterior elements, as well as a continuous and low-cost method for manufacturing a multilayer structural element. The multilayer structural element includes exterior elements and a heat-insulating layer therebetween. The top and bottom surface of the exterior elements have a longitudinal groove along the entire exterior element. The multilayer structural element enables both horizontal and vertical installation.

Claims

1.-7. (canceled)

8. A multi-layer construction element is made in a form of a shaped article, including outer elements and a thermal insulation layer placed between the outer elements, wherein a cross section of the multi-layer construction element has a shaped form, while an upper side of the outer elements at a right end and at a left end has small rectangular pans along the entire outer elements, and the thermal insulation layer is additionally fitted with a mirror series of rectangular pans above and below of a connection site, and a lower side of the outer elements is fitted with the small rectangular pans along the entire outer elements at a short distance from a right end and from a left end, while the multi-layer construction element is made for both horizontal and vertical laying.

9. The multi-layer construction element of claim 8, whereas the outer elements are made of glued beam, coreboard, or plywood.

10. The multi-layer construction element of claim 8, whereas the outer elements are made of bricks with a high degree of hollowness.

11. The multi-layer construction element of claim 8, whereas the outer elements are made of stone.

12. The multi-layer construction element of claim 8, whereas the thermal insulation layer is reinforced.

13. A process line for a production of multi-layer construction elements, including following interconnected elements: an outer elements feeding unit, a thermal insulation layer feeding unit, a pressing unit, a sawing unit, and a removal unit for ready-made multi-layer construction elements installed on a frame, whereas, the outer elements feeding unit is equipped with a side feed conveyor for outer elements made in a form of a belt conveyor with a possibility of vertical orientation of the outer elements during an installation on the conveyor, and the outer elements feeding unit is equipped with two outer guides and a middle guide, and the thermal insulation layer feeding unit is made with a possibility of mixing at least two components and supply of the mixture between the outer elements, and the pressing unit is made in a form of a two-level belt conveyor, and the frame in the pressing unit area is equipped with stands fixing a distance between levels of the two-level belt conveyor, where each of these stands is equipped with a height adjuster of the outer elements on a top, and a top level of the two-level conveyor is made shorter than a bottom level, and a central part of both levels is equipped with special dense stickers for formation of upper and lower working rectangular pans of a thermal insulation layer, and the two-level belt conveyor of the pressing unit is equipped with a paired thrust roller blocks fixing outer dimensions of the multi-layer construction element, and the thrust roller blocks are made at the lower level of the two-level conveyor and at a distance from each other, and a first pair of thrust roller blocks is made in an area of the thermal insulation layer feeding unit, and the sawing unit is made with a possibility of reciprocating motion of a saw with a speed of movement of the conveyor belt, and the removal unit for the ready-made multi-layer construction elements is made in a form of a roller conveyor with a side unloader for the ready-made multi-layer construction elements.

14. A method of production of a multi-layer construction element, including laying of outer elements, filling a space between the outer elements with a thermal insulation layer, aging and pressing of the multi-layer construction element, and removal of a finished multi-layer construction element from a process line, whereas, the outer elements are provisionally prepared by forming rectangular pans of an upper side and rectangular pans of a lower side of each outer element; the outer elements are then fed with vertical orientation from two opposite sides, the placed outer elements are then fixed with guides, and when the outer elements arrive at an insulation layer feeding unit, the outer elements are fixed with thrust roller blocks, after which a space between the outer elements is filled with a thermal insulation layer, components of which are pre-mixed, and the thermal insulation layer itself is fed from above, and then the outer elements with the thermal insulation layer are fed into a two-level conveyor of a pressing unit, where a level of a second layer is fixed with stands, and an upper and a lower level of the conveyor form upper and lower working rectangular pans of the thermal insulation layer, then the outer elements with the thermal insulation layer are pressed for 7-10 minutes at temperature of 20-65 C., after which the multi-layer construction element is fed to a sawing unit, where they are sawn into set pieces, after which ready-made multi-layer construction elements are fed into a removal unit and then removed from a production line by a side unloader.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The essence of the invention is explained in the drawings, where:

[0012] FIG. 1 shows schematic representation of a multi-layer construction element with a connecting element.

[0013] FIG. 2 shows schematic representation of a process line for multi-layer construction elements.

[0014] FIG. 3 shows the outer elements feeding unit and the thermal insulation layer feeding unit.

[0015] FIG. 4 shows a fragment of the outer elements feeding unit, the thermal insulation layer feeding unit, and a fragment of the pressing unit.

[0016] FIG. 5 shows a fragment of the pressing unit, the sawing unit, and a fragment of the removal unit.

[0017] FIG. 6 shows a fragment of the pressing unit, the sawing unit, and the removal unit.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0018] Multi-layer construction element (1) includes outer elements (2) and thermal insulation layer (3) placed between them made, for example, of polyurethane foam, polystyrene, polystyrene foam, urea formaldehyde foam, polycarbonate (polyurea). Due to the unique properties of these materials, thermal insulation layer (3) easily takes on the desired shape and is an excellent thermal and sound insulation. The materials used for the thermal insulation layer are also resistant to different weather conditions. The upper and lower surface (4) of the outer elements (2) of the multi-layer construction element (1) is made with a longitudinal joint (5) along the entire outer element (2). The multi-layer construction element (1) additionally contains longitudinal connecting elements (6) that are included in the joints (5) of the upper and lower surface (4) of outer elements (2). The connecting element (6) allows for easy formation of a construction structure of multi-layer construction elements (1) without additional fastening. Multi-layer construction element (1) is made with the possibility of both horizontal and vertical laying, which gives new opportunities in the design and construction. When gluing multi-layer construction elements (1) to each other, e.g. a two-component polyurethane adhesive is used, which allows for achievement of a continuous thermal circuit, including in the corners of the structure. When the bottom layer of the masonry is heated, warm air rises freely over the entire height of the wall and evenly warms its entire surface. Working joints (7) for the electrical wiring duct are made in the thermal insulation layer (3). The outer elements (2) can be made of glued beam, coreboard, plywood, bricks with a high degree of hollowness, or stone. Outer elements (2) of multi-layer construction element (1) do not require additional external finishing, which significantly reduces the facility commissioning time and reduces the cost of finishing works. The thermal insulation layer (3) can be reinforced. Reinforcement is performed, for example, with wooden, composite crosspieces, gratings made of metal, composite, basalt plastic fittings, composite, plastic gratings, metal shavings, etc. (see FIG. 1).

[0019] Process line (8) for the production of multi-layer construction elements (1), including the following interconnected elements: outer elements feeding unit (9), thermal insulation layer feeding unit (10), pressing unit (11), sawing unit (12), and removal unit (13) for ready-made multi-layer construction elements (1) installed on frame (14). Frame (14) is made of machine-tool aluminium, which makes the construction easier and ensures high precision of assembly. The outer elements feeding unit (9) is equipped with a side feed conveyor (15) for outer elements (2) made in the form of a belt conveyor (16) with the possibility of vertical orientation of outer elements (2) during the installation on the conveyor. The side feed conveyor (15) is made in the form of a sequence of belt conveyors (16), with possibility of feeding of outer elements (2) of different lengths and overturning unit for outer elements (2) from horizontal to vertical position. The outer elements feeding unit (9) is equipped with two outer guides (17) and middle guide (18). Outer guides (17) limit the outer elements (2) from the outside, and the inner guide (18) fixes the distance between the outer elements (2), and determines the width of the thermal insulation layer (3). The thermal insulation layer feeding unit (10) is designed to allow for mixing of at least two components and supply of mixture between outer elements (2). For mixing and supply of thermal insulation layer (3), a dosing unit with a mixer is used. Thermal insulation layer (3) is fed in liquid form, and its foaming and solidification takes place in the pressing unit (11). The pressing unit (11) is made in the form of a two-level belt conveyor (19). The upper level of the two-level conveyor belt (22) fits tightly to the outer elements (2), thus limiting and forming the top layer of thermal insulation (3). The frame (14) in the area of the pressing unit (11) is equipped with stands (20) fixing the distance between the levels of two-level belt conveyor (19), where each of these stands (20) is equipped with a height adjuster of outer elements (21) on the top. The upper level of the two-level conveyor (22) is shorter than the lower level (23) to provide a platform for the thermal insulation layer (10) on the lower level of the two-level conveyor (23), and the central part (24) of both levels (22) and (23) is equipped with special dense stickers (25) for the formation of the upper and lower working joints (7) of the thermal insulation layer. Special dense stickers (25) can be made, for example, of PVC. The two-level belt conveyor (19) of the pressing unit (11) is equipped with paired thrust roller blocks (26) that fix the outer dimensions of the multi-layer construction element (1). Thrust roller blocks (26) are located at the lower level (23) of the two-level conveyor and at a certain distance from each other, and the first pair of thrust roller blocks (27) is located in an area of thermal insulation layer feeding unit (10) for fixing outer elements (2) as the exit feeding unit (9) and transition to thermal insulation layer feeding unit (10). Sawing unit (12) is made with the possibility of reciprocating motion of saw (28) with the speed of the conveyor belt movement. Sawing unit (12) moves horizontally, in the same direction and with the belt speed in pressing unit (11); saw (28) makes a vertical movement from top to bottom for sawing multi-layer construction elements (1), then from bottom to top, returning the saw to its original position; sawing unit (12) goes back against the movement of the belt in pressing unit (11) and is ready for the next cut. Removal unit (13) for ready-made multi-layer construction elements (1) is made in the form of a roller conveyor (29) with a side unloader (30) for ready-made multi-layer construction elements (1). (See FIG. 2, 3, 4, 5, 6).

[0020] A method of production of multi-layer construction element (1), including laying of outer elements (2), filling the space between outer elements (2) with thermal insulation layer (3), aging and pressing of multi-layer construction element (1) and removal of finished multi-layer construction element (2) from the process line (8). The outer elements (2) are provisionally prepared by forming the upper and lower joint (5) of each outer element (2). The outer elements (2) are then fed with vertical orientation from two opposite sides. The outer elements (2) are then fixed with guides (17) and (18). When the outer elements (2) arrive at the insulation layer feeding unit (10), the outer elements (2) are fixed with thrust roller blocks (26). Then the space between outer elements (2) is filled with a thermal insulation layer (3), the components of which are pre-mixed, and the thermal insulation layer (3) itself is fed from above. Then outer elements (2) with a thermal insulation layer (3) are fed into the two-level conveyor (19) of the pressing unit (11), where the level of the second layer is fixed with stands (20), and the upper (22) and lower (23) levels of the conveyor forms the upper and lower working joints of the thermal insulation layer (7). After that, the outer elements (2) with the thermal insulation layer (3) are pressed for 7-10 minutes at a temperature of 20-65 C. After that, the multi-layer construction element (1) is fed into the sawing unit (12), where it is sawn to the specified lengths. The ready-made multi-layer construction elements (1) are fed into the removal unit (13) and then removed from the line by a side unloader (30). (See FIG. 2).

[0021] The following can be used for implementation of the proposed multi-layer construction element, a way of its production and a process line for the production of a multi-layer construction element: [0022] the room featuring dimensions of no more than 5018 meters, [0023] any low/high pressure filling machine with metering unit and mixer, [0024] air compressor.

[0025] The developers of the proposed multi-layer construction element, a way of production thereof and a process line for the production of a multi-layer construction element have performed tests of the multi-layer construction element that produced the following results: [0026] compression strength: from 20 kgf/cm.sup.2, [0027] bending strength: Ru32 over 25 MPa, [0028] layer adhesive strength: from 0.226 MPa, [0029] design heat transmission resistance: R over 10.

[0030] The advantages of the proposed method of corrosion processes control are the following: [0031] low cost of the multi-layer construction element, [0032] possibility to use multi-layer construction element without additional insulation, without steam or wind protection films, [0033] high speed of building the structures made of multi-layer construction element, [0034] possibility of vertical laying of multi-layer construction element during building, [0035] dense connection of outer elements due to self-adhesion, [0036] a variety of materials for outer elements, [0037] high performance of the process line, [0038] simplicity of process line equipment, [0039] simplicity of process line equipment maintenance, [0040] low power consumption of the process line, [0041] possibility to feed outer elements with vertical orientation, [0042] compactness of the process line placement, [0043] performance of the process line from 24,000 to 100,000 m.sup.2 per year, [0044] use of outer elements with a thickness from 18 to 60 mm and with a height from 150 to 400 mm.

[0045] The purpose, i.e. creation of a simple and convenient multi-layer construction element to combine in the structures that results in a minimum shrinkage with the possibility of using a multi-layer construction element for building bearing walls, internal partitions, floors and ceilings, as well as the production of ready-made walls with all the working holes by gluing and fastening in the production; a high-performance process line for multi-layer construction elements using well-known equipment with low energy consumption, as well as the possibility of supplying outer vertically oriented elements, and continuous and low-cost method of manufacturing multi-layer construction elements.

[0046] The data listed above confirm the industrial applicability of the proposed multi-layer construction element, the way of production thereof and the process line for the production of the multi-layer construction element.

LIST OF POSITIONS

[0047] 1. multi-layer construction element, [0048] 2. outer element, [0049] 3. thermal insulation layer, [0050] 4. upper and lower surface of outer elements, [0051] 5. longitudinal joint of upper and lower surface of outer elements, [0052] 6. connecting elements, [0053] 7. working joints in the thermal insulation layer, [0054] 8. process line, [0055] 9. outer element feeding unit, [0056] 10. thermal insulation layer feeding unit, [0057] 11. pressing unit, [0058] 12. sawing unit, [0059] 13. removal unit, [0060] 14. frame, [0061] 15. side feed conveyor for outer elements, [0062] 16. belt conveyor, [0063] 17. outer guide, [0064] 18. middle guide, [0065] 19. two-level belt conveyor, [0066] 20. stands, [0067] 21. outer element height regulator, [0068] 22. upper level of the two-level conveyor, [0069] 23. lower level of the two-level conveyor, [0070] 24. central part of the two-level conveyor, [0071] 25. special dense sticker, [0072] 26. paired thrust roller blocks, [0073] 27. first pair of thrust roller blocks, [0074] 28. saw, [0075] 29. roller conveyor, [0076] 30. side unloader.