GB2466437A - Structural building and or vehicle panel - Google Patents

Structural building and or vehicle panel Download PDF

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Publication number
GB2466437A
GB2466437A GB0822997A GB0822997A GB2466437A GB 2466437 A GB2466437 A GB 2466437A GB 0822997 A GB0822997 A GB 0822997A GB 0822997 A GB0822997 A GB 0822997A GB 2466437 A GB2466437 A GB 2466437A
Authority
GB
United Kingdom
Prior art keywords
outer envelope
structural building
panel
vehicle panel
inner filling
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Withdrawn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
GB0822997A
Other versions
GB0822997D0 (en
Inventor
Frederick George Best
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 GB0822997A priority Critical patent/GB2466437A/en
Publication of GB0822997D0 publication Critical patent/GB0822997D0/en
Priority to EP09803888A priority patent/EP2379819A2/en
Priority to PCT/GB2009/051745 priority patent/WO2010070358A2/en
Publication of GB2466437A publication Critical patent/GB2466437A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B62D29/002—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material a foamable synthetic material or metal being added in situ
    • 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
    • E04C2/28—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 combinations of materials fully covered by groups E04C2/04 and E04C2/08
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/78—Heat insulating elements
    • E04B1/80—Heat insulating elements slab-shaped
    • E04B1/803—Heat insulating elements slab-shaped with vacuum spaces included in the slab
    • 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
    • E04C2/292—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 sheet metal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00—Adapting or protecting infrastructure or their operation
    • Y02A30/24—Structural elements or technologies for improving thermal insulation
    • Y02A30/242—Slab shaped vacuum insulation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B80/00—Architectural or constructional elements improving the thermal performance of buildings
    • Y02B80/10—Insulation, e.g. vacuum or aerogel insulation

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Acoustics & Sound (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Body Structure For Vehicles (AREA)

Abstract

The invention relates to a structural building and/or vehicle panel 10 and comprises a compressible outer envelope 12, and an inner filling 14 which has a lower density than the material of the outer envelope. The inner filling is pre-stressed to make the panel rigid. The outer envelope is preferably formed from thin sheet metal or plastics. The filling material may be powder and or fibre such as fumed silica. The outer envelope may have one or more interior partitions (26 figure 2) extending laterally to the plane of the upper and lower sheets thereby forming interior compartments (28 figure 2). The pre-stressing of the inner filling is provided by applying a vacuum to the interior of the envelope. Alternatively the panel may be subjected to an external pressure. A method of forming a structural building and/or vehicle panel is also provided.

Description

Improvements in and relating to structural building andlor vehicle panels The present invention relates to a structural building and/or vehicle panel, and to a method of forming such a panel.
Pre-stressing concrete is a well known technique for overcoming concrete's natural weakness when in tension. However, concrete is particularly dense and heavy, and therefore not suitable for many applications involving light-weight panels, especially those relating to vehicles.
The present invention seeks to provide a solution to this problem.
According to a first aspect of the invention, there is provided a structural building or vehicle panel comprising a compressible outer envelope and an inner filling of lower density than the material of the outer envelope, the inner filling being pre-stressed to make the panel rigid.
Preferable and/or optional features of the first aspect of the invention are set forth in claims 2 to 11, inclusive.
According to a second aspect of the invention, there is provided a method of forming a structural building or vehicle panel in accordance with the first aspect of the invention, the method comprising the steps of: a) filling a compressible outer envelope with material of lower density, and b) pre-stressing the material within the outer envelope until the panel becomes rigid.
Preferable and/or optional features of the second aspect of the invention are set forth in claims 14 to 18, inclusive.
The invention will now be more particularly described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows a diagrammatic cross-sectional view of part of a first embodiment of a straight-sided panel, prior to pre-stressing of the inner filling and in accordance with the first aspect of the invention; Figure 2 shows a diagrammatic cross-sectional view of part of a second embodiment of a panel with internal strengthening members and prior to pre-stressing of the inner filling, in accordance with the first aspect of the invention; and Figure 3 shows a diagrammatic cross-sectional view of part of a third embodiment of a panel formed from upper and lower sheets sandwiching inner filling, subsequent to pre-stressing of the inner filling and in accordance with the first aspect of the invention.
Referring to Figure 1 of the drawings, a first embodiment of a high-strength low-density panel 10 for a structure, being a vehicle, including a car, lorry, bus, train, boat, aeroplane and/or space craft, and/or a building being any construction on earth or in space, is shown. The panel 10 includes a compressible hollow outer envelope 12 and an inner filling 14 which has a density lower than that of the material of the outer envelope 12. By way of example, the outer envelope 12 is preferably formed of thin metal sheet, such as stainless steel, having a thickness in the range of 0.075 mm to 0.25 mm.
However, the outer envelope 12 can be plastics, or any material having a high tensile strength. Due to the thinness of the walls 16 of the outer envelope 12, the outer envelope 12 taken by itself has little or no structural or weight bearing strength.
The outer envelope 12 is filled with the inner filling 14, which is generally in the form of powder and/or fibre 18. Initially, therefore, the inner filling is preferably loose and unfastened within the outer envelope 12.
The inner filling 14 may then be tamped down. Once filled, the air from within the outer envelope 12 is extracted through an opening 20, causing the outer envelope 12 to compress, and thus also to compress the inner filling 14. The inner filling 14 thus becomes pre-stressed by the outer envelope 12. The compression causes the inner filling 14 and outer envelope 12 to become rigid. The outer envelope 12 is then preferably air tightly or hermetically sealed to prevent the ingress of air and thus to hold the inner filling 14 in its pre-stressed condition. The rigidity of the resulting panel 10 through research and development has been found to be sufficient for structural applications, such as in vehicles and buildings. The resulting panel 10 is extremely low density, yet very strong. Depending upon size, densities of 0.14 g/cc have been achieved.
It has been found that an inner filling 14, such as or including fumed silica preferably with a particle size of 12 nanometres (nm), is particularly beneficial in creating a rigid, light and structurally strong panel 10. It has been found that a variety of different filling materials can impart additional properties such as thermal insulation.
The outer envelope 12 can be a single blank of material, sealed at its edges to form a cavity or chamber 22 for the inner filling 14. However, two blanks of material can be superposed and connected at their edges to form the cavity or chamber 22 of the outer envelope 12.
The outer envelope 12 of a second embodiment of a high-strength low-density panel 10 may have one or more interior partitions 26, thereby forming a plurality of interior compartments 28. See Figure 2. Like references refer to parts which are similar to those of the first embodiment, and thus further detailed description is omitted.
The interior partition or partitions 26 may be in the form of a wall or walls 30 which extend substantially laterally to the plane of the upper and/or lower sheets 32 of the outer envelope 12, or a sheet or sheets which are substantially in parallel with the upper and lower sheets thus providing multiple skins. The interior partition 26 may include one or more openings 34 to enable the passing of inner filling 14 between compartments 28.
The upper and/or lower sheets 32 may include a plurality of skins. In this case, channels may be provided between the inner and outer skins. The respective skins can be connected together at points which are spaced from each other, for example, via spot welding. Fluid, typically being a high pressure fluid, and being gas or liquid, can be provided between the skins when encased within a mould to increase their rigidity and strength after removing from the mould.
In the above described embodiment, pre-stressing of the inner filling 14 is provided by evacuation of the outer envelope 12. However, additionally or alternatively, the application of external pressure to the outer envelope 12 can achieve a similar result, as shown in Figure 3. Again, like references of this third embodiment refer to parts which are similar to those of the first embodiment, and thus further detailed description is omitted.
In this case, the outer envelope 12 of the third embodiment of a high-strength low-density panel 10 is typically crushed to tightly sandwich the inner filling 14 therebetween. This crushing forces air out from the inner filling 14 and from within the outer envelope 12, again resulting in pre-stressing of the inner filling 14. It is preferable that the material of the outer envelope 12 thus retains its crushed shape following the application of external pressure.
In this latter arrangement, it may be preferable to air tightly or hermetically seal the outer envelope 12. However, sealing may not be necessary depending on the material of the outer envelope 12.
To form the outer envelope 12 with a specific shape, a moulding process similar to blow moulding can be used. By forcing high pressure fluid into the interior cavity or chamber 22 of the outer envelope 12, typically whilst the outer envelope 12 is at an elevated temperature, and before the inner filling 14 is inserted, the outer envelope 12 can be expanded to take on the shape of the mould.
It is also feasible to form the outer envelope 12 into complex shapes by utilising a multi-part mould which can be moved in stages during the moulding process. In this case, an incompressible liquid is preferably used to expand the outer envelope 12 to the required shape as the parts of the mould are being positioned.
It is therefore possible to provide a high-strength low-density panel for a structure, particularly for a vehicle or building. The panel includes a low-density filling which is pre-stressed, thereby making the outer envelope extremely rigid and suitable for structural applications.
The embodiments described above are provided by way of examples only, and various modifications will be apparent to persons skilled in the art without departing from the scope of the appended claims.

Claims (17)

  1. Claims 1. A structural building and/or vehicle panel comprising a compressible outer envelope and an inner filling of lower density than the material of the outer envelope, the inner filling being pre-stressed to make the panel rigid.
  2. 2. A structural building and/or vehicle panel as claimed in claim 1, wherein the outer envelope is metal.
  3. 3. A structural building and/or vehicle panel as claimed in claim 1 or claim 2, wherein the filling is at least one of powder or fibres.
  4. 4. A structural building and/or vehicle panel as claimed in any one of the preceding claims, wherein the outer envelope is air tightly sealable.
  5. 5. A structural building and/or vehicle panel as claimed in any one of the preceding claims, wherein the inner filling is pre-stressed by evacuation of the outer envelope.
  6. 6. A structural building and/or vehicle panel as claimed in any one of the preceding claims, wherein the inner filling is pre-stressed by external compressing of the outer envelope.
  7. 7. A structural building and/or vehicle panel as claimed in any one of the preceding claims, wherein the outer envelope is formed of upper and lower interconnected sheets.
  8. 8. A structural building and/or vehicle panel as claimed in claim 7, wherein at least one further sheet is provided between the upper and lower sheets.
  9. 9. A structural building and/or vehicle panel as claimed in any one of the preceding claims, wherein the outer envelope includes at least two interior compartments.
  10. 10. A structural building and/or vehicle panel as claimed in any one of the preceding claims, wherein the structure is one of a vehicle and a building.
  11. 11. A structural building and/or vehicle panel having a panel substantially as hereinbefore described with reference to the accompanying drawings.
  12. 12. A method of forming a structural building and/or vehicle panel as claimed in any one of the preceding claims, the method comprising the steps of a) filling a compressible outer envelope with material of lower density, and b) pre-stressing the material within the outer envelope until the panel becomes rigid.
  13. 13. A method as claimed in claim 12, further comprising a step c subsequent to step b of closing the outer envelope.
  14. 14. A method as claimed in claim 13, wherein, in step c, the outer envelope is air tightly sealed.
  15. 15. A method as claimed in any one of claims 12 to 14, further comprising a step d prior to step a of forming the outer envelope using a mould, the outer envelope being internally expanded to the shape of the mould.
  16. 16. A method as claimed in claim 15, wherein the mould is movable during the moulding process for complex shapes.
  17. 17. A method as claimed in claim 16, wherein an incompressible fluid is utilised to expand the outer envelope.
GB0822997A 2008-12-18 2008-12-18 Structural building and or vehicle panel Withdrawn GB2466437A (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
GB0822997A GB2466437A (en) 2008-12-18 2008-12-18 Structural building and or vehicle panel
EP09803888A EP2379819A2 (en) 2008-12-18 2009-12-18 Improvements in and relating to structural building and/or vehicle panels
PCT/GB2009/051745 WO2010070358A2 (en) 2008-12-18 2009-12-18 Improvements in and relating to structural building and/or vehicle panels

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB0822997A GB2466437A (en) 2008-12-18 2008-12-18 Structural building and or vehicle panel

Publications (2)

Publication Number Publication Date
GB0822997D0 GB0822997D0 (en) 2009-01-28
GB2466437A true GB2466437A (en) 2010-06-23

Family

ID=40343735

Family Applications (1)

Application Number Title Priority Date Filing Date
GB0822997A Withdrawn GB2466437A (en) 2008-12-18 2008-12-18 Structural building and or vehicle panel

Country Status (3)

Country Link
EP (1) EP2379819A2 (en)
GB (1) GB2466437A (en)
WO (1) WO2010070358A2 (en)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3793789A (en) * 1972-01-24 1974-02-26 Building Structural Syst Inc Building structural system
US4024309A (en) * 1975-03-17 1977-05-17 Ronald P. Wilder Foam glass structural element and method of producing

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB715174A (en) * 1951-07-14 1954-09-08 Gen Electric Improvements in and relating to thermal insulation
US5094899A (en) * 1990-09-06 1992-03-10 Owens-Corning Fiberglas Corporation High r super insulation panel
DE10125964A1 (en) * 2001-05-29 2002-12-12 Oesterr Heraklith Gmbh moldings
AU2003256244A1 (en) * 2002-07-19 2004-02-09 Arcelik A.S. An insulated unit and a manufacturing method thereof
CA2624284A1 (en) * 2005-10-07 2007-04-19 Graham Clifford Garner Vacuum heat insulator, and refrigerator, car, and building using vacuum heat insulator

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3793789A (en) * 1972-01-24 1974-02-26 Building Structural Syst Inc Building structural system
US4024309A (en) * 1975-03-17 1977-05-17 Ronald P. Wilder Foam glass structural element and method of producing

Also Published As

Publication number Publication date
GB0822997D0 (en) 2009-01-28
WO2010070358A3 (en) 2011-04-14
WO2010070358A2 (en) 2010-06-24
EP2379819A2 (en) 2011-10-26

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