US20130192157A1 - Panel and a method for building panels - Google Patents
Panel and a method for building panels Download PDFInfo
- Publication number
- US20130192157A1 US20130192157A1 US13/567,395 US201213567395A US2013192157A1 US 20130192157 A1 US20130192157 A1 US 20130192157A1 US 201213567395 A US201213567395 A US 201213567395A US 2013192157 A1 US2013192157 A1 US 2013192157A1
- Authority
- US
- United States
- Prior art keywords
- rigid
- panel
- members
- modular
- rigid outer
- 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.)
- Abandoned
Links
- 238000000034 method Methods 0.000 title claims description 44
- 238000010276 construction Methods 0.000 claims abstract description 20
- 238000004519 manufacturing process Methods 0.000 claims abstract description 6
- 230000003014 reinforcing effect Effects 0.000 claims description 49
- 239000012774 insulation material Substances 0.000 claims description 22
- 239000002184 metal Substances 0.000 claims description 22
- 125000006850 spacer group Chemical group 0.000 claims description 12
- 238000009413 insulation Methods 0.000 claims description 5
- 238000007664 blowing Methods 0.000 claims description 2
- 239000002131 composite material Substances 0.000 description 10
- 239000011159 matrix material Substances 0.000 description 10
- 229920005830 Polyurethane Foam Polymers 0.000 description 6
- 239000002023 wood Substances 0.000 description 6
- 239000011152 fibreglass Substances 0.000 description 5
- 229920001431 Long-fiber-reinforced thermoplastic Polymers 0.000 description 4
- 239000004918 carbon fiber reinforced polymer Substances 0.000 description 4
- 238000010526 radical polymerization reaction Methods 0.000 description 4
- 229920001169 thermoplastic Polymers 0.000 description 4
- 239000004416 thermosoftening plastic Substances 0.000 description 4
- 239000004698 Polyethylene Substances 0.000 description 3
- 239000004793 Polystyrene Substances 0.000 description 3
- 239000011518 fibre cement Substances 0.000 description 3
- -1 polyethylene Polymers 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- 239000011495 polyisocyanurate Substances 0.000 description 3
- 229920000582 polyisocyanurate Polymers 0.000 description 3
- 229920002223 polystyrene Polymers 0.000 description 3
- 239000004814 polyurethane Substances 0.000 description 3
- 229920002635 polyurethane Polymers 0.000 description 3
- 239000011496 polyurethane foam Substances 0.000 description 3
- 239000010454 slate Substances 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 229920003043 Cellulose fiber Polymers 0.000 description 2
- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 2
- 229920002488 Hemicellulose Polymers 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 239000004760 aramid Substances 0.000 description 2
- 229920003235 aromatic polyamide Polymers 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 239000011151 fibre-reinforced plastic Substances 0.000 description 2
- 238000005304 joining Methods 0.000 description 2
- 229920005610 lignin Polymers 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 239000011202 short fiber thermoplastic Substances 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- 238000004026 adhesive bonding Methods 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000009431 timber framing Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Images
Classifications
-
- 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
- E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
- E04B1/14—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements being composed of two or more materials
-
- 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
- E04B1/38—Connections for building structures in general
- E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
- E04B1/6108—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
- E04B1/6116—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by locking means on lateral surfaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B21/047—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions
- B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
-
- 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
- E04B1/38—Connections for building structures in general
- E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
- E04B1/6108—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
- E04B2/562—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with fillings between the load-bearing elongated members
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
- E04B2/70—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood
- E04B2/706—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood with supporting function
- E04B2/707—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood with supporting function obturation by means of panels
-
- 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
- E04C2/296—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 non-metallic or unspecified sheet-material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/03—3 layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0278—Polyurethane
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/304—Insulating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2607/00—Walls, panels
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/74—Removable non-load-bearing partitions; Partitions with a free upper edge
- E04B2002/7461—Details of connection of sheet panels to frame or posts
- E04B2002/7475—Details of connection of sheet panels to frame or posts using connectors with claws penetrating the sheet panels
-
- 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49616—Structural member making
- Y10T29/49623—Static structure, e.g., a building component
- Y10T29/49629—Panel
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Building Environments (AREA)
- Laminated Bodies (AREA)
Abstract
A method of manufacturing a construction panel comprising the steps of laying a plurality of rigid support members on a preformed assembly jig, each rigid support member having two main planar surfaces with perimeter surfaces extending between these main planar surfaces, laying the plurality of rigid support members so that each rigid support member has at least one perimeter surface in an abutting relationship with the perimeter surface of an adjacent rigid support member, bridging at least part of the length of abutting perimeter surfaces with at least one connector means for connecting the plurality of rigid support members together into a predetermined shape and size of modular rigid panel member.
Description
- The instant application claims priority to GB Patent Application Serial No. 1113574.6, filed Aug. 5, 2011, pending, the entire specification of which is expressly incorporated herein by reference.
- The present invention relates to a panel and method for building panels and in particular to a method and arrangement for building structural insulated panels.
- Structural insulated panels (SIP's) have gained in popularity and market share over the previous five to ten years. These strong, lightweight, and highly efficient building panels are generally constructed from a thermal insulating core, formed from a material such as polyurethane foam, sandwiched between two orientated strand boards (OSB's), which are generally wood flakes or strands bonded together with resins, binders, and waxes. SIP panels have greater strength in terms of both axial loading and racking than conventional timber framing, are relatively simple to build with and provide extremely good thermal insulation.
- SIP panels are generally joined using an insert in the form of a dowel or spline that is placed between two panels, within a routered out cavity in the foam insulation. Fixings are then driven through the OSB's and into the inserts, forming a joint between two SIP panels. These inserts are typically either wooden or formed from small sections of SIP's. These joining methods are sufficient in terms of structure; however, the cost to create the cavities into which the inserts are placed can be expensive in terms of tooling and labour. SIP panels are generally manufactured in widths of 1.2 metres of various lengths up to 6 m long so to manufacture a roof, wall or floor panel with greater widths requires these prefabricated SIP panels to be jointed in these ways.
- It is an object of the present invention to obviate or mitigate the problem of incurring additional expense due to tooling and labor costs associated with joining small panels to produce large panels to span larger areas and in particular SIP panels.
- Accordingly, the present invention provides a method of manufacturing a construction panel comprising the steps of laying a plurality of rigid support members together, each rigid support member having two main planar surfaces with perimeter surfaces extending between these main planar surfaces, laying the plurality of rigid support members so that each rigid support member has at least one perimeter surface in an abutting relationship with the perimeter surface of an adjacent rigid support member, bridging at least part of the length of abutting perimeter surfaces with at least one connector means for connecting the plurality of rigid support members together into a predetermined shape and size of modular rigid panel member.
- Ideally, the method comprising manufacturing a sandwich type construction panel comprising the steps of forming a second similar shape and size of modular rigid panel member using the same method and placing an insulation means in a gap between the modular rigid panel members.
- Preferably, the method comprising the steps of laying the rigid support members on a preformed assembly jig.
- Advantageously, the present method avoids the problem of disposing of waste polyurethane foam generated as a result of the current method of creating oversized panels by jointing standard SIP panels. The disposal of PU foam is a major environmental issue as the PU foam requires special treatment for disposal because it is prohibited to burn PU foam.
- Preferably, the method comprising placing spacer means on at least one of the modular rigid panel members for supporting the two modular rigid panels members in a spaced apart relationship defining the gap there between.
- Preferably, the method comprising connecting the rigid support members by connector plates.
- Ideally, the method comprising providing connector means on at least one surface of at least one of the modular rigid panel members.
- Preferably, the method comprising pre-stressing the connector means.
- Advantageously, pre-stressing minimises the risk of bowing in rigid support members by holding them in compression. Pre-stressing the connector means also allows reduced depths of rigid support members to be used for equivalent design strengths. The pre-stressed rigid support members are resilient and will recover from the effects of a greater degree of overload than a similar unstressed rigid support member. Furthermore, if the rigid support member is subject to overload, cracks, which may develop, will close up on removal of the overload. The pre-stressing enables a modular rigid panel member to be formed from a number of segmented rigid support members. Furthermore, lighter elements permit the use of longer spanning members with a high strength to weight characteristic. The ability to control deflections in pre-stressed rigid support members permits longer spans to be achieved.
- Ideally, the method comprising fixing the connector means onto the planar surfaces of two adjacent rigid support members.
- Ideally, the method comprising mechanically fixing the connector means onto the planar surfaces of two adjacent rigid support members.
- Preferably, the method comprising mechanical fixing the connector means onto the planar surfaces of two adjacent rigid support members using spikes.
- Ideally, the spikes protrude from the main plane of the mechanical fixing means.
- Preferably, the method comprising retaining the connector means in the rigid support members via the mechanical fixing means having barbs.
- Ideally, the connector means can be fixed to the planar surfaces of two adjacent rigid support members by any mechanical fixing means such as nails, screws, studs, male and female members or any combination of such mechanical fixing means.
- Ideally, the connector means can be fixed to the planar surfaces of two adjacent rigid support members by bonding, gluing or welding or any combination of these.
- Preferably, the method comprising providing the insulation material from any one of or any combination of polystyrene, polyurethane, polyisocyanurate, polyethylene, wood panel or fibre glass.
- Preferably, the method comprising bonding or mechanically fixing the insulation material onto an internal facing surface of at least one of the modular rigid panel members.
- Alternatively, the method comprising blowing the insulation material into the gap between two mutually opposing internal facing surfaces of the two modular rigid panel members.
- Ideally, the method comprising providing the rigid support member from oriented strand boards, fibre cement boards or slate boards.
- Ideally, the method comprising providing reinforcing means in operable engagement with at least one rigid support member.
- Ideally, the method comprising providing reinforcing means on at least one surface of at least one of the rigid support members.
- Preferably, the method comprising providing the reinforcing means on both surfaces of at least one of the rigid support members.
- Preferably, the method comprising pre-stressing the reinforcing means.
- Ideally, the method comprising mechanically coupling the reinforcing means to at least one of the rigid support members along its perimeter.
- Ideally, the method comprising extending a plurality of reinforcing members along one or more surfaces of at least one of the rigid support members.
- Preferably, the method comprising retaining the spacer means in place when the insulation material is located into the gap between the mutually opposing modular rigid panel members.
- Ideally, the method comprising forming at least one aperture in the modular rigid panel members.
- Preferably, the method comprising placing a reinforcing liner at least partly around the aperture.
- Ideally, the method comprising at least partly surrounding the aperture with a reinforcing means.
- Accordingly, the present invention also provides a sandwich type construction panel comprising a plurality of rigid outer support members, each rigid outer support member having two main planar surfaces with perimeter surfaces extending between these main planar surfaces, the plurality of rigid outer support members being assembled so that each rigid outer support member has at least one perimeter surface in an abutting relationship with the perimeter surface of an adjacent rigid outer support member, at least one connector means bridging at least part of the length of abutting perimeter surfaces for connecting the plurality of rigid outer support members together into a predetermined shape and size of modular rigid outer panel member, a second similar shape and size of modular rigid outer panel member having generally the same configuration and an insulation means disposed in the gap between the modular rigid outer panel members.
- Preferably, a spacer means is located on at least one of the modular rigid outer panel members for supporting the two modular rigid outer panels members in a spaced apart relationship defining a gap between them.
- Preferably, the connector means is provided by connector plates.
- Ideally, the connector means are manufactured from metal.
- Preferably, the connector plates are steel.
- Ideally, the connector means is provided on at least one surface of at least one of the modular rigid outer panel members.
- Preferably, the connector means is pre-stressed.
- Ideally, the connector means comprising means for mechanically fixing the connector means onto the planar surfaces of two adjacent rigid outer support members.
- Preferably, the mechanical fixing means comprising spikes.
- Ideally, the spikes protrude in a spaced apart configuration from the main plane of the mechanical fixing means.
- Preferably, the mechanical fixing means have barbs for retaining the connector means in the rigid outer support members.
- Preferably, the insulation material is provided by any one of or any combination of polystyrene, polyurethane, polyisocyanurate, polyethylene, wood panel or fibre glass.
- Preferably, the insulation material is bonded or mechanically fixed onto an internal facing surface of at least one of the modular rigid outer panel members.
- Alternatively, the insulation material is blown into the gap between two mutually opposing internal facing surfaces of the two modular rigid outer panel members.
- Ideally, the rigid outer support member is provided by oriented strand boards, fibre cement boards or slate boards.
- Preferably, the rigid outer support member is made from a composite material.
- Ideally, the rigid outer support member is manufactured from a polymeric matrix reinforced with fibres.
- Ideally, the rigid outer support member is provided by fiber-reinforced polymers, FRPs, carbon-fiber reinforced plastic CFRP or glass-reinforced plastic GRP.
- Preferably, the matrix is provided by a thermoplastic composite.
- Ideally, the thermoplastic composite is a short fiber thermoplastics, a long fiber thermoplastics or a long fiber-reinforced thermoplastics.
- Alternatively, the matrix is provided by a thermoset composite.
- Ideally, the elongate composite member is provided by aramid fibre and carbon fibre in an epoxy resin matrix.
- Preferably, the FRPs include wood comprising cellulose fibers in a lignin and hemicellulose matrix.
- Ideally, reinforcing means is provided in operable engagement with at least one rigid outer support member.
- Preferably, the reinforcing means is provided by at least one metal component.
- Ideally, the reinforcing means is provided by at least one metal wire, metal lattice, metal rod or metal plate.
- Ideally, the reinforcing means is provided on at least one surface of at least one of the rigid outer support members.
- Preferably, the reinforcing means is provided on both surfaces of at least one of the rigid outer support members.
- Preferably, the reinforcing means is pre-stressed.
- Ideally, the reinforcing means is mechanically coupled to at least one of the rigid outer support members.
- Preferably, the reinforcing means is mechanically coupled to at least one of the rigid outer support members along its perimeter.
- Ideally, a plurality of reinforcing members extends along one or more surfaces of at least one of the rigid outer support members.
- Preferably, the spacer means comprises blocks of insulation material. Advantageously, the spacer means remain in place when the insulation material is located into the gap between the mutually opposing modular rigid outer panel members.
- Ideally, the modular rigid outer panel members having at least one aperture.
- Preferably, the aperture being reinforced with a liner.
- Ideally, the aperture having reinforcing means at least partly surrounding the aperture, most preferably pressed into the modular outer rigid support panels.
- Preferably, the sandwich type construction panel is for use a floor, wall or roof panel.
- According to a further aspect of the invention, there is provided a rigid support member, the rigid support member having two main planar surfaces with perimeter surfaces extending between these main planar surfaces and reinforcing means provided in operable engagement with the rigid support member.
- Preferably, the reinforcing means is provided by at least one metal component.
- Ideally, the reinforcing means is provided by at least one metal wire, metal lattice, metal strap, metal rod or metal plate.
- Ideally, the reinforcing means is provided on at least one surface of the rigid support member.
- Preferably, the reinforcing means is provided on both surfaces of the rigid support member.
- Preferably, the reinforcing means is pre-stressed.
- Ideally, the reinforcing means is mechanically coupled to the rigid support member.
- Preferably, the reinforcing means is mechanically coupled to the rigid support members along its perimeter.
- Ideally, a plurality of reinforcing members extends along one or more surfaces of the rigid support member.
- Ideally, the rigid support member is a construction panel made from the same range of materials described with reference to the rigid outer support member above.
- Preferably, the rigid support member is formed for use as part of a panel, preferably a sandwich type construction panel and most preferably a SIP panel.
- The invention will now be described with reference to the accompanying drawings which show by way of example only one embodiment of an oversized sandwich type construction panel in accordance with the invention. In the drawings:
-
FIG. 1 is a plan view of an oversized sandwich type construction panel; and -
FIG. 2 is a perspective view of a connector plate. - Referring to the drawings, there is shown a sandwich type construction panel indicated generally by the
reference numeral 1 having five rigidouter support members 2. Each rigidouter support member 2 has two mainplanar surfaces perimeter surfaces 5 extending between these mainplanar surfaces outer support members 2 are assembled so that each rigidouter support member 2 has at least oneperimeter surface 5 in an abutting relationship with theperimeter surface 5 of an adjacent rigidouter support member 2. Aconnector 7 bridges the length of abutting perimeter surfaces 5 for connecting two rigidouter support members 2 together into a predetermined shape and size of modular rigidouter panel member 8. A second similar shape and size of modular rigidouter panel member 8 having generally the same configuration is also provided. Aspacer arrangement 9 is located on at least one of the modular rigidouter panel members 8 for supporting the two modular rigidouter panels members 8 in a spaced apart relationship defining a gap between them and aninsulation material 10 is disposed in the gap. - The
connectors 7 are provided by connector plates which are manufactured from metal and preferably steel. Theconnectors 7 are provided on at least onesurface outer panel members 8. Theconnectors 7 are pre-stressed. Advantageously, pre-stressing minimises the risk of bowing in rigidouter support members 2 by holding them in compression. Pre-stressing theconnectors 7 also allows reduced depths of rigidouter support members 2 to be used for equivalent design strengths. The pre-stressed rigidouter support members 2 are resilient and will recover from the effects of a greater degree of overload than a similar unstressed rigidouter support member 2. Furthermore, if the rigidouter support member 2 is subject to overload, cracks, which may develop, will close up on removal of the overload. The pre-stressing enables a modular rigidouter panel member 8 to be formed from a number of segmented rigidouter support members 2. Furthermore, lighter elements permit the use of longer spanning members with a high strength to weight characteristic. The ability to control deflections in pre-stressed rigidouter support members 2 permits longer spans to be achieved. - The
connectors 7 have anarrangement 11 for mechanically fixing theconnectors 7 onto theplanar surfaces outer support members 2. Themechanical fixing arrangement 11 is an array ofspikes 11. Thespikes 11 protrude in a spaced apart configuration from themain plane 14 of themechanical fixing arrangement 11. Thespikes 11 havebarbs 15 for retaining theconnectors 7 in the rigidouter support members 2. - The insulation material is provided by any one of or any combination of polystyrene, polyurethane, polyisocyanurate, polyethylene, wood panel or fibre glass and most preferably polyurethane foam is used. The insulation material is bonded or mechanically fixed onto an internal facing surface of at least one of the modular rigid
outer panel members 8. In an alternative forming method the insulation material is blown into the gap between two mutually opposing internal facing surfaces of the two modular rigidouter panel members 8. The rigidouter support member 2 is provided by oriented strand boards, fibre cement boards or slate boards. - In an alternative construction, the rigid
outer support member 2 is made from a composite material. The rigidouter support member 2 is manufactured from a polymeric matrix reinforced with fibres. The rigidouter support member 2 is provided by fiber-reinforced polymers, FRPs, carbon-fiber reinforced plastic CFRP or glass-reinforced plastic GRP. The matrix is provided by a thermoplastic composite. The thermoplastic composite is a short fiber thermoplastic, a long fiber thermoplastic or a long fiber-reinforced thermoplastic. Alternatively, the matrix is provided by a thermoset composite. The elongate composite member is provided by aramid fibre and carbon fibre in an epoxy resin matrix. The FRPs include wood comprising cellulose fibers in a lignin and hemicellulose matrix. - A reinforcing
arrangement 21 is provided in operable engagement with at least one rigidouter support member 2. The reinforcingarrangement 21 is provided by at least one metal component. The reinforcingarrangement 21 is provided by at least one metal wire, metal lattice, metal rod, metal strap or metal plate. The reinforcingarrangement 21 is provided on at least onesurface 4, the internal surface in the embodiment shown inFIG. 1 , of at least one of the rigidouter support members 2. The reinforcingarrangement 21 can alternatively be provided on both surfaces of the rigidouter support member 2. The reinforcingarrangement 21 is pre-stressed. The reinforcingarrangement 21 is mechanically coupled to the rigidouter support members 2. The reinforcingarrangement 21 is mechanically coupled to the rigidouter support members 2 along their perimeter. A plurality of reinforcingmembers 21 extend along one or more surfaces of the rigidouter support member 2. - The
spacer arrangement 9 hasblocks 9 of insulation material. Advantageously, thespacer arrangement 9 remains in place when the insulation material is located into the gap between the mutually opposing modular rigidouter panel members 8. The modular rigidouter panel member 8 has at least oneaperture 33. Theaperture 33 is reinforced with aliner 34. Theaperture 33 has reinforcing members at least partly surrounding theaperture 33, most preferably pressed into the modular outerrigid support panels 8. - The sandwich
type construction panel 1 is for use as a floor, wall orroof panel 1. - In use, a sandwich
type construction panel 1 is manufactured comprising the steps of laying a plurality of rigidouter support members 2 on a preformed assembly jig. Each rigidouter support member 2 has two mainplanar surfaces perimeter surfaces 5 extending between these mainplanar surfaces outer support members 2 are laid so that each rigidouter support member 2 has at least oneperimeter surface 5 in an abutting relationship with theperimeter surface 5 of an adjacent rigidouter support member 2. At least part of the length of abutting perimeter surfaces 5 are bridged with at least oneconnector 7 for connecting the adjacent rigidouter support members 2 together into a predetermined shape and size of modular rigidouter panel member 8. A second similar shape and size of modular rigidouter panel member 8 is formed using the same method. Aninsulation material 10 is placed in the gap between the modular rigidouter panel members 8. Aspacer arrangement 9 is disposed on the modular rigidouter panel members 8 for supporting the two modular rigidouter panel members 8 in a spaced apart relationship defining a gap there between. - The rigid
outer support members 2 are connected byconnector plates 7 as shown inFIG. 2 . Theconnector plates 7 are placed on asurface outer panel member 8. Theconnector plates 7 are pre-stressed and are mechanically fixed onto the planar surfaces of two adjacent rigidouter support members 7 using spikes 11. Thespikes 11 protrude from the main plane of themechanical fixing arrangement 11. Theinsulation material 10 is bonded or mechanically fixed onto an internal facing surface of the modular rigidouter panel member 8. Alternatively, theinsulation material 10 is blown into the gap between two mutually opposing internal facing surfaces of the two modular rigidouter panel members 8. A reinforcingarrangement 21 is provided in operable engagement with a rigidouter support member 2. The reinforcingarrangement 21 is provided on a surface of the rigidouter support member 2 or on both surfaces of the rigidouter support member 2. The reinforcingarrangement 21 can be pre-stressed. The reinforcingarrangement 21 is mechanically coupled to the rigidouter support member 2 along its perimeter. The reinforcingarrangement 21 is provided by a plurality of reinforcing members along one or more surfaces of the rigidouter support member 2. Thespacer arrangement 9 is retained in place when the insulation material is located into the gap between the mutually opposing modular rigidouter panel members 8. Anaperture 33 is formed in the modular rigidouter panel members 8 and a reinforcingliner 34 is inserted to at least partly surround theaperture 33. It is also possible to at least partly surround theaperture 33 with a reinforcing arrangement, which can also be pre-stressed. It will of course be appreciated that any arrangement of apertures 44 can be formed in thepanel 1 to suit the bespoke installation arrangement. - In relation to the detailed description of the different embodiments of the invention, it will be understood that one or more technical features of one embodiment can be used in combination with one or more technical features of any other embodiment where the transferred use of the one or more technical features would be immediately apparent to a person of ordinary skill in the art to carry out a similar function in a similar way on the other embodiment.
- In the preceding discussion of the invention, unless stated to the contrary, the disclosure of alternative values for the upper or lower limit of the permitted range of a parameter, coupled with an indication that one of the said values is more highly preferred than the other, is to be construed as an implied statement that each intermediate value of said parameter, lying between the more preferred and the less preferred of said alternatives, is itself preferred to said less preferred value and also to each value lying between said less preferred value and said intermediate value.
- The features disclosed in the foregoing description or the following drawings, expressed in their specific forms or in terms of a means for performing a disclosed function, or a method or a process of attaining the disclosed result, as appropriate, may separately, or in any combination of such features be utilised for realising the invention in diverse forms thereof as defined in the appended claims.
Claims (15)
1. A method of manufacturing a construction panel, comprising the steps of laying a plurality of rigid support members together, each rigid support member having two main planar surfaces with perimeter surfaces extending between the main planar surfaces, laying the plurality of rigid support members so that each rigid support member has at least one perimeter surface in an abutting relationship with the perimeter surface of an adjacent rigid support member, and bridging at least part of a length of the abutting perimeter surfaces with at least one connector member for connecting the plurality of rigid support members together into a predetermined shape and size of a modular rigid panel member.
2. The method as claimed in claim 1 , further comprising the step of manufacturing a sandwich type construction panel comprising the steps of forming a second similar shape and size of the modular rigid panel member and placing an insulation material in a gap between the modular rigid panel members.
3. The method as claimed in claim 1 , further comprising the step of placing a spacer member on at least one of the modular rigid panel members for supporting the two modular rigid panel members in a spaced apart relationship defining the gap there between.
4. The method as claimed in claim 1 , further comprising the step of connecting the rigid support members by metal connector plates.
5. The method as claimed in claim 1 , further comprising the step of providing the connector member on at least one surface of the modular rigid panel members.
6. The method as claimed in claim 1 , further comprising the step of pre-stressing the connector member.
7. The method as claimed claim 1 , further comprising the step of fixing the connector member onto the planar surfaces of two adjacent rigid support members.
8. The method as claimed in claim 2 , further comprising the step of bonding or mechanically fixing the insulation material onto an internal facing surface of at least one of the modular rigid panel members or blowing the insulation material into the gap between two mutually opposing internal facing surfaces of the two modular rigid panel members.
9. The method as claimed in claim 1 , further comprising the step of providing a reinforcing member in operable engagement with at least one rigid support member.
10. The method as claimed in claim 9 , further comprising the step of pre-stressing the reinforcing member.
11. A sandwich type construction panel, comprising a plurality of rigid outer support members, each rigid outer support member having two main planar surfaces with perimeter surfaces extending between the main planar surfaces, the plurality of rigid outer support members being assembled so that each rigid outer support member has at least one perimeter surface in an abutting relationship with the perimeter surface of an adjacent rigid outer support member, at least one connector member bridging at least part of a length of abutting perimeter surfaces for connecting the plurality of rigid outer support members together into a predetermined shape and size of modular rigid outer panel member, a second similar shape and size of modular rigid outer panel member having substantially the same configuration and an insulation member disposed in a gap between spaced apart modular rigid outer panel members.
12. The sandwich type construction panel as claimed in claim 11 , further comprising a spacer member located on at least one of the modular rigid outer panel members for supporting the two modular rigid outer panels members in a spaced apart relationship defining the gap between them.
13. The sandwich type construction panel as claimed in claim 11 , wherein the connector member is provided by metal connector plates.
14. The sandwich type construction panel as claimed in claim 13 , further comprising a reinforcing member in operable engagement with at least one rigid outer support member.
15. The sandwich type construction panel as claimed in claim 14 , wherein the metal connector plates or the reinforcing member are pre-stressed.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GBGB1113574.6A GB201113574D0 (en) | 2011-08-05 | 2011-08-05 | A panel and a method for building panels |
GB1113574.6 | 2011-08-05 |
Publications (1)
Publication Number | Publication Date |
---|---|
US20130192157A1 true US20130192157A1 (en) | 2013-08-01 |
Family
ID=44735533
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/567,395 Abandoned US20130192157A1 (en) | 2011-08-05 | 2012-08-06 | Panel and a method for building panels |
Country Status (3)
Country | Link |
---|---|
US (1) | US20130192157A1 (en) |
EP (1) | EP2554756B1 (en) |
GB (1) | GB201113574D0 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2020065259A1 (en) * | 2018-09-24 | 2020-04-02 | Saint-Gobain Placo Sas | Partition comprising boards mounted onto upright elongate members and method for constructing the same |
US11214964B2 (en) * | 2019-06-14 | 2022-01-04 | Nexii Building Solutions Inc. | Reinforced structural insulation panel with corner blocks |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1381823A (en) * | 1918-04-30 | 1921-06-14 | Griffin Walter Burley | Building component |
US5274970A (en) * | 1992-04-07 | 1994-01-04 | Roberts Raymond P | Freestanding partition system |
US5743055A (en) * | 1996-06-04 | 1998-04-28 | Hon Industries Inc. | Wall panel connector system |
US5899035A (en) * | 1997-05-15 | 1999-05-04 | Steelcase, Inc. | Knock-down portable partition system |
US7549263B1 (en) * | 2006-06-20 | 2009-06-23 | Sip Home Systems, Inc. | Structural insulated panel with hold down chase |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE952299C (en) * | 1953-03-25 | 1956-11-15 | Siporex Int Ab | Support structure, in particular building ceiling or roof covering, made of adjacent lightweight concrete panels |
US2921462A (en) * | 1958-02-17 | 1960-01-19 | Wilson Thomas Woodrow | Interlocking pre-cast panels |
AT410233B (en) * | 1999-04-20 | 2003-03-25 | Wolf Johann | CONNECTOR |
US6364374B1 (en) * | 1999-10-27 | 2002-04-02 | Michael J. Noone | Methods and devices for joining panels |
CA2490941A1 (en) * | 2002-06-27 | 2004-01-08 | Eliyahu Maimon | Modular wall segments and method of making such segments |
US20090255204A1 (en) * | 2008-04-11 | 2009-10-15 | Innovida Holdings, Inc. | Straight joint for sandwich panels and method of fabricating same |
GB201109017D0 (en) * | 2011-05-27 | 2011-07-13 | Keystone Lintels Ltd | A method and arrangement for jointing structural insulated panels |
-
2011
- 2011-08-05 GB GBGB1113574.6A patent/GB201113574D0/en not_active Ceased
-
2012
- 2012-08-06 US US13/567,395 patent/US20130192157A1/en not_active Abandoned
- 2012-08-06 EP EP12179449.9A patent/EP2554756B1/en active Active
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1381823A (en) * | 1918-04-30 | 1921-06-14 | Griffin Walter Burley | Building component |
US5274970A (en) * | 1992-04-07 | 1994-01-04 | Roberts Raymond P | Freestanding partition system |
US5743055A (en) * | 1996-06-04 | 1998-04-28 | Hon Industries Inc. | Wall panel connector system |
US5899035A (en) * | 1997-05-15 | 1999-05-04 | Steelcase, Inc. | Knock-down portable partition system |
US7549263B1 (en) * | 2006-06-20 | 2009-06-23 | Sip Home Systems, Inc. | Structural insulated panel with hold down chase |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2020065259A1 (en) * | 2018-09-24 | 2020-04-02 | Saint-Gobain Placo Sas | Partition comprising boards mounted onto upright elongate members and method for constructing the same |
US11970854B2 (en) | 2018-09-24 | 2024-04-30 | Saint-Gobain Placo | Partition comprising boards mounted onto upright elongate members and method for constructing the same |
US11214964B2 (en) * | 2019-06-14 | 2022-01-04 | Nexii Building Solutions Inc. | Reinforced structural insulation panel with corner blocks |
Also Published As
Publication number | Publication date |
---|---|
GB201113574D0 (en) | 2011-09-21 |
EP2554756B1 (en) | 2021-03-10 |
EP2554756A2 (en) | 2013-02-06 |
EP2554756A3 (en) | 2016-12-14 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
CA2485804C (en) | Wood-concrete-composite systems | |
US8904737B2 (en) | Building panel assemblies and methods of use in wall structures | |
US20140308385A1 (en) | Mold for making fiber-reinforced polymeric building panels | |
US20120003462A1 (en) | Nail-plated composite structural system | |
US20090255204A1 (en) | Straight joint for sandwich panels and method of fabricating same | |
JP2018505330A (en) | Interlocking structural block reinforcing means and modular building system | |
US7601234B2 (en) | Housing created from high strength expanded thermoformable honeycomb structures with cementitious reinforcement | |
US20100050549A1 (en) | Joint of parallel sandwich panels | |
RU2656260C2 (en) | Method for constructing building having strong thermal insulation and building constructed by means of said method | |
US20080276559A1 (en) | Low Density Concrete Wall Panel With Reinforced Insulation Members | |
US6557201B1 (en) | Stressed-skin modular fiber reinforced plastic bridge | |
EP2554756B1 (en) | A panel and a method for building panels | |
CN204299009U (en) | A kind of pultruded GFRP pin-connected panel floor slab structure | |
US20090282777A1 (en) | Angle joint for sandwich panels and method of fabricating same | |
US20080199682A1 (en) | Structural Elements Made From Syntactic Foam Sandwich Panels | |
EP2530212B1 (en) | Method and apparatus for joining structural insulated panels | |
CN111630234A (en) | Panel for building structures having a predetermined curvature and method of manufacturing the panel | |
Uddin et al. | Thermoplastic composite structural insulated panels (CSIPs) for modular panelized construction | |
EP1583874A1 (en) | Constructional element and method for its manufacture | |
RU167860U1 (en) | MULTILAYER WALL PANEL | |
CN205444561U (en) | Lightweight concrete wall body | |
JPH10205032A (en) | Wall construction and execution method thereof | |
US8728374B1 (en) | Method of manufacturing a foundation wall panel | |
CN212926685U (en) | Bamboo wood and concrete combined wallboard finished piece | |
CN218437986U (en) | Floor board |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
STPP | Information on status: patent application and granting procedure in general |
Free format text: FINAL REJECTION MAILED |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |