GB2188281A - Structural panel - Google Patents

Structural panel Download PDF

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Publication number
GB2188281A
GB2188281A GB08607319A GB8607319A GB2188281A GB 2188281 A GB2188281 A GB 2188281A GB 08607319 A GB08607319 A GB 08607319A GB 8607319 A GB8607319 A GB 8607319A GB 2188281 A GB2188281 A GB 2188281A
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GB
United Kingdom
Prior art keywords
panel
layers
structural
layer
component
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.)
Granted
Application number
GB08607319A
Other versions
GB8607319D0 (en
GB2188281B (en
Inventor
Hector Tidd
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.)
TIDD STRONGBOX Ltd
Original Assignee
TIDD STRONGBOX 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
Application filed by TIDD STRONGBOX Ltd filed Critical TIDD STRONGBOX Ltd
Priority to GB8607319A priority Critical patent/GB2188281B/en
Publication of GB8607319D0 publication Critical patent/GB8607319D0/en
Publication of GB2188281A publication Critical patent/GB2188281A/en
Application granted granted Critical
Publication of GB2188281B publication Critical patent/GB2188281B/en
Expired legal-status Critical Current

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Classifications

    • 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
    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • 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
    • 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
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
    • E04C2/205—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced
    • 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
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • 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
    • B32B2311/00—Metals, their alloys or their compounds
    • B32B2311/24—Aluminium
    • 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
    • B32B2607/00—Walls, panels

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)

Abstract

A structural panel comprises a plurality of square cross-sectioned elements (20) of foamed plastics material assembled in layers (22, 28) by initial use of a zig-zag former to touch along corner edge lines in the first layer (22), with a wetted fibre mat (26) between each layer and conformed to the face of each layer to form a zig zag former for a similar next layer (28), thereby to produce a bonded block which is then chopped in planes normal to the layers and to the extruded lengths to form structural components butted in coplanar relationship and faced by aluminium sheets bonded to the major faces. <IMAGE>

Description

SPECIFICATION Structural panel Field of invention This invention relates to a structural panel, to a structural component for incorporation in the panel and to a method of making the panel and component.
Background to the invention Vehicle floors typically comprise aluminium faced wood panels supported by cross bearers transverse to the length ofthe panels. It is one object ofthis invention to provide a structural panel of inexpensive manufacture which is useful, amongst other applications, as a vehicle floor orwall panel, and which especially in the case of a floor panel is sufficiently strong to facilitate its support.
The invention According to one aspect of the invention, a structural panel comprises a plurality of layers of elements offoamed plastics material of regular cross-section,wherein in each layer the foamed plastics elements are juxtaposed parallel to their lengths and held in position by non-planar sheets of malleable mat which separate the layers one from the other, the layered construction forming a right rectangular component having its major faces perpendiculartothe layers, and a rigid preferably metal sheet bonded to at least one of said major faces.
According to another aspect of the invention, there is provided a method of making a structural componentwhich comprises the steps of: - extruding foamed plastics material to form elongate elements thereof, -juxtaposing a plurality of said foamed plastics elements in parallel touching relationship as a layer thereof on a non-planarformer, - laying a wet malleable matoverthe layerand shaping the mat to the non-planar surface ofthe layerto provide a formerfor another layer offoamed plastics elements, - repeating the layering step a plurality oftimes, -chopping the resulting layered construction in a direction perpendicularto the layers, thereby to form a plurality of right rectangularstructural components each having its majorfaces perpendiculartothe layers.
The invention also extends to a method of making the above-described structural panel which includes the furtherstep of - bonding a metal sheetto at leastone majorface of a structural component.
Moreover, the invention also extends to the structural component for incorporation in the above-described panel, and to the structural component produced by the above-described method. This component may find application, for example, as a filler in a structural panel of known type wherein hitherto a honeycomb or other conventional filler has been employed. It may also find application in fields wherein structural components having insulating properties are required, for example in building construction.
In a preferred component, high density foamed polyurethane is used as the foamed plastics material, and fibre glass mat as the malleable mat. In the preferred panel, aluminium sheet is employed as the durable facing(s).
The foamed plastics material may be extruded in any one of a variety of cross-section shapes uniform along the length of the extrusion, but preferred shapes are ones in which, when laid in the layers, adjacent elements touch along a line, whereby two successive malleable mats, when shaped to conform to the surfaces of the layer, will effectively meet at the said lines at which the extruded elements touch.
Effectively, therefore, each extruded element is individually bonded in position asthewetmalleable mats dry and become set in non-planarshape.
One suitable extrusion cross-sectional shape is square, the extruded elements being laid on a zig-zag forming surface of 90 degrees included angle, whereby adjacent elements touch along two longitudinal corner edges. However, other cross-sectional shapes, including a circular cross-sectional shape, are alternatively possible.
The structural panel in accordance with the invention may incorporate two or more structural components as hereinbefore described, butted in coplanar relationship, preferably along the longer edge faces, and held sandwiched between two aluminium orothermetal facing sheets. In this way, an integral panel say two and a half metres wide by up to ten or more metres in length may be produced, suitable for use as a load bearing vehicle floor in a bus, lorry or load-carrying trailer. The strength of the integrated floor structure is such as to minimise and simplify requirements for its support.
Brief description of drawings The invention will now be exemplified with reference to the accompanying drawings, in which:- Figure lisa cross-sectional view through a structural component in accordance with the invention; Figure2 shows an extruded foamed plastics element; Figure 3 shows the method of assembly of the foamed plastics elements in layers separated by malleable mats, in order to produce a structural component in accordance with the invention; Figure4shows a further step in production of the structural component; and Figure 5 shows a structural panel incorporating the structural components produced by the method illustrated in Figures 3 and 4.
Description ofembodiment Referring to Figure 1, a right-rectangularstructural panel generally referenced 10 has dimensions, for example, of about 1.25 metres by about 2.5 metres, with a thickness (normal to the paper) of about 0.1 of a metre.
The panel comprises layers, for example eight layers constituted by juxtaposed foamed plastics elements 12 of uniform square cross section, typically of 0.2 of a metre diagonal, the layers being separated by malleable mats 14which hold and bond the layers and elements thereof in position.
The panel may be faced on its major faces, in planes parallel to and respectively above and below the plane of the paper, by bonded metal sheets, thereby to produce a structural panel. The plastics elements are preferably of extruded high density polyurethane, the malleable mats are preferably of fibre glass, and the facing sheets are preferably of aluminium. Figure 5 shows thata plurality of abutted structural components 10 maybesandwiched between two larger aluminium sheets 16to produce an integrated panel which may measure 2.5 metres by up to 12.5 metres or more, thereby to enable its use as a one piece load-bearing vehicle floor orthe like.
Figures 2 to 4 illustrate the method of producing the component and panel.
Initially, the foamed polyurethane is extruded in lengths 20 of 2.5 metres, as indicated by Figure 2.
The extruded plastics lengths 20 are then assembled, on a zig-zag former 24, in parallel edge-touching relationship to form a layer 22, as indicated in Figure 3. Wet fibre-glass mat 26 is then laid on top ofthe layer 22 and shaped against the layer of the surface to provide a former for a second layer 28 of extruded plastics lengths 10. These steps are repeated to produce a bonded biock 30 of say eight layers, as indicated in Figure 4.
As also indicated in Figure4; the block 30 is then chopped, in planes 32 normal to the layers and the lengths ofthe extruded plastics lengths, into slabs constituting structural components about 0.15 of a metre thick.
It is these structural components 10 which are assembled in abutting relationship at their long edge faces and bonded as a sandwich between the aluminium facing sheets 16, as shown in Figure 5.
Various modifications are possible within the scope of the invention hereinbefore defined. In the first place, the stated dimensions are typical for a panel to be used as a vehicle floor, but other dimensions may be appropriate to other applications. Secondly, the facing sheets may be of metal otherthan aluminium orin some circumstances non-metallic rigid sheets may be employed to provide a durable facing. Thirdly, the foamed plastics elements may be extruded of a material other than polyurethane, and the malleable mats may be of a material otherthan fibre glass which, during production, can by virtue of its wetness or by other means be caused to set into a non-planar shape appropriate to bond the layers together. Moreover, the foamed plastics lengths may be extruded in regular cross-sectional shapes other than a square shape. Finally but not exhaustively as far as modifications are concerned, the structural component, devoid of one or more rigidfacings, may find application, for example for heat insulating purposes, in the construction of buildings and the like.

Claims (9)

1. Astructural panel comprising a plurality of layers of elements of foamed plastics material of regular cross-section, wherein in each layer the foamed plastics elements are juxtaposed parallel to their lengths and held in position by non-planar sheets of malleable mat which separate the layers one from the other, the layered construction forming a right rectangular component having its major faces perpendicularto the layers, and a rigid sheet bonded to at least one of the majorfaces.
2. A panel according to claim 1, wherein the said rigid sheet is a metal sheet.
3. A method of making a structural component which comprises the steps of: - extruding foamed plastics material to form elongate elements thereof, -juxtaposing a plurality of said foamed plastics elements in parallel touching relationship as a layer thereof on a non-planarformer, -laying awetmalleable matoverthe layerand shaping the mat to the non-planar surface of the layer to provide a former for another layer offoamed plastics elements, - repeating the layering step a plurality oftimes, - chopping the resulting layered construction in a direction perpendicularto the layers, thereby to form a plurality of right rectangularstructural components each having its major faces perpendiculartothe layers.
4. A method of making a structural panel which comprises making the structural component in accordance with claim 2 and then bonding a rigid metal sheet to at least one major face ofthe structural component.
5. A structural component made by the method ofclaim 3.
6. Astructural panel made by the method of claim 4.
7. A panel or component according to any of claims 1,2,5 or 6, wherein the foamed plastics material is high density foamed polyurethane.
8. A panel or component according to claim 7, wherein the malleable mat is a fibre glass mat.
9. A panel or component according to claim 1 or claim 2 oranyofclaims 5to 8 in which the extruded cross-sectional shape is square.
9. A panel or component according to claim 1 or claim 2 or any one of claims 5to 8, wherein the elongate elements are extruded in a cross-sectional shape uniform alongthe length oftheelementand such as to touch along a line when laid inthe aforesaid layers.
10. Apanel or component according to claim 9, in which the extruded cross-sectional shape is square.
11. A panel according to claim 1 or any claim appendant thereto, comprising two or more structural components butted in coplanar relationship and faced by a rigid sheet on at least a major face common to the said butted components.
12. Apanelaccordingtoclaim 11,whereinthe two or more structural components are butted together along their longer edge faces to form a composite panel elongate in a direction perpendiculartothe length ofthe individual structural components.
13. A structural component substantially as hereinbefore described with reference to the accompanying drawings.
14. Astructural panel substantially as hereinbefore described with reference to the accompanying drawings.
15. A method of making a structural component or panel substantially as hereinbefore described with reference to the accompanying drawings.
1. Astructural panel comprising : a plurality of layers of elongate elements made of foamed plastics material of regular cross-section, the elongate elements in each layer being juxtaposed parallel to their lengths and being held in position by non-planar sheets of malleable mat which separate the layers one from the other, the layered construction forming a right rectangular component having its major faces perpendicular to the layers, and a rigid sheet bonded to at least one ofthe major faces, wherein the elongate elements are extruded in a cross-sectional shape uniform along the length of the element and such asto touch along a line when laid in the aforesaid layers.
GB8607319A 1986-03-25 1986-03-25 Structural panel Expired GB2188281B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB8607319A GB2188281B (en) 1986-03-25 1986-03-25 Structural panel

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB8607319A GB2188281B (en) 1986-03-25 1986-03-25 Structural panel

Publications (3)

Publication Number Publication Date
GB8607319D0 GB8607319D0 (en) 1986-04-30
GB2188281A true GB2188281A (en) 1987-09-30
GB2188281B GB2188281B (en) 1989-11-15

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Family Applications (1)

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GB8607319A Expired GB2188281B (en) 1986-03-25 1986-03-25 Structural panel

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2225282A (en) * 1988-09-30 1990-05-30 Michael Sean Barron Fibre reinforced foam structural components
WO2018037016A1 (en) 2016-08-26 2018-03-01 Basf Se Fiber-reinforced foam material

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB577790A (en) * 1938-08-29 1946-05-31 Norman Adrian De Bruyne Improvements relating to the manufacture of light non-metallic structural material or components
GB1070890A (en) * 1965-09-07 1967-06-07 Midland Ross Corp A panel suitable for the floor of a cargo container
GB2147331A (en) * 1983-09-30 1985-05-09 Chen Kai Nan Insulating panel

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB577790A (en) * 1938-08-29 1946-05-31 Norman Adrian De Bruyne Improvements relating to the manufacture of light non-metallic structural material or components
GB1070890A (en) * 1965-09-07 1967-06-07 Midland Ross Corp A panel suitable for the floor of a cargo container
GB2147331A (en) * 1983-09-30 1985-05-09 Chen Kai Nan Insulating panel

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2225282A (en) * 1988-09-30 1990-05-30 Michael Sean Barron Fibre reinforced foam structural components
GB2225282B (en) * 1988-09-30 1992-07-15 Michael Sean Barron Fibre reinforced foam structural components.
WO2018037016A1 (en) 2016-08-26 2018-03-01 Basf Se Fiber-reinforced foam material

Also Published As

Publication number Publication date
GB8607319D0 (en) 1986-04-30
GB2188281B (en) 1989-11-15

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PCNP Patent ceased through non-payment of renewal fee