Assembly unit for building and method for fabricating and using the same

Abstract

An assembly unit for buildings and its fabrication method are disclosed. The assembly unit includes an expanded synthetic resin; a metal wire bent in a zigzag manner to have bent portions, inserted in the expanded synthetic resin, a certain length of the bent portions being exposed from front and rear surfaces of the expanded synthetic resin; and a metal wire mesh mounted on the front and rear surfaces of the expanded synthetic resin and combined with the bent portions of the metal wire, to thereby obtain the working stability, so that an operator may carry it easily, shorten construction time by removing the necessity of a series of works of making a concrete form, casting concrete and curing the concreted surface, improve surroundings, and reduce construction expenses, by simply using the expanded synthetic resin, the metal wire and the metal wire mesh, compared with those of when existing reinforced concrete structures are employed.

1 .- 9 . (canceled) 
     
     
         10 . An assembly unit for buildings, comprising:
 one or more expanded synthetic resin blocks disposed side by side, each of which having a top surface, a bottom surface, a first side surface, a second side surface, a front surface, and a rear surface, wherein two neighboring expanded synthetic resin blocks contact with each other on the side surfaces;   one or more metal wires embedded in each of the one or more expanded synthetic resin blocks generally in a first direction from the front surface to the rear surface, and fluctuating in a zigzag manner in a second direction perpendicular to the first direction, wherein each of one or more metal wires comprises a plurality of bent portions exposed from the front and rear surfaces of the expanded synthetic resin blocks;   one or more metal wire meshes, each of which being provided over one of the front and rear surfaces of the expanded synthetic resin blocks, wherein the one or more metal wire meshes is fixedly combined with the plurality of bent portions of the one or more metal wires;   one or more first coating layers provided on one of the front and rear surfaces of the expanded synthetic resin blocks, each of which embedding some of the plurality of bent portions of the one or more metal wires;   one or more second coating layers provided on the one or more first coating layers; and   one or more third coating layers provided on the one or more second coating layers.   
     
     
         11 . The assembly unit of  claim 10 , wherein the first coating layer comprises 75.366˜90.772 wt % of silica sand of 0.1˜1.5 mm, 6˜13 wt % of SiO 2 , 0.1˜0.8 wt % of Al 2 O 3 , 0.01˜0.08 wt % of Fe 2 O 3 , 3˜10 wt % of CaO, 0.005˜0.03 wt % of K 2 O, 0.005˜0.05 wt % of TiO 2 , 0.05˜0.3 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.005˜0.05 wt % of Na 2 O, 0.001˜0.008 wt % of ZrO 2 , 0.001˜0.008 wt % of SrO, and 0.05˜0.3 wt % of SO 3 . 
     
     
         12 . The assembly unit of  claim 10 , wherein the second coating layer comprises 66.218˜84.557 wt % of silica sand of 0.1˜1.5 mm, 10˜20 wt % of SiO 2 , 0.3˜0.9 wt % of Al 2 O 3 , 0.01˜0.1 wt % of Fe 2 O 3 , 5˜12 wt % of CaO, 0.005˜0.07 wt % of K 2 O, 0.005˜0.06 wt % of TiO 2 , 0.1˜0.5 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.08 wt % of Na 2 O, 0.001˜0.007 wt % of ZrO 2 , 0.001˜0.007 wt % of SrO, and 0.01˜0.05 wt % of SO 3 . 
     
     
         13 . The assembly unit of  claim 10 , wherein the third coating layer comprises 58.236˜74.557 wt % of silica sand of 0.1˜1.5 mm, 17˜25 wt % of SiO 2 , 0.2˜0.15 wt % of Al 2 O 3 , 0.01˜0.1 wt % of Fe 2 O 3 , 8˜15 wt % of CaO, 0.01˜0.07 wt % of K 2 O, 0.01˜0.07 wt % of TiO 2 , 0.1˜0.6 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.05 wt % of Na 2 O, 0.001˜0.008 wt % of ZrO 2 , 0.001˜0.008 wt % of SrO, and 0.1˜0.7 wt % of SO 3 . 
     
     
         14 . The assembly unit of  claim 10 , wherein the expanded synthetic resin block comprises one selected from the group consisting of flame-resistant expandable polystyrene (ESP), self-extinguishable expandable polystyrene and expandable polypropylene (EPP). 
     
     
         15 . The assembly unit of  claim 14 , wherein the flame-resistant expandable polystyrene comprises 5˜10 wt % of isopentane as a foaming agent and 10˜15 wt % of magnesium hydroxide (Mg(OH) 2 ) as a flame retardant to 75˜85 wt % of polystyrene. 
     
     
         16 . The assembly unit of  claim 14 , wherein the self-extinguishable expandable polystyrene is obtained by adding 6˜15 wt % of isopentane as a foaming agent and 4˜5 wt % of carbon dioxide (CO 2 ) to 80˜90 wt % of polystyrene. 
     
     
         17 . The assembly unit of  claim 14 , wherein the expandable polypropylene is obtained by adding 8˜12 wt % of isopentane as a foaming agent to 88˜92 wt % of polypropylene having a melting point (Tm) of 162.65° C. and density of 0.90 g/cm 3 . 
     
     
         18 . The assembly unit of  claim 10 , wherein the one or more metal wires are embedded side by side in the expanded synthetic resin block. 
     
     
         19 . The assembly unit of  claim 10 , wherein the metal wire mesh is combined with the bent portions of the metal wires through welding. 
     
     
         20 . The assembly unit of  claim 10 , wherein the one or more expanded synthetic resin blocks embedding with the metal wires are disposed between the one or more metal wire meshes. 
     
     
         21 . The assembly unit of  claim 10 , wherein the metal wire and the metal wire mesh comprise soft steel containing carbon of 0.12˜0.25% in iron. 
     
     
         22 . The assembly unit of  claim 10 , wherein the expanded synthetic resin block has an arch shape such that an assembled expanded synthetic resin blocks for a curved object. 
     
     
         23 . The assembly unit of  claim 10 , wherein the one or more metal wire meshes are connected into a cylindrical shape, wherein the first, second, third coating layers are cylindrical in shapes. 
     
     
         24 . A method for fabricating an assembly unit for buildings, the method comprising:
 forming a plurality of bent portions by bending a metal wire in a zigzag manner;   fixing the bent metal wire within a mold for shaping an expanded synthetic resin block;   injecting a synthetic resin and a foaming agent into the mold such that a certain length of the bent portions of the metal wire extrudes from front and rear surfaces of the expanded synthetic resin block to mold the expanded synthetic resin block;   positioning two metal wire mesh on both front and rear surfaces of the expanded synthetic resin block; and   welding the bent portions of the metal wire and the metal wire meshes to fix the metal wire mesh on the front and rear surfaces of the expanded synthetic resin block.   
     
     
         25 . The method of  claim 24 , further comprising:
 forming a first coating layer on both the front and rear surfaces or one of the front and rear surfaces of the expanded synthetic resin block and on the surface of the metal wire mesh;   curing the first coating layer;   forming a second coating layer on the first coating layer;   curing the second coating layer;   forming a third coating layer on the second coating layer; and   curing the third coating layer.   
     
     
         26 . The method of  claim 24 , wherein the first coating layer comprises 75.366˜90.772 wt % of silica sand of 0.1˜1.5 mm, 6˜13 wt % of SiO 2 , 0.1˜0.8 wt % of Al 2 O 2 , 0.01˜0.08 wt % of Fe 2 O 3 , 3˜10 wt % of CaO, 0.005˜0.03 wt % of K 2 O, 0.005˜0.05 wt % of TiO 2 , 0.05˜0.3 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.005˜0.05 wt % of Na 2 O, 0.001˜0.008 wt % of ZrO 2 , 0.001˜0.008 wt % of SrO, and 0.05˜0.3 wt % of SO 3 . 
     
     
         27 . The method of  claim 24 , wherein the second coating layer comprises 66.218˜84.557 wt % of silica sand of 0.1˜1.5 mm, 10˜20 wt % of SiO 2 , 0.3˜0.9 wt % of Al 2 O 3 , 0.01˜0.1 wt % of Fe 2 O 3 , 5˜12 wt % of CaO, 0.005˜0.07 wt % of K 2 O, 0.005˜0.06 wt % of TiO 2 , 0.1˜0.5 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.08 wt % of Na 2 O, 0.001˜0.007 wt % of ZrO 2 , 0.001˜0.007 wt % of SrO, and 0.01˜0.05 wt % of SO 3  to, on the first coating; 
     
     
         28 . The method of  claim 24 , wherein the third coating layer comprises 58.236˜74.557 wt % of silica sand of 0.1˜1.5 mm, 17˜25 wt % of SiO 2 , 0.2˜0.15 wt % of Al 2 O 3 , 0.01˜0.1 wt % of Fe 2 O 3 , 8˜15 wt % of CaO, 0.01˜0.07 wt % of K 2 O, 0.01˜0.07 wt % of TiO 2 , 0.1˜0.6 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.05 wt % of Na 2 O, 0.001˜0.008 wt % of ZrO 2 , 0.001˜0.008 wt % of SrO, and 0.1˜0.7 wt % of SO 3 .