Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
  • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
  • E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material

Definitions

• the object of this invention is a panel construction to be used in buildings in wall structures or in floor slabs, intermediate floor slabs, roof slabs, plinth plates etc., comprising a perforated frame plate and an insulation material layer.
• the present invention relates to panel constructions used in bxiilding,such as walls, floor slabs, intermedi ⁇ ate floor slabs, roof slabs, plinths and generally to structures that have to bear loads imposed upon them.
• Construction 1. - external facing
• the air cavity may be emitted, because the wall is airtight, bringing many advantages. For example, when the sun shines onto the external wall and the roof, it rapidly heats the surface of the panel construction, and hereby the temperature difference between the outer -and inner surfaces of the panel construction is decreased, directly affecting the need of heating. The better the thermal conduc- tivity of the material of the outer surface of the panel construction is, the sooner its temperature increases.
• the whole wall and roof surface functions as a "solar energy collector".
• Wood is the traditional frame material in such wallsI
• the use of steel as the frame material has not gained wide popularity,- at least not in the external wal s, as the frame has been placed inside the insulation. In this case a so-called cold bridge is formed in the wall.
• the large thickness of the wall is a cost-adding factor, especially in areas where the so-called space cost has to be taken into account.
• the production process of this construction comprises the of an as such known perforated steel sheet, its corrugation in a rolling apparatus, and its passing as an endless corrugated band into a foamed plastic applying machine.
• the perforated sheet acting as the reinforce ⁇ ment may also be manufactured by previously cutting it into pieces, 25 then perforating, corrugating and passing the pieces successively in a continuous manner into the foamed plastic applying machine.
• the present invention aims at creating a panel construction with a good bearing capacity, allowing the panel to be manufactured in a continuous 30 manner, among others so that an unperforated sheet is unrolled, corru ⁇ gated in a rolling apparatus and perforated in the same process only after corrugating, before passing the sheet into the machine that applies the foamable insulation component.
• An additional objective ' of this invention is to avoid the disadvantages described above and to create a panel construction in which several advantages of different character, being described later, are gained.
• the invention is mainly characterized in that for forming wall structures and/or floor structures or similar structures essen ⁇ tially entirely of the mentioned panel construction, the panel con ⁇ struction comprises as a structural exami ation at least the following layers:
• the said frame plate is a corrugated metal sheet with a gripping element series similar to nails, consis ⁇ ting of the sheet material deflected from the perforated positions, this gripping element series creating a mechanical gripping between the frame panel and the insulation material layer, and the perforation being such that it does not essentially weaken the frame plate
• I ORS mainly bears the loads imposed on the panel construction.
• the term insulation material denotes a foamable in ⁇ sulation material which by its gluing effect fastens on both sides to the perora-ted plate used as the frame structure.
• the plate used as the frame structure is situ ⁇ ated inside the insulation material so that if for example corrugated metal sheets are used, at least the grooves have been filled with the fo-amable i_nsulation material.
• a foamable insulation material such as polyurethane and polyisocyanu- rate or similar is airtight and does not absorb moisture, and thus the risk of the sheet being corroded or getting wet is e- ⁇ ininated, whereby the rusting and the moisture movements of the sheet tare prevented.
• the solid insulation material layer supports the sheet from all sides and decreases the risk of buckling or dinting of the sheet.
• the insu ⁇ lation capacity of the " panel construction is increased, as for example in the case of using a corrugated sheet the shape of the corrugated sheet does not locally make the insulation layer thinner.
• facings can be fixed to the panel mechanically, allowing this stage of work to be done, among others, on the worksite.
• a mechanical fastener for example a long screw or similar, penetrates through the insulation material and is fixed to the sheet.
• the type and form of the facing material can be selected freely; this ad ⁇ vantage is also achieved in the case that the facing material is glued by the insulation material to the panel construction already in the manufacturing stage. I a factory the selection of facing materials has to be however restricted, v ch is v * hy the possibility of mechani ⁇ cal fastening is a significant additional advantage.
• This kind of wall or floor structure or similar contains a frame, an insulation, and if necessary, facing on one side or on both sides. Also- shaped facing materials may of course be used on the external and internal surfaces of the panel construction.
• the bearing capacity and the stiffness of the panel construction ele ⁇ ments may still be improved by placing pipes or corresponding cavities inside the elements. These pipes constitute a component that stiffens the element- and increases its bearing capacity. If the pipes in ques ⁇ tion are filled by concrete or corresponding material, the bearing ca ⁇ pacity and the stiffness are still improved.
• this area is, for example in corrugated steel sheets, the area where the stresses of the sheet are first exceeded. Further it is known that in structural design exactly these areas are, as so-called yielding areas, not taken into account, even if there -were no holes at all in the centre of the flanges of the cross-section (in conventional corrugated sheet profiles that are used as load-bearing roof and wall structures) .
• the gripping elements may also be situated in other places than in connection with the holes, provided that they do not decrease the bearing capacity of the steel sheet or corresponding sheet.
• the said -tra ⁇ pezoid-shaped insulation material strip would easily get loosened from the corrugated sheet, and thereby also the facing panel would be loos- ⁇ ied.
• the moisture movement of fibreboards, particle- boards and asbestos cement boards may be 5-10 ⁇ t, which creates a shearing force in the joint between the steel sheet and the insulation. This shearing force has to be taken by a sufficient shearing strength between the sheet ccr ⁇ ponent and the insulation component. Only the mechanical joint applied in this invention can be reliable enough.
• the frame structure of the panel construction is a perforated corrugated steel sheet with a gripping mechanism
• the insulation material is polyurethane or polyisocyanurate.
• the invention is in no way limited to steel sheet and the said insulation materials, but the sheet constituting the frame structure may also be sane other metal sheet that can be provided with a gripping mechanism and perforation.
• the insulation material may also be some • other foamable insulation material that by its gluing effect fastens to the frame material, such as aerated concrete "Siporex" (trademark) or a corresponding material.
• the sheet When the steel sheet is sittiated in the panel construction of the in ⁇ vention in the form of a corrugated sheet, the sheet is enough to bear the loads imposed upon the structure, tut the sheet does not extend across the wall, and thus no cold bridges may arise.
• the joints be ⁇ tween the panel construction elements can also be sealed by other ma- terials than foamed polyurethane, and thus building in wintertime can also be managed by means of these solutions.
• the joints between the panel constructions may for example be fixed by mechanical fasteners, and thus they can be loosened and the panel construction can be moved to another place to be assembled again. This is a significant advan- tage as compared with the present wall and floor constructp.ons.
• the bearing capacity of the panel construction may be adjusted by means of changing the thickness and profile of the sheet. Similarly the thick ⁇ ness of the insulation may be selected so as to meet the requirements of the time and place of building.
• the perforated steel sheet replaces the frame columns, and thus a steel frame, an insulation, and if required, facings of the wall or other structure, are produced in the same time in the production stage of the panel construction.
• the production can be carried out simply in as such known moulds and in continuous production lines. Because the sheet is perforated, the foamed insulation material gets through to the other side of the sheet as well, which would not be possible without the perforation. Thus the sheet may be situated either above or under the injection point of the insulation material. Both of these ways are used in the production of the present known sandwich panels.
• OMPI insulation material is used, the insulation material fastens onto both surfaces of the sheet.
• the steel sheet or other sheet is perforated so that projecting parts remain on one edge or on both edges of the hole, either on one side or on both sides of the sheet, for example in the way described in the Finnish patent 54006.
• the projecting -parts may also be handle-like strips which in both ends remain fixed to the sheet at the edges of the holes in the sheet, or other projecting parts bent out of the ma- terial of the sheet.
• the insula ⁇ tion material fastens to these projecting parts both mechanically and by its gluing effect, and thus the gripping between the sheet and the insulation is .still improved.
• a facing material can be fixed to the panel construction, for example by casting a layer of concrete or other material on the panel element.
• the projecting parts may also function as distance-keeping spacers, when a cavity is required between the facing material and the panel. Due to this cavity the insulation glues the facing through its entire surface, and thus the gluing effect is improved and in the same time ' the protection of the sheet against corrosion and moisture are still improved.
• This cavity may also be formed by spacers or the like that are fixed to the sheet before the foaming of the insulation.
• the insulation material is a plastic-based insulation material
• the material on both sides of the sheet or other plate may be mineral wool, foamed polystyrene (styr ⁇ x) , excelsior plate, concrete, clinker plate, brick, aerated concrete (siporex) or wood-based fibreboard, metal sheet, panel or the like.
• the insulation of the "element” is water vapour tight, u ⁇ wetting, strong, permanent and chemically resistant polyurethane or polyiso- cyanurate or the like;
• the core plate of the "element” is for example hot zinc-coated steel sheet, and the insulation protects the sheet, and thus no risk of corrosion exists under any circumstances;
• the "element" is a building material that even the do-it-yourself builder is able to use.
• the superior heat insulation capacity of polyurethane and polyiso- cyanurate guarantees that the heat insulation capacity of the elements is maximized in the same time as the space cost is minimized. Moisture does not become condensed to the elements and tight joints are ob ⁇ tained.
• the building can be disassembled and moved to be assembled again.
• the elements do not need any special maintenance.
• the weight of the elements as supplied to the worksite is 12-21 kg/ ⁇ i .
• the maximum length of the elements is 12.5 m.
• a structure is obtained that can bear even high loads.
• the elements are safe against fire.
• the inflai-mability class of poly- isocyanurate is 1 and the fire-propagation class of the surface of the steel sheet coated element is I.
• Variations in shape of facades may be realized by varying the placing and the size of windows. Facing materials may also be varied in the same building project. The elements allow an almost * jnlimited freedom of alteration in facing materials. By using the same basic product it is possible to build a house with any required external facing.
• Fig. 8 is a schematic view of the principle of the batch mould used advantageously in the production of the panel constructions of this invention.
• Figures 9 and 10 present perspective views of some preferred joint methods and the projecting gripping elements of the panel construction of this invention.
• the panel construction comprises a frame plate 1;1a;1l->;1c;1d;1e;1f provided with perforation 1' and a gripping mechanism 1".
• this frame plate gives the panel construction a sufficient stiffness against loads with different directions.
• the frame plate 1;1a;1b;1c;1d;1e;1f is entirely inside the insulation layer 3.
• the insulation layer 3 is cast of foam ⁇ able insulation material and it can penetrate through the perforation 1' of the frame plate.
• the frame plate 1;1a;1b;1c;1d;1e;1f is directly connected to the .insulation material layer 3 by its gluing effect.
• the facings 4a, 4a , ;4b,4b , ;4c,4c , ;4d,4d , ;4f,4f , ;4g,4g , ;4h,4h , ;4i,4i « and 4j,4j' are connected to the construction.
• the mentioned separate facings are not needed in all cases, but the surfaces of the panel construction may be formed by the surfaces of the insulation material layer 3, in which, as is as such known, is formed a uniform plastic material surface layer with a density higher than"that of the rest of the foamed struc ⁇ ture, for example in the moulding stage due to the effect of the walls of the mould.
• Fig. 1 there is a corrugated sheet 1 provided with perforation 1 ' and a gripping mechanism 1", an insulation 3 and, depending on the production technology, a paper, an aluminium paper or similar coating 4a and 4a'. If batch moulds are used in the production, the surface of the insulation 3 must be coated by a coating 4a,4a' with at least the strength class of kraft paper, preferably an aluminium-coated paper. The same applies to continuous production lines. If the production is carried out in a process where the insulation 3 is allowed to expand freely, the paper 4a,4a* or the like may be left out.
• the upper surface coating 4a of Fig.1 has been replaced by a shaped plate 4b, in which case the production is carried out in batch moulds having an upper or a lower component of the corres ⁇ ponding shape, depending on whether the product is manufactured with the shaped plate upwards or downwards. Also a continuous production line may be in question here, in which case the shaped plate is for example a corrugated sheet. Both of the coatings 4b,4b' may be shaped. In other respects the construction is as shown in Fig. 1.
• Fig. 3 there is a clinker or brick plate 4c or the like on the upper surface of the panel construction and an even panel facing 4c' , for example a hard fibreboard, on the lower surface.
• the clinker plates or the like are, before injecting the insula ⁇ tion material, placed on for example a rubber mat having formed re ⁇ Grandes for the plates and projecting ridges between the recesses for seams between the plates, respectively.
• the panel construction shown in Fig. 3 can be manufactured primarily in batch moulding lines. The afterseaming of the seams between the wall plates is carried out by using known materials either in the factory or on the worksite. In continuous production lines this kind of solution is possible, if the rubber mat or the like is functioning like the wire of a paper machine and the speed of the line is so adjusted that there is time enough to place the plates on the mat either by machine or manually.
• Fig. 4 there are two corrugated sheets .1a and 1b oppo ⁇ site to each other.
• the tube formed by the sheets 1a and 1b has been cast concrete 8' or the like, and thus the bearing capacity and the stiffness of the panel construction element are still increased.
• Fig. 5 the coatings 4e and 4e' of the upper and lcwer surface have been fixed by mechanical fasteners 6, vjhich go through the insulation 3 are fasten to the corrugated sheet 1, in which case a separate battening or other basis for fastening is not needed.
• spacers 7 have been fixed to the corrugated sheet 1c.
• a wooden spacer When for example a wooden spacer is used, it functions as a nailing ground if for exa ⁇ ple a wooden panel or board facing is used.
• this spacer By means of this spacer it is also possible to adjust the posi ⁇ tion of- the plate 4f as required.
• different spacers made of sane insulation material or"the like may be used as spacers 7.
• tubes 8 made of steel, me ⁇ tal sheet, paperboard or the like, which tubes are glued in their position by means of the insulation material 3.
• the said tubes serve as moulds, when it is required to improve the bearing capacity and the stiffness of the panel construction element, by casting concrete 8' or the like into the said moulds. If the tubes 8 have been made of steel or the like, they increase already as such the bearing capacity and the stiffness of the element.
• Fig. 8 shows the principle of the batch mould.
• the foamable insulation material 3 is injected through the nozzle 5 into the mould 2, where it expands due to heat (or.other reason) , penetrates through the holes 1 ' of the corrugated sheet 1 also to the other side-of the sheet 1 and fills,the interior of the mould 2 reserved for the insulation in the same time as the insulation 3 glues all of the c ⁇ ponents to one tight and stiff.entity.
• the principle of continuous production lines is si ⁇ milar, but the closed mould is replaced by a curing tunnel.
• the char ⁇ acteristics of the insulation material 3 may be different depending on the production process. -
• pipelike channels may be formed either in the the moulding stage or later, if necessary, for electric, telephone, teleco ⁇ raunication and/or similar wires.
• these channels are made so that in connection with the moulding stage, pipes of metal, paperboard or other corresponding material are placed in the mould,for example fixed to the frame plate 1 or supported by it, with the interior of the pipes being left free from the insulation material 3.
• Such pipes may also serve as structural parts affecting the strength of the panel construction and at least partly they may replace the frame plate 1, or they are filled by casting into them concrete or other similar material, in which case the bearing capacity and the stiffness of the panel construction are still iitproved.
• edges of the mould 2 shown in Fig. 8 may be so formed that tongues and grooves or corresponding shapes are formed on the edges of the . in ⁇ sulation material layer 3 so that a sufficient tightness is obtained . in joints between adjacent panel construction elements.
• the mentioned tongues and grooves may also be so formed that their edges are lined by the frame plate 1. In this case the edges of the frame plates 1 of adjacent panel construction elements can be fixed to each other by screws or the like, and thus a very reliable fastening and a stiff construction is obtained.
• Fig. 9 shows in a partly cut perspective view a panel construction element and a joint solution between two elements.
• a perforation 1 ' and a gripping mechanism 1" a kind of nail system, in the frame plate 1.
• facing plates 4i,4i' and the insulation material 3 are seen in the figure.
• the edges 9,9' of the frame plates 1 form a kind of tongue-and-groove joint and over ⁇ lap each other.
• the frame plates of two adjacent pa- nel construction elements can be fixed to each other by screws 10 or the like through the plate 4i or the like, and thus a.reliable fasten ⁇ ing and a stiff construction is obtained.
• the joint may also be dis ⁇ assembled, in which case the elements can be assembled again.
• a grooving 11 which at the assembly stage of the elements is filled by polyurethane insulation material 12 or the like
• Fig. 10 shows a frame plate 1f, perforation 1' , a gripping mechanism 1", facing plates 4j and 4j* and and insulation 3.
• the frame plate 9 extending beyond the edge of one of the elements is pressed between the plate 4j and the edge 9' of the frame plate.
• the elements are fixed to.each other by means of screws or the like.
• the joints between the elements are sealed by po ⁇ lyurethane insulation material 12 or the like,or mineral wool or plas ⁇ tic sealing strip is used.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Building Environments (AREA)
• Laminated Bodies (AREA)

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• 1981
  • 1981-12-08 FI FI813925A patent/FI66454C/fi not_active IP Right Cessation
• 1982
  • 1982-12-08 WO PCT/FI1982/000061 patent/WO1983002127A1/en unknown
  • 1982-12-08 EP EP19830900036 patent/EP0097194A1/en not_active Withdrawn

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