EP0857244B1 - Panneaux - Google Patents

Panneaux Download PDF

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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
Application number
EP96935072A
Other languages
German (de)
English (en)
Other versions
EP0857244A1 (fr
Inventor
Ian Philip Wood
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Corus UK Ltd
Original Assignee
HH Robertson UK Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from GBGB9521713.9A external-priority patent/GB9521713D0/en
Priority claimed from GBGB9525470.2A external-priority patent/GB9525470D0/en
Application filed by HH Robertson UK Ltd filed Critical HH Robertson UK Ltd
Priority to EP99122668A priority Critical patent/EP0980937A3/fr
Publication of EP0857244A1 publication Critical patent/EP0857244A1/fr
Application granted granted Critical
Publication of EP0857244B1 publication Critical patent/EP0857244B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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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)
  • Finishing Walls (AREA)
  • Panels For Use In Building Construction (AREA)

Claims (27)

  1. Un panneau comprenant une paire de plaques opposées (12,14) et une âme (16) qui comprend une structure (22) à alvéoles ouvertes ayant des parois s'étendant entre les plaques opposées et une charge de mousse (26), le panneau étant caractérisé en ce qu'au moins une plaque opposée est profilée sous la forme de canaux longitudinaux (18,20) qui font saillie à partir de la surface externe de cet au moins un plaque opposée et sont remplis de charge de mousse, la structure à alvéoles ouvertes ne s'étendant pas dans les canaux.
  2. Un panneau selon la revendication 1, dans lequel la structure à alvéoles ouvertes est une structure en nids d'abeilles (22).
  3. Un panneau selon la revendication 2, dans lequel la structure en nids d'abeilles comprend des longueurs de matière liées ensemble par intervalles.
  4. Un panneau selon la revendication 2, dans lequel la structure en nids d'abeilles comprend des longueurs de matière entrelacées en un réseau.
  5. Un panneau selon l'une quelconque des revendications 1 à 4 dans lequel la structure à alvéoles ouvertes est en métal.
  6. Un panneau selon la revendication 5 dans lequel la structure à alvéoles ouvertes est en aluminium.
  7. Un panneau selon l'une quelconque des revendications 1 à 4 dans lequel la structure à alvéoles ouvertes est non-métallique.
  8. Un panneau selon la revendication 7 dans lequel la structure à alvéoles ouvertes est en papier ou en carton imprégné d'une matière de raidissement.
  9. Un panneau selon la revendication 8 dans lequel la matière de raidissement est une résine.
  10. Un panneau selon la revendication 9 dans lequel la résine est une résine phénolique.
  11. Un panneau selon la revendication 7 dans lequel la structure à alvéoles ouvertes est en une matière choisie parmi les feuilles de polyuréthane thermoplastique, les fibres de verre, les fibres de carbone dans une résine, des feuilles de polypropylènes et des feuilles de polyesters.
  12. Un panneau selon l'une quelconque des revendications 1 à 11 dans lequel la charge de mousse est une mousse synthétique.
  13. Un panneau selon la revendication 12 dans lequel la charge de mousse est choisie parmi les mousses de polyuréthane, de polyisocyanate et les mousses phénoliques.
  14. Un panneau selon l'une quelconque des revendications 1 à 13 dans lequel les plaques opposées sont en métal.
  15. Un panneau selon la revendication 14 dans lequel les plaques opposées sont en acier.
  16. Un panneau selon l'une quelconque des revendications 1 à 15 dans lequel les canaux longitudinaux sont trapézoïdaux en coupe et ont une base plus étroite que le côté ouvert.
  17. Un panneau selon l'une quelconque des revendications 14 à 16 dans lequel les faces externes de l'une ou des deux plaques opposées est ou sont couvertes d'une couche protectrice contre la corrosion.
  18. Un panneau selon l'une quelconque des revendications 1 à 13 dans lequel les plaques opposées sont en matière non-métallique.
  19. Un panneau selon la revendication 18 dans lequel les plaques opposées sont en une plaque rigide.
  20. Un panneau selon la revendication 19 dans lequel la plaque rigide est choisie parmi la plaque à particules, la plaque ardoisée concassée et la plaque de résine.
  21. Un panneau selon la revendication 18 dans lequel les plaques opposées sont en bois ou en bois composite.
  22. Un panneau selon la revendication 21 dans lequel les plaques opposées sont en contreplaqué ou en panneau d'aggloméré.
  23. Un panneau selon l'une quelconque des revendications 1 à 22 dans lequel on a ajouté des matières ignifuges aux plaques opposées ou on les a enduites avec celles-ci.
  24. Un panneau selon l'une quelconque des revendications 1 à 23 dans lequel les extrémités opposées des panneaux sont formées ou pourvues de formations complémentaires pour venir en engagement avec les extrémités des panneaux adjacents.
  25. Un panneau selon la revendication 24 dans lequel les formations complémentaires comprennent une langue à une extrémité et une rainure correspondante à l'autre extrémité du panneau.
  26. Un panneau selon la revendication 24 dans lequel les extrémités opposées du panneau comprennent des feuillures opposées de sorte qu'une feuillure d'un panneau est recouverte par la feuillure d'un panneau adjacent.
  27. Une méthode de fabrication d'un panneau comprenant une paire de plaques opposées profilées pour comporter des canaux longitudinaux qui font saillie depuis la face externe du panneau opposé respectif, et une âme qui comprend une structure à alvéoles ouvertes comprenant des parois s'étendant entre les plaques opposées et une charge de mousse, la méthode étant caractérisée par les étapes de mettre en place une plaque opposée profilée comprenant la structure à alvéoles ouvertes, verser la charge de mousse à l'état non durci ou à l'état partiellement non durci dans la structure à alvéoles ouvertes pour remplir les canaux longitudinaux, disposer d'autres plaques opposées sur le sommet de la structure à alvéoles ouvertes et durcir la charge de mousse pour former une structure cohérente, la structure à alvéoles ouvertes ne s'étendant pas dans les canaux.
EP96935072A 1995-10-24 1996-10-24 Panneaux Expired - Lifetime EP0857244B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP99122668A EP0980937A3 (fr) 1995-10-24 1996-10-24 Panneaux

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
GBGB9525470.2A GB9525470D0 (en) 1995-12-13 1995-12-13 Panels
GB9525470 1995-12-13
PCT/GB1996/002598 WO1997015736A1 (fr) 1995-10-24 1996-10-24 Panneaux

Related Child Applications (1)

Application Number Title Priority Date Filing Date
EP99122668A Division EP0980937A3 (fr) 1995-10-24 1996-10-24 Panneaux

Publications (2)

Publication Number Publication Date
EP0857244A1 EP0857244A1 (fr) 1998-08-12
EP0857244B1 true EP0857244B1 (fr) 2000-08-23

Family

ID=26307991

Family Applications (2)

Application Number Title Priority Date Filing Date
EP96935072A Expired - Lifetime EP0857244B1 (fr) 1995-10-24 1996-10-24 Panneaux
EP99122668A Withdrawn EP0980937A3 (fr) 1995-10-24 1996-10-24 Panneaux

Family Applications After (1)

Application Number Title Priority Date Filing Date
EP99122668A Withdrawn EP0980937A3 (fr) 1995-10-24 1996-10-24 Panneaux

Country Status (7)

Country Link
EP (2) EP0857244B1 (fr)
AT (1) ATE195781T1 (fr)
AU (1) AU7316796A (fr)
DE (1) DE69609981T2 (fr)
ES (1) ES2152046T3 (fr)
GB (1) GB2321482B (fr)
WO (1) WO1997015736A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013055968A1 (fr) * 2011-10-12 2013-04-18 Hunter Douglas Industries Switzerland Gmbh Panneaux de résine avec âmes structurées intégrées et procédés de réalisation de ceux-ci
USD810961S1 (en) 2009-05-13 2018-02-20 3Form, Llc Structured-core laminate panel

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1120509A1 (fr) * 2000-01-26 2001-08-01 Tonelli S.A. Méthode pour fabriquer des éléments structuraux renforcés en matière cellulosique et élément structurel correspondant
EP1295713B8 (fr) * 2001-08-30 2006-01-11 Kingspan Research and Developments Limited Matériau isolant en nid d'abeille
DE20316549U1 (de) * 2003-10-27 2005-03-03 Viessmann Kältetechnik AG Bodenplatte für begeh- und befahrbare Raumzellen, insbesondere Tiefkühl-, Kühl- und Frischhaltezellen
ES2302394B2 (es) 2003-11-19 2009-07-28 British Robertson, S.L.U. Panel con remates machihembrados para fachadas o cubiertas.
WO2013181716A1 (fr) * 2012-06-07 2013-12-12 Idc Solutions Pty Ltd Panneau
EP3031994A1 (fr) * 2014-12-08 2016-06-15 Svoboda Piotr Slebioda Panneau structurel ignifuge avec un noyau pir
DE102015121101A1 (de) * 2015-12-03 2017-06-08 Technische Universität Darmstadt Gebäudehüllelement

Family Cites Families (3)

* Cited by examiner, † Cited by third party
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

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
USD810961S1 (en) 2009-05-13 2018-02-20 3Form, Llc Structured-core laminate panel
WO2013055968A1 (fr) * 2011-10-12 2013-04-18 Hunter Douglas Industries Switzerland Gmbh Panneaux de résine avec âmes structurées intégrées et procédés de réalisation de ceux-ci

Also Published As

Publication number Publication date
EP0980937A2 (fr) 2000-02-23
EP0980937A3 (fr) 2000-03-15
WO1997015736A1 (fr) 1997-05-01
GB2321482A (en) 1998-07-29
EP0857244A1 (fr) 1998-08-12
DE69609981T2 (de) 2001-03-01
ES2152046T3 (es) 2001-01-16
AU7316796A (en) 1997-05-15
DE69609981D1 (de) 2000-09-28
GB2321482B (en) 2000-03-29
GB9808413D0 (en) 1998-06-17
ATE195781T1 (de) 2000-09-15

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