DE60215309T2 - BASE PLATE WITH SECTIONS OF DIFFERENT THICKNESS PRESSURE STRENGTH - Google Patents

Abstract

A building panel that comprises at least two panel domains, wherein each panel domain has an essentially homogeneous compressive strength and an average compressive strength and wherein at least two panel domains differ in average compressive strength, is useful for inserting into cavities having a variety of shapes, sizes, and obstacles therein.

Description

The The present invention relates to a building panel comprising at least two areas in the plate with different average compressive strength contains. The plate is for filling out of cavities usable, which have non-uniform dimensions, the obstacles have arranged in it, or both.

building structures typically include a scaffold, a variety of cavities defines the framework as walls the cavities serves. For example, buildings have buildings often a wooden or metal framework that Support and transversal bars, which are away from each other a certain distance. The supports and Crossbeams act as cavity walls. A distance between two supports or crossbeam defines a void space and a volume between two columns or two crossbeams defines a cavity. It is often desirable in a cavity a material such. As a thermal insulating agent to use. cavities However, they exist in a variety of sizes and shapes and can be one Have an obstacle, such as As an electrical line or piping, which lead along in it. The exact fitting of plates in cavities of varying dimensions and those that contain a multitude of obstacles in it, requires either creating a specific plate for each different cavity or the use of a plate, the is sufficiently flexible to accommodate different cavity sizes, shapes and To adjust obstacles.

Usual materials for the To fill of cavities shut down fibrous materials and polymer foam. Fibrous materials, such as Glass wool and cellulosic fibers typically require a special caution during the installation, as the inhalation and handling of fibers often is lovely. fibrous Cotton is also very flexible, which allows the cotton to bend, sag to let or hang them loose when a wide cavity needs to be overstretched, such as z. B. between rafter crossbeams. A tough polymer foam, such. B. Polystyrene (PS) and a tougher Polyurethane foam is attractive as a thermal insulation in cavities, but does less than the optimum in adapting to different ones Cavity sizes, shapes and obstacles. A tough one Polymer foam typically requires cutting to contact it to adjust a particular cavity. A flexible polymer foam, such as Flexible polyurethane foam (FPU) is easier to fit on cavity variations, as a tough foam board. Unfortunately allowed the flexibility the foam too, that it kinks, sags or hangs loose, though spans a wide cavity is, such. B. between rafter crossbeams.

Ideally has a plate for fitting in cavities a combination of flexible properties for adapting to cavity shapes, sizes and Obstacles and tough Properties to prevent buckling and sagging of the plate when installed in a cavity. The US patent application 09 / 706,110 ('110) discloses such a plate comprising a combination of hollow and solid coalesced foam strands includes (see page 14, lines 7-17).

It there is a need for a plate in cavities can be fitted, the different sizes, shapes and obstacles which, however, does not suffer from handicaps, the fibrous materials, tough foam or a flexible polymer foam, and the free is a combination of hollow and solid foam strands.

The German property right DE 8809539 U , published September 15, 1988, with reference to 1 therein a thermally insulating panel containing a hard plastic foam core with two longitudinal edges to which are attached strips of elastically deformable soft plastic foam. In use, the two strips are compressed and the plate is clamped between two rafters, with the strips resting against the rafters.

The German patent DE 2700468 B , published June 22, 1978, discloses a thermally insulating inner liner for a roof in which a thermally insulating plate is positioned between the rafters, compressible ther mix insulating strips are provided between the plate and the rafters, wherein the edges of the plate and the thermally insulating strips come to lie on support elements which are fixed between the rafters.

• (a) wenigstens zwei Bereiche in der Platte hat, die unterschiedliche mittlere Druckfestigkeiten haben;
• (b) im Wesentlichen frei von einer Kombination von hohlen und festen Schaumsträngen ist;
• (c) eine im Wesentlichen gleichmäßige Plattendicke hat;
• (d) wenigstens einen nachgiebigen Bereich in der Platte hat, der sich von einer primären Oberfläche zu einer dieser gegenüberliegenden Oberfläche ausdehnt und der, wenn er zusammengedrückt wird, wenigstens eine Dimension der Platte verringert, was es erlaubt, dass die Platte vollständig in einen Hohlraum eingepasst werden kann, der durch Hohlraumwände gebildet ist;
• (e) einen Schlitz hat, der bis in eine Tiefe vordringt, die geringer ist als die Dicke der Platte, welcher die primäre Oberfläche, oder die Oberfläche, die der primären Oberfläche gegenüberliegt, durchquert und der das Biegen der Platte in eine nichtplanare räumliche Anordnung für das Einpassen in diesen Hohlraum erleichtert; und
• (f) ein Kompressions-Rückstellvermögen hat, das, wenn die Platte in diesen Hohlraum eingepasst worden ist, einen ausreichenden Druck gegen die Wände des Hohlraums bereitstellt, dass die Bauplatte in dem Hohlraum durch Reibung verbleibt, wobei dieser Druck 100 N/m² oder mehr und 200.000 N/m² oder weniger beträgt; und

wobei, wenn diese Platte wenigstens zwei benachbarte Plattenbereiche hat, die faserförmiges Material mit einer Faserorientierung enthalten, die Faserorientierung eines Plattenbereiches nichtorthogonal ist zu der Faserorientierung wenigstens eines benachbarten Plattenbereiches.According to the present invention, there is provided a structural panel having at least two panel sections, each panel section having substantially homogeneous compressive strength and average compressive strength, the panel being:

• (a) has at least two regions in the plate having different average compressive strengths;
• (b) is substantially free of a combination of hollow and solid foam strands;
• (c) has a substantially uniform plate thickness;
• (d) has at least one compliant portion in the plate which expands from a primary surface to a surface opposite thereto and which, when compressed, reduces at least one dimension of the plate, allowing the plate to fully penetrate into a cavity can be fitted, which is formed by cavity walls;
• (e) has a slot that penetrates to a depth less than the thickness of the plate that traverses the primary surface, or the surface that faces the primary surface, and that flexes the plate into a non-planar spatial configuration facilitates fitting into this cavity; and
• (f) has a compression resilience which, when the plate has been fitted in this cavity, provides sufficient pressure against the walls of the cavity to frictionally maintain the structural plate in the cavity, said pressure being 100 N / m ² or more and 200,000 N / m ² or less; and

wherein, when said plate has at least two adjacent plate regions containing fibrous material having a fiber orientation, the fiber orientation of a plate region is non-orthogonal to the fiber orientation of at least one adjacent plate region.

In a preferred embodiment at least one plate area is a deformable plate area, which allows the plate reversibly from a planar to a Non-planar configuration to bend.

The present invention fulfills a claim by providing a plate which can be fitted into cavities of various sizes, shapes and obstructions, but does not suffer from handicaps associated with fibrous materials, a tough foam or a flexible polymer foam, and which is free of hollow and solid foam strands. Unlike the plate that is in DE 8809539 U is taught, the plate of the present invention has a slot which facilitates bending the plate into a non-planar configuration for insertion into a cavity. Unlike the plate that is in DE 2700468 B is taught, the plate of the present invention does not require the use of separate support members to hold them between the cavities.

As mentioned above was, the present invention relates to a building board. A "building board" refers to a single object used for making buildings and Structures, the cavities contained, is usable. Herein "building board" and "plate" are interchangeable.

A Building board can have any shape or dimension, the two opposite each other Has surfaces, at least one of which is a "primary surface." The primary surface of a building panel has one Surface area, the one of the utmost surface of the surface area on the plate corresponds. A building board can have two primary surfaces, as long as they are facing each other and not adjacent. A primary surface is preferably a square or a rectangle, though it may have some shape, including one circular. Building boards with a square shaped or rectangular primary surface are square-shaped, or rectangular building panels.

Prefers is a primary surface parallel to their opposite Surface. The surface or the surfaces, the one primary surface with her opposite surface connect / connect, are smaller surfaces that circulate around the Make building board. examples for smaller surfaces shut down opposite each other Ends and opposite Edges of a square shaped or rectangular building board.

The "plate thickness" corresponds to the vertical one Distance between a primary surface and their opposite Surface. The plate thickness at each point of a primary surface of the building panel is preferred one centimeter (cm) or larger, further preferably 2 cm or larger and can be 5 cm or larger, 10 cm or bigger or even 20 cm or larger. There is no known functional limit to how thick a building board can be can. Building panels having a panel thickness of less than 1 cm, tend to be too thin too be to the width of a cavity without kinking, sagging or both, to span.

A Building board may have contours on one or more surfaces. For example, a primary surface have a decorative design or a functional contour, like z. B. cone-like protuberances for one acoustic damping. The building board may have grooves to adapt around obstacles within a cavity, or bending the plate to facilitate.

The Building panels of the present invention have a substantially uniform plate thickness. Herein, a building board has a substantially uniform plate thickness, if a difference in plate thickness at any two points on the primary surface of a building board smaller as 10 percent (%) of the average of the plate thickness at this is two points, or 5 millimeters (mm), whichever is greater. Preferably, the structural panel has a difference in panel thickness less than 3 mm, more preferably less than 2 mm between any two points on the building board.

A Building panel of the present invention further contains at least two Disk areas. A "plate area" is a section on a building board that is over the length, Width, thickness or a combination of the construction plate expands. A plate area contains typically at least 1%, preferably at least 2%, more preferably at least 5%, more preferably at least 10% and less as 100% of the volume of a building board. Examples of suitable Enclose plate areas bands Stripes, fillings (such as cylindrical fillings, which are over the thickness of a building panel) or a combination thereof one. Preferred are plate areas (bands). Ribbons are plate areas, the one primary surface of a Cross construction panel. Preferably, a band also extends over the thickness of the plate. Eg For example, a band can extend through the panel thickness and open up the opposite Ends (the length) extend a rectangular building board. Disk areas can be any Have shape and size and can in size, the Shape and physical properties within a building board differ. Preferably, at least one plate area has, further preferably at least two plate areas, even more preferred all plate areas in a building board thermal conductivity of 0.1 watts per meter Kelvin (W / m · K) or less, more preferably 0.065 W / m · K or less, most preferably 0.045 W / m · K or less. The thermal conductivity is according to the ASTM method C-518-98.

Everyone Plate area has a substantially homogeneous compressive strength and an average compressive strength. "Essentially homogeneous Compressive strength "means that each section of the plate area that is 20% of the volume of the plate section comprises an average compressive strength in each Has direction within 20%, preferably within 10% of any other section with the same dimensions of the plate area, which comprises 20% of the volume of the plate area which is in the same Direction and orientation is compressed. The values for compressive strength are according to the American Society for Testing and Materials (ASTM) to measure method D1621, unless otherwise stated. The "mean compressive strength" is the mean Pressure resistance over a pressure range of 0-50%, more preferably about a pressure range of 0-80%. Close here Set the limits unless otherwise specified.

The Plate areas can made of wood, metal, glass, rubber, fibrous materials, inorganic foams, organic Foam and combinations thereof.

Examples for fibrous Close materials Cotton fibers, glass wool, mineral wool, polymer fiber wadding, carbon fibers and rock wool. The building panels can at least two adjacent Have areas containing fibrous material, provided that when the fibrous material has a fiber orientation, the Fiber orientation of a domain not orthogonal to the fiber orientation in at least one adjacent one domain is. For example, U.S. Patent 4,025,680 discloses a fibrous thermal Isolation, which is a multitude of adjacent parallel Strip of fibers has, with the fiber orientation in the strip alternating to the fibers in the adjacent strips in the right one Angle (see column 2, lines 5-11). Such a material is not within the scope of the present invention, since the fiber orientation each strip (or plate area) at a right angle (orthogonal) to the fiber orientation of each adjacent strip is.

Prefers at least one plate area is free of fibrous materials, more preferably, the entire building board is free of fibrous materials. More preferably, at least one plate region is a polymer foam: most preferably, all panel areas are contained in one building panel Polymer foam.

suitable polymer foams shut down those having one or more of the following: polystyrene (PS) Polymers and Copolymers; Polyester, polyolefins, such as. B. Polyethylene (PE), polypropylene (PP), PE copolymers, such as. B. ethylene / styrene interpolymers (ESI) and PP copolymers; and polyurethane. Polymer foams can Contain mixture of polymers, such as. B. PP and PE mixtures.

Polymer foams preferably have a density of 100 kilograms per cubic meter (kg / m ³ ) or less, more preferably 50 kg / m ³ or less. Foams having a density of greater than 100 kg / m ³ generally have unsatisfactory thermal insulation properties. Foams generally have one Density greater than 5 kg / m ³ .

Have polymer foams a mean cell diameter. The mean cell diameter is by measuring the cell diameter at a cross section of a To determine foam. The mean cell diameter for the foam is a mean diameter for 20 or more arbitrarily selected Cell cross sections on the foam cross section. The diameter of non-spherical cells is the mean of the longest and shortest Straight line through the center of the cell cross-section. The foam cross section is using an optical or electron microscope consider. The polymer foams, which are useful in this invention preferably have a middle one Cell diameter of 0.01 mm or larger, more preferably 0.1 mm or larger, and even more preferably 0.3 mm or larger. Preferably, the middle one Cell diameter 10 mm or smaller, more preferably 4 mm or smaller, and more preferably 2 mm or smaller. A foam, having a mean cell diameter below 0.01 mm, tends to be an undesirable to have high density. A foam that has a mean cell diameter from bigger than 10 mm, tends to be a poor thermal insulator.

building panels of the present invention contain at least two plate areas, which differ in the mean pressure resistance. The compressive strength is to be measured on the same plate area sections of the same Size and shape are by squeezing in the same direction and orientation. Preferably differentiate the two plate areas are in the middle compressive strength, when compressed in one direction, the width the building board corresponds. Preferably, the two differ Plate areas in the average compressive strength by at least 5 %, preferably at least 10%, more preferably at least 25% and they can in the medium compressive strength by 50% or more, 100% or more, even 200% or more different.

At least a plate area is deformable. A deformable plate area is squeezable and elastic, whereby the building panel availability and a relaxation from the compressed State is awarded. A deformable plate area is preferred smaller in the dimension of squeezing than in each one other dimension, causing a buckling of the plate area during the compression is prevented.

The compressibility at 10% pressure characterizes the compressibility of a panel area. A deformable plate area preferably has a compressive strength at 10% pressure at 0.1 kilopascal (kPa) or more, more preferably 0.2 kPa or more and more preferably 0.3 kPa or more and 200 kPa or more less, more preferably 50 kPa or less, even more preferred 20 kPa or less. A panel area with a compressive strength of less than 0.1 kPa, there is typically a lack of sufficient Hardness, while a panel area with a compressive strength greater than 200 kPa is generally too difficult to compress.

Of the Percent reexpansion characterized by 50% pressure exertion the elasticity a plate area. The percentage of re-expansion becomes measured by applying a compressive force to a plate area, which is sufficient to keep the panel area at 50% of its unclamped Thickness to compress. The pressure force is removed and the thickness of the plate area measured after 24 hours. The thickness of the plate area 24 hours after removing the compressive force divided by the uncompressed one Plate area thickness is the compression recovery for the panel area. A deformable plate area preferably has a compression recovery of 60% or more more preferably 70% or more and still more preferably 80% or more.

The Compressing at least one deformable plate area in a building board reduces at least one dimension of the building board. Reducing one dimension of a structural panel may require insertion the building board in z. B. a cavity with a width that is smaller is as the uncompressed Dimension of the building board, allow.

The structural panel has compression resilience when the moldable panel (s) are no longer compressed. The compression resilience of a structural panel provides sufficient pressure against the cavity walls to frictionally hold the structural panel within a cavity. The compression resilience causes a structural panel to exert a pressure between 100 Newton per square meter (N / m ² ) or more and 200,000 N / m ² or less. Preferably, the pressure is 200 N / m ² or more, more preferably 300 N / m ² or more. A pressure of less than 100 N / m ² is generally not sufficient to hold a building board by friction within a cavity without kinking or sagging. In addition, the pressure is preferably 50,000 N / m ² or less, more preferably 30,000 N / m ² or less. Building panels that exert a pressure of more than 200,000 N / m ² are typically very difficult to compress.

suitable deformable plate areas include a polymer foam and fibrous materials, such. B. cotton wool, glass wool, carbon fibers and mineral wool. The deformable plate area is preferred a polymer foam, more preferably an open-cell polymer foam. foams for the Use in deformable plate areas preferably have one Open cell content of 5% or more, more preferably 10 % or more, more preferably 30% or more and most preferably 50% or more, according to ASTM method D2856-A. A polymer foam with less than 5% open cell content often lasts at a desirable compressibility absence.

neighboring Panel areas within a building panel can be sharp, gradual or have variable limits. Two adjacent plate areas have one sharp boundary, if at least one property of the building board, such as As the compressive strength or density, abruptly from the changes a disk area to the other disk area. A abrupt change is one that is at a distance of 0.5 cm or less, preferred 0.2 cm or less, more preferably 0.1 cm or less occurs. For example, the sticking together of two pieces of one Polymer foam with different compressive strengths along adjacent Edges produce a building board, the two plate areas and a has sharp boundary between such plate areas. sharp Boundaries that separate plate areas by more than 0.5 cm, tend to become gradual boundaries or variable boundaries or even another panel area.

alternative can two plate areas have a gradual boundary, at least a property either between those of each individual plate area is or gradually from that of a plate area to the an adjacent plate area changes. For example, that can Extrude two foams with different densities, so they interact with each other an interface to make a building board that has a gradual boundary, which varies gradually from the density of one plate area to the other of the adjacent plate area changes. The interfaces between two plate areas connected by an overlapping connection are, would also represent a gradual border.

Two Plate areas can instead have a variable limit, with at least one property the board is variable, but not on the binding of the one plate area to that of the other constantly changes.

A Variation of the present invention is a square or rectangular building board with ribbons. Ribbons preferably bridge the longest Dimension of a primary surface (the length the building board) and its opposite surface. Tapes can become orthogonal from one end of the building panel to the opposite End extend the building board diagonal through, such. B. from a corner to an opposite Corner or you can from one end to another in a nonlinear form extend. bands can have any shape and size, although they are preferably thicker than they are wide to buckle while of squeezing to avoid.

A preferred configuration of the building board contains a deformable band at least one edge of a square or rectangular building board. Such a band is a "deformable Edgeband " edgebandings allow the building board to obstacles, such. B. a line and piping along walls to adapt to a cavity. Another advantageous structural panel configuration Contains deformable Plate areas along the ends of the building board, which are at obstacles can be adjusted extending through the end of the building board within a cavity extend. A building board, whether square, rectangular or any other shape, may have a circumference, one or more deformable Contains disk areas.

A further variation of the square-shaped or rectangular building board at least one deformable band inside the building board that makes it allows the structural panel to be bent into a non-planar configuration, which facilitates insertion into a cavity.

A preferred configuration of a panel area for the structural panels of the present invention has alternating deformable and solid panel areas, or alternating rigid and deformable bands. A solid plate area is a plate area with a higher average compressive strength than any deformable plate area associated therewith. For example, a square or rectangular building panel may have alternating solid and deformable bands. The 1 . 2a . 2 B and 2c show examples of building panels with alternating deformable and solid plate areas.

A preferred embodiment The present invention will now be described with reference to FIG on the attached Drawings in which:

1 a plate (not according to the present invention) which has two plate areas.

2a . 2 B and 2c shows an example of a panel according to the present invention which is inserted into a cavity by reversibly bending from a planar to a non-planar configuration.

3a a plate (not according to the present invention) having a deformable plate area along the circumference of the plate.

3b a plate (not according to the present invention) having a plurality of deformable plate portions along the circumference of the plate.

4a and 4b a view from the end of two plates, (not according to the present invention) show, one with a tongue profile and another with a groove profile, which are inserted under connection in a cavity.

5a and 5b show a plate with two regions (not according to the present invention) cooperating with a plate with a single plate region to span a cavity.

The 1 shows an example of a building board 10 (not according to the present invention) having a plate thickness T and comprising two plate regions, 20 and 30 , The plate areas 20 and 30 are bands inside the building panel 10 , The plate area 20 has a higher average compressive strength than the plate area 30 , A primary surface 15 the building board 10 includes the surfaces 22 respectively. 23 the plate areas 20 and 30 , The 1 shows an interface 40 between the plate areas 20 and 30 as a variable connection. The 1 shows a corner 12 the building board 10 which also acts as a corner of the panel area 30 serves. The building board 10 has a length L, that of the plate area 30 equals. The building board 10 has a width W.

The 2a . 2 B and 2c show an example of a building board 50 according to the present invention, the five plate areas, 60 . 70 . 80 . 90 and 100 Has. All 5 plate areas are strips of the building board 50 , The plate areas 60 . 80 and 100 are deformable. The plate area 80 allowed the building board 50 is bent into a non-planar configuration. The 2a shows the building board 50 and the cavity 115 , The width W 'of the building board 50 is longer than the space between the cavity walls 110 and 120 which the cavity 115 define. The 2 B shows the building board 50 after bending into a non-planar configuration for insertion into the cavity 115 , The application of a force F against the plate area 80 leads the building board 50 into a planar configuration within the cavity 115 back, while squeezing the Plattenberei surface 60 . 80 and 100 , The 2c shows the building board 50 inside the cavity 115 ,

The structural panels of the present invention include at least one slot passing through at least one primary surface or surface of a primary surface and extending to a depth less than the panel thickness. Such slots facilitate bending of a building panel into a non-planar configuration for insertion into a cavity. The 2a . 2 B and 2c also show such a slot 82 in a plate area 80 , The 2 B shows the slot 82 slightly open when the building board 50 bends into a non-planar configuration, causing the structural panel to bend 50 is relieved.

The 3a shows a building board 130 (not according to the present invention) with two plate areas 132 and 134 , The plate area 134 is a deformable plate area around the perimeter of the building board 130 is available. The 3a shows a plate area 134 as a single piece, but it can consist of several pieces. The 3b shows a similar building board 140 (not according to the present invention) with a plate area 142 and a plurality of deformable plate areas 144 . 146 . 148 and 150 along the circumference of the building board 140 ,

Building panels may have a tongue or groove profile on at least one smaller surface. A tongue profile comprises a tongue and preferably one or two shoulders. Likewise, a groove profile includes a groove and preferably one or two shoulders. A tongue on a building board fits vorteilhaf terweise in a groove on the adjacent building board to make a connection between the building boards. Any tongue and groove shape is possible, but rounded shapes are advantageous because they enable the tongue of one building board to roll into the groove of the other building plate. The shoulders help prevent the tongue of one building panel from moving out of the groove of the adjacent building panel, causing it to buckle or sag at the junction between the two building panels. The shoulders, when present, are more than zero percent, preferably 5 percent or more, more preferably 10 percent or more of the plate thickness, and desirably 95 or less, preferably 80 percent or less and more preferably 60 percent or less of the plate thickness. If the shoulders are more than 95% of the plate thickness, the tongue tends to break easily.

The 4a and 4b show a view from the end of two building panels 160 and 170 (Not according to the present invention), and the cavity 185 , defined by the walls 180 and 190 of the cavity. The building board 160 contains a deformable plate area 162 and a fixed plate area 163 with a tongue profile comprising a tongue 164 and the shoulders 166 and 168 , The building board 170 contains a deformable plate area 172 and a fixed plate area 173 with a groove profile comprising a groove 174 and the shoulders 176 and 178 , The construction panels 160 and 170 are connecting in the cavity 185 used in which the deformable plate areas 162 and 172 against the cavity walls 180 respectively. 190 be set and the slipping of the tongue 164 into the groove 174 while a force F 'against the fixed plate areas 163 and 173 is created. The 4b shows building boards 160 and 170 connecting to the cavity 185 are used, wherein the deformable plate areas 162 and 172 slightly compressed.

in the Generally, if two or more building boards are mutually connected Connecting a cavity, the pressure resulting from the elasticity of a compressed Panel area, sufficient to the adjacent To hold construction boards together. The adjacent edges of two adjacent building panels can however, have an adhesive between them to prevent the building panels separate. Likewise, the application can an adhesive tape or any type of fastening means along the primary surfaces of adjoining construction panels and along adjacent ones Edges help to prevent the building board from each other separate.

One suitable method for the manufacture of structural panels of the present invention is, by Joining together of individual plate areas, such. B. different pieces of polymer foam or combinations of polymer foam and fibrous Materials to form a single building board. A skilled specialist Anyone can identify a number of tools that are appropriate is to connect two panel sections together, including double-sided Adhesive tape, epoxy or polyurethane adhesives, latex adhesives, Hinges and wires, the in and possibly be pulled through adjacent plate areas. The welding together Melting of polymeric plate areas using heat or solvent is also acceptable.

One another suitable method of making the building panels of the present invention Invention is by chemical, mechanical or both chemical as well as mechanically modifying at least one region within a building board, originally has a substantially homogeneous compressive strength. For example kinking or breaking cell walls or perforating, Slitting or removing parts of a polymer foam / plate area tends to reduce the compressive strength of this panel area. Cuts within a plate area can either be in one plane or perpendicular to a level of squeezing and humbling the pressure resistance of the plate area even further. Cuts in the level of compression can lead to a local buckling of the plate area. The chemical modification a plate region of the polymer foam can also plate areas create with different pressure resistance. For example, the Adding a plasticizer to a polymer foam, reduce its compressive strength while adding a crosslinker causes to increase the pressure resistance of the foam. The chemical and mechanical modifications are also made for creating areas suitable with different compressive strengths in building boards, the not original have a substantially homogeneous compressive strength.

One another acceptable method for the manufacture of a building panel of the present invention is the simultaneously producing the plate areas in such a way that adjacent plate areas connect during manufacture. For example, by coextruding different polymer foams through nozzles, which are adjacent to each other, so that the polymer foams during the Expand each other and unite at a connection where contact occurs. The different foams then form different plate areas in a polymer foam building board.

As well is the technology of interconnecting foam strands for manufacturing Building panels of the present invention acceptable. Actually has the technology of interconnecting foam strands unique Advantages over other technologies for the manufacture of construction panels.

The Technology of interconnecting foam strands precludes extrusion a foamable Gels through a nozzle, the several holes contains to form a foam strand. The "strands" extrude through the holes, expand and bind together, forming a structure train, such. B. a building board comprising several foam strands. A foam structure containing a number of interconnected foam strands includes is a strand foam. Each strand has a skin and a Core. The skin is tied around the core and has a higher density as the core. Tie the strands typically cling together as their skins connect during expansion. The use of an adhesive to tie the strands, or about binding the strands to support each other, is also acceptable.

The Compressive strength of a strand foam is a function of many parameters. Here, the compressive strength corresponds to a compressive strength during one radial compression of a strand when used with respect to a strand foam becomes. For example, has a strand foam with a predetermined number on strands per cross-sectional area typically a higher compressive strength than a Strand foam with fewer strands per cross-sectional area. A possible reason for a higher one Compressive strength in the strand foam with more strands per cross-sectional area is that more strands correspond to more skin in a strand foam cross-section. The skin gives a support structure through the strand foam cross section, which resists compression.

Spaces between the strands also reduce the compressive strength of a strand foam. Spaces between the strands form when the strands are sufficiently small or with a sufficient distance from each other are removed so that adjacent strands touch only periodically as they expand. The places where the strands do not touch remain as gaps between the strands. These gaps are spaces between the strands. The rooms between the strands reduce the compressive strength of a strand foam by using it allow the strands in the rooms be compressed into it, rather than into a neighboring strand.

One Professional with usual Specialized education can be done without undue experimentation identify many ways to produce strand foams with different compressive strengths produce.

The Modification of a nozzle, through the foam strands can extrude, modify many extruded foam parameters, including the Compressive strength of a strand foam. The holes have a specific shape, Size and one certain orientation in the nozzle. For a given foamable Gel that through the nozzle is extruded to form a strand foam, gives the number the holes per unit area in the nozzle the number of strands per unit in cross-sectional area in the resulting strand foam in front. The hole shape dictates the shape of the foam strand. The hole size gives the strand size before. The Hole orientation gives orientation between the strands the strand foam before.

The Extrude a foamable Gels through a nozzle with two or more sections that are in at least one of Distinguish between: number of holes per unit area, hole shape and hole distances can form a strand foam, the different plate areas Has. For example, a portion of a nozzle may have a certain number of holes per unit area and may have an adjacent section of the nozzle less holes per unit area. Is a foamable gel by such Nozzle expands, will form a strand foam construction board, which is a plate area with a certain number of strands per cross-sectional area has, adjacent to another plate area with fewer strands per Cross-sectional area. The plate area with fewer strands per Cross sectional area will have a lower compressive strength than the plate area with more strands per cross-sectional area.

The foam strands may be solid or hollow. Solid strands have foam throughout the entire cross section of the strand. Hollow strands have foam only along a circumference of the strand cross-section so that the center of the strand cross-section does not contain any foam. Hollow strands and their preparation are also described in U.S. Patent Application Serial No. 09 / 706,110 ('110) (see page 2, line 30 to page 5, line 17). Hollow strands tend to have lower compressive strength when radially compressed than solid strands. Building panels of the present invention may contain hollow strands or solid strands, but are substantially free of a combination of hollow and solid strands solid strands. A structural panel is substantially free of a combination of hollow and solid strands if the differences between the number of solid foam strands and the number of hollow foam strands is greater than 90%, preferably greater than 95% and more preferably greater than 98% of the total number on strands.

Of the Contains polymer strand foam typically at least one organic polymer for production of polymeric strand foam. Organic polymers include aromatic Alkylene polymers, polyolefins, rubber-modified aromatic Alkylene polymers, aromatic alkylene copolymers, aromatic hydrogenated Alkylene polymers and copolymers, α-olefin homopolymers and copolymers or mixtures of the aforementioned polymers with a Rubber. Preferred polymers include homopolymers and copolymers made of PP, PE and PS, including ESI, a.

Building panels of the present invention may cooperate with building panels outside the scope of the present invention to span a cavity. The 5a and 5b show the building boards 220 and 230 (both not according to the present invention), which work together to a cavity 205 to span. The building board 22o contains the plate areas 222 and 224 , The plate area 222 is deformable. The building board 230 contains a single plate area 232 with opposite edges 234 and 236 , The 5a shows the building boards 220 and 230 when inserting into the cavity 205 , with the plate area 222 against the wall 200 of the cavity and the edge 234 of the plate area 232 against the wall 210 of the cavity. To the building boards 220 and 230 in the cavity 205 insert, the edge becomes 226 the building board 220 against the edge 236 the building board 230 set and the force F '' against the edge 226 and 236 created. The plate area 222 Compresses when the building boards in the cavity 205 be inserted. The 5b shows the building boards 220 and 230 inside the cavity 205 ,

A Building panel of the present invention may be at least one other Building board, which is within the scope of the present invention may or may not have contact using at least one hinge to a hinged one Building panel to form. A hinged building board is able to reversibly bend at the hinge (s) in order to a non-planar configuration for insertion in a cavity to accept.

As well For example, at least one plate area may be added to at least one other plate area via at least one of the plate areas have a hinge contact. Suitable hinges include flexible polymer or metal strip, polymer or metal foils or actual Devices for the hinged joining of structures were designed. Hinges can to the primary surfaces be attached to the adjacent building panels or plate areas, to the smaller surfaces be attached by adjacent building panels or plate areas or penetrate into adjacent building panels or panel area. A Variation of a building panel closes a hinge between one or two deformable plate areas, wherein by inserting the Building board into a cavity the deformable board area (s) be compressed and deform around the hinge to engage with the plate area, to it about the hinge is connected to be firmly in contact.

The Plate areas, even complete Building boards can on at least one surface, in particular a primary surface have a veneer. Suitable veneers include polymer films, metal layers and foils (such as aluminum foil), paper, woven and not woven materials, including fiberglass and tissues and combinations thereof, a. Such veneers can be one Building board additional air barrier properties lend, can can act as a hinge between panel areas, the decorative Support the nature of the building board and help to prevent the building board from kinking or sagging protect. Veneers can, have to not, however, a complete one surface cover a building board.

Lots Configurations of the building panel are within the scope of the present invention conceivable. For example, a foam board that is a single Contains foam, cylindrical fillings another foam (or some other panel material) which either has a higher one or has a lower compressive strength than the foam board, and which is due to the foam thickness in a particular pattern pulls to compress a foam that is under pressure to determine. Alternatively you can Building panels containing a principal principal material themselves tapered or groove-shaped sections that are filled with one main material that is another, as the principal principal material of the plate. A specialist can many different configurations think in the scope of the present invention.

Building panels of the present invention are as thermal insulation, acoustic dampers and Isola doors, decorations, or simply to fill a cavity, for example, to prevent insects or rodents from entering the cavity. The building boards are particularly suitable for insertion in walls and roof cavities in houses, garages and other buildings. The building panels of the present invention are also suitable for insertion in wall cavities, of e.g. B. in portable insulating containers.

The The following examples describe the invention in more detail and are intended to illustrate limit the scope in any way.

The Values for the compressive strength (stress) are calculated using the European standard (EN) 826 or as otherwise indicated. The thermal conductivity is according to EN 28301 at 10 ° C too determine.

Examples (Ex) 1 and 2.

comparison of building boards with and without deformable edge bands

example 1 explained a building panel of the present invention, which in a single Stranded foam board has its origin. Example 1 contains a deformable plate area, not along a plate edge lies.

Example 2 illustrates a structural panel of the present invention which is similar to Example 1, which also includes a deformable panel area on opposing panel edges ("deformable edge bands"). Example 2 is similar to the plate in Figs 2a and 2 B , Example 2 can be adapted to larger diameter obstacles on the wall of a cavity, as a same plate having no deformable edge bands, such. Example 1.

Example 1 and Example 2 is 130 cm long, 60 m wide, and 10 cm thick, using polyolefin-based composite foam backing sheets (such as PROPEL ^™ 12-20 polymer foam, PROPEL is a trademark of Dow Chemical Company). produced. A deformable panel area is created in Example 1 and Example 2 by perforating through the foam in a 10 cm wide band through the center of the building panel. Perforation is accomplished by piercing with a needle using 2 mm diameter needles positioned 5 mm apart along orthogonal axes. The deformable edge bands in Example 2 are formed by perforating a panel area 5 cm wide along the edges in Example 2, using the same needle piercing method as when forming the 10 cm wide malleable band. The non-perforated plate areas in Example 1 and Example 2 are fixed plate areas. Both Example 1 and Example 2 represent structural panels having panel areas that are bands.

Table 1 shows the compressive strengths for the solid and deformable plate sections of Examples 1 and 2. The percent loading corresponds to the percent compression. Table 1. Compressive strength in kPa for the panel areas in Examples 1 and 2

Of the 10 cm wide deformable plate area is further modified by cutting a 90 to 95 mcm deep slot along the length of the plate area, generally in the center of the width dimension, using a hot Blade.

Form a test cavity by placing two pillars parallel to each other at a certain distance from each other, with a larger planar surface of one pillar facing a larger planar surface of the other pillar. The volume between the two pillars defines the cavity, with the spacing between the pillars defining the cavity width. The surface of each prop has a width (which defines the depth of the cavity) of more than 10 cm. Tilt the supports so that the cavity is at a 45 ° angle to the horizontal to simulate a sloping roof.

you Place a cylindrical object with a certain diameter along the larger planar surfaces a prop. The object simulates z. As a cable, a pipe, or a pipe along a pillar or a crossbeam.

Place either Example 1 or Example 2 in the cavity by first bending the structural panel along the slot in the 10 cm wide malleable band, inserting the panel edges into the cavity and seating against the surfaces of the support and then along the slot is pressed until the building board is completely inside the cavity (see eg. 2a and 2 B ). Both Example 1 and Example 2 fit snugly into the cavity without kinking when the spacing of the supports is between 60 cm and 56 cm. Buckling occurs in the building panel when the distance is less than 56 cm, with buckling being most likely in the 10 cm wide deformable band.

example 1 fits a cylindrical object with a diameter 5 mm or less, with a close connection with the support formed. Example 1 does not close tightly around a cylindrical one Object having a diameter of 10 mm or larger.

example 2 adapts to a cylindrical object with a diameter of 15 mm, which forms a tight seal with the support.

Example 3: A building board, containing a deformable panel area of polyurethane foam

Example 3 illustrates a structural panel of the present invention containing a deformable polyurethane foam panel area. Example 3 also illustrates the advantage of having a deformable edge band to conform to objects on a cavity wall. Example 3 has a structure similar to that of the building board in the 2a and 2 B like. The plate areas in Example 3 are examples of tapes.

Cut two solid sections 130 cm long, 20 cm wide and 10 cm thick from a PS foam board such. B. a STYROFOAM ^® Roofmate SL polymeric foam insulation (STYROFOAM is a trademark of Dow Chemical Company). Cut three deformable tapes 130 cm long and 10 cm thick, two of these 5 cm wide and one of these 10 cm wide, of flexible polyurethane (PU) foam (such as PU foam 16F from Metzeler Mousse) ). Store the panel sections using a two-part epoxy adhesive along the 130 cm long and 10 cm thick edges to create a structural panel having the same dimensions as in Example 2 and the following orientation of the panel areas:
5 cm PU foam / PS foam / 10 cm PU foam / PS foam / 5 cm PU foam

Table 3 shows the profiles of compressive strength for the PU foam. For comparison, the compressive strength for the PS foam is 229 kPa in yield. Table 3. Compressive strength of flexible polyurethane foam (in kPa)

you place Example 3 in the test cavity using the method, as described in Examples 1 and 2, a. Example 3 fits in cavities, which have a distance of 60 cm to 56 cm without kinking and fits exactly to a cylindrical object, the one Diameter of 15 mm, on a larger planar surface of the Cavity wall.

Example 4. Polyurethane structural panel

Prepare a building panel as described for Example 3, with the exception of using a rigid polyurethane foam instead of a PS foam. The solid polyurethane foam has a density of 35 kg / m ³ , corresponding to EN1602, a compressive strength of 146 kPa in yield, and a thermal conductivity of 19 milliwatts per meter-Kelvin (mW / m · K).

example 4 is the same as Example 3 and also provides a building panel of the present invention Invention containing polyurethane foam. The thermal conductivity The hard polyurethane foam makes this a particularly attractive thermally insulating building board.

Example 5. Building board with rock wool

example 5 represents a complete Fiberboard of the present invention.

Cut a piece of rockwool with a density of 55 kg / m ³ (such as ROCKPLUS ^™ insulation material, ROCKPLUS is a trademark of Rockwool) into a plate that is 130 cm long, 60 cm wide and 10 cm thick. Press a 10 cm wide malleable band over the full 130 cm length through the center of the plate to 20% of its original thickness using either a roll or a hydraulic press. The compression of the plate makes the structure of the rock wool elastic, forming a deformable area. The plate assumes a fixed band / deformable band / solid band configuration. This plate is Example 5.

Table 4 shows the compressive strengths of the uncompressed (solid) bands and the compressed (deformable) band. Table 4. Compressive strengths in kPa for compressed and uncompressed bands in Example 5.

example 5 fits securely into a cavity measuring 57 cm, using the cavity wall / test system of Example 1.

Claims (10)

A structural panel comprising at least two areas in the panel, each area in the panel having substantially uniform compressive strength and an average compressive strength, the panel having: (a) at least two areas in the panel having different average compressive strengths; (b) is substantially free of a combination of hollow and solid foam strands; (c) has a substantially uniform plate thickness; (d) has at least one compliant portion in the plate which expands from a primary surface to a surface opposite thereto and which, when compressed, reduces at least one dimension of the plate, allowing the plate to fully penetrate into a cavity can be fitted, which is formed by cavity walls; (e) has a slot that penetrates to a depth less than the thickness of the plate that traverses the primary surface, or the surface that faces the primary surface, and that flexes the plate into a non-planar spatial configuration facilitates fitting into this cavity; and (f) has compression resilience which, when the plate has been fitted in this cavity, provides sufficient pressure against the walls of the cavity to frictionally maintain the structural plate in the cavity, said pressure being 100 N / m ² or more and 200,000 N / m ² or less; and wherein, if said plate has at least two adjacent plate regions containing fibrous material having a fiber orientation, the fiber orientation of a plate region is non-orthogonal to the fiber orientation of at least one adjacent plate region. The plate of claim 1, wherein each plate area contains a polymer foam. The plate according to claim 1 or 2, wherein at least a plate area is a compliant plate area that allows the plate reversible from a planar to a non-planar arrangement to bend. The plate according to any one of claims 1 to 3, wherein the plate has alternately yielding and solid plate areas. The plate according to any one of claims 1 to 4, wherein the plate portions exist as a strip. The plate according to any one of claims 1 to 5, wherein at least a panel area comprises coalescing polymer foam strips. The plate according to any one of claims 1 to 6, wherein at least One plate area is a polymer foam having an open content Cells of 5% or more according to the American Society for Testing and Materials Method D2856-A. The plate according to claim 7, wherein the average cell diameter of the foam is within a range of 0.1 mm to 4 mm, the density of the foam is within a range of 5 kg / m ³ to 50 kg / m ³ , and wherein the foam has an open cell content of 50% or more according to the American Society for Testing and Materials Method D2856-A. The plate according to any one of claims 1 to 8, wherein at least a primary one surface a decorative design, a functional profile or both decorative design, as well as a functional profile includes. The plate according to any one of claims 1 to 9, wherein said plate square or rectangular, and wherein this plate at least includes a resilient edge strip.