RU69539U1 - EASY WALL PANEL - Google Patents

Abstract

A wall panel is proposed with an internal frame made of wooden plates connected by adhesive layers, external and internal cladding, between which a structural insulation, mainly monolithic, is placed, for example, ecowool - cellulose with additives of antiseptics and flame retardants. To increase the strength and rigidity of the panel, the plates are layered so that the plates of the subsequent layer overlap the joints between the plates of the previous one at least half their width.

The plates of the inner layers can be laid at intervals in which embedded parts can be installed.

The side of the skin facing the insulation may be provided with means for improving the adhesion of the skin to the insulation.

Description

The utility model relates to building elements, more precisely, to lightweight enclosing structures, mainly for residential low-rise buildings, in particular, three-layer wall panels with a rigid inner frame, sheet sheathing and heat insulation from effective heat-insulating materials.

In accordance with the terminology adopted in the construction business, non-structural insulation in this application will be called a heater that does not perform any other function than thermal insulation. Structural insulation, being an integral part of the general design of the panel, bears a certain mechanical load or resists it when it occurs.

Further, the panel sheathing facing the mounted panel inside the building will be referred to as the inner skin for brevity, and the sheathing facing the mounted panel outside the building will be referred to as the outer sheathing.

Known three-layer building panel containing a rigid inner frame of longitudinal ribs made of steel sheet profiles, and sheathing of asbestos-cement sheets connected to the frame with glue [S. S. Pan. “Composite reinforced building board made of asbestos-cement or similar sheets”, A.S. USSR No. 147311, class E04C 2/34, publ. in 1964]. The disadvantages of the known panel are the low decorativeness of the casing, the use of expensive metal for the inner frame, the relatively low bearing capacity, due to the low strength of the frame, as well as the asbestos toxicity of the sheet material used as the casing. Sufficient rigidity and strength of the known panel are provided only in assembled form, when the frame and the casing bonded to it work as a whole. This requires the use of relatively thick skins, thicker than what is required only by the fencing, and therefore increases the weight of the panel.

Also known is a three-layer wall panel containing casing made of asbestos-cement sheet, an internal hidden rigid frame made of polystyrene foam and non-structural insulation from mineral wool plates,

moreover, the casing is connected to the frame with glue [L.V. Laikhtman et al. “Three-layer wall panel”, a.s. USSR, No. 727786, class Е04С 2/26, Е04В 1/94, publ. 04/20/80]. A disadvantage of the known panel is its low decorativeness, requiring additional finishing of the surfaces of the skin after the panel is installed in the building. Another disadvantage of the known panel is that the organization of its manufacture requires significant capital costs for special equipment (foaming chamber, steam boiler) and its production is relatively energy intensive.

It is also known the use of profiled panels of plastic materials for finishing the external walls of buildings. The panels can take the form of boards (see, for example, US Patent Publication No. 2006101767 to CL E04D 1/00) or sheets, their surface is often profiled both to connect the panels to each other and to give an aesthetically more attractive appearance, for example, in the form of natural stone or brickwork. A disadvantage of the known panels is that they perform only decorative and protective functions, requiring fixing on the supporting walls of the building. This increases the cost of construction.

Flexible decorative panels are known whose surface imitates natural materials: masonry or brickwork, wood paneling [US Pat. No. 6,237,294 by class. B28B 7/00]. Panels are fixed on the outer surface of the bearing walls of structures with the purpose of decorating them and protecting them from atmospheric influences. The disadvantage of the panels is that they are not load-bearing and insulating.

Also known is a glue-veneer coating panel, including a lower skin made of glued plywood profiles of corrugated cross-section, and an upper monolithic skin made of pouring foam, which plays the role of a structural insulation, equipped with longitudinal wooden beams flush-embedded into the upper skin [a.c. USSR No. 969858 by class E04C 2/26]. The disadvantages of the known panel are low mechanical strength, not allowing its use as a wall and low resistance to weathering.

Also known is a three-layer wall panel containing a frame of wooden beams, structural rigid insulation and cladding, equipped with rectangular protrusions on the inner side [and.with. USSR No. 1135877 by class E04C 2/32]. In this panel, the stiffness and form stability of the panel

provided by the use of skins as elements that give it rigidity and therefore thicker and more massive than is required to perform only the enclosing function. At the same time, their value as thermal insulation is very small. In addition, the dimensional stability of the panel is determined by the quality of the wooden beams, which should be made of high-quality dry wood. And nevertheless, with a cyclical change in temperature and humidity, the bars, and, consequently, the panel, inevitably begin to warp.

The closest to the proposed technical essence and the achieved result is a three-layer wall panel containing a frame of wooden beams, to which flat asbestos-cement sheathing sheets are attached from two sides on the screws. A rigid non-structural insulation (polystyrene) is placed between the sheathing sheets [Typical structures of buildings and structures. Series 1.832-1. Lightweight wall panels for agricultural production buildings. Issue 1. 3 m long panels on a wooden frame with asbestos-cement sheathing]. The disadvantages of the known panel are low decorativeness, requiring additional finishing of the surfaces of the cladding after installation in the building, a large mass due to the fact that the cladding is involved in ensuring the rigidity of the panel and therefore thicker than is required to perform only the enclosing function.

The technical results of this proposal are to reduce the weight, reduce the cost of the panel and construction with its use, increase the decorativeness and weather resistance of the panel.

These results are achieved by the fact that in the known three-layer wall panel containing an internal wooden frame, insulation and cladding, the outer skin is made of decorative profiled plastic panels, the frame is glued from wooden plates laid in layers, and the plates of each subsequent layer overlap the joints of the plates of the previous layer at least half its width, and the insulation is rigid structural and forms at least with the outer skin an integral connection.

In addition, part of the plates are laid at intervals.

In addition, part of the plates forming the perimeter of the frame is laid at intervals in which embedded parts are installed, for example, for connecting the panels to each other.

In addition, a rigid structural insulation is made monolithic.

In addition, ecowool - cellulose with the addition of flame retardants and antiseptics was used as a rigid structural insulation.

In addition, at least the outer skin on the side facing the rigid insulation has means for improving the adhesion of the skin to the insulation, for example, protrusions expanding towards the ends.

By making the frame glued from wooden plates and by laying the plates so that the distance between the joints of the plates of each subsequent layer and the joints of the plates of the previous layer is at least half the width of the plate, the weight of the panel is reduced and the cost of construction using the panel is reduced. Due to this, the rigidity and strength of the panel become so high that there is no need for additional reinforcement of the frame with skins. In turn, this allows the use of thin-walled and fragile decorative plastic panels as external cladding, and the thickness of the internal cladding can be assigned no more than is required by the operating conditions of the interior. The proposed panel is immediately made with a decorative external surface, which reduces the cost of construction.

Due to the fact that the rigid structural insulation forms an integral connection with the outer skin, for example, it is glued to it, it acts as a support for thin skin, thereby ensuring the rigidity of the panel surface. If such an integral connection is also formed with the inner lining, then this creates the possibility of reducing the thickness and inner lining while maintaining its rigidity due to reinforcement with insulation.

Laying part of the plates at intervals reduces the weight of the panel and reduces its cost by reducing the consumption of frame material. This is possible because with panel sizes of not more than three meters, the strength of a continuous glued frame is excessive.

The installation of embedded parts in the gaps between the plates from which the frame is glued reduces the cost of construction by facilitating installation operations.

The protrusions on the inner surface of the plastic panels increase the adhesion of the panels to the monolithic insulation in cases when there is no reliable adhesion of the insulation and cladding.

The essence of the proposal is illustrated by drawings.

Figure 1 shows the proposed panel in plan.

Figure 2 shows a section of the panel secant plane perpendicular to the plane of the panel.

Figure 3-6 shows the layered arrangement of the plates in the frame of the panel. The numbering of the layers corresponds to the order of their laying during the manufacture of the panel.

The proposed panel consists of a wooden frame 1 assembled from wooden plates 2 connected by adhesive layers. On both sides, the outer 3 and inner 4 skin are adjacent to the frame, connected to it by glue or screws 5 (shown in FIG. 6). Between the casing 3 and 4 inside the frame 1 is a rigid structural insulation 6.

The plates 2 forming the bars 7 of the frame 1 are laid in layers. The joints 8 between the plates of successive layers are spaced so that the plates of the previous layer overlap the plates of the subsequent at least half their width. This is illustrated by the drawings of FIGS. 3-6.

To facilitate the panel and reduce the consumption of lumber, the plates 2 in the middle layers of the beams 7 can be stacked at intervals. The gap can be the larger, the smaller the size and weight of the panel. In between can be installed embedded parts 9 (figure 4) for connecting the panels to each other or with ceilings.

To engage in small-sized lumber, the layer of plates 2 preferably inside the beams 7 can be composed of several short plates 2, as shown in Fig.5.

To engage narrow lumber in the case, improve the adhesion of the insulation 6 with the frame and the formation of grooves on the outer edges of the frame beams, when gluing the frame, the plate layers can consist of plates of different widths (figure 2).

The outer skin 3 is made of plastic panels having the form of boards (figure 1), similar to those proposed in the aforementioned US patent publication No. 2006101767, or another type of surface, or made

in the form of a solid sheet, as proposed in the aforementioned US patent No. 6237294. In all cases, the casing is not rigid and is not capable of bearing significant loads. The skin can be fixed on top of the frame 1 (the right side of figure 1) or at the same level with it, depending on the specific type of plastic panels.

For internal cladding 4, the most rational use of cement-bonded particleboard. Due to the high rigidity of the proposed frame and the support of the casing with a rigid structural insulation 6, the thickness of the inner casing can be reduced by approximately 1.5 times compared with known panels, for example, from 12 mm to 8 mm. This greatly facilitates and cheapens the panel without compromising its strength and rigidity.

The support for external cladding is played by rigid structural insulation 6. The most technologically advanced use is cast insulation, for example, known under the trade name "ecowool", a cellulose-based insulation with additives of antiseptics and flame retardants. It is the cheapest, environmentally friendly, technologically advanced and forms a hard massif with low thermal conductivity after solidification.

If the structural rigid insulation 6 has low adhesion to the skin material, then to prevent the skin from lagging behind it, the latter is equipped with means for improving the protrusions 10, the width of which at the base A is less than the width B at the ends, for example, like a swallow tail, as shown in FIG. .2. If the insulation 6 in the manufacture of the panel is poured through the technological holes in the frame 1, then both skin 3 and 4 can be provided with similar means.

The proposed panel is made as follows.

An external plastic casing 3 is laid on the mounting table and fastened to the first layer of plates 2 (Fig. 1). The plates are smeared with glue and a second layer of plates is laid on them so that the joints 8 between the plates of the first layer would be overlapped by the plates of the second layer at least half the width of the plates (Fig. 3). If the frame 1 of the panel has internal beams, then the components of their plate 2 are also stacked with overlapping joints of the layers. It was experimentally established that when the distance between the joints of adjacent layers is less than half the width of the plates 2, there are cases of kinks of long (over 6 meters) panels when they are lifted at two adjacent corners.

In the drawings, for example, a panel is presented, the frame of which is glued from five layers of plates. Depending on the size of the panel, there may be more or less layers. Preferably, the protuberances of the annual rings of the wood of the plates of adjacent layers are directed in opposite directions. This reduces the risk of warpage. In the spaces between the plates of the middle layers can be installed embedded parts 9 (figure 4). After laying the last (in this example, fifth) layer of the plates (Fig.6) they are pressed or pulled together with screws (nails) 12, excess glue protruding on the side edges of the frame are removed.

A rigid structural insulation 6 is poured inside the frame 1, an inner lining 4 is laid over the frame with a heater, which is fastened to the frame 1 with screws 5 or glue. If the rheological properties of the insulation 6 allow, then first the inner skin 4 is attached to the frame, and then inside the almost finished panel through the specially provided holes in the bars of the frame 1, the insulation 6 is poured.

An important advantage of the proposed panel is the undemanding quality of the lumber of the plates, which can be one or two grades lower than is usually accepted in the manufacture of three-layer panels with a wooden inner frame. Cracks, knots, tearing and other defects practically do not affect the strength of the panel assembly. The plates are not planed, since the villi remaining on their surface after sawing reinforce the adhesive joint well.

Due to the small thickness, the non-structural external decorative cladding has a small mass compared to the cement-bonded particleboard. This allows you to reduce the cross-section of the beams of the frame of the panel, which further facilitates the panel. The average weight reduction over several sizes compared to conventional panels is 31%.

Claims (6)

1. A lightweight wall panel containing an internal wooden frame, insulation and sheathing, characterized in that the outer skin is made of decorative profiled plastic panels, the frame is glued from wooden plates laid in layers, and the plates of each subsequent layer overlap the joints of the plates of the previous layer, at least half its width, and the insulation is rigid structural and forms, at least with the outer skin, an integral connection. 2. The lightweight wall panel according to claim 1, characterized in that part of the plates are laid at intervals. 3. The light wall panel according to claim 2, characterized in that embedded parts are installed in the gaps along the perimeter of the frame, for example, for connecting the panels to each other. 4. The lightweight wall panel according to claim 1, characterized in that the rigid structural insulation is made integral. 5. The lightweight wall panel according to claim 1, characterized in that ecowool - cellulose with the addition of flame retardants and antiseptics is used as a rigid structural insulation. 6. The lightweight wall panel according to claim 1, characterized in that at least the outer skin on the side facing the rigid insulation has means for improving the adhesion of the skin to the insulation, for example, protrusions expanding towards the ends.