KR20030089696A - Building panel having at least two panel domains of different average compressive strength - Google Patents

Abstract

A building panel that comprises at least two panel domains, wherein each panel domain has an essentially homogeneous compressive strength and an average compressive strength and wherein at least two panel domains differ in average compressive strength, is useful for inserting into cavities having a variety of shapes, sizes, and obstacles therein.

Description

BUILDING PANEL HAVING AT LEAST TWO PANEL DOMAINS OF DIFFERENT AVERAGE COMPRESSIVE STRENGTH}

Building structures typically include a framework that has a framework that acts as a cavity wall and defines a plurality of cavities. For example, buildings often have wood or metal frameworks composed of joists and studs spaced at arbitrary distances. Consideration and beams act as common walls. The distance between two views or beams defines a cavity spacing and the volume between two views or beams defines a cavity. It is often desirable to insert a material, such as a thermal insulator, into the cavity. However, the cavities come in a variety of sizes and shapes and obstacles such as electrical conduits or plumbing pipes may be disposed therein. Tightly fitting panels in cavities with varying areas and containing various obstacles may be used to fabricate specific panels for each of the different cavities or to use panels with sufficient flexibility to accommodate various cavity sizes, shapes, and obstacles. Require.

Typical materials for filling the cavities include fibrous materials and polymeric foams. Fibrous materials, such as glass wool and cellulose fibers, usually require special consideration during mounting because handling and suction of the fibers are problematic. Fibrous batting is also particularly flexible, thus allowing for tightening, stretching and hanging the batting when connecting wide cavities such as between rafter beams. Rigid polymeric foams such as polystyrene (PS) and rigid polyurethane foams are suitable as insulation in cavities, but are somewhat lacking in optimal performance in compliance with various cavity sizes, shapes, and obstacles. Rigid polymeric foams typically need to be cut to conform to a particular cavity. Flexible polymeric foams, such as flexible polyurethane foams (FPU), are more readily compliant to the amount of co-change than rigid foam plates. Unfortunately, flexibility also allows the foam to tighten, stretch and hang when connecting wide cavities such as between rafter beams.

Ideally, a panel fitted in a cavity has a combination of cavity shape, size, and flexible properties for adapting to obstacles and rigid properties that resist tightening and sagging of the panel when placed in the cavity. US patent application Ser. No. 09 / 706,110 ('110) discloses one such panel comprising a combination of hollow and solid coal foam strands (see lines 14, lines 7 to 17).

There is a need for panels that can fit within cavities with various sizes, shapes, obstacles and are free from a combination of hollow and solid foam strands without the obstacles caused by fibrous materials, rigid foams, or flexible polymeric foams.

The present invention relates to building panels having at least two panel domains differing in average compressive strength. Panels are useful for filling cavities with non-uniform areas with obstacles disposed therein or on both sides.

1 shows a panel comprising two panel domains.

2A, 2B and 2C show examples of panels inserted into a cavity by bending back from a planar configuration to a nonplanar configuration.

3A shows a panel with a compliant panel domain around the perimeter of the panel.

3B shows a panel with multiple compliant panel domains around the perimeter of the panel.

Figure 4a shows an end view of two panels, one in the tongue profile and one in the groove profile, connected and inserted into the cavity.

5A and 5B show a panel of the present invention that works with a panel having a single panel domain to connect the cavity ends.

In a first aspect, the invention is an architectural panel comprising at least two panel domains, each panel domain having essentially homogeneous compressive strength and average compressive strength, wherein the panels have (a) different average compressive strengths. One having at least two panel domains and (b) essentially free from the combination of solid and hollow foam strands, wherein the panel has at least two adjacent panel domains comprising a fibrous material having a fibrous orientation The fibrous orientation of the panel domain of is not perpendicular to the fibrous orientation of at least one adjacent panel domain.

A particularly useful variant of the first aspect includes at least one compliant panel domain that when pressed compresses at least one area of the panel to allow insertion of the panel into the cavity, the panel retains frictional retention of the panel within the cavity. It also has a compressive recovery that results. That is, the compliant panel domain presses against the cavity walls of the cavity at a pressure sufficient to hold the building panel in the cavity due to the friction between the cavity wall and the compliant panel.

Another useful variant of the first aspect includes a compliant panel domain within a panel, which allows the panel to bend backwards into a non-planar configuration in a planar configuration.

In a second aspect, the invention relates to a method of at least partially filling a cavity, the method comprising inserting at least one panel into the cavity, wherein the at least one inserted panel is a panel of the first aspect.

The present invention is needed by providing a panel that can fit within a cavity having various sizes, shapes, obstacles and is free from hollow and solid foam strands without the obstacles contributing to fibrous materials, rigid foams, or flexible polymeric foams. Corresponds to

The present invention relates to a building panel. "Building panel" refers to a single item useful for manufacturing buildings and structures, including cavities. As used herein, the terms "building panel" and "panel" may be used interchangeably.

The building panel can be of any shape or area having two opposing faces, at least one of which is a "first face." The first face of the building panel has the same surface area as the top surface area face on the panel. The building panels may have two major faces that are opposite but not adjacent to each other. Although may be of any shape including a circle, the first face is preferably square or rectangular. Building panels having a square or rectangular first face are square or square building panels, respectively. Preferably, the first face is parallel to the opposite face. The face or faces for connecting the first face to the opposite face is a second face that forms a perimeter around the building panel. Examples of the second face include opposing ends and opposing edges of square or rectangular building panels.

"Panel thickness" is the vertical distance between the first face and its opposite face. The panel thickness at any point on the first side of the building panel is preferably at least 1 centimeter (cm), more preferably at least 2 cm and at least 5 cm, at least 10 cm, even at least 20 cm. There is no known functional limitation on the thickness of building panels. Building panels with a panel thickness of less than 1 cm tend to be so thin that they do not tighten, stretch or hang and do not connect the ends of the cavity widths.

The building panel may have a contour on one or more surfaces. For example, the first face may have a functional contour or decorative design, such as a conical protrusion for acoustic attenuation. The building panel may include grooves to facilitate compliance around obstacles in the cavity and to bend the panel.

Architectural panels are not necessary but preferably have an essentially uniform panel thickness. Herein, the building panel is one wherein the difference in panel thickness at any two points on the first side of the building panel is less than 10 percent (%) or 5 millimeters (mm) of the average thickness of the panel at the two points. If smaller, it has an essentially uniform panel thickness. Preferably, the building panel has a panel thickness difference that is less than 3 mm, more preferably less than 2 mm, between the two points of the building panel.

The building panel of the present invention further comprises at least two panel domains. A "panel domain" is a section of a building panel that extends the length, width, thickness, or combination thereof. The panel domain typically comprises at least 1 percent, preferably at least 2 percent, more preferably at least 5 percent, more preferably at least 10 percent and less than 100 percent of the volume of the building panel. Examples of suitable panel domains include a band, strip, plug (such as a cylindrical plug extending the thickness of the building panel), or a combination thereof. Preferably, the panel domain is "band". The band is a panel domain that crosses the first side of the building panel. Preferably, the band also extends the thickness of the panel. For example, the band may extend through the thickness of the panel and to the opposite end (length) of the rectangular building panel. Panel domains may have any shape and size, and may vary in size, shape, and physical properties within building panels. Preferably, at least one panel domain of the building panel, more preferably at least two panel domains, more preferably all panel domains is less than or equal to 0.1 Watts per meter-kelvin (W / m * K), more preferably It has a thermal conductivity of 0.065 W / m * K or less, most preferably 0.045 W / m * K or less. Thermal conductivity is determined according to ASTM method C-518-98.

Each panel domain has inherently homogeneous compressive strength and average compressive strength. By “essentially homogeneous compressive strength” is meant any section of the same area of the panel domain in which any section of the panel domain comprising 20 percent of the panel domain volume comprises 20 percent of the panel domain volume compressed in the same direction or orientation. Within 20 percent of the other section, preferably within 10 percent, means average compressive strength in any direction. Unless otherwise indicated, compressive strength values are measured according to the American Society for Experimental and Material Method D1621 (ASTM). "Average compressive strength" is the average compressive strength over a compression range of 0 to 50 percent, more preferably a compression range of 0 to 80 percent. As used herein, the ranges include boundaries unless otherwise indicated.

Panel domains may be made of wood, metal, glass, rubber, fibrous materials, inorganic foams, organic foams, and combinations thereof.

Examples of fibrous materials include fibrous batting, glass wool, mineral wool, polymeric fibrous batting, carbonaceous fibers, and rock wool. The building panel includes at least two adjacent domains comprising the fibrous material provided that the fibrous orientation of one domain is not perpendicular to the fibrous orientation of at least one adjacent domain when the fibrous material has a fibrous orientation. It may also include. For example, US Pat. No. 4,025,680 discloses a fibrous insulation comprising a plurality of adjacent parallel strips of fibers having a fibrous orientation in the strips alternating at right angles in adjacent strips (see two columns 5-11). Such materials are not within the scope of the present invention because the fibrous orientation of each strip (or panel domain) is perpendicular (vertical) to the fibrous orientation of each adjacent strip.

Preferably, at least one panel domain is free of fibrous material, and more preferably the entire building panel is free of fibrous material. More preferably, at least one panel domain is a polymeric foam, and most preferably all panel domains of the building panel comprise polymeric foam.

Suitable polymeric foams include those comprising one or more of the following: polystyrene (PS) polymers and copolymers; Polyesters, polyolefins such as polyethylene (PE), polypropylene (PP), PE copolymers such as ethylene / styrene copolymer (ESI), and PP copolymers; And polyurethane. The polymeric foam may comprise a polymer mixture, such as a PP and PE mixture.

The polymeric foam has a density of up to 100 kilograms (kg / m ³ ) per cubic meter, more preferably up to 50 kg / m ³ . Foams having a density of at least 100 kg / m ³ usually have undesirable thermal insulation properties. The foam has a density in excess of 5 kg / m ³ .

The polymeric foam has an average cell diameter. The average cell diameter is determined by measuring the cell diameter on the cross section of the foam. The average cell diameter for the foam is the average diameter for at least 20 randomly selected cell cross sections on the foam cross section. The diameter of an aspherical cell is the average of the longest and shortest chords through the center of the cell cross section. Observe the foam cross section using an optical or electron microscope. The polymeric foams useful in the present invention preferably have an average cell diameter of at least 0.01 mm, more preferably at least 0.1 mm, more preferably at least 0.3 mm. Preferably, the average cell diameter is less than 10 mm, more preferably less than 4 mm, more preferably less than 2 mm. Foams having an average cell diameter of less than 0.01 mm tend to have undesirable high densities. Foams with average cell diameters greater than 10 mm tend to be poor thermal insulators.

The building panels of the present invention comprise at least two panels that differ in average compressive strength. Compressive strength is measured by compressing the same direction and orientation in similar panel domains of similar size and shape. Preferably, the average compressive strength is different when the two panel domains are compressed to an area corresponding to the width of the building panel. Preferably, the two panel domains differ in average compressive strength by at least 5 percent, preferably at least 10 percent, more preferably at least 25 percent, and at least 50 percent, at least 100 percent or even at least 200 percent. Can be different.

Preferably, at least one panel domain is compliant. The compliant panel domain is compressible and elastic, providing compressive recovery and compressibility for building panels. It is advantageous for the compliant panel domain to have a compression area smaller than any other area to prevent tightness of the panel domain during compression.

At 10 percent compression, the compressibility characterizes the compressibility of the panel domain. The compliant panel domain is compressed to 10 percent compression of at least 0.1 kilopascals (kPa), more preferably at least 0.2 kPa, more preferably at least 0.3 kPa and at most 200 kPa, more preferably at most 50 kPa, more preferably at most 20 kPa. Has strength. Panel domains having a compressive strength of less than 0.1 kPa lack sufficient durability and panel domains having a compressive strength above 200 kPa are typically difficult to compress.

The percent recovery for 50 percent compression is indicative of the elasticity of the panel domain. The recovery percentage is measured by applying a compressive force to the panel domain sufficient to compress the panel domain to 50 percent of its uncompressed thickness. The compressive force is alleviated and the panel domain thickness is measured after 24 hours. The compressive force divided by the uncompressed thickness of the panel domain is alleviated and the panel domain thickness after 24 hours is the compressive recovery for the panel domain. The compliant panel domains have a compressive recovery of at least 60 percent, more preferably at least 70 percent, more preferably at least 80 percent.

Preferably, compressing at least one compliant panel domain of the building panel reduces the area of at least one of the building panels. Reducing the area of the building panel may allow for insertion of the building panel into a cavity, for example, having a width less than the uncompressed area of the building panel.

More preferably, the building panel has a degree of compression recovery when the compliant panel domain (s) are no longer compressed. Compression recovery of the building panels is desirable to supply sufficient pressure against the cavity walls to frictionally retain the building panels in the cavity. Typically, the compression recovery will exert a building panel is 100 square meters per Newton (N / m ²⁾ or more, preferably 200N / m ² or more, more preferably 300N / m ² or more of pressure. Pressures below 100 N / m ² are usually insufficient to frictionally retain the building panels in the cavity without tightening or sagging. Typically, the pressure is 200,000N / m ² or less, preferably 50,000 N / m ² or less, more preferably 30,000N / m ² or less. Building panels applying a pressure of 200,000 N / m ² or more are usually very difficult to compress.

Suitable compliant panel domains include polymeric foams and fibrous materials such as fibrous elastics, glass wool, carbonaceous fibers, mineral wool. Preferably, the compliant panel domain is a polymeric foam, more preferably an open cell polymeric foam. The foam for use in the compliant panel domain preferably has at least 5 percent, more preferably at least 10 percent, more preferably at least 30 percent, and most preferably at least 50 percent open cell content according to ASTM method D2856-A. Has Polymeric foams with an open cell content of less than 5 percent often lack good compressive force.

Adjacent panel domains within a building panel may have specific, gradient, or variable boundaries. Two adjacent panel domains have certain boundaries when at least one building panel characteristic such as compressive strength or density suddenly changes from one panel domain to another. Sudden changes occur at distances of 0.5 cm or less, preferably 0.2 cm or less, more preferably 0.1 cm or less. For example, joining two polymeric foams having different compressive strengths along adjacent edges together may create a building panel having two panel domains and a specific boundary between these panel domains. Certain boundaries that separate panel domains by more than 0.5 cm tend to be gradient boundaries or variable boundaries or even other panel domains.

Alternatively, the two panel domains may have a gradient boundary where at least one characteristic is between the characteristics of each of the individual panel domains or gradually changes from the characteristics of one panel domain to the characteristics of an adjacent panel domain. For example, projecting two foams of different densities to mix together at an interface produces a building panel having a gradient boundary that gradually varies from the density of one panel domain to the density of adjacent panel domains. In addition, the interface between the two panel domains connected to the fold seam will constitute a gradient boundary.

The two panel domains may instead have variable borders where at least one architectural panel property is variable but does not regularly vary across the border from the properties of one panel domain to the properties of the other panel domain.

One variation of the invention is a square or rectangular building panel with a band. The band preferably crosses the maximum area (building panel length) of the first face and the maximum area of its opposite face. The band may extend at right angles from one end of the building panel to the opposite end, traverse the building panel diagonally, such as from one corner to the opposite edge, or may extend from one end to the other in a non-linear shape. The band may be of any shape and size, but is preferably thick enough to prevent tightening during compression.

One preferred building panel configuration includes a compliant band along at least one edge of a square or rectangular building panel. Such a band is a "compliant edge band". Compliant edge bands allow building panels to conform to obstacles such as conduits and plumbing pipes along the cavity walls. Another advantageous building panel configuration includes a compliant panel domain along an end of the building panel that can fit into an obstacle extending into the cavity across the end of the building panel. Square, rectangular or any other shaped building panel may have a perimeter including one or more compliant panel domains.

Another variation of a square or rectangular building panel includes at least one compliant band in the building panel that allows the building panel to be curved in a non-planar configuration to facilitate insertion into the cavity.

One preferred panel domain configuration for building panels of the present invention has alternating compliant and rigid panel domains or alternating rigid and compliant bands. Hard panel domains are panel domains with a higher average compressive strength than any bonded compliant panel domain. For example, square or rectangular building panels may have alternating rigid and compliant bands. 1, 2A, 2B, and 2C show examples of building panels with alternating compliant and rigid panel domains.

1 shows an example of a building panel 10 having a panel thickness T and two panel domains 20, 30. Panel domains 20 and 30 are bands within building panel 10. The panel domain 20 has a greater average compressive strength than the panel domain 30. The first face 15 of the building panel 10 includes faces 22, 32 of the panel domains 20, 30, respectively. 1 shows the interface 40 between panel domains 20 and 30 as a variable boundary. 1 shows the edge 12 of the building panel 10, which also functions as the edge of the panel domain 30. The building panel 10 has the same length L as the panel domain 30. Building panel 10 has a width (W).

2A, 2B and 2C show an example of building panel 50 with five panel domains 60, 70, 80, 90, 100. All five panel domains are bands of architectural panel 50. Panel domains 60, 80, 100 are compliant. Panel domain 80 allows building panel 50 to be curved in a non-planar configuration. 2A shows building panel 50 and cavity 115. The width W ′ of the building panel 50 is wider than the gap between the cavity walls 110, 120 defining the cavity 115. 2B shows building panel 50 after bending in a non-planar configuration for insertion into cavity 115. Force F is applied against panel domain 80 to return building panel 50 to the planar configuration within cavity 115 and to compress panel domains 60, 80, 100. 2C shows building panel 50 in cavity 115.

The building panel of the present invention may have at least one slit that crosses the first face or the face opposite the first face and extends to a depth less than the panel thickness. This slit facilitates bending the building panel into a non-planar configuration for insertion into the cavity. 2A, 2B, and 2C also show this optional slit 82 in the panel domain 80. 2B shows that the slit 82 is somewhat open when the building panel 50 is curved in a non-planar configuration to facilitate the building panel 50.

3A shows building panel 130 with two panel domains 132, 134. Panel domain 134 is a compliant panel domain disposed around the perimeter of building panel 130. 3A shows panel domain 134 as a single piece, but may also be composed of multiple pieces. 3B shows a similar building panel 140 having a panel domain 142 and multiple compliant panel domains 144, 146, 148, 150 around the perimeter of the building panel 140.

The building panel may have a tongue or groove profile on at least one second side. The tongue profile comprises the tongue, preferably one or two shoulders. Similarly, the groove profile comprises a groove, preferably one or two shoulders. The tongues on one building panel are advantageously fitted in grooves on adjacent building panels to form seams between the building panels. While any tongue and groove shape is feasible, the rounded shape is useful, making it possible to press the tongue of one building panel into the groove of another building panel. The shoulder helps to keep the tongue of one building panel moving out of the groove of the adjacent building panel, thereby causing a tightening or sagging at the joint between the two building panels. The shoulder, if present, is at least zero percent, preferably at least 5 percent, more preferably at least 10 percent, preferably at most 95 percent, preferably at most 80 percent, more preferably at most 60 percent of the panel thickness. It is composed. If the shoulder consists of more than 95 percent of the panel thickness, the tongue tends to break easily.

4A and 4B show end views of a cavity 185 and two building panels 160, 170 defined by cavity walls 180, 190. Building panel 160 includes a rigid panel domain 163 having a compliant panel domain 162 and tongue profile including tongue 164 and shoulders 166, 168. The building panel 170 includes a rigid panel domain 173 having a compliant panel domain 172 and a groove profile comprising grooves 174 and shoulders 176 and 178. The building panels 160 and 170 The compliant panel domains 162, 172 are disposed against the cavity walls 180, 190, respectively, and the tongue 164 is grooved while applying a force F 'against the hard panel domains 163, 173. It is inserted into the cavity 185 by sliding in 174. 4B shows building panels 160 and 170 connected and inserted into cavity 185 with the somewhat compliant panel domains 162 and 172 compressed.

Typically, when two or more building panels are in contact with other panels in a cavity, the pressure caused by the elasticity of the compressed panel domain is sufficient to hold adjacent building panels together. However, adjacent edges of two adjacent building panels may have an adhesive therebetween to prevent the building panels from separating. Similarly, applying adhesive tape or any form of fasteners across adjacent edges along the first side of the adjacent building panel can help prevent building panels from being separated.

One suitable method for preparing the building panels of the present invention is to adjoin together certain panel domains, such as several polymeric foams or a combination of polymeric foams and fibrous materials, to form a single architectural panel. One skilled in the art can identify any of several means suitable for adjoining two panel domains, including wires, epoxy or polyurethane adhesives, latex adhesives, hinges, and double-sided tapes that can be inserted into and penetrate adjacent panel domains. . It is also acceptable to melt weld the polymer panel domains using heat or solvent.

Another suitable method for preparing the building panels of the present invention is to chemically, mechanically, or both chemically and mechanically modify at least one domain in the building panel that has initially essentially homogeneous compressive strength. For example, tightening or crushing cell walls, or perforating, slicing or removing a portion of the polymeric foam panel domains would lower the compressive strength of the panel domains. The slice in the panel domain may be or perpendicular to the compression plane, which still degrades the compressive strength of the panel domain. Slices into the compression plane may result in local tightening of the panel domain. Chemically altering the panel domains of the polymeric foam can also produce panel domains that differ in compressive strength. For example, adding plasticizer to the polymeric foam lowers the compressive strength but tends to add a crosslinker to increase the compressive strength of the foam. Chemical and mechanical modifications are also useful for creating domains of differing compressive strengths in building panels that do not initially have essentially homogeneous compressive strength.

Another acceptable method for preparing the building panels of the present invention is the simultaneous manufacture of panel domains in such a way that adjacent panel domains are adjacent during manufacture. For example, different polymeric foams are coextruded adjacent to one another through a die such that the polymeric foams are brought into contact with each other during expansion and coalesce at the joint where contact occurs. The various foams then form various panel domains in the polymeric foam building panel.

Similarly, strand foam coalescence techniques are acceptable for preparing the building panels of the present invention. In fact, strand foam coalescence technology has inherent advantages over other foam technologies in preparing building panels.

Strand foam coalescence techniques involve extruding molding gel through a die comprising multiple holes to form strand foam. The “strands” are extruded through the holes and expand to each other to create a structure such as a building panel that includes multiple foam strands. Foam structures comprising a plurality of coal foam strands are strand foams. Each strand has an epidermis and a core. The epidermis wraps around the core and is denser than the core. The strands bind together as their epidermis coalesces during expansion. The use of an adhesive to join the strands and to help join the strands is also acceptable.

The compressive strength of the strand foam is a function of a number of parameters. Here, the compressive strength corresponds to the compressive strength during radial strand compression in the case of strand foam. For example, strand foams having a predetermined number of strands in cross-sectional area have a higher compressive strength than strand foams having a few strands in cross-sectional area. A good reason for higher compressive strength in strand foams with many strands per cross-sectional area is that the more strands, the more skin there is in the strand foam cross-sectional area. The skin installs the support structure through the strand foam cross section which resists compression.

The interstrand space also lowers the compressive strength of the strand foam. Interstrand space is formed when the strands are small enough or are spaced enough to periodically contact neighboring strands only during expansion. The places where the strands do not contact remain as voids between the strands. These voids are interstrand spaces. The interstrand spacing reduces the compressive strength of the strand foam by causing the strand to compress into space instead of neighboring strands.

One skilled in the art can identify several methods without improper experiments to prepare strand foams having different compressive strengths.

By changing the die from which the foam strands are extruded, a number of strand foam parameters can be changed, including the compressive strength of the strand foam. Dies typically have any number of holes per unit area. The holes have any shape, size, and any orientation in the die. For a given molding gel extruded through a die to form strand foam, the number of holes per unit area of the die refers to the number of strands per cross sectional area of the final strand foam. Hole shape refers to the shape of the foam strand. Hole size refers to strand size. Hole orientation refers to the interstrand orientation of the strand foam.

Extruding the forming gel through a die having two or more sections is different in at least one of the following: hole spacing, number of holes per unit area and hole shape that can produce strand foam having various panel domains. For example, one section of the die may have a characteristic number of holes per unit area and adjacent sections of the die may have fewer holes per unit area. Extruding the forming gel through such a die will produce a stranded foam building panel with one panel domain of a particular strand number per cross-sectional area adjacent to another panel domain with less strand per cross-sectional area. Panel domains with less strands per cross-sectional area will have less compressive strength than panel domains with more strands per cross-sectional area.

Foam strands may be solid or hollow. Solid strands have foam over the entire cross-sectional area of the strand. The hollow strand has foam only around the perimeter of the strand cross section so that the center of the strand cross section does not comprise foam. Hollow strands and their preparation are further described in US patent application Ser. No. 09 / 706,110 ('110; see page 2, line 30 to page 5, 17, 17). Hollow strands have a compressive strength less than solid strands when compressed in the radial direction. The building panels of the present invention may comprise hollow strands or solid strands, but are essentially independent of the combination of hollow and solid strands. Building panels are essentially bound to a combination of hollow and solid strands if the difference between the number of solid foam strands and the number of hollow foam strands exceeds 90 percent, preferably 95 percent, more preferably 98 percent of the total number of strands. Do not receive.

Polymeric strand foams typically comprise at least one organic polymer for preparing polymer strand foams. The organic polymers are alkylene aromatic polymers, polyolefins, rubber modified alkylene aromatic polymers, alkylene aromatic copolymers, cured alkylene aromatic polymers and copolymers, alpha-olepin homopolymers and copolymers, or rubbers and the polymers described above. With a mixture of. Preferred polymers include homopolymers and copolymers of PS, PE, and PP, including ESI.

The building panel of the present invention may function in conjunction with the building panel outside the scope of the present invention to connect the joint ends. For example, FIGS. 5A and 5B illustrate building panels 220 and 230 that act in combination to connect the ends of the cavities 205. Building panel 220 includes panel domains 222, 224. Panel domain 222 is compliant. Building panel 230 includes a single panel domain 232 having opposing edges 234, 236. 5A shows building panel 2220 with panel domain 222 inserted into cavity 205 with cavity wall 200 against and edge 234 of panel domain 232 against cavity wall 210. 230 is shown. Position the edge 226 of the building panel 220 against the edge 236 of the building panel 230 and at the edges 226, 236 to position the building panels 220, 230 within the cavity 205. A force F ″ is applied against it. The panel domain 222 is compressed as the building panel is inserted into the cavity 205. FIG. 5B shows building panels 220 and 230 in the cavity 205. As shown in FIG.

The building panels of the present invention may be connected to at least one other building panel, which may or may not be within the scope of the present invention, using at least one hinge to create a hinged building panel. The hinged building panels can be reversely curved at the hinge (s) to take a nonplanar configuration for insertion into the cavity. Similarly, at least one panel domain may connect at least one other panel domain via at least one hinge. Suitable hinges have actual devices designed to hinge connect the curved polymer or metal strip, the polymer or metal membrane, or the structure. The hinge may be attached to the first side of the adjacent building panel or panel domain, may be attached to the second side of the adjacent building panel or panel domain, or may penetrate into the adjacent building panel or panel domain. One building panel variant is between one or two compliant panel domains compliant around the hinges such that the compliant panel domain (s) are compressed and in close contact with the hinged panel domain upon insertion of the building panel into the cavity. It is provided with a hinge.

The panel domain, even the entire building panel, may have a facer on at least one side, in particular on the first side. Suitable phasers include polymer membranes, metal sheets and foils (such as aluminum foils), paper, textile materials and nonwoven materials including glass fibers and cloth, and combinations thereof. These phasers can impart additional air barrier properties to building panels, can act as a hinge between panel domains, improve the decorative properties of building panels, and help keep building panels tightened or stretched. . The pacer does not have to, but it can cover the entire face of the building panel.

Many building panel configurations are within the scope of the present invention. For example, a foam building panel comprising a single foam may be formed of other foams (or any other panel domain material) with a compressive strength greater or less than that of the foam building panels disposed over the foam thickness in a characteristic pattern to direct compression of the foam under pressure. It may have a cylindrical plug. Optionally, the building panel comprising the main domain material may have a tapered or grooved section filled with a domain material different from the main panel domain material. Those skilled in the art can understand many different configurations that are within the scope of the present invention.

The building panels of the present invention are useful for insulation, acoustic dampers and insulators, for decoration, or for simply filling the cavity, for example to prevent insects or rodents from entering the cavity. Building panels are particularly useful for being located within roof cavities and walls of homes, garages and other structures. The building panel of the present invention is also useful, for example, for positioning in the wall cavity of a portable thermal container.

The following example further describes the invention and does not limit the scope in any way. Compressive strength (stress) is determined using the European standard (EN) 826 or as otherwise indicated. The thermal conductivity is determined according to EN 28301 at 10 ° C.

First and second example. Comparative example of building panel with or without compliant edge band

Example 1 shows a building panel of the present invention oriented from a single stranded foam panel. Example 1 includes a compliant panel domain that does not follow the panel edges.

Example 2 shows an architectural panel of the present invention similar to Example 1 further comprising a compliant panel domain on an opposite panel edge (“compliant edge band”). Example 2 is similar to the panels of FIGS. 2A and 2B. Example 2 may conform to larger diameter obstructions on the walls of the cavity than similar panels that are not bound by the compliant edge band as in Example 1.

130 cm long, 60 cm wide and 10 cm thick [Procel is the same as Dow Chemical's registered propel® 12-20 polymerized foam] Examples 1 and 2 using a panel of polyolefin-based composite strand foam Prepare example 2. Compliant domains are created in Examples 1 and 2 by penetrating the foam with a 10 cm wide band through the center of the building panel. It is penetrated by needle puncture using a 2 mm diameter needle placed 5 mm apart along the right axis. A compliant edge band is created in Example 2 by penetrating a 5 cm wide panel domain along the edge of Example 2 using the same needle perforation procedure as in the case of forming a 10 cm wide compliant band. The non-penetrating panel domains of Examples 1 and 2 are hard panel domains. Both Examples 1 and 2 show building panels with panel domains that are bands.

Table 1 shows the compressive strengths for the rigid and compliant panel domains of Examples 1 and 2. Strain percentages correspond to compression percentages.

Table 1. Compressive strength of kPa for panel domains in Examples 1 and 2

Example 1 and Example 2.

Panel domain 10% strain 25% strain 50% strain 70% strain 90% strain reshuffle 23.3 29.0 72.8 123 294 Compliant 12.5 20.8 33.6 54.8 191

Further deformation of the 10 cm wide compliant panel domain is achieved by slicing a 90 to 95 mm deep slit along the length of the panel domain at the center of the widthwise area using a hot blade.

An experimental cavity is created by placing two chambers spaced at a certain distance in parallel with each other while the main plane of one chamber is facing the first plane of the other shell. The volume between the two delimitations defines a cavity having a delimitation gap that defines the cavity width. The surface of each considered has a width (limiting the depth of the cavity) in excess of 10 cm. The cavity is tilted at an angle of 45 degrees to the horizontal to stimulate the roof pitch.

A cylindrical object of a certain diameter is placed along the first plane of view. The object, for example, excites a cable, conduit, or pipe along a beam or beam.

Example 1 or 2 by bending the building panel first along the slit of a 10 cm wide compliant band, inserting the panel edges against the face of the cavity and pressing along the slit until the building panel is completely inside the cavity. Placed in a cavity (see eg FIGS. 2A and 2B). Both Examples 1 and 2 fit tightly into the cavity without tightening when the considered spacing is between 60 cm and 56 cm. Tightening is most evident in the 10 cm wide compliant band, which occurs in building panels when the gap is less than 56 cm.

Example 1 conforms to a cylindrical object having a diameter of 5 m or less, which forms a tight seal with the core. Example 1 does not form a tight seal around a cylindrical object having a diameter of 10 mm or more.

Example 2 conforms to a cylindrical object having a diameter of 15 mm forming a seal and a tight seal.

Example 3: Building Panel with Polyurethane Foam-compliant Panel Domain

Example 3 illustrates a building panel of the present invention comprising a polyurethane foam compliant panel domain. Example 3 further demonstrates the advantage of having a compliant edge band to conform around the object on the cavity wall. Example 3 has a structure similar to that of the building panel in FIGS. 2A and 2B. The panel domain of Example 3 is an example of a band.

Cut two hard domains of 130 cm long, 20 cm wide and 10 cm thick on PS foam plates such as Styrofoam® loopmate SL polymeric foam insulation (Styrofoam is a registered trademark of Dow Chemical). In a flexible polyurethane (PU) foam (same as PU foam 16F from Mételle Mauissa), three compliant bands of 130 cm long, 10 cm thick, two 5 cm wide and one 10 cm wide were cut. The panel domains are glued together using a two part epoxy adhesive along an edge 130 cm long and 10 cm thick to produce a building panel having an area similar to Example 2 and having the next panel domain orientation.

5cm PU Foam / PS Foam / 10cm PU Foam / PS Foam / 5cm PU Foam

Table 3 shows the compressive strength profiles for PU foams. For comparison, the compressive strength for PS foam is 229 kPa at yield.

Table 3. Compressive Strength (kPa) of Flexible Polyurethane Foam

10% strain 25% strain 50% strain 70% strain 90% strain 5.07 5.47 5.77 8.72 61.96

Insert Example 3 into the experimental cavity using the procedure described in Examples 1 and 2. Example 3 fits tightly around a cylindrical object having a 15 mm diameter on the first plane of the cavity wall and fitted into a cavity with a gap of 60 cm to 56 cm without tightening.

Example 4. Polyurethane construction panels

Building panels were prepared as described in Example 3 except that rigid polyurethane foam was used instead of PS foam. Rigid polyurethane foams have a density of 35 kg / m ³ according to EN1602, a compressive strength of 146 kPa at yield and a thermal conductivity of 19 milliwatts per meter-kelvin (mW / m * K).

Example 4 further shows the building panel of the present invention performed similarly to Example 3 and composed of polyurethane foam. The thermal conductivity of rigid polyurethane foams forms particularly good thermally conductive building panels.

Example 5. Rock wool construction panels

Example 5 shows all fiber building panels of the present invention.

[RockPlus is the same as Rockplus®, a registered trademark of rock wool] One piece of rock wool having a density of 55 kg / m ³ is cut into panels 130 cm long, 60 cm wide and 10 cm thick. Using a roller or hydraulic press through the center of the panel, a 10 cm wide 130 cm full length compliant band is compressed to 20 percent of its original thickness. Compressing the panel imparts elasticity to the rockwool structure, creating a compliant domain. The panel takes a hard band / compliant band / hard band configuration. This panel is example 5.

Table 4 shows the compressive strengths of the uncompressed (rigid) band and the compressed (compliant) band.

Table 4. Compressive strength (kPa) for the compressed and uncompressed bands of Example 5

Panel domain 5% strain 10% strain 25% strain 50% strain Non-Pickup Type (Hard) 2.5 5.2 9.9 18 Compression (compliant) 1.1 1.4 2.9 16

Example 5 is fixedly fitted with a cavity spacing of 57 cm using the cavity wall test apparatus in Example 1.

Claims (20)

An architectural panel containing at least two panel domains, Each panel domain has inherently homogeneous compressive strength and average compressive strength. The panel is (a) has at least two panel domains with different average compressive strengths, (b) essentially independent of the combination of solid and hollow foam strands, If the panel has at least two adjacent panel domains comprising a fibrous material having a fibrous orientation, the fibrous orientation of one panel domain is not perpendicular to the fibrous orientation of at least one adjacent panel domain, i) the panel comprises a slit transverse to a first face or a face opposite the first face and extending to a depth less than the panel thickness, ii) the panel includes a compliant domain around its periphery, iii) at least one domain comprises coalesced strand foam Building panel corresponding to at least one of the above requirements. The building panel of claim 1, wherein the at least one panel domain comprises a polymeric foam. The building panel of claim 1, wherein each panel domain comprises a polymeric foam. 4. The building panel according to claim 1, wherein at least two panel domains differ in average compressive strength by at least 5 percent. 5. The panel according to claim 1, wherein the at least one panel domain is a compliant panel domain which, when compressed, reduces the at least one area of the panel to allow insertion of the panel into the cavity. And has a compressive recovery force causing frictional retention of the panel in the cavity. The building panel of claim 1, wherein the at least one panel domain is a compliant panel domain that allows the panel to bend backward from a planar to a nonplanar configuration. The panel according to claim 1, wherein the panel traverses a first face, a face opposite to the first face, a panel thickness, and a face facing the first face or the first face. A building panel comprising a slit penetrating a depth less than a parmal thickness. The building panel of claim 1, wherein the panel has alternating compliant and rigid panel domains. The building panel according to claim 1, wherein the panel has a compliant panel domain along at least one edge. The building panel according to claim 1, wherein the panel domain is a band. The building panel according to claim 1, wherein the panel has at least one edge comprising a tongue or groove profile. The building panel of claim 1, wherein the at least one panel domain comprises coalesced polymeric foam strands. The building panel of claim 13, wherein the coalescent polymeric foam strand comprises polypropylene. The building panel of claim 1, wherein the at least one panel domain comprises coalesced polymeric foam strands with spaces between the strands. 4. A building panel according to claim 2 or 3, wherein the foam has a density of at least 5 kilograms per cubic meter and less than 100 kilograms per cubic meter. The building panel of claim 2, wherein the at least one polymeric foam panel domain has an open cell content of at least 5 percent, according to the American Society for Experimental and Material Methods D2856-A. The panel of claim 1, wherein the panel comprises a coalesced polypropylene foam strand having an average cell diameter in the range of 0.01 to 10 millimeters and a density in the range of 5 kilograms per cubic meter to 100 kilograms per cubic meter, and at least one panel domain Building panel characterized by having an open cell content of at least 5 percent, according to the American Society for Experimental and Material Methods D2856-A. The method of claim 2, wherein the average diameter of the foam cell is in the range of 0.1 to 4 millimeters, and the density of the foam is in the range of 5 kilograms per cubic meter to 50 kilograms per cubic meter, wherein the foam is experimental and material method D2856-. Architectural panel according to the American Institute for A, having an open cell content of at least 50 percent. 4. The building panel according to claim 1, wherein at least one first face comprises both a decorative design, a functional contour or both a decorative design and a functional contour. 4. The opposing second of claim 1, wherein the panel has an opposite second having a compliant domain on at least two opposing second surfaces of the panel in the absence of a compliant domain around the periphery of the panel. Architectural panel characterized by having a surface.