Title:
Method for constructing a laminated and corrugated wall plate
Kind Code:
A1


Abstract:
A method for constructing a laminated and corrugated wall plate includes building a light steel frame made of one or more layers of corrugated cold-bent plates. A wire gauze is wrapped on the outer periphery of the light steel frame and locked in position by screws. Then, the outer surface is applied on reinforcing bonding agents and cement mortar orderly. A first bonding coating is applied on a convex surface of the frame and the hollowed wire gauze to be combined together with the cement mortar as a bonding grout layer; after the bonding grout layer becomes hardened to produce pre-cracks, the bonding grout layer has its outer side applied with a second bonding coating. The second bonding coating is pressed to permeate into said pre-cracks and is applied between the new and old cement structural surfaces; after the surface-covering grout layer is applied on the second bonding coating and then becomes smoothed and hardened to shrink and produce pre-cracks, its outer surface is coated with a protective coating which can be colored for beautification.



Inventors:
Chen, Yung-hsing (Yen Shui Town, TW)
Application Number:
11/504612
Publication Date:
02/21/2008
Filing Date:
08/16/2006
Primary Class:
International Classes:
E04C5/08
View Patent Images:
Related US Applications:
20060075712Moisture diverting insulated siding panelApril, 2006Gilbert et al.
20100024338PASS-THROUGH FIRESTOP APPARATUS AND METHODSFebruary, 2010Cordts
20090183443UNIVERSAL STRUCTURAL ATTACHMENT FOR SEISMIC BRACEJuly, 2009Osborn et al.
20040160086Carrier beams for housesAugust, 2004Kerr
20060112650Method and system for multi-dimensional live sound performanceJune, 2006Kogut
20080104905METAL BUILDING DROP CEILINGMay, 2008Kinzler
20080083185Wall hole patching deviceApril, 2008Lin
20020062625Access floor panel and systemMay, 2002Foden
20030101675Building frame bracing panel and methodJune, 2003Wilson
20090113844Access floor grounding fastenerMay, 2009Mead
20070095008Wind turbine assembly tower and method for constructing the sameMay, 2007Arsene



Primary Examiner:
FLETCHER III, WILLIAM P
Attorney, Agent or Firm:
ROSENBERG, KLEIN & LEE (ELLICOTT CITY, MD, US)
Claims:
What is claimed is:

1. A method for constructing a laminated and corrugated wall plate comprising building a light steel frame made of corrugated cold-bent plates, said light steel frame and said wire gauze having the outer periphery wrapped up with a wire gauze locked in position by screws, said light steel frame having its outer side applied with a first bonding coating, said first bonding coating having its outer side applied with a bonding grout layer, then said bonding grout layer applied thereon with a second bonding coating, then said second bonding coating having its surface applied with a shaping-smoothing surface-covering grout layer, then said surface-covering grout layer having its outer side applied with a protective coating, thus said wall plate composed of bonded layers together with reinforcement: said light steel frame shaped as a corrugated frame made up by said cold-bent plates with concave portions and convex surfaces; said wire gauze wrapped on said concave portions of said corrugated light steel frame, said wire gauze locked on said convex surfaces of said light steel frame by said screws to form tensile confined enforcement as a basic material; said first bonding coating functioning to combine together the interfaces of different materials between said convex surfaces of said light steel frame and said bonding grout layer; said bonding grout layer being cement mortar, said cement mortar pressed and rammed in said hollow wire gauze and bonded on said convex surfaces of said light steel frame, said bonding grout layer flattened and hardened to shrink and produce pre-cracks; said second bonding coating pressed to permeate into said pre-cracks and the superficial pores of said bonding grout layer, said second bonding coating serving as a medium layer between the new and old cement structural surfaces of said bonding grout layer and said shaping-smoothing surface-covering grout layer; said shaping-smoothing surface-covering grout layer being cement mortar used for shaping and smoothing, said surface-covering grout layer smoothed and hardened to shrink and produce pre-cracks; said protective coating being adhesive agent used for moistening, said adhesive agent able to be mixed with weatherproof paint to be roller pressed to permeate into said pre-cracks and the superficial pores of said shaping-smoothing surface-covering grout layer, said protective coating employed for restraining cement laminated structure from efflorescing and deliquescing and for beautification. Thus, said cold-bent plates assembled together to make up said corrugated frame having its outer periphery wrapped and locked with said wire gauze, said wire gauze sealing said concave portions of said light steel frame for facilitating bonding and reinforcing the laminated structure, needless to use molds for assistance in the constructing course.

2. The method for constructing a laminated and corrugated wall plate as claimed in claim 1, wherein said light steel frame is made of more than one corrugated and assembled cold-bent plates.

3. The method for constructing a laminated and corrugated wall plate as claimed in claim 1, wherein said first and said second bonding coating are reinforcing bonding agents used for bonding grout layers as the medium layers.

4. The method for constructing a laminated and corrugated wall plate as claimed in claim 1, wherein said bonding grout layer and said shaping-smoothing surface-covering grout layer are cement mortar with high-proportional cement, which is able to produce comparatively great bonding strength for cement structure and facilitates to be reinforced after hardened to shrink and produce pre-cracks.

Description:

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a method for constructing a laminated and corrugated wall plate, particularly to one including constructing a light steel frame made of corrugated cold-bent plates with concave portions. A wire gauze is wrapped on the periphery of the light steel frame and locked in position by screws. Then, the connecting portion between the wire gauze and metal plate is applied with a first bonding coating, a bonding grout layer and, after hardened to produce pre-cracks, the bonding grout layer has its outer side applied with a second bonding coating and then a shaping surface-covering grout layer. After hardened to produce pre-cracks, the shaping surface-covering grout layer has its outer side applied with a protective coating, which can be colored for beautification. By so designing, respective layers of the wall plates can be bonded together with reinforcement and the whole structure can be completely sealed and protected.

2. Description of the Prior Art

Conventional building construction is mainly classified into cement structure, steel structure and wooden structure. The cement structure is incombustible, non-rusted, non-corrodible and impossible to be decomposed in water, and has property of plasticity and is easy to be obtained at low price; therefore, the cement structure is superior to the structure made of other materials in the field of constructing the outer perimeter of a wall plate. The perimeter construction of the steel structure and the wooden structure is inferior to the cement structure in strength, performance and durability; therefore, they can only be used for interior refurbishing and for building a framework.

The cement structure contains hydrated crystal calcium hydroxide (generally, the ratio of cements to sands is 1:3 or 1:4), which is formed by inorganic agglutinative material and enables silicic acid sandstone-made skeleton and tensile-resistant and reinforcing steel bars to be bonded together and solidified into a strong and firm structure like stone. Generally, in the course of solidification, cement will produce a phenomenon of hardening and shrinking; especially cement mortar, which is used for embellishing and has no stone mixed for fixation, will soon produce cracks. Calcium hydroxide used as latex or plaster will act with the carbon dioxide in the air and after that, the calcium hydroxide will be reduced to form calcium carbonate, and such a stage is called efflorescence, which may bring about consequences described as follows.


Ca(OH)2+CO2→efflorescence→CaCO3+H2O↑exhausting out.

1. Latex Ca(OH)2 will effloresce and reduces to form CaCO3 and the moisture of hydration will be exhausted out, thus producing incessant dry-shrinking and cracks.

2. Since no hydroxyl is bonded between the new and the old cement surface, the whitewash layer of the cement is likely to become arched, fall off and peel off.

3. The cement will be continuously neutralized to form passivated membrance, which fails to protect the steel bars, and in consequence the steel bars will be rusted, corroded and expanded, and the cement structure around the steel bars will be squeezed and broken.

4. The structure will become hard and fragile and fails to consolidate the sandstone skeleton, likely to result in conditions of pulverizing, sand dropping, getting mildewed and multiplying lice.

After the hydrated crystal calcium hydroxide effloresces and is reduced into calcium carbonate, it will gather moisture due to its porosity and hydrophilic characteristics. The moisture in the cool and humid cement structure will form carbonic acid and cause dissolution and corrosion. This stage is called deliquescence, which may result in such consequences as described below.

1. The carbonic acid and the calcium carbonate are combined into calcium hydrogen carbonate to separate out a destructive substance commonly known as “wall cancer”.

2. The foresaid phenomenon may gradually disintegrate the structure and make the cement structure lose its strength and bring forth latent danger.

3. The whole structure may gradually lose its water-tightness and air-tightness and increase erosion by external force, consequently causing leaking, corroding, rusting and having the structure between the new and the old cement hollowed out. As a result, the structure may be pulled down.

To apply cement structure, steel structure and wooden structure to wall plate engineering, it is necessary to make use of their advantages for making up their shortcomings and the following points should be noted.

1. Try to prevent cement structure from efflorescing and deliquescing.

2. Try to solve the problem of interface reinforced bonding and prevention of corrosion and rust between the cement structure and the steel structure as well as the wooden structure.

3. Try to reinforce the structure of the outer enclosure of a wall plate.

SUMMARY OF THE INVENTION

The objective of the invention is to offer a method for constructing a laminated and corrugated wall plate, which allows the wall plates of a house to form with a hollow and tubular structure is applicable to facilities that require being anti-shock, soundproof and heatproof and able to carry out piping maintenance; besides, the laminated layers reinforce the wall plates of the house to be waterproof, fireproof and durable. This cement structure of high compressive strength and the metallic unit of high tensile strength can be bonded together by the reinforcing bonding agent as the grout layer to form a tough and light structure of the wall plates which have overcome the well-known defects.

Therefore, the objective of the invention is to offer a method for constructing a laminated and corrugated wall plate, which fabricates the metallic cold-bent plates to form the corrugated wall plates and has a wire gauze being wrapped on the periphery of the light steel frame as a laminated base without the auxiliary of molds. Then, both of the reinforcing bonding agent as the grout layer and the cement mortar with high-proportional cement are applied on the base for reinforcing the whole structure so that as long as the wall plate engineering can apply on cement material, metallic material, wooden material and stone material, the bonded structure can have more composite functions to meet with the requirement of landscaping construction.

BRIEF DESCRIPTION OF DRAWINGS

This invention will be better understood by referring to the accompanying drawings, wherein:

FIG. 1 is a cross-sectional view of a first preferred embodiment of a method for constructing a laminated and corrugated wall plate in the present invention;

FIG. 2 is a cross-sectional view of a second preferred embodiment of a method for constructing laminated and corrugated wall plate in the present invention;

FIG. 3 is a cross-sectional view of a third preferred embodiment of a method for constructing a laminated and corrugated wall plate in the present invention; and

FIG. 4 is a side cross-sectional view of a fourth preferred embodiment of a method for constructing an arc-shaped laminated and corrugated wall plate in the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A first preferred embodiment of a method for constructing a laminated and corrugated wall plate in the present invention, as shown in FIG. 1, includes a wall plate 1 composed from the inside to the outside of a light steel frame 11, a wire gauze 12, screws 13, a first bonding coating 14, a bonding grout layer 15, a second bonding coating 16, a shaping-smoothing surface-covering grout layer 17 and a protective coating 18.

The light steel frame 11 is made of one or more layers of corrugated cold-bent plates with concave portions 111 and convex surfaces 112 laminated and assembled together in a corrugated shape. The light steel frame 11 could be pressed steel plates or corrugated steel plates.

The wire gauze 12 is covered on the outer periphery of the light steel frame 11 supported by the corrugated cold-bent plates. The wire gauze 12 is locked on the convex surfaces 112 of the light steel frame 11 by the screws 13.

The first bonding coating 14 serves as a medium layer of cement or metal for helping the light steel frame 11 and the hollowed wire gauze 12 to be combined together with the bonding grout layer 15. The material of the first bonding coating 14 could be reinforcing bonding agent for a thickness of 2 mm.

The bonding grout layer 15 is cement mortar whose ratio of cements to sands is 1:1 or 1:2 to be pressed and rammed in the hollowed wire gauze 12 for a thickness of 15 mm and bonded on the convex surfaces 112 of the light steel frame 11. After the bonding grout layer 15 is flattened and hardened, it will shrink and produce pre-cracks.

The second bonding coating 16 is pressed to permeate into the pre-cracks and the superficial pores of the bonding grout layer 15 for a thickness of 1 mm to serve as a medium layer between the structural surfaces of the bonding grout layer 15 and the shaping-smoothing surface-covering grout layer 17. The material of the second bonding coating 16 could be reinforcing bonding agent.

The shaping-smoothing surface-covering grout layer 17 is cement mortar whose ratio of cements to sands is 1:1 or 1:2 for a thickness of 10 mm. After the surface-covering grout layer 17 is completely smoothed and hardened, it will shrink and produce pre-cracks.

The protective coating 18 is an adhesive agent used for moistening. The adhesive agent can be mixed with weather-proof paint to be roller pressed to permeate into the pre-cracks and the superficial pores of the shaping-smoothing surface-covering grout layer 17 for a thickness of 0.2 mm for restraining the cement layer structure from efflorescing and deliquescing and for beautification.

In constructing, referring to FIGS. 1, 2 and 3, firstly, the inner corrugated cold-bent plates are assembled together to make up the light steel frame 11, which can be composed of one or more layers. If the light steel frame 11 is composed of two or three layers, its concave portions 111 and its convex surfaces 112 are respectively corresponding with each other to form a corresponding and tubular structure. Next, the wire gauze 12 is wrapped on the concave portions 111 of the light steel frame 11 and locked in position on the convex surfaces 112 of the light steel frame 11 by the screws 13. Subsequently, the convex surfaces 112 of the light steel frame 11 have their outer sides applied with the first bonding coating 14 to help the light steel frame 11 and the hollowed wire gauze 12 to be firmly combined with the bonding grout layer 15. Then, the bonding grout layer 15 is pressed and rammed in the hollowed wire gauze 12 and bonded on the convex surfaces 112 of the light steel frame 11. After the bonding grout layer 15 is flattened and hardened to shrink and produce pre-cracks, its outer surface is applied with the second bonding coating 16, which is pressed to permeate into the pre-cracks and the superficial pores of the bonding grout layer 15 to serve as medium layer for helping combine the bonding grout layer 15 together with the shaping-smoothing surface-covering grout layer 17. With the help of this medium layer, the cement mortar of the surface-covering grout layer 17 can be smoothly applied on the outer side of the second bonding coating 16. After the surface-covering grout layer 17 is smoothed and hardened to shrink and produce pre-cracks, its outer surface is coated with moistening adhesive agent, which can be mixed with weather-proof paint to serve as the protective coating 18 to be applied on the outer side of the surface-covering grout layer 17 for protecting the surface layer of a wall plate from efflorescing and deliquescing.

Thus, the wall plate is composed of the light steel frame 11 having its outer periphery wrapped with the wire gauze 12 locked in position by the screws 13, and then the outer side of the light steel frame 11 and the wire gauze 12 is orderly applied with the first bonding coating 14, the bonding grout layer 15, the second bonding coating 16 and the surface-covering layer 17 as well as the protective coating 18. Such laminated construction method can make use of the advantage of the material of each layer; therefore, the wall plate constructed in this way has tough and resilient structural strength and also has waterproof, fireproof, soundproof and heatproof properties. In addition, such a wall plate can be strengthened in structure and is easy in shaping and piping maintenance and also has functions of overcoming shrinkage and expansion and resisting shock.

Referring to FIG. 4, the method for constructing an arc-shaped wall plate has the same procedures as those described in the first preferred embodiment. The arc-shaped wall plate 2 has its inner layer fixed with an arc-shaped steel frame 21 as a foundation so all the coating work of respective layer is done on the outward arc-shaped surface layer. The arc-shaped frame 21 is basically made of steel tubes or angle steel. A wire gauze 22 is wrapped and secured on the outer periphery of the arc-shaped steel frame 21 by means of screws 23. Then, the outer side of the convex surface of the arc-shaped steel frame 21 is applied with a first bonding coating 24, which enables the arc-shaped steel frame 21 and the hollowed wire gauze 22 to be combined with a bonding grout layer 25. Subsequently, the bonding grout layer 25 is pressed and rammed in the hollowed wire gauze 22 and bonded on the convex surfaces of the arc-shaped steel frame 21. After the bonding grout layer 25 is flattened and hardened to shrink and produce pre-cracks, a second bonding coating 26 is pressed to permeate into the pre-cracks and the superficial pores of the bonding grout layer 25 to serve as a medium layer between the cement structural surfaces of the bonding grout layer 25 and a shaping-smoothing surface-covering grout layer 27. This medium coating functions to help strengthen the laminated structure between the surface-covering grout layer 27 and the bonding grout layer 25. After the surface-covering grout layer 27 is completely smoothed and hardened to shrink and produce pre-cracks, adhesive agent used for moistening is mixed with weather-proof paint to serve as a protective coating 28 applied to the outer surface of the surface-covering grout layer 27 so as to protect and prevent the surface layer of the wall plate from efflorescing and deliquescing.

As can be understood from the above description, the method for constructing a laminated and corrugated wall plate has the following advantages.

1. After the corrugated cold-bent steel plates are assembled to make up the steel frame, and the wire gauze is wrapped and locked on the outer periphery of the steel frame, the steel frame has its outer periphery orderly applied with the first bonding coating, the bonding grout layer, the second bonding coating, the shaping-smoothing surface-covering grout layer and the protective coating. This laminated constructing method makes use of the advantage of the material of respective layer; therefore, the wall plate constructed in this way has tough and light tubular structural strength and has waterproof, fireproof soundproof and heatproof properties. In addition, such a wall plate is convenient in shaping and piping maintenance and has effects on overcoming shrinkage and expansion and resisting shock, conforming to the requirement of landscaping construction and the policy of making homes on a river or on a lake or on a loose and soft land.

2. The laminated wall plate constructed with the above-mentioned method can be widely used, having great economic value and able to improve the drawbacks of conventional wall plates, such as reinforced concrete wall plates, brick walls, curtain walls, corrugated metal plates used as the outer enclosure of an iron house, steel tiled roofs, wooden partitions and all kind of traditional confined structures.

3. The construction method mentioned above can also be applied to construction of original and various shaped frames and, with the same method, it is easy to create another laminated structure with an imitative ecologic-cement thin shell without help of molds and special tools in the whole constructing course.

While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications may be made therein and the appended claims are intended to cover all such modifications that may fall within the spirit and scope of the invention.