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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material

Definitions

• the present invention relates to liner panels and in particular panels of the type used for lining internal walls or ceilings in dwellings, and in addition panels used for suspended ceilings.
• Plasterboards are relatively inexpensive, easily repaired and worked, papered, plastered and painted. Plasterboards however do have the inherent disadvantage of being easily damaged by moisture, and of being relatively heavy and are not suitable for suspended ceiling applications.
• Materials used for forming panels for suspended ceilings where weight is a consideration include gypsum, cork, fibreboards and the like. Whilst these materials are satisfactory they tend to break easily and often become unsightly even after a short period of use.
• United States Patent No. 4121958 discloses wall board structures based on a rigid closed cell polyurethane core.
• the patent also describes in some detail the problems associated with laminating with this material.
• EPS expanded polystyrene foam
• EPS materials have the advantage of being lightweight, have relatively good insulation qualities, are water resistant, and are relatively tough.
• the low thermal conductivity of EPS is made up from the conductivity of air within the cellular structure, the conduction of the solid polystyrene, and radiation across the fine cellular structure of each bead that forms the sheet.
• EPS polystyrene itself
• this contribution is in the order of 10% of the total only.
• Still air is an excellent insulating material. Because of this, the permanently entrapped air within the cells of EPS ensures its very low thermal conductivity.
• a liner panel comprising a laminate of flexible sheet including a paper and a semirigid foam material characterised in that the flexible material is interposed between two layers of the rigid material.
• the rigid material can be EPS.
• the wallboard can comprise a first layer of kraft paper, a second layer of polystyrene foam, a third layer of paper and a fourth layer of polystyrene foam.
• the panel may include a fifth layer of paper laminated to said fourth layer of polystyrene foam.
• the panel can be approximately 20mm thick. Sheets of the laminate can be attached using a fire retardant bonding agent or adhesive.
• a suitable fire retardant adhesive can be obtained from C.W. Hartley Pty Limited, 116 Kitchener Road, Ascot, Queensland, 4007.
• the sheets of polystyrene can be of substantially equal thickness.
• the sheets of the paper can be of equal or variable thicknesses.
• the laminate can be formed in a single stage process.
• the laminate can be formed in a two-stage process.
• the laminate can be crushed to improve rigidity, to reduce thickness and to improve impact resistance.
• the preferred flexible sheets for use in the present invention include paper or cardboard with paper being especially preferred.
• the paper may be formed from (i) sulphite, (ii) sulphate or (iii) "soda” processes as is known in the art and may be bleached paper or unbleached paper. It is especially preferred to utilise kraft paper which is derived from the sulphate process referred to above. Preferably the kraft paper which is utilised has a thickness of 33-215 gsm (gram per square metre) although this is not essential.
• Outer sheets for use in the laminate of the invention may be of any suitable type and comprise plastics sheets, sheets formed from metal foil such as aluminium foil, or sheets formed from textile fabric.
• Figure 2 is a plan view of a form of panel according to another aspect of the present invention and, Figure 2a is an end view of the sheet material of figure 2, and Figure 3 is a cross-sectional drawing of a panel according to a further aspect of the present invention, and
• FIGS. 4 and 4a are schematic drawings in side view and plan of a laminating process according to another aspect of the present invention.
• a panel according to the present invention can be a laminate of sheet materials comprising;
• the core layer A may be a sheet of expanded polystyrene form (EPS).
• EPS expanded polystyrene form
• External layer B may be fibreboard such as kraft paper.
• An external layer C & D may be a pre-made laminate of kraft paper and another material such as aluminium foil, plastics sheeting or the like.
• the core layer A may be lined on one side with a material B such as kraft paper and on another side with a material such as plastics or foil film combined with an innermost kraft paper.
• FIGS. 2 and 2a of the drawings illustrate a sheet material wherein opposed edges 1 have been mechanically crushed by rollers or the like to produce an edge of reduced thickness.
• the edges can be used in butt joints to facilitate the job of plastering joints, and to avoid bulging and excessive finishing work.
• the panel comprises a laminate of core layers A1 of a semi-rigid material such as EPS an intermediate layer of kraft paper E with at least one of the external surfaces lined with kraft paper F or a pre-made laminate of an innermost kraft paper and another material such as aluminium foil, plastics sheeting or the like.
• a semi-rigid material such as EPS an intermediate layer of kraft paper E with at least one of the external surfaces lined with kraft paper F or a pre-made laminate of an innermost kraft paper and another material such as aluminium foil, plastics sheeting or the like.
• the illustration to the right of figure 3 shows the sheet material which has been mechanically crushed to reduce the depth of the sheet from a post laminated depth S of approximately 20mm to a depth S1 of approximately 12 mm.
• the reduction in thickness is permanent and greatly reduces impact resistance.
• the sheet material can be crushed to suit various depth requirements.
• the laminating process of the present invention involves loading sheets 2 onto a feed-on chute 3 the sheets 2 are then moved one at a time onto a moving conveyor 4. As each sheet 2 progresses to the rollers 5 in a laminating area, the next sheet may be raised and pushed onto the conveyor 4. A layer of kraft paper from a roll 6 passes through an adhesive bath 7 and is rolled onto the core sheet.
• the excess paper on the edges may be rebate rolled and rollformed underneath the core.
• the laminate passes through several pressure rollers 4a to bond the surfaces together.
• the sheets are cut to the desired length by cutting apparatus at 9 and proceed to the take off chute in region 10, which works the opposite direction to the feed on chute 3.
• Both chutes 3 and 10 both feed sheets across the path of the conveyor 4. This allows one chute to empty or fill while the second is filled or emptied.
• the adhesive baths and the kraft liner board reels may be on rails to enable cleaning of the adhesive baths at the end of runs to refill the linerboard reels by forklift and to thread the new linerboard through the adhesive baths without crawling under and over the laminating machine.
• a boardwalk may be provided to enable the reel of linerboard to fit under the laminating bench.
• the process described can be used to produce the liner panels of figures 1 to 3.
• two panels having a core layer of EPS and outer layers of kraft paper can be separately formed and then joined together.
• the kraft paper side destined to be innermost can be chosen from a lighter grade of paper because two layers of paper are back-to-back in the figure 3 structure.
• the liners are readily suited to common forms of attachment to frames and walls such as fasteners such as nails and screws, glues and the like,
• the EPS core materials are non-toxic
• the use of fire retardant adhesives provides enhanced fire resistance
• the liners will not readily crack or splinter
• the liners provide excellent insulation which can be enhanced by the use of reflective foils and the like, and (i) the liners can be readily coated for enhanced durability and decorative affect.

Landscapes

• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Laminated Bodies (AREA)
• Panels For Use In Building Construction (AREA)

Applications Claiming Priority (3)

Publications (2)

Family

ID=3833189

Family Applications (1)

Country Status (6)

Families Citing this family (6)

Citations (9)

Family Cites Families (21)

• 2001
  • 2001-12-18 AU AUPR9574A patent/AUPR957401A0/en not_active Abandoned
• 2002
  • 2002-12-17 CN CNB028272366A patent/CN100350115C/zh not_active Expired - Fee Related
  • 2002-12-17 WO PCT/AU2002/001709 patent/WO2003052214A1/en not_active Application Discontinuation
  • 2002-12-17 US US10/499,928 patent/US20050000179A1/en not_active Abandoned
  • 2002-12-17 EP EP02782529A patent/EP1497505A4/de not_active Withdrawn
• 2005
  • 2005-11-01 HK HK05109716A patent/HK1077859A1/xx not_active IP Right Cessation

Patent Citations (9)

Non-Patent Citations (1)

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