EP0857244A1 - Panels - Google Patents
PanelsInfo
- Publication number
- EP0857244A1 EP0857244A1 EP96935072A EP96935072A EP0857244A1 EP 0857244 A1 EP0857244 A1 EP 0857244A1 EP 96935072 A EP96935072 A EP 96935072A EP 96935072 A EP96935072 A EP 96935072A EP 0857244 A1 EP0857244 A1 EP 0857244A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- panel
- open cell
- cell structure
- sheets
- facing sheets
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000006260 foam Substances 0.000 claims abstract description 25
- 239000000463 material Substances 0.000 claims description 15
- 229920005989 resin Polymers 0.000 claims description 9
- 239000011347 resin Substances 0.000 claims description 9
- 239000004814 polyurethane Substances 0.000 claims description 7
- 229920002635 polyurethane Polymers 0.000 claims description 7
- 239000002184 metal Substances 0.000 claims description 6
- 229910052751 metal Inorganic materials 0.000 claims description 6
- 239000005056 polyisocyanate Substances 0.000 claims description 6
- 229920001228 polyisocyanate Polymers 0.000 claims description 6
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 5
- 229910000831 Steel Inorganic materials 0.000 claims description 5
- 239000002245 particle Substances 0.000 claims description 5
- 239000005011 phenolic resin Substances 0.000 claims description 5
- 229920001568 phenolic resin Polymers 0.000 claims description 5
- 239000010959 steel Substances 0.000 claims description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 3
- 239000004743 Polypropylene Substances 0.000 claims description 3
- 230000015572 biosynthetic process Effects 0.000 claims description 3
- 229910052799 carbon Inorganic materials 0.000 claims description 3
- 239000001913 cellulose Substances 0.000 claims description 3
- 229920002678 cellulose Polymers 0.000 claims description 3
- 230000000295 complement effect Effects 0.000 claims description 3
- 230000007797 corrosion Effects 0.000 claims description 3
- 238000005260 corrosion Methods 0.000 claims description 3
- 239000000835 fiber Substances 0.000 claims description 3
- 239000011152 fibreglass Substances 0.000 claims description 3
- 230000009970 fire resistant effect Effects 0.000 claims description 3
- 238000005755 formation reaction Methods 0.000 claims description 3
- 239000010440 gypsum Substances 0.000 claims description 3
- 229910052602 gypsum Inorganic materials 0.000 claims description 3
- 239000007769 metal material Substances 0.000 claims description 3
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims description 3
- 229920000728 polyester Polymers 0.000 claims description 3
- -1 polypropylene Polymers 0.000 claims description 3
- 229920001155 polypropylene Polymers 0.000 claims description 3
- 239000010454 slate Substances 0.000 claims description 3
- 239000004433 Thermoplastic polyurethane Substances 0.000 claims description 2
- 239000011111 cardboard Substances 0.000 claims description 2
- 239000011093 chipboard Substances 0.000 claims description 2
- 239000002131 composite material Substances 0.000 claims description 2
- 238000000034 method Methods 0.000 claims description 2
- 239000011087 paperboard Substances 0.000 claims description 2
- 239000011120 plywood Substances 0.000 claims description 2
- 229920002803 thermoplastic polyurethane Polymers 0.000 claims description 2
- 239000002023 wood Substances 0.000 claims 2
- 238000004519 manufacturing process Methods 0.000 claims 1
- 239000004411 aluminium Substances 0.000 description 4
- 229910052782 aluminium Inorganic materials 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- 239000004568 cement Substances 0.000 description 4
- 229920005830 Polyurethane Foam Polymers 0.000 description 3
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 239000003517 fume Substances 0.000 description 3
- 239000000123 paper Substances 0.000 description 3
- 239000011496 polyurethane foam Substances 0.000 description 3
- 239000000779 smoke Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 150000002118 epoxides Chemical class 0.000 description 1
- 230000009969 flowable effect Effects 0.000 description 1
- 239000006261 foam material Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 231100000331 toxic Toxicity 0.000 description 1
- 230000002588 toxic effect Effects 0.000 description 1
- 238000013022 venting Methods 0.000 description 1
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
- E04C2/292—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 sheet metal
-
- 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
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
- E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
- E04C2/365—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels by honeycomb structures
Definitions
- This invention concerns panels, especially building panels for use in constructing walls and roofs.
- Building panels which comprise metal facing sheets and a core of polyurethane foam. Whilst having good insulation properties, these panels do have some disadvantages.
- One disadvantage is that they have a limit on their load bearing capacity even when made relatively thick because polyurethane foam is not particularly strong.
- Another disadvantage arises simply from the use of polyurethane foam which gives off toxic fumes in fire situations. Increasingly, therefore, there is a movement away from using such wall panels.
- An object of this invention is to provide useful panels.
- a panel comprising a pair of facing sheets and a core, wherein the core comprises an open cell structure having walls extending between the facing sheets and a foam filling.
- the facing sheets may be of metal, especially of steel, more especially of galvanised steel.
- One or both of the facing sheets may be profiled.
- Preferably outer faces of the or each facing sheet is covered or coated with a corrosion protection layer.
- Profiling is preferably in the form of longitudinal internal channels protruding from the outer face of a facing sheet of a panel.
- the channels are trapezoidal in section having a narrower base than open side.
- the profile channels will be filled with the foam material but the open cell structure will not necessarily extend thereinto. That means that in a fire situation, the profile channels can provide passages for escape of fumes from the foam unhindered by the open cell structure. The fumes can, therefore, be directed upwards out of top edges of panels and away from the interior of the building.
- the facing sheets may alternatively be made of non-metallic materials and as such are preferably rigid boards.
- suitable rigid boards for use in the invention include particle boards, cement particle boards, glass fibre reinforced cement boards, cellulose reinforced gypsum boards, crushed slate boards and resin boards.
- Wooden facing sheets or composite wooden facing sheets may also be used in forming panels of the invention, including, for example, plywood and chipboard.
- Preferably facing sheets used in the invention are able to offer some fire resistance due to their composition, the addition of fire resistant materials or coating thereof with fire resistant materials.
- the open cell structure forming part of the core of a panel according to the invention is preferably a honeycomb structure, wherein lengths of material are bonded together at intervals or are formed into a lattice by being interwoven.
- a honeycomb structure suitable as a core There are two principle ways of producing a honeycomb structure suitable as a core. The first way is the expansion process, in which sheets of material, having adhesive applied in strips, are cut and stacked on top of each other and then the adhesive is cured, usually under pressure and at elevated temperature. Slices are then cut to the required thickness and expanded to give the honeycomb structures.
- the other way of making honeycomb structures is to corrugate sheets of material, apply adhesive to nodes and stack the sheets in an oven to cure.
- the material used to form the open cell structure may be metallic or non-metallic. Aluminium is a preferred metal for forming the open cell structure. Suitable non-metallic materials for forming the open cell structure include paper and cardboard impregnated with a stiffening material, such as a resin, especially a phenolic resin, thermoplastic polyurethane sheets, fibreglass, carbon fibre in a resin, such as phenolic, epoxide or polyumide resin, and polypropylene or polyester sheets.
- a stiffening material such as a resin, especially a phenolic resin, thermoplastic polyurethane sheets, fibreglass, carbon fibre in a resin, such as phenolic, epoxide or polyumide resin, and polypropylene or polyester sheets.
- the honeycomb structure may be of a conventional hexagonal cell type or may be reinforced by flatsheets between each node to form trapezoidal cells.
- the foam filling for the core of panels of the invention is preferably a synthetic foam, suitable examples of which include polyurethane, polyisocyanate and phenolic foams.
- Opposed panel ends may be shaped or provided with complementary formations for engagement with ends of adjacent panels, such as in tongue and groove fashion or by provision of overlapping rebates.
- Panels according to the invention may be fabricated in the following manner. One facing sheet is laid out and the open cell structure laid out thereon. The foam filling is poured into the open cell structure in uncured or partially cured state and the other facing sheet laid on top. As the foam cures the foam bonds with the facing sheets to form a cohesive structure.
- Panels of the invention are suitable as building panels and as such may be used, for example, as wall panels, roof panels, floor panels (decking) and for making doors, especially fire doors or roller shutter doors.
- Figure 1 shows a first panel according to the invention
- Figure 2 shows a second panel according to the invention.
- Figure 3 shows a third panel according to the invention.
- a wall panel 10 comprises inner and outer facing sheets 12 and 14 respectively sandwiching a core 16.
- the outer facing sheet 12 is of embossed galvanised steel with spaced, parallel, alternate wide and narrow trapezoidal section profiles 18 and 20 respectively.
- the inner facing sheet 14 is also of embossed, galvanised steel. Both sheets 12 and 14 have on their outer faces coatings for protection against corrosion.
- the core 16 comprises a honeycomb structure 22 with its cells 24 bridging to the facing sheets and a filling 26 of polyurethane or polyisocyanate foam.
- the honeycomb structure 22 may be of aluminium or of phenolic resin impregnated paper.
- a wall panel 100 comprises inner and outer substantially flat facing sheets 102 and 104 respectively and a core 106. Ends of the facing sheets are bent and shaped to from at opposite ends of the panel tongue and groove jointing profiles 108 and 110 respectively for joining panels end to end.
- the core 106 comprises a honeycomb structure 112 of aluminium or phenolic resin impregnated paper and a polyurethane or polyisocyanate foam filling 114.
- One facing sheet is load down and the honeycomb structure load thereon.
- Uncured or partially cured polyurethane or polyisocyanate foam in flowable form is poured onto the honeycomb structure, the underlying facing sheet acting as a tray.
- the other facing sheet is laid on top and the foam cured. As the foam cures it bonds to the two facing sheets.
- a panel 200 comprises inner and outer flat facing sheets 202 and 204 of cement particle board and a core 206.
- Alternative materials for the facing sheets include particle boards, glass reinforced cement boards, cellulose reinforced gypsum boards, crushed slate boards and resin boards.
- the core 206 comprises a honeycomb structure 208 of aluminium or phenolic resin impregnated paper and a polyurethane or polyisocyanate foam filling 210.
- honeycomb structures used in each of the illustrated embodiments may, of course, be substituted by a honeycomb structure made of any other suitable material such as of sheets of polyurethane, fibreglass. carbon fibre, polypropylene or polyester.
- Panels of the invention may have several advantages over prior art panels.
- the open cell core provides strength enhancing load spanning
- the panels perform better in fire situations in the respects of structural integrity and control of spread of smoke.
- the open cell core structure can retain smoke and hence delay its
- Panels having an outer profiled facing sheet also provides a means for venting smoke to the exterior of a building upwards along the profiles.
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Laminated Bodies (AREA)
- Building Environments (AREA)
- Panels For Use In Building Construction (AREA)
- Finishing Walls (AREA)
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP99122668A EP0980937A3 (en) | 1995-10-24 | 1996-10-24 | Panels |
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GBGB9521713.9A GB9521713D0 (en) | 1995-10-24 | 1995-10-24 | Panels |
GB9521713 | 1995-10-24 | ||
GB9525470 | 1995-12-13 | ||
GBGB9525470.2A GB9525470D0 (en) | 1995-12-13 | 1995-12-13 | Panels |
PCT/GB1996/002598 WO1997015736A1 (en) | 1995-10-24 | 1996-10-24 | Panels |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP99122668A Division EP0980937A3 (en) | 1995-10-24 | 1996-10-24 | Panels |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0857244A1 true EP0857244A1 (en) | 1998-08-12 |
EP0857244B1 EP0857244B1 (en) | 2000-08-23 |
Family
ID=26307991
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP99122668A Withdrawn EP0980937A3 (en) | 1995-10-24 | 1996-10-24 | Panels |
EP96935072A Expired - Lifetime EP0857244B1 (en) | 1995-10-24 | 1996-10-24 | Panels |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP99122668A Withdrawn EP0980937A3 (en) | 1995-10-24 | 1996-10-24 | Panels |
Country Status (7)
Country | Link |
---|---|
EP (2) | EP0980937A3 (en) |
AT (1) | ATE195781T1 (en) |
AU (1) | AU7316796A (en) |
DE (1) | DE69609981T2 (en) |
ES (1) | ES2152046T3 (en) |
GB (1) | GB2321482B (en) |
WO (1) | WO1997015736A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9091066B2 (en) | 2009-05-13 | 2015-07-28 | 3Form, Llc | Structured-core laminate panels and methods of forming the same |
US9097015B2 (en) | 2011-10-12 | 2015-08-04 | 3Form, Llc | Resin panels with embedded structured-cores and methods of making the same |
Families Citing this family (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1120509A1 (en) * | 2000-01-26 | 2001-08-01 | Tonelli S.A. | Method for manufacturing structural elements substantially made of cellulose-based material, stiffened, and related structural element |
GB2380971B (en) * | 2001-08-30 | 2004-12-29 | Kingspan Res & Dev Ltd | Honeycomb insulating panels |
DE20316549U1 (en) * | 2003-10-27 | 2005-03-03 | Viessmann Kältetechnik AG | Insulated floor for cold room has cellular underlay construction between two sandwich panels |
ES2302394B2 (en) | 2003-11-19 | 2009-07-28 | British Robertson, S.L.U. | PANEL WITH MACHIHEMBRATED REMATES FOR FACADES OR COVERS. |
WO2013181716A1 (en) * | 2012-06-07 | 2013-12-12 | Idc Solutions Pty Ltd | Panel |
EP3031994A1 (en) * | 2014-12-08 | 2016-06-15 | Svoboda Piotr Slebioda | Fire resistant structural panel with a pir core |
DE102015121101A1 (en) * | 2015-12-03 | 2017-06-08 | Technische Universität Darmstadt | Gebäudehüllelement |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2744042A (en) * | 1951-06-21 | 1956-05-01 | Goodyear Tire & Rubber | Laminated panels |
GB802686A (en) * | 1955-03-31 | 1958-10-08 | Bettinger Corp | Improvements in or relating to honeycomb structures |
US3998024A (en) * | 1975-08-04 | 1976-12-21 | H. H. Robertson Company | Double-skin insulated building panel |
-
1996
- 1996-10-24 DE DE69609981T patent/DE69609981T2/en not_active Expired - Fee Related
- 1996-10-24 AT AT96935072T patent/ATE195781T1/en active
- 1996-10-24 GB GB9808413A patent/GB2321482B/en not_active Expired - Lifetime
- 1996-10-24 ES ES96935072T patent/ES2152046T3/en not_active Expired - Lifetime
- 1996-10-24 WO PCT/GB1996/002598 patent/WO1997015736A1/en active IP Right Grant
- 1996-10-24 EP EP99122668A patent/EP0980937A3/en not_active Withdrawn
- 1996-10-24 EP EP96935072A patent/EP0857244B1/en not_active Expired - Lifetime
- 1996-10-24 AU AU73167/96A patent/AU7316796A/en not_active Abandoned
Non-Patent Citations (1)
Title |
---|
See references of WO9715736A1 * |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9091066B2 (en) | 2009-05-13 | 2015-07-28 | 3Form, Llc | Structured-core laminate panels and methods of forming the same |
US9091067B2 (en) | 2009-05-13 | 2015-07-28 | 3Form, Llc | Structured-core laminate panels and methods of forming the same |
US9097015B2 (en) | 2011-10-12 | 2015-08-04 | 3Form, Llc | Resin panels with embedded structured-cores and methods of making the same |
Also Published As
Publication number | Publication date |
---|---|
WO1997015736A1 (en) | 1997-05-01 |
GB9808413D0 (en) | 1998-06-17 |
ES2152046T3 (en) | 2001-01-16 |
EP0857244B1 (en) | 2000-08-23 |
DE69609981T2 (en) | 2001-03-01 |
GB2321482A (en) | 1998-07-29 |
EP0980937A3 (en) | 2000-03-15 |
ATE195781T1 (en) | 2000-09-15 |
DE69609981D1 (en) | 2000-09-28 |
GB2321482B (en) | 2000-03-29 |
EP0980937A2 (en) | 2000-02-23 |
AU7316796A (en) | 1997-05-15 |
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