EP1522648B1 - Flat wall panel at least substantially made of cellulose material - Google Patents

Flat wall panel at least substantially made of cellulose material Download PDF

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Publication number
EP1522648B1
EP1522648B1 EP04104942A EP04104942A EP1522648B1 EP 1522648 B1 EP1522648 B1 EP 1522648B1 EP 04104942 A EP04104942 A EP 04104942A EP 04104942 A EP04104942 A EP 04104942A EP 1522648 B1 EP1522648 B1 EP 1522648B1
Authority
EP
European Patent Office
Prior art keywords
wall panel
layer
paper
cardboard
layers
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.)
Not-in-force
Application number
EP04104942A
Other languages
German (de)
French (fr)
Other versions
EP1522648A1 (en
Inventor
Wilhelmus Jan Reinier Karel Snel
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.)
Unda Maris BV
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Unda Maris BV
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Filing date
Publication date
Application filed by Unda Maris BV filed Critical Unda Maris BV
Publication of EP1522648A1 publication Critical patent/EP1522648A1/en
Application granted granted Critical
Publication of EP1522648B1 publication Critical patent/EP1522648B1/en
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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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
    • E04C2/30—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
    • E04C2/3405—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 profiled spacer sheets
    • 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
    • E04C2/3405—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 profiled spacer sheets
    • E04C2002/3444—Corrugated sheets
    • E04C2002/345—Corrugated sheets with triangular corrugations

Definitions

  • the invention relates to a flat wall panel at least substantially made of cellulose material, wherein the wall panel is at least substantially made of layers of paper/cardboard, each layer at least substantially being made up of a corrugated sublayer and a flat sublayer provided on one side thereof, which layers of paper/cardboard are interconnected via an adhesive, wherein the wall panel is impregnated, and wherein at least one strengthening layer having a greater elasticity modulus than the layers of paper/cardboard is provided, which strengthening layer is connected to a layer of paper/cardboard on one side of the wall panel via an adhesive.
  • the invention also relates to a method for manufacturing said wall panel.
  • Such a wall panel is known from British patent publication no. 1,542,730 (Tri-Wall Containers Ltd).
  • a flame resistant, fire retardant material is mentioned, particularly containing a borax or an ammonium based compound, said material being applied through a dipping process.
  • a disadvantage of this known wall panel is that in practice it suffers from a lack of constructional stiffness, which severely limits its practical use.
  • the object of the invention is to improve the wall panel that is known from the aforesaid British patent publication, in the sense that a wall panel having an optimum constructional stiffness is provided for use as a construction element of a building, as a wall panel in, for example, a separation wall, etc.
  • the term wall panel is understood to include an element for use in a wall, a floor, a ceiling, a roof, etc.
  • a wall panel of the kind referred to in the introduction is characterized in that the wall panel is impregnated with a resinous material, and that the wall panel is at least substantially made of an even number of layers of paper/cardboard, wherein the wall panel is mirror symmetrical with respect to a central longitudinal plane of the wall panel, said at least one strengthening layer having an elasticity modulus greater than or equal to 50 GPA.
  • a plate-shaped material which is hardly deformable, if at all, wherein "warping" is prevented at all times.
  • the constructional stiffness is increased even further by using a strengthening layer having an elasticity modulus greater than or equal to 100 GPA, in particular greater than or equal to 150 GPA, more in particular greater than or equal to 200 GPA, more in particular greater than or equal to 300 GPA, more in particular greater than or equal to 400 GPA.
  • the aforesaid resinous material with which the wall panel according to the invention is impregnated is preferably an epoxy resin, a polyurethane resin, a polyester resin or a phenol resin. Fire-resistant and/or fire-retarding agents may be added thereto.
  • the resinous material with which the wall panel according to the invention is impregnated also functions as an adhesive for adhering two layers of paper/cardboard together, so that a separate adhesive, such as a glue, is not required.
  • sets consisting of a corrugated sublayer and a flat sublayer provided on one side thereof, which sublayers are already impregnated with the resinous material, can be placed on top of each other so as to be adhered together (after the resinous material has dried).
  • the wall panel comprises two strengthening layers, which are connected to a layer of paper/cardboard on either side of the wall panel via an adhesive.
  • impregnating the wall panel with, for example, a resinous material not only has the advantage of providing a greater constructional stiffness, but also of providing protection against external influences, such as moisture.
  • Said impregnation preferably takes place by means of vapour deposition, spraying or otherwise, said vapour deposition or spraying taking place in a direction parallel to the direction of the "cell structure" of the corrugated paper/cardboard that is used.
  • Said impregnation may also be effected with mechanical means, wherein toothed and/or flat rollers are used for pressing the impregnating medium into the paper/cardboard.
  • the strengthening layer comprise a fibre material.
  • the fibre material consists of glass fibres, carbon fibres, mineral fibres and/or synthetic fibres.
  • Said synthetic fibres may e.g. be fibres of the type known under the brand names "Kevlar” or "Twaron”.
  • the strengthening layer comprises a layer of a plastic material.
  • the plastic of said layer of plastic material is preferably selected from the group consisting of PVC-U, PP, PE, ABS, PVC-C and PVDF. It is noted that the above abbreviations relate to the following (plastic) materials.
  • the strengthening layer comprises a layer of rubber.
  • the rubber of said layer of rubber is preferably selected from the group consisting of EPDM or NBR.
  • the strengthening layer is made of a metal, in particular stainless steel, or wood.
  • the invention also relates to a method for manufacturing a wall panel according to the invention wherein the wall panel is at least substantially made of an even number of layers of paper/cardboard, each layer at least substantially being made up of a corrugated sublayer and a flat sublayer provided on one side thereof, which layers of paper/cardboard are interconnected via an adhesive applied to the corrugations of the corrugated sublayers, wherein the wall panel is impregnated, with a resinous material, wherein at least one strengthening layer having a greater elasticity modulus than the layers of paper/cardboard is provided, which strengthening layer is connected to a layer of paper/cardboard on one side of the wall panel via an adhesive, and wherein the wall panel is mirror symmetrical with respect to a central longitudinal plane of the wall panel, said at least one strengthening layer having an elasticity modulus greater than or equal to 50 GPA.
  • paper is usually used for lighter types of paper; in the case of a heavier quality, the term cardboard is frequently used.
  • the terms paper, cardboard and weight are not intended to be limitative as regards the type of material to be used.
  • Fig. 1 is a schematic, perspective view of the present wall panel
  • Fig. 2 is a detail view of Fig. 1
  • Fig. 3 is an exploded view of the wall panel of Fig. 1.
  • the figure shows a flat wall panel 1 according to the invention in the form of a sandwich", in the sense that a core 2 built up of several layers of corrugated cardboard is connected on either side to a less elastic strengthening layer 3 of a thin material having an elasticity modulus of about 400 Gpa.
  • corrugated cardboard four layers of corrugated cardboard are provided, which are each built up of corrugated sublayer 4 and a flat sublayer 5 glued to one side thereof, using a glue applied to the corrugations 6 of the corrugated sublayer 4.
  • the core 2 is impregnated with a resinous material.
  • the strengthening layers 3 are glued to both sides of the core 2.
  • the wall panel 1 is mirror symmetrical with respect to a central longitudinal plane 7 of the wall panel 1.
  • the wall panel may exhibit a (slight) curvature, whilst the wall panel may also comprise a curved longitudinal edge.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)
  • Diaphragms For Electromechanical Transducers (AREA)
  • Polysaccharides And Polysaccharide Derivatives (AREA)
  • Panels For Use In Building Construction (AREA)

Abstract

The panel (1) is made from layers of paper or card(board), each of which comprises a corrugated layer with a flat face layer on one side. The layers are bonded together via adhesive applied to the tips of the pleats (6) in the corrugated layer. The panel is impregnated, preferably with a resin, and contains at least one reinforcing layer (3) which has a greater elasticity modulus than the paper or card(board) layers and is bonded on one side to a paper or card(board) layer using adhesive.

Description

  • The invention relates to a flat wall panel at least substantially made of cellulose material, wherein the wall panel is at least substantially made of layers of paper/cardboard, each layer at least substantially being made up of a corrugated sublayer and a flat sublayer provided on one side thereof, which layers of paper/cardboard are interconnected via an adhesive, wherein the wall panel is impregnated, and wherein at least one strengthening layer having a greater elasticity modulus than the layers of paper/cardboard is provided, which strengthening layer is connected to a layer of paper/cardboard on one side of the wall panel via an adhesive. The invention also relates to a method for manufacturing said wall panel.
  • Such a wall panel is known from British patent publication no. 1,542,730 (Tri-Wall Containers Ltd). In this prior art document a flame resistant, fire retardant material is mentioned, particularly containing a borax or an ammonium based compound, said material being applied through a dipping process. A disadvantage of this known wall panel is that in practice it suffers from a lack of constructional stiffness, which severely limits its practical use.
    The object of the invention is to improve the wall panel that is known from the aforesaid British patent publication, in the sense that a wall panel having an optimum constructional stiffness is provided for use as a construction element of a building, as a wall panel in, for example, a separation wall, etc. It is noted that the term wall panel is understood to include an element for use in a wall, a floor, a ceiling, a roof, etc.
  • According to the invention, a wall panel of the kind referred to in the introduction is characterized in that the wall panel is impregnated with a resinous material, and that the wall panel is at least substantially made of an even number of layers of paper/cardboard, wherein the wall panel is mirror symmetrical with respect to a central longitudinal plane of the wall panel, said at least one strengthening layer having an elasticity modulus greater than or equal to 50 GPA.
  • In other words, a plate-shaped material is provided which is hardly deformable, if at all, wherein "warping" is prevented at all times. Experiments have shown that the present construction leads to an unexpectedly great constructional stiffness of the wall panel, so that it is possible to subject the wall panel to large forces without the dimensional stability being affected. The constructional stiffness is increased even further by using a strengthening layer having an elasticity modulus greater than or equal to 100 GPA, in particular greater than or equal to 150 GPA, more in particular greater than or equal to 200 GPA, more in particular greater than or equal to 300 GPA, more in particular greater than or equal to 400 GPA.
  • The aforesaid resinous material with which the wall panel according to the invention is impregnated, is preferably an epoxy resin, a polyurethane resin, a polyester resin or a phenol resin. Fire-resistant and/or fire-retarding agents may be added thereto. Preferably, the resinous material with which the wall panel according to the invention is impregnated also functions as an adhesive for adhering two layers of paper/cardboard together, so that a separate adhesive, such as a glue, is not required. To that end, sets consisting of a corrugated sublayer and a flat sublayer provided on one side thereof, which sublayers are already impregnated with the resinous material, can be placed on top of each other so as to be adhered together (after the resinous material has dried).
  • In a preferred embodiment of a wall panel according to the invention, the wall panel comprises two strengthening layers, which are connected to a layer of paper/cardboard on either side of the wall panel via an adhesive. Thus a sandwich construction is obtained, in which the whole of various adhered-together layers of paper/cardboard is connected to a less elastic strengthening layer on both flat outer sides. The result is an even greater constructional stiffness having a corresponding dimensional stability.
  • It is noted that impregnating the wall panel with, for example, a resinous material not only has the advantage of providing a greater constructional stiffness, but also of providing protection against external influences, such as moisture. As a result of said additional stiffness, fewer layers of corrugated paper/cardboard are in principle needed in order to give the flat panel the required stiffness. Said impregnation preferably takes place by means of vapour deposition, spraying or otherwise, said vapour deposition or spraying taking place in a direction parallel to the direction of the "cell structure" of the corrugated paper/cardboard that is used. Said impregnation may also be effected with mechanical means, wherein toothed and/or flat rollers are used for pressing the impregnating medium into the paper/cardboard.
  • In another preferred embodiment of a wall panel according to the invention, the strengthening layer comprise a fibre material. In particular, the fibre material consists of glass fibres, carbon fibres, mineral fibres and/or synthetic fibres. Said synthetic fibres may e.g. be fibres of the type known under the brand names "Kevlar" or "Twaron".
  • In another preferred embodiment of a plate-shaped material according to the invention, the strengthening layer comprises a layer of a plastic material. The plastic of said layer of plastic material is preferably selected from the group consisting of PVC-U, PP, PE, ABS, PVC-C and PVDF. It is noted that the above abbreviations relate to the following (plastic) materials.
    • PVC-U
    Polyvinyl chloride (without plasticizer)
    PP
    Polypropylene
    PE
    Polyethylene
    ABS
    Acrylonitrile-Butadiene-Styrene
    PVC-C
    Polyvinyl chloride (post-chlorinated)
    PVDF
    Polyvinylydene fluoride
  • In another preferred embodiment of wall panel according to the invention, the strengthening layer comprises a layer of rubber. The rubber of said layer of rubber is preferably selected from the group consisting of EPDM or NBR. In another preferred variant, the strengthening layer is made of a metal, in particular stainless steel, or wood.
  • As already said before, the invention also relates to a method for manufacturing a wall panel according to the invention wherein the wall panel is at least substantially made of an even number of layers of paper/cardboard, each layer at least substantially being made up of a corrugated sublayer and a flat sublayer provided on one side thereof, which layers of paper/cardboard are interconnected via an adhesive applied to the corrugations of the corrugated sublayers, wherein the wall panel is impregnated, with a resinous material, wherein at least one strengthening layer having a greater elasticity modulus than the layers of paper/cardboard is provided, which strengthening layer is connected to a layer of paper/cardboard on one side of the wall panel via an adhesive, and wherein the wall panel is mirror symmetrical with respect to a central longitudinal plane of the wall panel, said at least one strengthening layer having an elasticity modulus greater than or equal to 50 GPA.
  • It is noted that the term paper is usually used for lighter types of paper; in the case of a heavier quality, the term cardboard is frequently used. Within the framework of the invention, the terms paper, cardboard and weight are not intended to be limitative as regards the type of material to be used.
  • The invention will now be explained in more detail with reference to figures illustrated in a drawing of a preferred variant of the invention, in which Fig. 1 is a schematic, perspective view of the present wall panel, Fig. 2 is a detail view of Fig. 1, and Fig. 3 is an exploded view of the wall panel of Fig. 1.
  • The figure shows a flat wall panel 1 according to the invention in the form of a sandwich", in the sense that a core 2 built up of several layers of corrugated cardboard is connected on either side to a less elastic strengthening layer 3 of a thin material having an elasticity modulus of about 400 Gpa.
  • In this case, four layers of corrugated cardboard are provided, which are each built up of corrugated sublayer 4 and a flat sublayer 5 glued to one side thereof, using a glue applied to the corrugations 6 of the corrugated sublayer 4. The core 2 is impregnated with a resinous material. As already said before, the strengthening layers 3 are glued to both sides of the core 2.
  • The wall panel 1 is mirror symmetrical with respect to a central longitudinal plane 7 of the wall panel 1.
  • It is noted that the invention is not limited to the embodiment as shown in the figures, but that it also extends to other variants that fall within the scope of the appended claims. Thus it will be apparent to those skilled in the art that the wall panel may exhibit a (slight) curvature, whilst the wall panel may also comprise a curved longitudinal edge.

Claims (9)

  1. A flat wall panel (1) at least substantially made of cellulose material, wherein the wall panel (1) is at least substantially made of layers of paper/cardboard, each layer (4) at least substantially being made up of a corrugated sublayer (5) and a flat sublayer provided on one side thereof, which layers of paper/cardboard are interconnected via an adhesive, wherein the wall panel (1) is impregnated, and wherein at least one strengthening layer (3) having a greater elasticity modulus than the layers of paper/cardboard is provided, which strengthening layer (3) is connected to a layer of paper/cardboard on one side of the wall panel (1) via an adhesive, characterized in that the wall panel (1) is impregnated with a resinous material, and that the wall panel (1) is at least substantially made of an even number of layers of paper/cardboard, wherein the wall panel (1) is mirror symmetrical with respect to a central longitudinal plane (7) of the wall panel (1), said at least one strengthening layer (3) having an elasticity modulus greater than or equal to 50 GPA.
  2. A wall panel (1) according to claim 1, wherein two strengthening layers (3) are provided, which are connected to a layer of paper/cardboard on either side of the wall panel (1) via an adhesive.
  3. A wall panel (1) according to claim 1 or 2, wherein the strengthening layer(s) (3) comprise(s) a fibre material.
  4. A wall panel (1) according to claim 3, wherein the fibre material consists of glass fibres, carbon fibres, mineral fibres and/or synthetic fibres.
  5. A wall panel (1) according to any one of the preceding claims 1-4, wherein the strengthening layer(s) (3) comprise(s) a layer of plastic material.
  6. A wall panel (1) according to any one of the preceding claims 1-5, wherein the strengthening layer(s) (3) comprise(s) a layer of rubber.
  7. A wall panel (1) according to any one of the preceding claims 1-6, wherein the strengthening layer(s) (3) is (are) made of a metal.
  8. A wall panel (1) according to any one of the preceding claims 1-7, wherein the strengthening layer(s) (3) is (are) made of wood.
  9. A method for manufacturing a flat wall panel (1) according to any one of the preceding claims 1-8, characterized in that the wall panel (1) is at least substantially made of an even number of layers of paper/cardboard, each layer at least substantially being made up of a corrugated sublayer (4) and a flat sublayer (5) provided on one side thereof, which layers of paper/cardboard are interconnected via an adhesive applied to the corrugations (6) of the corrugated sublayers (4), wherein the wall panel (1) is impregnated, with a resinous material, wherein at least one strengthening layer (3) having a greater elasticity modulus than the layers of paper/cardboard is provided, which strengthening layer (3) is connected to a layer of paper/cardboard on one side of the wall panel (1) via an adhesive, and wherein the wall panel (1) is mirror symmetrical with respect to a central longitudinal plane (7) of the wall panel (1), said at least one strengthening layer (3) having an elasticity modulus greater than or equal to 50 GPA.
EP04104942A 2003-10-10 2004-10-08 Flat wall panel at least substantially made of cellulose material Not-in-force EP1522648B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NL1024505 2003-10-10
NL1024505A NL1024505C2 (en) 2003-10-10 2003-10-10 Flat wall panel made from cellulose material, comprises impregnated panel formed from corrugated paper or cardboard layers and reinforcing layer with greater elasticity modulus

Publications (2)

Publication Number Publication Date
EP1522648A1 EP1522648A1 (en) 2005-04-13
EP1522648B1 true EP1522648B1 (en) 2007-02-14

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP04104942A Not-in-force EP1522648B1 (en) 2003-10-10 2004-10-08 Flat wall panel at least substantially made of cellulose material

Country Status (6)

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US (1) US20050138879A1 (en)
EP (1) EP1522648B1 (en)
AT (1) ATE354005T1 (en)
CA (1) CA2484414A1 (en)
DE (1) DE602004004717T2 (en)
NL (1) NL1024505C2 (en)

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NL2000111C2 (en) * 2006-06-21 2007-12-27 Unda Maris Holding N V Building accessible to people.
US20080053022A1 (en) * 2006-07-13 2008-03-06 Marschke Carl R Hollow core floor and deck element
US8475894B2 (en) 2008-03-28 2013-07-02 Nobel Environmental Technologies Corp. Engineered molded fiberboard panels, methods of making the panels, and products fabricated from the panels
WO2012113423A1 (en) * 2011-02-25 2012-08-30 Peter Meyer Lightweight construction element which is capable of bearing or is bearing
ITMI20120771A1 (en) * 2012-05-08 2013-11-09 Politec Polimeri Tecnici Sa TRANSPARENT STRUCTURAL ELEMENT FOR ROOFING
US20150004371A1 (en) * 2013-06-28 2015-01-01 Noble Environmental Technologies Corporation Composite structural panels and components
KR102094969B1 (en) * 2013-08-13 2020-03-31 삼성디스플레이 주식회사 Backlight unit and display device including the same
US9676165B2 (en) * 2013-11-27 2017-06-13 Liberty Diversified International, Inc. Structural batten
DE102013021801B4 (en) * 2013-12-23 2019-10-31 Rainer Köppen Basin for a swimming pool or a pond
AU201612585S (en) * 2016-05-13 2016-06-03 Smart Walling Systems Pty Ltd Modular Wall Panel with Integral Form Work

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GB600607A (en) * 1944-03-29 1948-04-14 Parnall & Sons Ltd An improved method of manufacture of reinforced partitions or the like
GB1100951A (en) * 1963-05-02 1968-01-31 Goole Plastic Homes Ltd Improvements in laminar building components
US3542636A (en) * 1965-07-28 1970-11-24 Kurt Wandel Corrugated board
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GB1542730A (en) * 1977-12-02 1979-03-21 Tri Wall Containers Ltd Panel
US4351870A (en) * 1979-10-22 1982-09-28 English Jr Edgar Maximized strength-to-weight ratio panel material
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US5425207A (en) * 1994-02-22 1995-06-20 Shayman; Harry I. Method of constructing buildings and other structures using corrugated material
NL1015909C2 (en) * 2000-08-10 2002-02-12 Snel Golfkarton B V Wall element made at least substantially from cellulose material.
US20040123555A1 (en) * 2002-12-26 2004-07-01 Cole Jefferson Anthony Pre manufactured structural panel consisting of a flame retardant external crust and an aeroboard core fabricated from laminations of uncompressed cardboard, impregnated by resin solutions recovered from post consumer thermoplastics

Also Published As

Publication number Publication date
EP1522648A1 (en) 2005-04-13
CA2484414A1 (en) 2005-04-10
DE602004004717T2 (en) 2007-11-22
ATE354005T1 (en) 2007-03-15
US20050138879A1 (en) 2005-06-30
DE602004004717D1 (en) 2007-03-29
NL1024505C2 (en) 2004-10-04

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