EP0857244B1 - Panels - Google Patents
Panels Download PDFInfo
- Publication number
- EP0857244B1 EP0857244B1 EP96935072A EP96935072A EP0857244B1 EP 0857244 B1 EP0857244 B1 EP 0857244B1 EP 96935072 A EP96935072 A EP 96935072A EP 96935072 A EP96935072 A EP 96935072A EP 0857244 B1 EP0857244 B1 EP 0857244B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- panel
- open cell
- cell structure
- 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.)
- Expired - Lifetime
Links
- 239000006260 foam Substances 0.000 claims abstract description 24
- 239000000463 material Substances 0.000 claims description 14
- 229920005989 resin Polymers 0.000 claims description 8
- 239000011347 resin Substances 0.000 claims description 8
- 229910000831 Steel Inorganic materials 0.000 claims description 5
- 239000002184 metal Substances 0.000 claims description 5
- 229910052751 metal Inorganic materials 0.000 claims description 5
- 239000004814 polyurethane Substances 0.000 claims description 5
- 229920002635 polyurethane Polymers 0.000 claims description 5
- 239000010959 steel Substances 0.000 claims description 5
- 229920001568 phenolic resin Polymers 0.000 claims description 4
- 239000005056 polyisocyanate Substances 0.000 claims description 4
- 229920001228 polyisocyanate Polymers 0.000 claims description 4
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 3
- 239000004743 Polypropylene Substances 0.000 claims description 3
- 239000004411 aluminium Substances 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 3
- 230000015572 biosynthetic process Effects 0.000 claims description 3
- 229910052799 carbon Inorganic materials 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
- 239000007769 metal material Substances 0.000 claims description 3
- 238000000034 method Methods 0.000 claims description 3
- 239000002245 particle 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
- 239000005011 phenolic resin Substances 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
- 239000004433 Thermoplastic polyurethane Substances 0.000 claims description 2
- 239000011111 cardboard Substances 0.000 claims description 2
- 239000001913 cellulose Substances 0.000 claims description 2
- 229920002678 cellulose Polymers 0.000 claims description 2
- 239000011093 chipboard Substances 0.000 claims description 2
- 239000002131 composite material Substances 0.000 claims description 2
- 239000010440 gypsum Substances 0.000 claims description 2
- 229910052602 gypsum Inorganic materials 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 claims description 2
- 239000011087 paperboard Substances 0.000 claims description 2
- 239000011120 plywood Substances 0.000 claims description 2
- 239000010454 slate Substances 0.000 claims description 2
- 229920002803 thermoplastic polyurethane Polymers 0.000 claims description 2
- 239000002023 wood Substances 0.000 claims 2
- 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
- 239000011496 polyurethane foam Substances 0.000 description 3
- 239000000779 smoke Substances 0.000 description 3
- 239000004568 cement Substances 0.000 description 2
- 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
- 239000003365 glass fiber Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
- 229920006122 polyamide resin Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 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
Images
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.
- a known building panel is disclosed in US-A-2744042.
- the disclosed panel is a laminate in which a foamed resin is disposed within the interstices of a honeycomb structure in order to secure minimum density and still return relatively good strength, and impact resistance.
- An object of this invention is to provide panels which do not suffer from, or at least alleviate, the disadvantages referred to above.
- a panel comprising a pair of facing sheets and a core which comprises an open cell structure having walls extending between the facing sheets and a foam filling, the panel being characterised in that at least one facing sheet is profiled in the form of longitudinal channels which protrude from the outer face of the said at least one facing panel and are filled with the foam filling with the open cell structure not extending into the channels.
- the facing sheets may be of metal, especially of steel, more especially of galvanised steel.
- the outer faces of the or each facing sheet are covered or coated with a corrosion protection layer.
- the channels are trapezoidal in section having a narrower base than open side.
- the profile channels 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 polyamide 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 polyamide 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.
- the invention provides a method of making a panel comprising a pair of facing sheets profiled to include longitudinal channels which protrude from an outer face of the respective facing sheet and a core, wherein the core comprises an open cell structure having walls extending between the facing sheets and a foam filling, the method comprising the steps of laying out one profiled facing sheet with the open cell structure thereon, pouring the foam filling in uncured or partially uncured state into the open cell structure to fill the longitudinal channels, laying the other facing sheet on top of the open cell structure and curing the foam filling to form a cohesive structure, the open cell structure not extending into the channels.
- Advantage of panels according to the invention may also include improved strength against impact damage as well as dimensional stability.
- 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.
- 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 with channels 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.
- the panel illustrated in Figure 1 of the accompanying drawings may be made in the following way.
- 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.
- honeycomb structure used in the illustrated embodiment 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 characteristics of the panels and the overall flatness of the panels can be improved relative to prior art panels.
- 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 escape.
- Panels having an outer profiled facing sheet also provide 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 (27)
- A panel comprising a pair of facing sheets (12, 14) and a core (16) which comprises an open cell structure (22) having walls extending between the facing sheets and a foam filling (26), the panel being characterised in that at least one facing sheet is profiled in the form of longitudinal channels (18, 20) which protrude from the outer face of the said at least one facing panel and are filled with the foam filling with the open cell structure not extending into the channels.
- A panel as claimed in claim 1, wherein the open cell structure is a honeycomb structure (22).
- A panel as claimed in claim 2, wherein the honeycomb structure comprises lengths of material bonded together at intervals.
- A panel as claimed in claim 2, wherein the honeycomb structure comprises lengths of material interwoven into a lattice.
- A panel as claimed in any one of claims 1 to 4, wherein the open cell structure is of metal.
- A panel as claimed in claim 5, wherein the open cell structure is of aluminium.
- A panel as claimed in any one of claims 1 to 4, wherein the open cell structure is non-metallic.
- A panel as claimed in claim 7, wherein the open cell structure is of paper or cardboard impregnated with a stiffening material.
- A panel as claimed in claim 8, wherein the stiffening material is a resin.
- A panel as claimed in claim 9, wherein the resin is a phenolic resin.
- A panel as claimed in claim 7, wherein the open cell structure is of a material selected from thermoplastic polyurethane sheets, fibreglass, carbon fibre in a resin, polypropylene sheets and polyester sheets.
- A panel as claimed in any one of claims 1 to 11, wherein the foam filling is a synthetic foam.
- A panel as claimed in claim 12, wherein the foam filling is selected from polyurethane, polyisocyanate and phenolic foams.
- A panel as claimed in any one of claims 1 to 13, wherein the facing sheets are of metal.
- A panel as claimed in claim 14, wherein the facing sheets are of steel.
- A panel as claimed in any one of claims 1 to 15, wherein the longitudinal channels are trapezoidal in section having a narrower base than open side.
- A panel as claimed in any one of claims 14 to 16, wherein outer faces of one or both of the facing sheets is or are covered with a corrosion protection layer.
- A panel as claimed in any one of claims 1 to 13, wherein the facing sheets are of non-metallic material.
- A panel as claimed in claim 18, wherein the facing sheets are of rigid board.
- A panel as claimed in claim 19, wherein the rigid board is selected from particle boards, cellulose reinforced gypsum boards, crushed slate boards and resin boards.
- A panel as claimed in claim 18, wherein the facing sheets are of wood or a wood composite.
- A panel as claimed in claim 21, wherein the facing sheets are of plywood or chipboard.
- A panel as claimed in any one of claims 1 to 22, wherein facing sheets have fire resistant materials added thereto or are coated therewith.
- A panel as claimed in any one of claims 1 to 23, wherein opposed panel ends are shaped or provided with complementary formations for engagement with ends of adjacent panels.
- A panel as claimed in claim 24, wherein said complementary formations comprise a tongue on one end and a corresponding groove on the other end of the panel.
- A panel as claimed in claim 24, wherein opposite ends of the panel are rebated oppositely whereby a rebate of one panel is over-lappable with a rebate of an adjacent panel.
- A method of making a panel comprising a pair of facing sheets profiled to include longitudinal channels which protrude from the outer face of the respective facing sheet, and a core which comprises an open cell structure having walls extending between the facing sheets and a foam filling, the method being characterised by the steps of laying out one profiled facing sheet with the open cell structure thereon, pouring the foam filling in uncured or partially uncured state into the open cell structure to fill the longitudinal channels, laying the other facing sheet on top of the open cell structure and curing the foam filling to form a cohesive structure, the open cell structure not extending into the channels.
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 EP0857244A1 (en) | 1998-08-12 |
EP0857244B1 true 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 |
---|---|---|---|---|
WO2013055968A1 (en) * | 2011-10-12 | 2013-04-18 | Hunter Douglas Industries Switzerland Gmbh | Resin panels with embedded structured-cores and methods of making the same |
USD810961S1 (en) | 2009-05-13 | 2018-02-20 | 3Form, Llc | Structured-core laminate panel |
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
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
USD810961S1 (en) | 2009-05-13 | 2018-02-20 | 3Form, Llc | Structured-core laminate panel |
WO2013055968A1 (en) * | 2011-10-12 | 2013-04-18 | Hunter Douglas Industries Switzerland Gmbh | Resin panels with embedded structured-cores and methods of making the same |
Also Published As
Publication number | Publication date |
---|---|
EP0857244A1 (en) | 1998-08-12 |
WO1997015736A1 (en) | 1997-05-01 |
GB9808413D0 (en) | 1998-06-17 |
ES2152046T3 (en) | 2001-01-16 |
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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