EP2142722A1

EP2142722A1 - Wall element

Info

Publication number: EP2142722A1
Application number: EP08741684A
Authority: EP
Inventors: Wilhelmus Jan Reinier Karel Snel
Original assignee: UNDA MARIS HOLDING NV
Current assignee: UNDA MARIS HOLDING NV
Priority date: 2007-04-27
Filing date: 2008-04-28
Publication date: 2010-01-13
Also published as: NL2001525A1; WO2008133519A1; CN101688397A; NL2001525C2

Abstract

A wall element comprising two outer layers extending at least substantially parallel to each other, between which an intermediate layer is provided, which intermediate layer extends in zigzag fashion between the outer layers, said intermediate layer comprising first parts, which extend at least substantially parallel to the outer layers, and second parts, which extend between adjacent first parts, wherein first parts of the intermediate layer facing towards one outer layer are connected to said one outer layer, and wherein first parts of the intermediate layer facing towards the other outer layer are connected to said other outer layer, a special feature being that the intermediate layer is at least substantially made of a plate-shaped metal material, with a corrugated (in cross-section) profile formed in the plane of the plate-shaped material, the corrugations of which profile extend in a meander-like fashion in the plane of the plate-shaped material and over several first parts of the intermediate layer.

Description

WALL ELEMENT

The invention relates to a wall element comprising two outer layers extending at least substantially parallel to each other, between which an intermediate layer is provided, which intermediate layer extends in zigzag fashion between the outer layers, said intermediate layer comprising first parts, which extend at least substantially parallel to the outer layers, and second parts, which extend between adjacent first parts, wherein first parts of the intermediate layer facing towards one outer layer are connected to said one outer layer, and wherein first parts of the intermediate layer facing towards the other outer layer are connected to said other outer layer. The invention also relates to a method for manufacturing said wall element .

Such a wall element is described in German patent No. 23 49 436 (Baltzer) .

The object of the invention is to improve the wall element that is known from the aforesaid German patent publication, in the sense that a wall element exhibiting an optimum constructional stiffness is provided for use as (part of) a wall panel, for example a partition wall, etc., and which is at the same time light in weight. Incidentally, it is noted that the term "wall panel" is understood to include an element for a wall, a floor, a ceiling, a roof, etc.

In order to accomplish that object, a wall element of the kind referred to in the introduction is characterised in that the intermediate layer is at least substantially made of a plate-shaped metal material, with a corrugated (in cross- section) profile formed in the plane of the plate-shaped material, the corrugations of which profile extend in a meander-like fashion in the plane of the plate-shaped material and over several first parts of the intermediate layer. It is noted that within the context of the invention the term "meander-like" is understood to include any winding (from the left to the right) shape. Preferably, the corrugations extend in zigzag fashion in the plane of the plate-shaped material, so that corrugations are provided with alternately make a more or less acute angle to the left and to the right. In another preferred variant, the corrugations extend in serpentine fashion in the plane of the plate-shaped material. Research has shown that the present construction results in an unexpectedly great constructional stiffness of the wall element, so that the wall element can be exposed to large forces without losing any of its shape stability. At the same time, a surprisingly light construction is obtained, which makes the wall element easier to handle. The corrugations preferably extend in parallel fashion in the plane of the plate-shaped material rather than in a converging or diverging fashion. The profile is in particular provided over at least substantially the entire length of the plate-shaped material and extends over all the first parts of the intermediate layer.

Experiments have shown that the metal intermediate layer is capable of resisting temperatures as high as 1000 ^*C and higher. Moreover, said experiments have shown that expansion of the metal will hardly result in warping of the intermediate layer, if at all, since the profile is capable of compensating said expansion in various directions, viz. both in the longitudinal direction and in the transverse direction of the profile. The present wall element is quite suitable for use as (part of) a partition wall in a building, for example a hospital, since the metal intermediate layer is capable of stopping electromagnetic radiation that is used in the hospital.

In a preferred embodiment of a wall element according to the invention, the corrugations extend sinusoidally in the plane of the plate-shaped material. The spacing between two adjacent corrugation ridges of the sine shape preferably ranges between 0.25 and 2 times the amplitude of the sine shape. More in particular, the spacing between two adjacent corrugation ridges of the sine shape at least substantially equals the amplitude of the sine shape. Tests have shown that in this way a construction having an optimum constructional stiffness is obtained, which construction is at the same time light in weight.

In another preferred embodiment of a wall element according to the invention, the plate-shaped material is made of a metal selected from the group consisting of iron, steel, copper and aluminium, or of an alloy of one or more of said metals. The profile has preferably been rolled into the plate-shaped material, as will be explained in more detail yet hereinafter.

In another preferred embodiment of a wall element according to the invention, the outer layers are glued to the first parts of the intermediate layer. The adhesive that is used is preferably a swellable adhesive, in particular a foamable adhesive, more in particular a foamable adhesive with a base of polyurethane. In another preferred embodiment of a wall element according to the invention, the outer layers are at least substantially made of a material selected from the group consisting of fibre material, plastic, rubber, metal, paper/cardboard and wood. In another preferred variant, gypsum boards are used as the outer layers.

The fibre material in particular comprises glass fibres, carbon fibres, mineral fibres and/or synthetic fibres. Said synthetic fibres may for example be fibres of the type known by the brand names "Kevlar" or "Twaron" .

The plastic layer is preferably selected from the group consisting of PVC-U, PP, PE, ABS, PVC-C and PVDF. It is noted that the above material 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 Polyvinylidene fluoride

The rubber layer is in particular selected from the group consisting of EPDM or NBR. In another preferred variant, the outer layers are made of a metal, in particular stainless steel, or wood, such as two-ply or three-ply wood.

In another preferred embodiment of a wall element according to the invention, the outer layers are 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 affixed to one side thereof, wherein said paper/cardboard layers are connected together by means of an adhesive applied to the corrugations of the corrugated sublayers. It is noted that the term "paper" is generally used to indicate lighter sorts of paper, whilst the term "cardboard" is frequently used for heavier grades of paper. Within the framework of the invention, no restriction as regards the sort of material is intended when using the terms paper or cardboard and weight . The outer layers are preferably impregnated, in particular with a resinous material, such as polyurethane or polyester resin. It is noted that impregnation with, for example, a resinous material not only has the advantage of increasing the constructional rigidity, but also of providing protection against external influences, such as moisture. Because of the additional rigidity, fewer layers of corrugated paper/cardboard are in principle required for giving the flat wall panel the required stiffness. Said impregnation preferably takes place by vapour deposition, spraying or otherwise, with the direction of said vapour deposition or spraying extending parallel to the direction of the "cellular structure" of the corrugated paper/cardboard that is used. Impregnation can also take place by mechanical means, in which case toothed and/or flat rollers are used for pressing the impregnating agent into the paper/cardboard.

In another preferred embodiment of a wall element according to the invention, the intermediate layer is staggered relative to the outer layers, with the wall element being provided with a profile along a first part of the circumferential edge and with an at least outwardly extending lip along a second part of the circumferential edge, wherein a lip of one wall element is inserted in a corresponding profile of the other wall element in the interconnected position of adjacent wall elements. Such a staggered intermediate layer makes it possible to realise a simple and strong connection between various wall elements.

In an alternative preferred embodiment, the wall element is provided with a profile along a first part of the circumferential edge at both ends and with an at least outwardly extending lip along an adjacent part of the circumferential edge, wherein a lip of one wall element is inserted into a corresponding profile of the other wall element at both ends in the interconnected position of adjacent wall elements.

In another preferred embodiment, the compartments formed by the outer layers and the zigzag-shaped intermediate layer are at least partially filled with an insulation material.

Preferably, the intermediate layer is bent over in a direction transversely to the outer layers at at least one edge of the wall element parallel to the bent-over portions of the intermediate layer. Preferably, said edge is bent over once again in a direction parallel to the outer layers, oriented towards the centre in the plane of the wall panel. In this way a surface is formed transversely to the plane of the plate at an edge of the wall element, so that a closed edge is formed. This surface is advantageous in particular at the location of the lip and/or the profile. The additionally bent-over edge gives the surface additional rigidity, especially when said edge is also attached to an outer layer. As already said before, the invention also relates to a method for producing a wall element according to the invention, which method is characterised in that

a corrugated (seen in cross-section) profile is rolled into the plane of a plate-shaped metal material, with corrugations of the profile extending in a meander-like fashion in the plane of the plate- shaped material;

the plate-shaped material is subsequently bent to a zigzag shape;

outer layers are affixed to either side of the plate- shaped material; and

parts of the intermediate layer facing towards one outer layer and extending substantially parallel thereto are connected to said one outer layer, and parts of the intermediate layer facing towards the other outer layer and extending substantially parallel thereto are connected to said other outer layer .

A non-profiled plate-shaped metal material is to that end first fed to an inlet between two profiled rollers rotating in opposite directions, after which the profile is formed in the plate-shaped metal material by means of a rolling technique. Then the plate-shaped material thus profiled is bent to a zigzag shape, using bending tools. Finally, the outer layers are glued to both sides of the zigzag-shaped intermediate layer thus formed. Important is that the corrugations extend over several (preferably all) first parts of the intermediate layer.

The invention will now be explained with reference to embodiments of the invention as shown in a drawing, in the figures of which like parts are provided with the same numerals, and in which:

Figure 1 shows a wall element according to the invention;

Figure 2 shows a part of the wall element of figure 1 in the direction indicated at II;

- Figure 3 schematically shows the plate-shaped material for use in the intermediate layer;

Figure 4 shows wall panel according to the invention in perspective view;

Figures 5 and 6 show an alternative embodiment of a wall panel according to the invention;

Figures 7 and 8 show another alternative embodiment of wall panel according to the invention;

Figures 9 and 10 show another alternative embodiment of a wall panel according to the invention;

- Figures 11 and 12 show another alternative embodiment of a wall panel according to the invention; and Figures 13 and 14 show another alternative embodiment of a wall panel according to the invention.

In figure 1 a wall element 1 according to the invention is shown. The wall element 1 is substantially plate-shaped and is built up of two outer layers 2 and 3 extending parallel to each other. Arranged between the outer layers 2 and 3 is an intermediate layer 4, which extends in zigzag fashion between the outer layers 2 and 3.

Figure 2 shows a part of the wall element 1 in the direction II in figure 1. The intermediate layer 4 is a plate-shaped material, which has been bent over to form (inter-alia) first parts 5a and 5b and second parts 6. The first parts 5a, which extend parallel to the outer layers 2 and 3, are connected to the outer layer 2, and the first parts 5b, which likewise extend parallel to the outer layers 2 and 3, are connected to the outer layer 3. Between the first parts 5a and 5b, the second parts 6 extend at a specific angle to the outer layers 2 and 3, thus forming a zigzag structure.

To make it possible to attach wall elements 1 together, for example in order to create a wall, the intermediate layer 4 is slightly staggered relative to the outer layers 2 and 3, as indicated at x. The outer edges of the intermediate layer 4 have been bent over in a direction transversely to the outer layers 2 and 3 to form ends 9a and 9b. The edge has been bent over once again to form portions 11a and lib, which are connected to the outer layer 2, which imparts additional rigidity to the ends 9a and 9b. The end 9a forms a lip 12 along a circumferential edge of the wall element 1, and the end 9b forms a profile 13 in said circumferential edge. In connected condition, a lip 12 can be inserted into a profile 13 of an adjacent wall element. The end 9a of one wall element 1 will slide against the end 9b of an adjacent wall element 1 in that case.

In figure 3 the plate shaped material for use in the intermediate layer 4 is shown. A corrugated (in cross- section) profile comprising ridges 7 and troughs 8 has been formed in the plane of the plate-shaped material, with the corrugations 10 of the profile extending sinusoidally and parallel to each other in the plane of the plate-shaped material.

Figure 4 is a more detailed perspective view of the wall element 1. As the figure shows, the intermediate layer 4 has been bent over transversely to the corrugations 10 so as to form the zigzag structure, with a corrugation 10 extending over all the first parts 5a and 5b and the second parts 6. It has been found that an intermediate layer 4 bent over in this manner leads to an unexpectedly high constructional stiffness and shape stability of the wall element 1.

The intermediate layer 4 has been affixed to the outer layers 2 and 3 by applying an adhesive to the ridges 7 facing towards the outer layer 2 on the first parts 5a and the troughs 8 facing towards the outer layer 3 on the first parts 5b. Similarly, the parts 11a and lib are affixed to the outer layer 2 by means of an adhesive.

In the alternative embodiments shown in figures 5 and 6, figures 7 and 8 and also in figures 9 and 10, a lip 12a, 12b has been formed at both ends 9a, 9b. The ends of the intermediate layer 4 have been bent over in such a manner that, in addition to the lips 12a, 2b, a profile 13a, 13b has been formed in the circumferential edge at both ends 9a, 9b. In connected condition, a lip 12a, 12b can be inserted into a profile 13a, 13b of an adjacent wall element at both ends 9a, 9b. In the embodiments shown in figures 7 and 8 and figures 9 and 10, the ends 14a, 14b of the intermediate layer 4 have been bent over to an inclined orientation, in such a manner that when a lip 12a, 12b is inserted into a profile 13a, 13b, said lips 12a, 12b are guided to the correct position under elastic deformation of the bent-over ends 14a, 14b, so that the panels fit together without play. In the embodiments shown in figures 11 and 12 and figures 13 and 14, the ends 16a, 16b of the intermediate layer 4 have been bent over towards the inside.

As shown in figures 13 and 14, the compartments formed between the outer layers 2, 3 by the meandering intermediate layer 4 may at least partially be filled with an insulation material 15a, 15b, such as rock wool. The same may be the case with all the other embodiments.

Claims

1. A wall element comprising two outer layers extending at least substantially parallel to each other, between which an intermediate layer is provided, which intermediate layer extends in zigzag fashion between the outer layers, said intermediate layer comprising first parts, which extend at least substantially parallel to the outer layers, and second parts, which extend between adjacent first parts, wherein first parts of the intermediate layer facing towards one outer layer are connected to said one outer layer, and wherein first parts of the intermediate layer facing towards the other outer layer are connected to said other outer layer, characterised in that the intermediate layer is at least substantially made of a plate-shaped metal material, with a corrugated (in cross-section) profile formed in the plane of the plate-shaped material, the corrugations of which profile extend in a meander-like fashion in the plane of the plate-shaped material and over several first parts of the intermediate layer.

2. A wall element according to claim 1, wherein the corrugations extend parallel to each other in the plane of the plate-shaped material.

3. A wall element according to claim 1 or 2, wherein the corrugations extend in zigzag fashion in the plane of the plate-shaped material .

4. A wall element according to claim 1 or 2, wherein the corrugations extend in serpentine fashion in the plane of the plate-shaped material.

5. A wall element according to claim 4, wherein the corrugations extend sinusoidally in the plane of the plate-shaped material.

6. A wall element according to claim 5, wherein the spacing between two adjacent corrugation ridges of the sine shape ranges between 0.25 and 2 times the amplitude of the sine shape .

7. A wall element according to claim 6, wherein the spacing between two adjacent corrugation ridges of the sine shape at least substantially equals the amplitude of the sine shape .

8. A wall element according to any one of the preceding claims 1 - 7, wherein the profile has been formed over substantially the entire length of the plate-shaped material.

9. A wall element according to any one of the preceding claims 1 - 8, wherein the plate-shaped material is made of a metal selected from the group consisting of iron, steel, copper and aluminium, or of an alloy of one or more of said metals.

10. A wall element according to any one of the preceding claims 1 - 9, wherein the outer layers are glued to the first parts of the intermediate layer.

11. A wall element according to any one of the preceding claims 1 - 10, wherein the outer layers are at least substantially made of a material selected from the group consisting of fibre material, plastic, rubber, metal, paper/cardboard and wood.

12. A wall element according to claim 11, wherein the fibre material comprises glass fibres, carbon fibres, mineral fibres and/or synthetic fibres.

13. A wall element according to claim 11, wherein the outer layers are 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 affixed to one side thereof, wherein said paper/cardboard layers are connected together by means of an adhesive applied to the corrugations of the corrugated sublayers.

14. A wall element according to claim 13, wherein the outer layers are impregnated, in particular with a resinous material.

15. A wall element according to claim 11, wherein the outer layers are substantially made of two-ply or three-ply wood.

16. A wall element according to any one of the preceding claims 1 - 15, wherein the intermediate layer is staggered relative to the outer layers, with the wall element being provided with a profile along a first part of the circumferential edge and with an at least outwardly extending lip along a second part of the circumferential edge, wherein a lip of one wall element is inserted in a corresponding profile of the other wall element in the interconnected position of adjacent wall elements.

17. A wall element according to any one of the preceding claims 1 - 16, wherein the intermediate layer is bent over in a direction transversely to the outer layers at at least one edge of the wall element parallel to the bent-over portions of the intermediate layer.

18. A wall element according to claim 17, wherein said edge is bent over once again in a direction parallel to the outer layers, oriented towards the centre in the plane of the wall panel.

19. A wall element according to any one of the preceding claims 1 - 18, wherein the wall element is provided with a profile along a first part of the circumferential edge at both ends and with an at least outwardly extending lip along an adjacent part of the circumferential edge, wherein a lip of one wall element is inserted into a corresponding profile of the other wall element at both ends in the interconnected position of adjacent wall elements.

20. A wall element according to any one of the preceding claims 1 - 19, wherein the compartments formed by the outer layers and the zigzag-shaped intermediate layer are at least partially filled with an insulation material .

21. A method for manufacturing a wall element according to any one of the preceding claims 1-20, characterised in thai: a corrugated (seen in cross-section) profile is rolled into the plane of a plate-shaped metal material, with corrugations of the profile extending in a meander-like fashion in the plane of the plate- shaped material;

the plate-shaped material is subsequently bent to a zigzag shape;

outer layers are affixed to either side of the plate- shaped material; and

parts of the intermediate layer facing towards one outer layer and extending substantially parallel thereto are connected to said one outer layer, and parts of the intermediate layer facing towards the other outer layer and extending substantially parallel thereto are connected to said other outer layer.