EP2567042B1

EP2567042B1 - Sheet-shaped structural elements for buildings

Info

Publication number: EP2567042B1
Application number: EP11734931.6A
Authority: EP
Inventors: Mikael ÖSTLING
Original assignee: Isotimber Holding (publ) AB
Current assignee: Isotimber Holding (publ) AB
Priority date: 2010-01-21
Filing date: 2011-01-20
Publication date: 2023-10-18
Anticipated expiration: 2031-01-20
Also published as: WO2011090418A1; EP2567042A1; SE535391C2; ES2967350T3; SE1200498A1; PL2567042T3; SE1000057A1; EP2567042C0; EP2567042A4

Description

Field of the Invention

The present invention concerns a sheet-shaped structural element for buildings in accordance with the claims.

Background of the Invention

Today, the demand for houses built of sustainable materials such as wood has become more and more apparent. Building houses of wood is nothing new. Building houses of timber that is to say to build houses of logs, has for example long been known. A number of problems exist with timbered buildings and also the erection of timbered buildings. One problem is that timber (log) walls change shape in connection with the logs drying out. It is for example not unusual for such a timber wall (log structure) to shrink between eight to ten percent in connection with its drying. Shrinkage may lead to damage in the form of cracks and the like occurring on interior walls and similar. Further, significant problems exist with the logs in a log structure twisting (warping) in connection with their drying. This twisting (warping) easily leads to the formation of thermal bridges in walls. There exists a need for a structural element which is similar to a log but which shrinks substantially less than existing logs do.
A further problem with existing designs of walls, such as for example cross-beam walls, is that they have a limited sound-dampening effect. There is therefore a need for a structural element that has an improved sound-dampening effect.
A yet further problem with existing designs of walls in buildings is that they do not include the possibility of controlling the amount of heat in the wall. This is especially significant in warmer climates. It is therefore costly to cool buildings.
A further problem with existing buildings, especially in warmer climates, is that they need to be cooled by AC in order for them to be comfortable to dwell in.
A further problem with existing building structures is that it is difficult to monitor if there is a risk of moisture damage in the walls, floors, ceilings and the like. Normally, moisture damage will not be recognized until significant damage has already incurred in the building. Moisture damage leads to other consequential damages incurring in the building such as mold (mildew) and the like. There is therefore also a need to create a monitoring system that in the early stages of water leakage, or essentially immediately, detects whether a water leakage or the like exists in a building structure (structural elements). Further, there is also a need for a device and a method for the early detection of the presence of mold in a structural element.
Yet another problem found in building materials that partially or completely consist of wood such as for example boards, planks, beams and the like is the fact that their form and thickness does not allow for their complete impregnation against damage from for example fire, insects, rot, moisture etcetera. The form and thickness of most wood materials does not allow for complete saturation of the material. Only the outermost portion of the wood material receives adequate protection from an impregnation agent. The interior area of impregnated wood receives little or no impregnation leaving the material unprotected. Unnecessary costs may arise from this lack of impregnation. Especially problematic is the limited protection afforded by current fire retardation impregnation in existing wood elements. This is also a clear need for a design that can lessen or alleviate the problems of inadequate impregnation.

Prior Art

A variant of a log-like structural element, which includes an insulating core, is already known by way of international patent application WO9530807 . This log-like structural element includes an insulating core that consists of an insulating material. The insulating material is on its one side provided with at least one material layer and its second opposite side (of the first side) is provided with at least one second material layer. This design meets its intended purposes, but has the flaw that its insulating core is made of petroleum-based raw materials, that is to say, made of non-renewable resources. Furthermore, the insulating core does not include elongated channels in accordance with the present design and this is why the design can not be used in a similar way as the present design. DE-A-19833474 discloses a sheet-shaped structural element according to the preamble of claim 1.

Brief Description of the Invention Concept

The main purpose of the design according to the present invention is to create a substantially improved structural element for buildings.
A further purpose of the present invention is to create a structural element which has a significantly improved sound-dampening capacity
A further purpose of the present invention is to create a building element in the form of a sheet (panel, board) which can be used in floors.
Yet another purpose of the present invention is to create a design that allows for the complete and total impregnation of all wood material in the present insulating core.

Detailed Description of the Invention

The invention will be described in greater detail below with reference to the accompanying schematic drawings that in an exemplifying purpose show the current preferred embodiments of the invention.

Figure 1 shows a structural element.
Figure 2 shows a insulating core element.
Figure 3 shows a first embodiment of the insulating core element.
Figure 4 shows a second embodiment of the insulating core element.
Figures 5A-5C show structural elements.
Figures 6A-6B show a sheet-shaped structural element according to the invention.

With reference to the figures a structural element 1 in accordance with the present invention is shown. The structural element 1 includes at least one insulating core (course) 2. The insulating course (core) 2 is on one side (outside) 3 provided with at least a first material layer 4. The insulating core 2 is on the opposite side (inside) 5 provided with at least one second material layer 6. Furthermore, it is also conceivable that the structural element 1 is comprised of more than one material layer on each respective side of the core. The joining of material layer 4 and the core 2 and also material layer 6 and the core 2 is preferably accomplished by gluing or other for the purpose suitable joining method.
What is unique with the present structural element 1 is that its insulating core 2 includes at least one elongated core element 7 and preferably several core elements 7. The core element 7 is preferably comprised of wood (wood material), or a material which mainly includes wood. In alternative embodiments, it is conceivable that the core element 7 is made of another suitable material for the purpose such as for example a composite material. Preferably, the core element 7 has an essentially quadrangular cross-section such as for example a rectangular or a square cross-section. The core element 7 includes a first main side 8 and a second main side 9. Further, the core element includes a third side 10 with an opposite fourth side 11.
The core element has preferably an elongated form. Further, the core element 7 includes at least one elongated channel (groove) 12 which stretches along part or all of the elongated core element's 7 length.
According to the invention, the core element includes a first number of channels 12 in the core element's first main side 8 with a first set of flanges 13 between the channels 12. The flanges 13 are given at least one thickness. The channels 12 are given an extension length in depth from the core element's (piece of wood) first main side 8 toward its second main side 9 and given a depth which preferably amounts to more than half the distance between the first main side 8 and the second main side 9 and less than the distance between the first main side 8 and the second main side 9.
According to the invention the core element's 7 first main side 8 includes a first set of channels 12 with intermediate flanges 13. The flanges 13 are given at least one thickness. The channels 12 have an extension length in depth from the core element's 7 first main side 8 toward its second main side 9 that preferably amounts to less than half the distance between the first main side 8 and the second main side 9.
The second main side 9 includes a second number of channels 14 with a second set of flanges 15. The flanges 15 are given at least one thickness. The channels 14 are given an extension length in depth from the core element's 7 second main side 9 toward the piece of wood's first main side 8. The second number of channel's 14 depth is preferably just as large as the depth of the mentioned first number of channels 12.
In figure 4 is shown another conceivable variant of the core element 7 which has a third side 10 provided with at least one longitudinal channel 16. It is also conceivable that the fourth side 11 is provided with at least one longitudinal channel 17.
The number of channels 12, 13, 16 and 17 as well as the core element's 7 dimensions may vary considerably within the scope of the present invention. The channels' and the flanges' respective width as well as their thickness are dimensioned according to the requirements placed on a structure's load bearing capacity and other parameters.
Preferably, the core 2 is made up of several core elements 7 which are joined flange against flange (such as is shown in the figures). By joining flange against flange longitudinal channels are formed in the structural element. The joining of flange against flange is accomplished by gluing or other for the purpose suitable joining method. In figure 5 is shown an example of an embodiment of the present invention, where it includes at least one first insulating core 2 and at least one second insulating core 18. The first insulating core 2 and the second insulating core 18 are preferably separated by at least one material layer 19. The first insulating core 2 and the second insulating core 18 include in the exemplified embodiment a first core element 7, a second core element 20, a third core element 21, a fourth core element 22, a fifth core element 23 and a sixth core element 24. The design may include several more core elements than shown in the figures.
The figures even exemplify a second outer material layer 25 and a second inner material layer. Additional layers may be found in alternative embodiments.
The structural element 1 may be elongated as a log, which is an example which is not covered by the claim scope. Figures 5A - 5C exemplify the use of the structural element 1.
The figures show how a first longitudinal structural element can be connected together to form a tie (corner) 26 together with a second structural element. In order to allow the connection of several structural elements, they are in their ends, or in their ends' proximity, provided with at least one notch (recess) 27 with which a unifying tie between at least one first structural element and one second structural element is created. In the exemplifying embodiment the elongated structural element in its first end, or in its end's proximity, is given a first notch 27, a second notch 28, a third notch 29 and a fourth notch 30.
The J elongated structural element in its second end, or in its end's proximity, is given a first notch 27, a second notch 28, a third notch 29 and a fourth notch 30. With this design a tie 26 can be created between at least a first elongated structural element and a second elongated structural element and as such included in a first wall and a second wall. What is unique with the present tie is that it does not build in height (that is to say in the vertical direction).
The structural elements may even be provided with at least one protruding segment (not shown in the figures) which may for example be used at the tie or with the connection of several structural elements on one another in the vertical direction. In alternative embodiments the number of notches may be more numerous or less and be of another for the purpose suitable form.
In order to ease the connection of a first structural element with at least one second structural element, the first material layer 4 and the second material layer 6 are displaced in relation to the core 2. When used as a log the displacement in the vertical direction and relating to sheet material (for example floor frame work) the displacement is in the horizontal direction.
The core elements will dry substantially faster than existing logs dry thanks to the channels in the core elements as well as the intermediate flanges in the core elements. The core element will preferably dry before the core (comprised of several core elements) is assembled (glued together). Thanks to each respective core element being dried before assembly, the core will essentially have finished shrinking before it is assembled. When using the structural element as a log, the problems caused by shrinkage in common logs will thereby essentially be eliminated.
In figure 6A and figure 6B, a structural element according to the invention is shown which can be used for example in a floor frame work. Size and thickness of the sheet-formed structural element may vary greatly within the scope of the present patent application. For example, the present structural element may be sheet-shaped (panel-shaped). When using the structural element in a floor frame work, it is intended to be placed so that the core 2 on its top side is provided with at least one first material layer 4 and on its bottom side is provided with at least one second material layer 6. The channels 12 and 14 are preferably placed in the transverse direction in relation to material layer 4 and material layer 6. Figure 6B shows a structural element that can include at least one second core 18 with at least one second intermediate material layer.
What is unique with the present invention is that the structural element includes elongated channels. The elongated channels have resulted in the above stated technical effect that a flow of air through the channels can occur. For example, at least one fan can induce a stream of air to flow through the channels. This design allows for the channels to be used for both cooling and heating the wall.
Relative cooler outdoor air can for example be used at night to cool the wall, which can be accomplished by the relative cooler outdoor air being conveyed into the walls (structural elements) elongated channels (channel 12 and channel 14). The channels in several structural elements are intended to be connected with one another. A wall's temperature can be reduced at night by using this method. This reduction of a wall's temperature at night can be utilized to cool a room during parts of the day. It is further conceivable that the opposite effect can be achieved, that is to say that the wall can be warmed during the day so it can radiate warmth at night. This is made possible since the structural element includes elongated channels through which a stream of relative cooler or relative warmer air can flow. This flow is created by at least one fan emitting a flow of air channeled into channel 12 and channel 14. The fan's emitted air can be supplied from outdoor air. The emitted air may even be temperature conditioned with an AC system or similar temperature conditioning device. Furthermore, a dehumidifier, in accordance with earlier known technology, can be hooked up to dehumidify the air that is brought into channel 12 and channel 14.
In alternative embodiments, it is conceivable that the channels may be used to monitor moisture levels in a wall, floor frame work or similar. Moisture may for example derive from leakages in a water pipes or the like. Monitoring may be accomplished by a stream of air flowing through the channels, which is created for example by at least one fan. At least one sensor is put in a place along the channels length that is suitable for the purpose. The sensor consists preferably of a moisture sensor that detects the level of moisture and changes in the moisture level in the airflow. Detection of changes in moisture levels in the air flowing through the channels may be accomplished by use of at least two sensors. The moisture level of the incoming air into the structural element is measured and then compared with the moisture level in the air flowing out from the channels 12 and 14 in the structural element. If the moisture level rises above a predetermined level an alarm is set off. The sensors can transmit information wirelessly or with wires to a monitoring system for moisture, mold or similar. This monitoring system is based on earlier known technology or future technology that will be available for a person skilled in the art, and this is why the monitoring system is not described in more detail in this patent application. If channels 12 and 14 are connected between several structural elements (enclosed elongated channels that run on from one structural element to at least one other structural element and preferably to several structural elements), the detection of moisture, the presence of mold and the like may be accomplished by one or two sensors for several structural elements. This is also applicable in combination with the earlier mentioned cooling and heating of the introduced air.
An unexpected technical effect has arisen during the impregnation of the insulating core 2. It has been shown that the present design allows for the complete saturation and thereby total impregnation (100 %) of all the wood material in the present insulating core 2. In an alternative embodiment the present invention may be impregnated by different kinds of impregnation agents that for example retard fire, protect against rot, mold and/or insect damage or similar. A complete and total impregnation of all wood material in the insulating core 2 is made possible by the present invention's unique design. Complete and total impregnation (100 %) of all wood material in the insulating core 2 is achieved with current known impregnation techniques and this is why the impregnation procedure is not discussed further in this patent application.
Even if certain preferred embodiments have been described in detail, variations and modifications within the scope of the invention can become apparent for specialists in the field and all such are regarded as falling within the scope of the following claims. It is conceivable that the present invention is a method for use of the present structural element. It is also conceivable that at least one of the third sides and the fourth sides are provided with at least one material layer.

Advantages of the Invention

The present invention has a number of advantages. The most obvious is that structural elements are obtained, which liken a log, but shrink less than existing logs. Another advantage of the present invention is that a structural element which substantially eliminates thermal bridges is obtained. A still further advantage of the present invention is that a sound-dampening structural element is obtained. A yet further advantage of the present invention is that it allows for economical cooling and heating of walls. The unexpected technical effect of complete and total (100 %) impregnation of the present invention, thanks to its unique design, is of great advantage in minimizing and even eliminating the risks of and damage of building structures from fire, insects, mold, rot and other similar negative effects.

Claims

A sheet-shaped structural element (1) intended for use in a wall or a floor of a building including at least one insulating core (2), each of said at least one insulating core (2) including at least two core elements (7), each core elements (7) having a first main side (8) and an opposite second main side (9),
each core element including
a first number of channels (12), with a first number of intermediate flanges (13), which range in depth from said first main side (8) toward said second main side (9), and

a second number of channels (14), with an intermediate second number of flanges (15), which range in depth from said second main side (9) toward said first main side (8),

wherein the depth of the first set of channels (12) amounts to less than half the distance between the first main side (8) and the second main side (9) and the depth of the second set of channels (14) amounts to less than half the distance between the second main side (9) and the first main side (8),

characterized in that said sheet-shaped structural element is provided with at least one first material layer (4) on its main side (3) and at least one second material layer (6) on its opposite main side (5), and in that

said core elements (7) are arranged such that the intermediate flanges are oriented transverse with respect to said at least one first material layer (4) and said at least one second material layer (6).
The sheet-shaped structural element (1) in accordance with claim 1, wherein adjacent core elements are joined flange against flange.
The sheet-shaped structural element (1) in accordance with claim 1, further comprising at least one second core (18) and at least one intermediate material layer (19) arranged to separate adjacent cores.
The sheet-shaped structural element (1) in accordance any preceding claim, wherein a third side (10) of said core elements further includes at least one channel (16).
The sheet-shaped structural element (1) in accordance with any preceding claim, wherein a fourth side (11) of said core elements (7) includes at least one channel (17).
The sheet-shaped structural element (1) in accordance with any preceding claim, wherein said core element (7) is made of wood or wood material.
The sheet-shaped structural element (1) in accordance with any preceding claim, wherein the structural element includes at least one moisture detecting sensor.
The sheet-shaped structural element (1) in accordance with any preceding claim, wherein at least one insulating core (2) is impregnated, to a degree of impregnation of 100 percent, with impregnating agents that retard fire, protect against rot, mold or mildew, insect damage and similar.
The sheet-shaped structural element (1) in accordance with any preceding claim characterized by that at least one core element (7) in the insulating core (2) is impregnated, to a degree of impregnation of 100 percent, with impregnating agents that retard fire, protect against rot, mold or mildew, insect damage and similar.
A floor frame work comprising several sheet-shaped structural elements according to any preceding claim attached to each other and, wherein the core of each structural element is provided with a first material layer (4) on its top side, and a second material layer (6) on its bottom side, and wherein the depth of the channels extends in a transverse direction in relation to the first and second material layers.