GB2456659A - High structural strength sandwich panel - Google Patents

High structural strength sandwich panel Download PDF

Info

Publication number
GB2456659A
GB2456659A GB0823731A GB0823731A GB2456659A GB 2456659 A GB2456659 A GB 2456659A GB 0823731 A GB0823731 A GB 0823731A GB 0823731 A GB0823731 A GB 0823731A GB 2456659 A GB2456659 A GB 2456659A
Authority
GB
United Kingdom
Prior art keywords
sandwich panel
panel according
core
lattice
filler
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Withdrawn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
GB0823731A
Other versions
GB0823731D0 (en
Inventor
Matthew Smyth
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.)
Individual
Original Assignee
Individual
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 Individual filed Critical Individual
Priority to GB0823731A priority Critical patent/GB2456659A/en
Publication of GB0823731D0 publication Critical patent/GB0823731D0/en
Publication of GB2456659A publication Critical patent/GB2456659A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10Building 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
    • E04C2/20Building 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
    • E04C2/205Building 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered 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
    • B32B3/10Layered 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 discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12Layered 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 discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building 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
    • E04C2/34Building 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
    • E04C2/36Building 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
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building 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
    • E04C2/34Building 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
    • E04C2/36Building 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
    • E04C2/365Building 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 by honeycomb structures
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building 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
    • E04C2/34Building 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
    • E04C2002/3488Building 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 frame like structures

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

High structural strength sandwich panel 12 comprising a prefabricated core, which consists of a lattice 2 filled with a filler 7, and skins 9 bonded to the core. The lattice may be a one-piece grating or a plurality of crisscrossed strips, both being rigid and made from fibre reinforced polymers. The filler may comprise polymeric foam or an aerated cement based product. A method of applying the skins is also claimed which may comprise the steps of covering each face with a prepared wet resin and pressing fibre reinforcements into the wet resin to achieve full impregnation. The wet resin may be epoxy, polyester, phenolic, vinyl ester, acrylic or other suitable polymeric resins. The fibre reinforcement may be glass, carbon, polymer and may take the form of chopped strands, woven roving, multi-axial or similar mats.

Description

HIGH STRUCTURAL STRENGTH SANDWICH PANEL
This invention relates to a high structural strength sandwich panel, a product composed of two sheets of rigid material bonded to either side of a prefabricated core. In addition, the invention addresses the method of assembly which provides full adhesion between the said sheets and core.
Sandwich panels normally consist of sheets, or skins', made from a variety of materials -typically metals, plastics, timber, minerals, -which are bonded to core materials such as foam, timber, honeycomb, polymers or similar and are used in a wide range of applications including construction, industrial, mass transit, aerospace and many similar industries. These panels are widely accepted for their positive strength to weight ratios and are particularly suitable for audio and thermal insulation systems. The majority of such panels are used in vertical and overhead applications such as walls, partitions, cladding, ceilings and similar where there are limited structural demands. Such panels are rarely used for base levels such as floors, decks or thoroughfares where traffic -pedestrian, vehicular or otherwise -is common. This is mainly due to the relatively low compressive strength of the light weight core -usually foam -and, in many cases, its friability. A further problem with conventional sandwich panels relates to the adhesion between skin and core. Unless total surface adhesion is achieved voids, caused by air entrapment or a diaphragm', can occur and severely reduce a panels' strength.
This invention seeks to overcome such deficiencies by combining methods and materials that will result in relatively lOw cost, easy to manufacture, high structural strength sandwich panels suitable for base levels. In particular, this invention seeks to replace metallic manhole, drain, sewer, trench and road covers where theft of such versions for raw material scrap value costs relevant authorities world wide large sums in replacement and compensation claims due to resultant property and personal damage. By combining a unique prefabricated core with an assembly method to ensure full adhesion to the skins results in a sandwich panel with high flexural, tensile and compressive strengths. These aspects will now be described as follows and with reference to the accompanying drawings in which; Figure 1 shows an isometric view of the sandwich panel with a section of top skin removed to reveal the core structure containing the lattice and filler.
Figure 2 shows a side elevation of the lattice made from strips of solid material with embossed vertical wall faces, Figure 3 shows the resin and fibre application.
The Core I -this contains two main elements; i) A lattice 2. Lattice structures are manufactured using long established methods involving notching and crisscrossing strips of solid material. In this invention such strips would have embossed vertical wall faces 3 which would act as a key to hold the filler in position. One-piece cast gratings, whilst having a similar shape and material content as lattice structures, have superior strength to equivalent lattice structures and can alternatively be used in this invention for the same purpose. For clarity, both crisscrossed strip and grating versions will be referred to as lattice. Lattices are available in metallic and non-metallic materials, the latter being the more acceptable choice for low weight and low residual scrap value. The most suitable material in this category are fibre reinforced polymers -commonly referred to as GRP -and, as such, can be made available in a variety of sizes where wall thickness 4, height 5, and pitch 6 are chosen to define physical performance requirements and thus suit the particular end application.
ii) The Filler 7. This part of the core has to completely fill every cavity of the lattice and can be any of a wide variety of polymeric foams, most notably polyurethane, or aerated cement based products such as foam concrete.
Methods exist to apply such fillers manually or mechanically.
All lattice cavities are filled to (naximum capacity with the filler 7 so that flat, level surfaces 8 remain. It is to these surfaces 8 that the skins 9 are bonded and it can be seen that the filler 7 need only provide a platform for the skin 9 and thus the filler 7 requires having good tensile strength to prevent delaminating of the finished panel. This is an essential feature of this invention.
The Skins 9.
These can be produced from a wide range of materials including, but not restricted to, metals, timber, minerals and/or plastics and all can be applied using adhesives and conventional techniques such as pressing, vacuum bagging or similar. However, to ensure uniformity and no bonding voids, this invention uses curing wet resins 10 and reinforcements II to manufacture the skin 9 direct on to the core thus using the wet resin as an adhesive. The preferred resin 10 is epoxy due to its adhesive quality, high strength and low shrinkage although other wet resins such as, but not limited to, polyester, phenolic, vinyl ester and acrylic can be used. Compatibility between the resin and the core materials has to be verified initially as some foams and resins are incompatible. The method of skin 9 manufacture used in this invention is known in the composites industry as wet lay-up' and can be applied manually or mechanically using a variety of tried and tested processes. The filled lattice core us laid horizontally on a flat surface which may be a table, bench, conveyor or similar. A predetermined quantity of prepared resin 10 is applied to the full upper surface of the core I. Reinforcements II including, but not limited to, glass, carbon and polymer, are supplied in various forms including, but not limited to, chopped strands, wovens, co-axials, multi-axials and similar mat products. A chosen amount are placed on the resin 10 coated core I and are pressed into the resin 10 until full impregnation of the reinforcement 11 is achieved. This process, which can be manual or mechanised, is repeated until the desired laminate thickness and strength are obtained at which time the finish coating is applied. This may consist of textured, smooth, non-slip, painted or similar surfaces as required for which many methods exist. When the skin is cured, that is, hardened, the core I is reversed and the skin application process repeated on the opposite face. /

Claims (10)

Claims.
1. A sandwich panel comprising a prefabricated core containing a lattice structure filled throughout with filler material and a method of applying skins to both main faces of the core,
2. A sandwich panel according to claim I in which the lattice structure is a one piece solid grating.
3. A sandwich panel according to claim I in which the lattice structure is strips of solid material crisscrossed to form a lattice.
4. A sandwich panel according to claim 3 in which the strips of solid material have an embossed finish on the vertical wall faces,
5. A sandwich panel according to claims 2 and 3 in which the lattice material is a fibre reinforced polymer.
6. A sandwich panel according to claim 1 in which the filler material is polymeric foam.
7. A sandwich panel according to claim I in which the filler is an aerated cement based product.
8. A sandwich panel according to claim 1 in which the prefabricated core consists of the lattice structure totally filled to maximum level with the filler.
9. A sandwich panel according to claim I in which the method of applying the skins to both main core faces is by covering each face totally with prepared wet resin and pressing fibre reinforcements into the resin to achieve full impregnation.
10. An improved method of applying skins to both main faces of a prefabricated core according to claim 9 in which the wet resin is epoxy, polyester, phenolic, vinyl ester, acrylic or other suitable polymeric resins and which contains an appropriate curing agent which solidifies the resin and thus the skin.
I I. An improved method of applying skins to both main faces of a sandwich panel according to claim 9 in which the fibre reinforcement is glass, carbon, polymer or similar as used in the composites industry and is presented in one or more forms such as chopped strands, woven roving, multi-axial or similar mat products.
GB0823731A 2008-01-22 2008-01-22 High structural strength sandwich panel Withdrawn GB2456659A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB0823731A GB2456659A (en) 2008-01-22 2008-01-22 High structural strength sandwich panel

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB0823731A GB2456659A (en) 2008-01-22 2008-01-22 High structural strength sandwich panel

Publications (2)

Publication Number Publication Date
GB0823731D0 GB0823731D0 (en) 2009-03-25
GB2456659A true GB2456659A (en) 2009-07-29

Family

ID=40527037

Family Applications (1)

Application Number Title Priority Date Filing Date
GB0823731A Withdrawn GB2456659A (en) 2008-01-22 2008-01-22 High structural strength sandwich panel

Country Status (1)

Country Link
GB (1) GB2456659A (en)

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100205722A1 (en) * 2008-11-24 2010-08-19 Daniel Kim Resilient pad composite having floating reinforcing structure
ITAR20090033A1 (en) * 2009-08-10 2011-02-11 Carlo Izzo COMPOSITE PANEL FOR CIVIL, INDUSTRIAL AND RESIDENTIAL BUILDING, PARTICULARLY FOR BUFFERS, FLOORS AND SHEETS IN PREFABRICATED BUILDINGS
ITCO20100052A1 (en) * 2010-09-13 2012-03-14 Botta S N C Di Alberto Anna E Michele Botta STRUCTURAL SANDWICH PANEL WITH RETICULAR SUPPORT IN MAGNESIUM OXIDE
CN103046691A (en) * 2012-12-17 2013-04-17 沈阳瑞福工业住宅有限公司 Flow-guiding type foaming structure and prefabricated member composite wallboard and preparation method thereof
CN103266717A (en) * 2013-04-02 2013-08-28 殷国祥 Lightweight partition board with density variation
EP2803780A3 (en) * 2013-05-14 2015-02-25 Keystone Lintels Limited A reinforced building panel
WO2016026217A1 (en) * 2014-08-19 2016-02-25 株洲时代新材料科技股份有限公司 Flame-retardant lightweight structural core and manufacturing method therefor
CN107745554A (en) * 2017-10-16 2018-03-02 佛山佛塑科技集团股份有限公司 Sandwich structure composite and its preparation and application
GB2590505A (en) * 2019-12-20 2021-06-30 Agr Living Ltd Structural insulated panel (SIP) for a modular building
EP4019706A1 (en) * 2020-12-23 2022-06-29 Alfred Iseli Insulation board
WO2023277830A1 (en) * 2021-06-29 2023-01-05 Trifi Karim Plate construction method for buildings
US11890843B2 (en) 2010-11-24 2024-02-06 Applied Ft Composite Solutions Inc. Composite cushioning material and jigless method for making the same

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112726941A (en) * 2020-12-29 2021-04-30 兰州理工大学 Double-grid shear wall for fabricated building, manufacturing method and construction method
CN113211904B (en) * 2021-04-29 2023-03-07 西安建筑科技大学 Corrugated reinforced metal/fiber mixed structure plate and preparation method thereof
CN114801259A (en) * 2022-03-09 2022-07-29 中国船舶重工集团公司第七二五研究所 Preparation method of interlocking type bidirectional grid structure reinforced foam sandwich composite material

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0008960A2 (en) * 1978-09-13 1980-03-19 Sekisui Kagaku Kogyo Kabushiki Kaisha A foamed resin structural material and process for manufacturing the same
JPS5555838A (en) * 1978-10-20 1980-04-24 Sekisui Chem Co Ltd Manufacture of light sheet material
WO2006082595A1 (en) * 2005-02-02 2006-08-10 Defence Research & Development Organisation Lightweight structural composite for load bearing application
WO2006134079A1 (en) * 2005-06-15 2006-12-21 Antoine Antoine Composite part such as a panel, comprising a honeycomb structure
EP2009190A2 (en) * 2007-06-29 2008-12-31 Wolfgang Karl Müller Building element and method for manufacture

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0008960A2 (en) * 1978-09-13 1980-03-19 Sekisui Kagaku Kogyo Kabushiki Kaisha A foamed resin structural material and process for manufacturing the same
JPS5555838A (en) * 1978-10-20 1980-04-24 Sekisui Chem Co Ltd Manufacture of light sheet material
WO2006082595A1 (en) * 2005-02-02 2006-08-10 Defence Research & Development Organisation Lightweight structural composite for load bearing application
WO2006134079A1 (en) * 2005-06-15 2006-12-21 Antoine Antoine Composite part such as a panel, comprising a honeycomb structure
EP2009190A2 (en) * 2007-06-29 2008-12-31 Wolfgang Karl Müller Building element and method for manufacture

Cited By (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9604442B2 (en) 2008-11-24 2017-03-28 Applied Ft Composite Solutions Inc. Peeling process for making resilient pad composite
US20100205722A1 (en) * 2008-11-24 2010-08-19 Daniel Kim Resilient pad composite having floating reinforcing structure
US8956715B2 (en) * 2008-11-24 2015-02-17 Applied Ft Composite Solutions Resilient pad composite having floating reinforcing structure
US8980412B2 (en) 2008-11-24 2015-03-17 Applied Ft Composite Solutions Inc. Resilient pad composite and process for making same
US9155342B2 (en) 2008-11-24 2015-10-13 Applied Ft Composite Solutions Inc. Resilient pad composite having bound reinforcing structure
ITAR20090033A1 (en) * 2009-08-10 2011-02-11 Carlo Izzo COMPOSITE PANEL FOR CIVIL, INDUSTRIAL AND RESIDENTIAL BUILDING, PARTICULARLY FOR BUFFERS, FLOORS AND SHEETS IN PREFABRICATED BUILDINGS
EP2295665A1 (en) * 2009-08-10 2011-03-16 Carlo Izzo Composite panel for civil, industrial and residential building, particularly for curtain walls, floor slabs and roofing panels in prefabricated buildings
ITCO20100052A1 (en) * 2010-09-13 2012-03-14 Botta S N C Di Alberto Anna E Michele Botta STRUCTURAL SANDWICH PANEL WITH RETICULAR SUPPORT IN MAGNESIUM OXIDE
US11890843B2 (en) 2010-11-24 2024-02-06 Applied Ft Composite Solutions Inc. Composite cushioning material and jigless method for making the same
CN103046691A (en) * 2012-12-17 2013-04-17 沈阳瑞福工业住宅有限公司 Flow-guiding type foaming structure and prefabricated member composite wallboard and preparation method thereof
WO2014094343A1 (en) * 2012-12-17 2014-06-26 沈阳瑞福工业住宅有限公司 Flow-guide-type foamed structure and prefab composite wall panel, and preparation method thereof
CN103046691B (en) * 2012-12-17 2015-09-30 沈阳瑞福工业住宅有限公司 A kind of flow-guiding type foaming structure and prefabricated component combined wall board and preparation method thereof
CN103266717A (en) * 2013-04-02 2013-08-28 殷国祥 Lightweight partition board with density variation
EP2803780A3 (en) * 2013-05-14 2015-02-25 Keystone Lintels Limited A reinforced building panel
WO2016026217A1 (en) * 2014-08-19 2016-02-25 株洲时代新材料科技股份有限公司 Flame-retardant lightweight structural core and manufacturing method therefor
CN107745554A (en) * 2017-10-16 2018-03-02 佛山佛塑科技集团股份有限公司 Sandwich structure composite and its preparation and application
GB2590505A (en) * 2019-12-20 2021-06-30 Agr Living Ltd Structural insulated panel (SIP) for a modular building
GB2590505B (en) * 2019-12-20 2022-04-06 Agr Living Ltd Structural insulated panel (SIP) for a modular building
EP4019706A1 (en) * 2020-12-23 2022-06-29 Alfred Iseli Insulation board
WO2023277830A1 (en) * 2021-06-29 2023-01-05 Trifi Karim Plate construction method for buildings

Also Published As

Publication number Publication date
GB0823731D0 (en) 2009-03-25

Similar Documents

Publication Publication Date Title
GB2456659A (en) High structural strength sandwich panel
US8484918B2 (en) Composite structural elements and method of making same
AU621884B2 (en) Foam composite and method of forming same
US6509078B1 (en) Composite material
FI78333B (en) SANDWICH ELEMENT.
SE521525C2 (en) Panels utilizing a pre-cured reinforced core and method for manufacturing the same
JPH07503191A (en) Composite structure with waste plastic core material and its manufacturing method
WO2008131005A1 (en) Structural panels
US20140329060A1 (en) Construction Panel and Manufacture Thereof
US20240002632A1 (en) Composition and Method to Form a Composite Core Material
US7105120B2 (en) Moulding methods
US3480497A (en) Method of making a reinforced resin panel using a soluble cover sheet
TWI832842B (en) Laminated materials for reinforcing structures, reinforcing methods and reinforcing structures
KR20100086237A (en) Composition panel and manufacturing method thereof
GB2218438A (en) Mineral faced panels
US20080199682A1 (en) Structural Elements Made From Syntactic Foam Sandwich Panels
US3649424A (en) Panels
WO2006088364A1 (en) Building element and methods for manufacturing thereof
WO2009059361A1 (en) A structural element
EP3795763A1 (en) A wall
RU2634016C2 (en) Method to produce multilayer article of polymer composite material
KR101497983B1 (en) Method for Manufacturing Exposed Concrete Panel
CN1739960A (en) Composite reinforcing material for thin stone plate and its prepn process
EP1645697A1 (en) Method and apparatus for producing construction panels, construction panels obtained thereby, method of construction using said panels and constructions obtained therewith
CN2860829Y (en) Polyurethane hard foam plastic composite board with elastic bonding transition layer

Legal Events

Date Code Title Description
WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)