CZ31849U1 - A wood-based sandwich panel - Google Patents

Description

Technical field

The present technical solution relates to a wood-based sandwich panel with a center made of a molded part for use as a load-bearing or insulating-load-bearing panel in interior or exterior furniture or joinery products as a lightweight panel or wall and ceiling cladding. BACKGROUND OF THE INVENTION

At present, various wall, partition, or ceiling panels are used for the construction of panel wooden buildings. These panels have not only different thicknesses but also construction and are prefabricated in production halls. Currently, the panels are manufactured either in the form of a sandwich, where the insulation is sandwiched between the boards and load-bearing wooden posts, or in the form of cross-glued wood.

In the case of sandwich panels, the walls must be relatively thick because of the load-bearing capacity of the building, thus removing the insulation and the panel does not have a completely homogeneous structure. Electricity distribution is then solved by installation screens, ceiling soffits or raised floor.

With massive cross-glued panels, the load-bearing walls are weaker as they acquire external insulation to meet energy standards. However, there are high demands on the design of electrical wiring, which is difficult to change after implementation. Glued panels are homogeneous in structure, as they do not contain other load-bearing elements, but the consumption of wood is very high, which is also reflected in their cost.

The common feature of these systems is a high degree of prefabrication and a high demand for production preparation and design. However, both systems described above contain a number of different compositions and structural elements, from which the entire building is further constructed.

The essence of the technical solution

Disadvantages of the prior art are solved by the present technical solution which relates to the construction of a load-bearing and / or sound-insulating sandwich panel with a molded core made of wood-based material. The sandwich panel may be load-bearing or insulating-bearing with the center of a shaped wood-based panel, the panel may be hollow or filled with insulating material.

The panel is first assembled depending on the application, and the resulting cavities are then filled with insulating material with the required properties or left empty. The tile panel ensures excellent mechanical and physical properties while maintaining low weight and easy machinability. To maintain shape stability, the panel layers should be stacked symmetrically.

The object of the present invention is a wood-based sandwich panel comprising two parallel planar outer layers between which at least one inner molding layer and possibly also at least one inner planar layer are positioned, wherein the inner molding layer is attached to at least a part of its surface to at least one planar outer layer or to an inner planar layer or to another inner shaped layer, and wherein the material of the individual layers is wood-based and is preferably selected from the group consisting of solid wood, wood slats, multilayer wood panels, plywood, particleboard and / or fibreboard boards. The inner and outer planar layers are planar-shaped layers having a straight line profile (i.e., a rectangular cross-section). The inner molding layer is a non-planar shape layer characterized by its profile, which, unlike the planar layers, is not a straight line (does not have a rectangular cross-section), but the inner molding layer is bent at regular intervals. Its profile thus has a non-linear shape, preferably a wavy profile (the cross-section has the shape of a wavy line), a trapezoidal profile (the cross-section has the shape of juxtaposed trapezoids) or a triangular profile (the cross-section has the shape of juxtaposed triangles) or a rectangular profile placed rectangles). The thickness of the outer planar layer is preferably in the range of 3 mm to 30 mm, more preferably in the range of 5 mm to 15 mm. The thickness of the inner planar layer is preferably in the range of 3 mm to 30 mm, more preferably in the range of 5 mm

Up to 15 mm. The material thickness of the inner molding layer is preferably in the range of 3 mm to 30 mm, more preferably in the range of 5 mm to 15 mm. The total thickness of the inner molding, taking into account the profile height (e.g., waves, trapezoids, triangles) is preferably in the range of 10 mm to 400 mm, more preferably in the range of 25 mm to 200 mm. The inner molding layer in the panel provides a significant increase in the mechanical properties of the panel, the cavities between the inner molding layer and the outer planar layer or between the inner planar layer and the inner molding layer or between two inner molding layers offer the possibility of filling with insulating material or easy installation of utility lines such as electricity, water and other networks. The panels can be used as load-bearing elements of wooden buildings, where all building elements (external walls, partitions and ceilings) can have the same basic building structure and can differ only in dimensions, number and order of inner layers, or used insulation material.

A wood-based sandwich panel refers to either a solid wood, i.e. a solid panel, as well as a wood-based panel comprising wood slats, multilayer boards, plywood, particleboard or fibreboard, and other cellulose-based materials used in the construction. In a preferred embodiment, the outer planar layers are of solid wood and the inner layers are based on wood, comprising wood slats, multilayer boards, plywood, particle board or fibreboard. Shaped part means any wooden part formed in two planes or three planes, most often into a corrugated profile, or a trapezoidal or triangular profile, allowing easy filling of the panel with insulating material. The shape of the inner molding and the composition of the entire sandwich panel can be optimized for a given use of the panel, by optimization it is meant to create a shape that can facilitate manufacture of the sandwich panel or provide the necessary mechanical or physical properties of the panel according to the end use.

The overall thickness of the sandwich panel according to the present invention depends on the intended use of the panel (vertical load-bearing perimeter structures, vertical non-load-bearing dividing structures, horizontal load-bearing and non-load-bearing ceiling and floor structures). Preferably, the total thickness of the sandwich panel is in the range of 16 mm to 460 mm, more preferably in the range of 35 mm to 230 mm.

In one embodiment, the sandwich panel according to the present invention further comprises an insulating pad placed between the outer planar layer and the inner molding layer and / or between the inner planar layer and the inner molding layer and / or between the two inner molding layers, wherein the insulating filler is selected from the group. comprising sound and / or impact and / or heat and / or anti-vibration and / or fire insulation materials, preferably insulating fillers polyurethane and / or polystyrene and / or cellulose and / or mineral and / or silicate and / or rubber.

In one embodiment, the inner molding has a corrugated profile and / or a trapezoidal profile and / or a triangular profile.

The sandwich panel itself may comprise three or more layers of wood-based materials as defined above. The individual layers may be raw, surface treated or coated with any covering and / or protective layer. In one embodiment, the outer planar layer of the sandwich panel is surface treated, preferably coated with a cover and / or protective layer and / or paint and / or varnish and / or fabric and / or metal element layer and / or plastic layer and / or or resin and / or paper and / or veneer and / or laminate.

The inner planar and inner shaped layers, as well as the insulating fillers between each other, may be in different order, as well as the direction of flow of the wood fibers, if possible, may be different according to the intended use of the panel. For example, the individual layers may be arranged as described in the following embodiments:

In one embodiment, the order of the layers is: outer planar layer - insulation - inner shaped layer - insulation - outer planar layer.

In another embodiment, the order of the layers is: outer planar layer - insulation - inner shaped layer - outer planar layer.

In another embodiment, the order of the layers is: outer planar layer - insulation - inner shape layer - inner planar layer - inner shape layer - insulation - outer planar layer.

-2GB 31849 U1

In another embodiment, the order of the layers is: outer planar layer - inner shaped layer - inner shaped layer - inner shaped layer - outer planar layer.

In another embodiment, the order of the layers is: outer planar layer - inner shape layer - inner form layer - outer planar layer.

In another embodiment, the order of layers is: outer planar layer - inner shaped layer - inner planar layer - inner planar layer - inner shaped layer - outer planar layer.

In one embodiment, the sandwich panel according to the present invention further comprises utility lines distributed in cavities between the inner molding layer and the outer planar layer and / or between the inner planar layer and the inner molding layer and / or between the two inner molding layers. Thus, in the construction of a sandwich panel according to the present technical solution, some cavities can be left unfilled with insulating filler, for the purpose of installing utility networks (various piping or cabling). Cavities can be left blank based on grid design that can be installed either before final panel compression or in steps after panel panel compression.

The individual layers of the sandwich panel according to the present invention are preferably bonded to each other by means of an isocyanate or phenol-formaldehyde or urea-formaldehyde or melamine-formaldehyde or resorcinol-formaldehyde or polyvinyl acetate or epoxy or acrylate or rubber or silicate based adhesive or combinations thereof. Pressing is preferably used to cure the bonded surfaces.

In one embodiment, the two inner moldings can be glued crosswise over each other, creating cavities for distribution in both needed directions.

In a further preferred embodiment, a plurality of internal shaped pieces can be glued to each other, thereby increasing the thickness of the insulating layer while increasing the load-bearing capacity of the panel. It is also possible to create an installation wall.

In one embodiment, the sandwich panel according to the present invention has circumferential dimensions of the outer planar layers greater than the circumferential dimensions of the inner shaped layers and the inner planar layers. Thus, the sandwich panel includes an overlap of the outer planar layers over the inner layers to attach the sandwich panel to the flange or perimeter frame. One embodiment also includes allowing the outer planar layers to overlap the inner layers to provide the possibility of joining the panel into a groove. In this way, it is possible to install the upper or lower wooden flange or perimeter frame, thus creating wooden I-beams or panels with the possibility of anchoring to the foundations by means of classical anchoring angles.

One embodiment of the present invention allows the perimeter frame to be glued directly between the outer planar layers by offsetting the inner layers, thereby providing a lightweight insulating support panel suitable for manufacturing aperture fillings or partitions in vehicles with the possibility of installing fittings around the perimeter of the panel.

In one embodiment, the sandwich panel further comprises a flange or perimeter frame, preferably the material of the flange or perimeter frame is based on cellulose, more preferably selected from the group consisting of solid wood, wood slats, multilayer wood panels, plywood, particleboard and / or fibreboard.

In a preferred embodiment, the circumferential frame (preferably an inserted circumferential frame) is a shape adapted for a length and width adjustment joint, preferably a tongue, groove or rebate or lock joint type.

The present technical solution is also suitable for use in interior or exterior construction of furniture or joinery products as a lightweight part or lining of walls and ceilings.

The process for producing a wood-based sandwich panel comprises several phases. The production stage of the individual planar and / or shaped elements, the deposition of the adhesive mixture, the stacking of the individual layers, the pressing and the insertion of the insulating layer into the resulting cavities. In some preferred applications, the insulating material may be inserted or layered by folding. Alternatively, the insulating material may simultaneously serve as a binder for the individual layers of the panel. In some applications, at least 0.5 mm of the shaped part may be formed by milling or drilling in planar layers to precisely define the position of the shaped part between planar parts. The adhesive composition can be applied by hand or by machine, by surface, spot, caterpillar or a combination of these processes. The type of adhesive may vary depending on the intended use of the panel. The layers may be folded manually, mechanically or by a combination of these methods. The pressing pressure varies according to the composition of the panel and the thickness of the individual layers.

Clarification of drawings

Figure 1: Axonometric view - Basic composition of sandwich panel: 1 - outer planar layers of the panel, 2 - inner shape layer of the panel, 3 - insulating filler, 4 - utility lines inside the panel with omitted filler

Figure 2: Axonometric view - Basic system elements: A - rung sandwich panels frameless and with frame inserted. B - sandwich panels for framed and framed external walls. C - Cross-glued corrugated sandwich panels, shown to better illustrate the inner layers without the outer planar layers and with the outer planar layers. D - sandwich panels for horizontal structures, eg ceilings.

Figure 3: Axonometric view - Other examples of sandwich panel compositions: A - single-layer sandwich panel. B - sandwich panels double four-layer. C - sandwich panels double five-layer. D - six-layer sandwich panels (with double inner planar layer)

Figure 4: Axonometric view - Examples of sandwich panels with an embedded frame with side panel treatment: A - sandwich panel without side panel treatment. B - sandwich panel with rebate. C - sandwich panel with perodrážka. D - sandwich panel with stepped locking joint

Figure 5: Axonometric view - Method of placing panels and I-beams in the perimeter frame in straight grooves with offset of the shaped part.

Figure 6: Different profiles of inner shape layer: A - corrugated; B - trapezoidal; C - trapezoidal-triangular; D - triangular; E - rectangular.

Examples of technical solutions

The following examples are intended to illustrate the invention without limiting it in any way.

Example 1: Basic composition of a sandwich panel

An example of a basic composition of a sandwich panel according to the present invention is shown in Figure 1. The wood-based sandwich panel comprises two parallel planar outer layers 1 between which at least one inner molding layer 2 is placed between at least a part of its surface. The planar outer layer 1, wherein the material of the individual layers is wood-based and is preferably selected from the group consisting of solid wood, wood slats, multilayer wood panels, plywood, particle board and / or fibreboard. The outer planar layers 1 are planar-shaped layers having a straight line profile (i.e., a rectangular cross-section). The inner molding layer 2 is a non-planar shape layer characterized by its profile, which, unlike the planar layers, is not a straight line (does not have a rectangular cross section), but the inner molding layer 2 is bent at regular intervals. Thus its profile has a non-linear shape, in Figure 1 it is a wavy profile (the cross section has the shape of a wavy line). The thickness of the outer planar layer 1 is preferably in the range of 3 mm to 30 mm, more preferably in the range of 5 mm to 15 mm. The material thickness of the inner molding layer 2 is preferably in the range of 3 mm to 30 mm, more preferably in the range of 5 mm to 15 mm. The overall thickness of the inner molding layer taking into account the profile height (eg, waves) is preferably in the range of 10 mm to 400 mm, more preferably in the range of 25 mm to 200 mm. The inner shaped layer 2 in the panel provides a significant increase in the mechanical properties of the panel, the cavity between the inner shaped

31849 U1 layer 2 and the outer planar layer I are filled with an insulating filler 3, or contain wiring 4 of utility lines, such as electricity, water and other networks. The panels can be used as load-bearing elements of wooden buildings, where all building elements (external walls, partitions and ceilings) can have the same basic building structure and can differ only in dimensions, number and order of inner layers, or used insulation material.

Example 2: Panels for vertical load-bearing structures

An example of these panels is shown in Figure 2 (B) and is a structure with increased thickness (ranging from 200 mm to 500 mm), which is based on the design load determined by the standard calculation for timber structures. This thickness can be achieved by the wave height of the 3D panel, resulting in a single panel, such as Figure 3 (A), or by making a double (Figure 3 (B)), double (Figure 3 (C)) or toupled panel (Figure 3 (D) ). The panels are filled with suitable thermal insulation material and thus have an additional insulation function. Electrical, plumbing, gas or other utilities can be installed in the unfilled sections of the panels during manufacture, see Figure 1. Panels can be layered either in parallel (Figure 3) or perpendicular to each other (Figure 2 (C)) . The panels can be joined by available conventional fasteners. The connection to the base plate is solved using conventionally used angles.

Example 3: Panel for vertical non-load-bearing partition structures

Figure 2 (A) shows slender panels for non-bearing vertical structures. The structure is the same as the panels for perimeter structures, but does not have to carry the supporting function and therefore have a smaller thickness (in the range of 40 mm to 200 mm), thus not wasting much of the interior space of the building. The panels are again filled with suitable insulating material and can also be used for pre-installed utility lines. The panels may be plain frameless or may be provided with an inner circumferential frame, as shown in Figure 2 (A) and Figure 4, where the basic methods of width connection are also shown.

Example 4: Panel for horizontal bearing and non-bearing ceiling and floor constructions

Figure 2 (D) shows a panel for horizontal building structures such as ceilings and floor panels. Again, they have the same structure as the panel in Figure 1. Through their cavities, utility lines can be routed or filled with insulating material, such as thermal insulation or impact sound insulation material. The panels are load-bearing in smaller spans and, for larger spans, are laid on support beams perpendicular to the direction of the ceiling panels based on the calculation according to the design standards for timber structures.

Example 5: Universal cladding panel for floors, soffit wall cladding and installation wall

In Figure 4, there are embodiments of panels with an embedded frame that are intended for use as wall, floor or ceiling tiles for interiors and, after suitable surface treatment, also for exterior. The advantage of these panels is the possibility of milling various joints for width and length adjustment such as rebate (Figure 4 (B)), rebate (Figure 4 (C)), stair joint (Figure 4 (D)) or other interlocking joints panels left without milled butt joint profile (Figure 4 (A)).

Claims (9)

Wood-based sandwich panel, characterized in that it comprises two parallel planar outer layers (1) arranged in parallel between which at least one inner molding layer (2) and possibly also at least one inner planar layer (2) are disposed, the inner molding layer (2) ) is attached to at least one of the outer planar layer (1) or to the inner And wherein the material of the individual layers is based on wood and is preferably selected from the group consisting of solid wood, wood slats, multi-layer wood panels, plywood, particleboard and / or fibreboard. boards. Sandwich panel according to claim 1, characterized in that it further comprises an insulating filler (3) positioned between the outer planar layer (1) and the inner molding (2) and / or between the inner planar layer and the inner molding (2), and / or between two inner molding layers (2), wherein the insulating filler (3) is selected from the group comprising sound and / or impact and / or heat and / or anti-vibration and / or fire insulation materials, preferably isocyanate insulation materials and / or polystyrene and / or cellulose and / or mineral and / or silicate and / or rubber. Sandwich panel according to claim 1 or 2, characterized in that the inner shaped layer (2) has a corrugated or trapezoidal or trapezoidal profile. Sandwich panel according to any one of the preceding claims, characterized in that the outer planar layer (1) is surface-treated, preferably coated with a covering and / or protective layer and / or paint and / or varnish and / or fabric and / or a layer on metal element base and / or plastic based layer and / or resin and / or paper and / or veneer and / or laminate. Sandwich panel according to any one of the preceding claims, characterized in that it further comprises utility lines (4) disposed in cavities between the inner molding (2) and the outer planar layer (1) and / or between the inner planar layer and the inner molding. a layer (2) and / or between two inner shaped layers (2). Sandwich panel according to any one of the preceding claims, characterized in that the individual layers are bonded together by means of an isocyanate or phenol-formaldehyde or urea-formaldehyde or melamine-formaldehyde or resorcinol-formaldehyde or polyvinyl acetate or epoxide or acrylate or rubber or silicate adhesive or a combination thereof. Sandwich panel according to any one of the preceding claims, characterized in that the circumferential dimensions of the outer planar layers (1) are larger than the circumferential dimensions of the inner shaped layers (2) and the inner planar layers, the sandwich panel thus comprising an overlap of the outer planar layers (1) over inner layers to attach the sandwich panel to the flange or perimeter frame. Sandwich panel according to any one of the preceding claims, characterized in that it further comprises a flange or perimeter frame, preferably the material of the flange or perimeter frame is based on cellulose, more preferably selected from the group comprising wood solid, wood slats, multilayer wood panels, plywood , particle board and / or fibreboard. The sandwich panel according to claim 8, characterized in that the peripheral frame is shaped to accommodate a length and width adjustment joint, preferably a tongue, groove or rebate or lock joint type.