GB2448047A - Insulated building panel - Google Patents

Insulated building panel Download PDF

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Publication number
GB2448047A
GB2448047A GB0805183A GB0805183A GB2448047A GB 2448047 A GB2448047 A GB 2448047A GB 0805183 A GB0805183 A GB 0805183A GB 0805183 A GB0805183 A GB 0805183A GB 2448047 A GB2448047 A GB 2448047A
Authority
GB
United Kingdom
Prior art keywords
panel
panel according
layer
insulating material
cavities
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.)
Withdrawn
Application number
GB0805183A
Other versions
GB0805183D0 (en
Inventor
Roger Alfred Bullivant
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.)
Roxbury Ltd
Original Assignee
Roxbury 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 Roxbury Ltd filed Critical Roxbury Ltd
Publication of GB0805183D0 publication Critical patent/GB0805183D0/en
Publication of GB2448047A publication Critical patent/GB2448047A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—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 concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/049—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 concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres completely or partially of insulating material, e.g. cellular concrete or foamed plaster
    • 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
    • E04C2/04—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 concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/06—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 concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres 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
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—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 concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/044—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 concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of concrete
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • E04C2/2885—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material with the insulating material being completely surrounded by, or embedded in, a stone-like material, e.g. the insulating material being discontinuous

Landscapes

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

Abstract

The invention relates to a building panel 10 comprising a layer of bodies 14 embedded within the panel 10. Each body 14 is hollow and defines a cavity 16 within the panel 10. The cavities 16 provide insulation space within the panel 10 thereby improving the thermal and acoustic insulation properties of the panel 10. The panel 10 may be formed by introducing a cementitious material (30 figure 6) into a mould to a depth corresponding with the depth of layer (20a figure 6) which is made from two sheets of polythene and forms the cavities 14. Layer (20a figure 6) is then laid onto the material and further cementitious material is introduced on top of layer (20a figure 6). A mesh reinforcing layer (32 figure 6) may then be introduced before the remainder of the cement (30 figure 6) is introduced to form the panel 10 to the desired thickness. The material is then left to set before the panel 10 is removed from the mould. The panel 10 may also comprise at least one tie member (36 figure 7) which extends through the layers of the panel 10 to tie the layers together. The panel 10 may also comprise at least one layer of polystyrene foam (40 figure 9) as an insulating material.

Description

I
Building Panel The present invention relates to building panels.
Embodiments of the present invention provide a building panel comprising at least one body embedded within the panel and defining an insulating cavity within the panel.
The body may be hollow. There may be a plurality of bodies embedded within the panel. The bodies may be connected to form a layer of insulating cavities. The panel may comprise multiple layers of insuiating cavities. The bodies of the or each layer may be defined by sheets of material attached together to define cavities. The sheets may be attached along a closed line to form a wholly enclosed cavity. The or each cavity may be wholly enclosed by the or a corresponding body.
The panel may further comprise at least one layer of settable material.
The settable material may be a cementitious material. The settable material may be a cement mix or a plaster mix or a mixture of these materials. The 21) settable material may contain thermal insulating material, which may be in bead form and which may be a polymer material. The insulating material may be polystyrene.
The panel may further comprise at least one layer of insulating material which may be in sheet form and which may be a polymer material. The insulating material may be polystyrene.
The panel may further comprise at least one reinforcing layer. The reinforcing layer may comprise reinforcing members. The reinforcing 31) members may be in the form of a mesh. The reinforcing members may be of metal and/or synthetic fibre.
The panel may further comprise at least one tie member extending through multiple layers of the panel to tie the layers together. The or each tie member may extend through at least one layer of settable material to be retained in position by the settable material after setting.
The panel may further comprise at least one attachment member for attachment of the panel to lifting means.
The panel may further comprise at least one aperture through the panel, for use as a door or window.
Embodiments of the present invention will now be described in more detail, by way of example only, and with reference to the accompanying drawings, in which: Fig. 1 is an elevation of a finished panel according to one embodiment of the invention; Fig. 2 is a partial section through the panel of Fig. 1, along the line 2-2 of Fig 1; Fig. 3 is a partial perspective view of one layer of the panel of Figs 1 and2; Figs. 4 and 5 are section and plan views of the layer of Fig. 3; and Figs. 6 to 11 are highly schematic sections through panels constructed in accordance with various embodiments of the invention.
Figs. 1 and 2 show a building panel 10. The panel 10 may be pre-fabricated and transported to a building site for incorporation into a building.
In the example of Fig. 1, the panel 10 is formed with apertures 12 into which a door and a window can be fitted as part of the construction of the building.
The internal construction of the panel 10 is broadly indicated in Fig. 2.
S Additional detail is illustrated in Figs. 6 to 11, and described in relation to those figures. Fig. 2 illustrates the presence of a line of bodies 14, embedded within the panel 10. Each body 14 is hollow. Thus, each body 14 defines a cavity 16 within the panel 10. The cavities 16 provide insulation space within the panel 10, improving the thermal and acoustic insulation properties of the panel 10.
The plurality of bodies 14 are connected at 18 to form a layer of insulating cavities 16.
I 5 One example embodiment of a layer of insulating cavities is illustrated in Figs. 3 to 5. The layer 20 of Figs. 3 to 5 is formed from two sheets 22 of flexible material such as polythene. The sheets 22 are attached together at 18 (Fig 4) to.leave cavities 16 between the upper and lower sheets 22. Each cavity 16 is defined by a closed line 26 of attachment between the sheets 22 2(1 (Fig 5), so that each cavity 16 is wholly enclosed by the body 14 formed by attachment of the sheets 22. The cavities 16 can thus be considered as a layer of wholly enclosed bubbles, connected to their neighbours at 18 to form a layer of bodies 14 defining insulating cavities 16.
The attachment between the sheets 22, at the connections 18, may be provided by heating the sheets 22 to fuse or weld the sheets together.
In the example of Fig. 1, the layer 20 is embedded within the panel 10, which is otherwise of a settable material which may be cementitious. The settable material may be a cement mix or a plaster mix or a mixture of these materials and may contain thermal insulating material. The thermal insulating material may be in bead form and may be a polymer material, such as polystyrene.
The remaining drawings illustrate alternative examples of panels, incorporating additional features and combinations of features. Where features of the various drawings correspond with features shown in other drawings, the same reference numerals are repeated with suffixes a, b etc. The panel lOa (Fig. 6) has a body of settable material 30 within which a layer 20a is embedded to define insulating cavities 16a within the panel lOa.
The settable material may be a cementitious material as described above.
The panel Wa further includes a reinforcing layer 32 in the form of a mesh of elongate reinforcing members 34 embedded within the material 30.
The panel lOa may be formed by introducing settable material into a mould, to a depth corresponding with the depth of the layer 20a within the panel lOa. The layer 20a is then laid onto the material and further settable material is then introduced on top of the layer 20a. The reinforcing layer 32 is then introduced before the remainder of the settable material 30 is introduced to form the panel iQa to the desired thickness. The settable material is then left to set before the panel lOa is removed from the mould.
Fig. 7 shows a panel lOb which includes a layer 20b of cavities 16b, and a reinforcing layer 32a. The layer 20b and the reinforcing layer 32a generally correspond with the layers 20a and 32 of Fig. 6.
The panel lOb includes tie bars 36. The tie bars 36 extend through multiple layers of the panel lOb, as can be seen from the drawing. Thus, the tie bars 36 extend through the settable material 30 above the layer 32a (in the orientation shown in Fig. 7), through the reinforcing layer 32a, through the layer 2Db and through the settable material 30 below the layer 20b. The tie bars 36 are held in position by the setting of the settable material 30, thereafter tying the various layers together, to further strengthen the panel.
Fig. 8 illustrates a panel lOc having many similarities with the panel lOb. In the example of Fig. 8, there is a single layer 20c of cavities 16c, embedded within settable material 30. Two reinforcing layers 32b are provided. The cavity layer 20c is between the reinforcing layers 32b. Tie bars 36a are provided, as described above.
Fig. 9 illustrates a panel lOd. The panel lOd has a layer 20d of cavities 16d. The cavity layer 20d is faced on both faces with layers 40 of insulating material. In this example, the layers 40 are polymer material such as polystyrene, in foamed or expanded form. The layers 20d, 40 are embedded within settable material 30. A reinforcing layer 32d is also embedded within the settable material 30. Tie bars 36d extend through the two layers of settable material 30, the layers 40 and the layer 20d.
Fig. 10 illustrates a further panel lOe. In this example, three layers 20e of cavities 16e are embedded within settable material 30, which forms the outer layers of the panel lOe. It can be seen from Fig. 10 that the cavities 16e of the middle layer 20e are larger than the cavities 16f of the outer layers 20e.
The layers 20e are between two reinforcing layers 32e. Tie bars 36c extend between the two external layers of settable material 30. This ties together the outer layers and the layers 20e, 32e.
Additional settable material may be provided between the cavity layers 20e.
Fig. 11 shows a panel lOf having a single layer 20f of cavities 16f, sandwiched between layers 40a formed of sheets of insulating material such as expanded or foamed polystyrene or other polymer material, as described above The layers 20f, 40a are embedded within layers of settable material 30, within which reinforcing layers 32f are also embedded. Ties 36d extend through the panel lOf, between the outer layers of settable material, to tie together the various layers of the panel 1 Of.
Many variations and modifications can be made from the arrangements described above, without departing from the scope of the invention being described. Each of the panels described above includes at least one body embedded within the panel to define an insulating cavity within the panel.
However, the form of the body and of the cavity can vary. In particular, the dimensions of the cavity can vary. One or more insulating cavities can be used optionally with other features described, including insulating layers, settable material of various types, reinforcing layers and tie arrangements.
In each of the examples described above, the existence of the cavities results in a building panel which is fighter than a corresponding panel formed entirely of settable material (by virtue of the cavities), but has improved thermal and acoustic insulation properties (again by virtue of the cavities).
The examples may be used in constructing internal or external walls, which may be load-bearing or non load-bearing. Those examples which have no layer of insulation material, such as polystyrene, may. be more appropriate for internal use. The presence of the cavities will provide enhanced acoustic properties, such as sound insulation between adjacent rooms. Those examples which include layers of insulation material, such as polystyrene, will provide enhanced thermal insulation and may be more appropriate for external walls. Those examples which include reinforcing layers may be more appropriate for load-bearing use, than those which do not. In any of the examples, the external layers of settable material may be of different thicknesses, to provide a thicker, structural layer on one face and a thinner, cosmetic layer on the other face, which may be the external face when used for an external wall.
The tie bars may be of steel, carbon fibre, fibreglass or other material.
The reinforcing members may be steel. The tie bars may be inserted in various arrangements. In one example tie bars may be inserted at angles in the range of 30 to 60 degrees from the perpendicular to the panel, and further tie bars angles in the range 120 to 150 degrees. Spacing may be 300 mm for I 0 example Tie bars may be positioned at lattice points.of a grid, such as a square grid.
Any of the panels may incorporate attachment members, such as lifting eyes 42 (Fig. 1), to assist in lifting the panel into position. Lifting eyes may be I 5 connected with reinforcing or other layers within the panel.
Whilst endeavourir,g in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon,

Claims (29)

1. A building panel comprising at least one body embedded within the panel and defining an insulating cavity within the pane!.
D
2. A panel according to claim 1, wherein the body is hollow.
3. A panel according to claim 1 or 2, comprising a plurality of bodies embedded within the panel. l0
4. A panel according to claim 3, wherein the bodies are connected to form a layer of insulating cavities.
5. A panel according to any preceding claim, comprising multiple layers of insulating cavities.
6. A panel according to any preceding claim, wherein the bodies of the or each layer are defined by sheets of material attached together to define cavities.
7. A panel according to claim 6, wherein the sheets are attached along a closed line to form a wholly enclosed cavity.
8. A panel according to any preceding claim, wherein the or each cavity is wholly enclosed by the or a corresponding body.
9 A panel according to any preceding claim, further comprising at least one layer of settable material.
10. A panel according to claim 9, wherein the settable material is a cementitious material.
11. A panel according to claim 9 or 10, wherein the settable material is a cement mix or a plaster mix or a mixture of these materials.
12 A panel accordug to claim 9, 10 or 11, wherein the settable material contains thermal insulating material.
13. A panel according to claim 12, wherein the thermal insulating material is in bead form.
JO
14. A panel according to claim 12 or 13, wherein the thermal insulating material is a polymer material.
15. A panel according to claim 12, 13 or 14, wherein the thermal insulating material is polystyrene.
IS
16. A panel according to any preceding claim, further comprising at least one layer of insulating material.
17. A panel according to claim 16, wherein the layer of insulating material is in sheet form.
18. A panel according to claim 16 or 17, wherein the insulating material is a polymer material.
19. A panel according to claim 16, 17 or 18, wherein the insulating material is polystyrene.
20. A panel according to any preceding claim, further comprising at least one reinforcing layer. So
21. A panel according to claim 20, wherein the reinforcing layer comprises reinforcing members.
22. A panel according to claim 21, wherein the reinforcing members are in the form of a mesh
23 A panel according to claim 22, wherein the reinforcing members are of metal and/or synthetic fibre.
24 A panel according to any preceding claim, comprising at least one tie member extending through multiple layers of the panel to tie the layers together.
25. A panel according to claim 24, wherein the or each tie member extends through at least one layer of settable material to be retained in position by the settable material after setting. I5
26. A panel according to any preceding claim, further comprising at least one attachment member for attachment of the panel to lifting means.
27. A panel according to any preceding claim, further comprising at least one aperture through the panel, for use as a door or window.
28. A building panel substantially as described above, with reference to the accompanying drawings.
29. Any novel subject matter or combination including novel subject matter disclosed herein, whether or not within the scope of or relating to the same invention as any of the preceding claims.
GB0805183A 2007-03-24 2008-03-20 Insulated building panel Withdrawn GB2448047A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GBGB0705680.7A GB0705680D0 (en) 2007-03-24 2007-03-24 Building panel

Publications (2)

Publication Number Publication Date
GB0805183D0 GB0805183D0 (en) 2008-04-30
GB2448047A true GB2448047A (en) 2008-10-01

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GBGB0705680.7A Ceased GB0705680D0 (en) 2007-03-24 2007-03-24 Building panel
GB0805183A Withdrawn GB2448047A (en) 2007-03-24 2008-03-20 Insulated building panel

Family Applications Before (1)

Application Number Title Priority Date Filing Date
GBGB0705680.7A Ceased GB0705680D0 (en) 2007-03-24 2007-03-24 Building panel

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2483985A1 (en) * 1980-06-06 1981-12-11 Alcaraz Christian Heat and noise insulating building wall - is constructed by casting mortar over string of light hollow spheres
US4597237A (en) * 1984-01-11 1986-07-01 Aldo Celli Modular wall panel and building wall constructed therefrom
DE19724416A1 (en) * 1997-06-10 1998-12-17 Schraps Hans Juergen Method of introducing defined hollow-chamber structures into construction materials
EP1126094A2 (en) * 2000-02-18 2001-08-22 Sergio Zambelli Prefabricated concrete panel for industrialized building with high thermal and/or acoustic insulation
US20030192272A1 (en) * 2002-04-15 2003-10-16 Bravinski Leonid G. System and method for the reinforcement of concrete

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2483985A1 (en) * 1980-06-06 1981-12-11 Alcaraz Christian Heat and noise insulating building wall - is constructed by casting mortar over string of light hollow spheres
US4597237A (en) * 1984-01-11 1986-07-01 Aldo Celli Modular wall panel and building wall constructed therefrom
DE19724416A1 (en) * 1997-06-10 1998-12-17 Schraps Hans Juergen Method of introducing defined hollow-chamber structures into construction materials
EP1126094A2 (en) * 2000-02-18 2001-08-22 Sergio Zambelli Prefabricated concrete panel for industrialized building with high thermal and/or acoustic insulation
US20030192272A1 (en) * 2002-04-15 2003-10-16 Bravinski Leonid G. System and method for the reinforcement of concrete

Also Published As

Publication number Publication date
GB0705680D0 (en) 2007-05-02
GB0805183D0 (en) 2008-04-30

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