WO2003085226A1

WO2003085226A1 - Walling system

Info

Publication number: WO2003085226A1
Application number: PCT/US2003/009957
Authority: WO
Inventors: Allan Marshall
Original assignee: Omnova Wallcovering (Uk) Limited; Omnova Solutions Inc.
Priority date: 2002-04-02
Filing date: 2003-04-01
Publication date: 2003-10-16
Also published as: GB0207639D0

Abstract

An inflatable panel includes a front sheet and a rear sheet connected to each other around their peripheries. An expandable structure is located between the front and rear sheets and is connected to them for limiting inflation of the wall panel. A series of panels can be used in conjunction with a frame so as to form a wall or other structural component.

Description

WALLING SYSTEM

BACKGROUND INFORMATION This invention relates to a method for producing walls, and which is also suitable for producing other articles such as floors, roofs, ceilings and shields. Conventional walling systems require the use of heavy, bulky articles such as bricks and/or plasterboard panels which have several disadvantages including being inconvenient to move due to their weight and bulk (some regulations demand that they be moved by at least two people) and assembling a wall therewith requires considerable time and skill.

In a conventional interior stud partition wall, a wooden or metal frame extends from floor to ceiling; one or two layers of plasterboard panels are nailed or screwed to the frame; and the gaps between the panels are filled, covered with tape, and skimmed with a further layer of plaster to mask the panel joints.

All of the foregoing, especially the plastering procedures, require considerable skill. Additionally, such assembly is time-consuming, messy, and disruptive if done in an area where other activities are ongoing.

Soundproofing and fire safety are taking increasing importance in building design. Achieving adequate soundproofing using many traditional wall constructions is difficult. To get a good acoustic seal between one side of the wall and the other, avoiding air gaps between one side of the wall and the other is important but difficult to do with traditional systems. Additionally, wooden frames are of course flammable. The bulk and rigid nature of the materials that are used with traditional walling systems limits the size in which they can be delivered to a building site.

Large, single surfaces such as the walls of lift shafts must be built up from many individual components (e.g., plasterboard sheets).

DESCRIPTION OF THE INVENTION

Briefly, the present invention provides an inflatable panel that includes front and rear sheets connected around their peripheries and an expandable member located between and connected to them for limiting inflation of the wall panel.

In another aspect, the present invention provides a process for forming a panel. The process includes inflation of an inflatable panel of the type just described.

Further, the present invention provides a method for forming a wall. In the method, a frame that includes a plurality of linear members arranged to define apertures therebetween is assembled. An inflatable panel is arranged in each of the apertures. The panels then are inflated to occupy the apertures. Preferably, the panels used are of the type described above.

The front and rear sheets preferably are substantially impermeable. One or both of the front and rear sheets may conveniently have a coating of another material, for example for aesthetic purposes. An example of such a decorated sheet is a typical wallcovering, such as those made of fabric reinforced PVC. The front and rear sheets are suitably connected to each other by a substantially impermeable seal around a portion of their peripheries. One or more inflation ducts can pass through the seal whereby pressure may be applied to the space between the sheets so as to inflate the wall panel. The inflation duct(s) may take the form of a tube. The front and rear sheets may be connected to each other by a substantially impermeable seal around their entire peripheries. This type of wall panel can include a source of inflatant (i.e., an inflation source) located between the sheets and activatable from outside the wall panel by, for example, heat so as to cause release of the inflatant. The structure of the expandable member preferably is honeycomb in form. The honeycomb structure can, for instance, be formed by a laminated set of sheets, each being joined at a first set of locations to one of the sheets adjacent thereto and joined at a second set of locations offset in the plane of the sheets from the first set of locations to the other of the sheets adjacent thereto. These joints can be linear.

The expandable member can be in the form of a sheet, which optionally can be bonded to the front and rear sheets across its entire major surfaces. The expandable member optionally can be formed from a flexible material that can be set in shape on exposure to heat (i.e., thermoset) and, upon being set, become rigid or semi-rigid. Where the panel includes an expandable member that can be thermoset, the panel can be inflated with a material that is at a temperature sufficient to cause the flexible material to set. An example of such a super-ambient inflating material is steam.

Inflation of the panel also can be effected by, for example, curable foams and/or gases. (Obviously, unless such inflatants are provided at sufficiently high temperatures, they will not thermoset the aforementioned flexible material.) Panels of the type just described optionally can be arranged in a frame prior to or after inflation. A plurality of such panels clearly could be arranged to form larger structures such as, for example, building walls, shields, portable shelters, rapidly deployable structures (e.g., tents or igloos), and the like. Such panels can be inflated by injection of an inflatant, which can be done through the frame into each panel. The inflatant can be a foam, preferably one capable of setting or hardening after injection so as to stiffen the panel. In the accompanying drawings:

Fig. 1 is a side view of a framework for a stud partition wall; Fig. 2 is a cross section of the framework of Fig.1 on line A-A; Fig. 3 is a side view of a stud partition wall; Fig. 4 is a cross section of the wall of Fig. 3 on line B-B before inflation;

Fig. 5 is a cross section of the wall of Fig. 3 on line B-B after inflation; Fig. 6 illustrates detail of an upper frame member; Fig. 7 and 8 illustrate details of lower frame members; Fig. 9 illustrates a walling unit structure; and

Fig. 10 is a partial cut-away diagram of a wall unit construction. The present invention will now be described with reference to the drawings.

The framework of Figs. 1 and 2, which can be a precursor for the wall of Figs. 3 to 5, is arranged between a floor 1 and a ceiling 2. The frame is made up of a number of vertical members 3 which extend between a lower horizontal member 4, attached to floor 1 , and an upper horizontal member 5, attached to ceiling 2. (The frame need not be connected to floor 1 and ceiling 2, as other arrangements are possible.) The frame members define a number of rectangular apertures 6 between them. The front 7 and back 8 faces of the frame members typically are flat. The sides of the frame members that open into apertures 6 typically are concave along at least part of their length for receiving and securing walling units to be received in the apertures. (See Figs. 3 to 5.) At the sides of upper horizontal member 5 that face into the apertures there are attachment points 9 from which the walling members can be hung. Inflation tubes 10 extend through the lower horizontal members and out of their sides facing the apertures.

Figs. 3 to 5 show the framework of Figs. 1 and 2 with the walling units in place. Each walling unit 15 includes outer sheets 20, 21 of flexible, impermeable material and sized generally to fit apertures 6. The sheets are joined along their top, side and bottom edges in such a way as to form an impermeable seal 22 around the rim of the walling unit. At the top of each walling unit are attachment points, spaced in such a way that they can be attached to attachment points 9 of the frame to hang the walling unit in aperture 6. At the bottom of each walling unit, inflation ducts 24 pass through seal 22 so that the unit can be inflated by increasing the pressure within the space between the sheets relative to the ambient pressure. Inflation ducts 24 are spaced in such a way that they can be mounted on inflation tubes 10 when the walling unit is located in aperture 6.

Inside the walling units are tensile restraints 25 which extend between outer sheets 20 and 21. The restraints are intended to resist overinflation of the walling unit by limiting movement of the sheets apart from each other. Restraints 25 preferably are arranged so that, when the wall unit is inflated, the exposed central portions of outer sheets 20 and 21 are flush with the front and back faces 7, 8 of the walling members.

Each walling unit 15 is hung from attachment points 9 in an aperture 6 with its sides arranged against the sides of the vertical walling members 3 that face the aperture, and its inflation ducts 24 coupled to inflation tubes 10. Walling unit 15 is inflated by means of inflation tubes 10. Steps can be taken during and/or after inflation so that walling unit 15 remains in its inflated form. For example, inflation tubes 10 may be sealed after inflation or may contain one-way valves; walling unit 15 may be inflated with a material such as a curable foam 26 (Fig. 5) that sets or hardens after inflation; or the walling units may themselves include a setting compound activated by the material with which they are inflated.

Inflated walling units can form a rigid or semi-rigid wall in conjunction with the framing members. This form of walling has a number of potential advantages over conventional walling techniques, some of which include:

• quick assembly,

• little specialized skills on the part of the installer(s),

• less risk of damage during storage due to the nature of the component materials (e.g., traditional plasterboard is prone to damage from moisture, whereas the component polymeric materials of this system are not),

• ease of transport due to the light weight and low risk of damage (because the walling system is not rigid until inflation on site), • increased flexibility in size and design (relative to traditional materials such as plasterboard which must be kept small enough to move and install at the construction site), resulting in a single sheet being able to cover a much greater area, and

• increased strength and/or stiffness (depending on the materials used) which means that accompanying products (e.g., battens) can be used more sparingly, i.e., spaced farther apart. The wall construction now will be described in more detail. The frame members are preferably configured so that they can be connected together in a simple way. This can reduce construction time and allow the construction to be performed by unskilled workers. For example, the frame members may be clipped, bolted, or adhered to one another.

The frame members may be formed of any suitable material, for example aluminium, plastics, wood or processed wood chips/pulp materials.

The frame members may be fitted with the attachment points 9, the recesses 30 (see Fig. 2) that are to receive the extremities of wall units 15 and inflation tubes 10 once they have been assembled into a frame. However, these operations preferably are done before assembly of the frame, and most preferably even before the frame members are delivered to the site where the wall is to be assembled. For example, during their initial manufacture, the frame members can be pre-formed to the required profile and pre-fitted with attachment points and inflation tubes.

Fig. 6 shows one form that attachment points 9 can take. In this arrangement, attachment points 9 are loops set in recess 30. The loops are sized and spaced to engage corresponding hooks on wall units 15. Since the loops are within recess 30, they are concealed when the wall is completed. Attachment points 9 can take many other forms such as, for example, hooks that engage eyes on the wall unit; recesses are arranged to receive clips on the wall units; or catches arranged to catch the sheets 20, 21 of the wall units directly. The wall units can be attached with adhesive to the frame. Other schemes could also be used. Alternatively, the attachment points could be omitted and, for example, the wall units could be held temporarily in place by hand until being caused to fit snugly into the apertures in the frame by inflation. In some situations, tensioning the whole wall unit before inflation might be preferred. If so, attachment points could be provided along both sides and optionally also at the bottom of the aperture.

Fig. 7 shows one form of the inflation tubes in the lower frame member. The inflation tube comprises a connection point 40 for attachment to a corresponding socket on the wall unit, a hose 41 for attachment to an inflation device, and a pipe 42 which connects connection point 40 to hose 41. Pipe 42 passes through the body of lower frame member 4.

Fig. 8 shows another arrangement that can facilitate inflation. In this arrangement, pipe 42 connects one hose to a number of connection points, acting as a manifold that allows pressure to be applied simultaneously through a number of connection points. Those inflation points may be connected to one or more wall units, allowing those units to be inflated in a single step and from a single inflation device. Instead of a hose 41 , pipe 42 could terminate in a socket flush with lower frame member 4. This could make it easier to conceal inflation apparatus 10, for example by covering the socket with a flush-fitting cap, after the wall has been formed.

Fig. 9 shows one suitable arrangement for wall units 15 having a honeycomb construction. Between outer sheets 20 and 21 are interior sheets 50 welded together at offset points so that they can permit the wall unit to expand by movement of outer sheets 20, 21 away from each other in a limited, controlled fashion. The honeycomb structure is advantageous in that it offers considerable strength for little weight. Channels 51 are formed between interior sheets 50. These channels communicate at the top and bottom of the wall unit, and optionally at other points, to allow full inflation. Alternatively, the channels could fit directly on to respective inflation points on the frame. The channels could run from top to bottom or from side-to-side, or in other directions. In this system, the honeycomb acts as the restraints 25. Fig. 9 also illustrates a weld 54 that can form the impermeable seam 22 around the periphery of the walling unit. If the outer sheets are thermoplastic, weld 52 conveniently can be formed under heating. The honeycomb structure could have a special configuration at the edges of the wall to help it conform to the channels 30 in the frame members. The outer sheets 20, 21 form a facing for the wall. They may be coated to make them visually attractive. Although they should be flexible, it may be advantageous in some situations for them to have some small degree of stiffness so that they resist creasing and tend to offer a smooth surface between the points at which restraints 25 are attached to them. Suitable materials for the outer sheets include PVC, paper, glass, fibre and non-woven materials. The outer sheets should be impermeable to the medium that is used for inflation of the wall unit. If the wall is to be a fire-resistant wall then the sheets could be made of a fire retardant material, such as glass fibre, or an intumescent material. Where the outer sheets do not possess the desired aesthetic qualities, they could be covered with an aesthetically pleasing outer layer or with a layer of a lining paper than can then easily be painted or covered by conventional decorating techniques.

Outer sheets 20, 21 and interior sheets 50 can be formed of polymeric sheet or laminate, a fibrous material, or other materials. Fibrous materials may be preferred in some situations as they can offer a relatively high surface area and therefore wick the material that is used to inflate the wall unit. This can improve adhesion between the sheet and that material. Another advantage of fibrous materials is that they can offer some inherent extensibility that can allow the wall member to stretch during inflation. This could be useful in ensuring that it stays filling the aperture in which it is to be fitted, instead of shrinking laterally as it is inflated. High-strength fibres such as glass, carbon or aramid can be used in situations where the wall needs to be particularly strong. The wall unit could contain reinforcing pieces, such as rigid rods. These could all lie parallel to each other so as not to prevent rolling of the wall unit.

Fig. 10 illustrates a preferred construction for the wall unit. A multilayer honeycomb expandable sheet 60 is laminated between two impermeable sheets 61 , 62. Sheets 61 , 62 represent outer sheets 20, 21. Sheets 61 , 62 could be of a polymeric material such as PVC. Sheets 61 , 62 are fixed to the multilayer honeycomb sheet by adhesive. To prevent the adhesive from permeating the multilayer honeycomb sheet and stopping it expanding, the outer layers of the multilayer honeycomb sheet could be of a material that resists passage of the adhesive therethrough. Alternatively, the adhesive could be applied in the form of a dry melt sheet interposed between sheets 61 , 62 and the multilayer honeycomb sheet; then the structure could be compressed and heated (for example by passing it through heated rollers) to activate the adhesive. The dry melt sheet could be of thermoplastic polyurethane elastomer adhesive, for instance. Alternatively, the dry melt sheet could be omitted and the outer sheets simply heat-fused to the multilayer honeycomb sheet.

The wall unit is preferably flexible prior to inflation. This can allow the wall unit to be rolled for delivery, making it relatively easy to transport in comparison to prior wall systems that call for bulky, rigid sheets. The fact that the wall unit is considerably smaller in volume and weight than the finished wall also enhances its portability.

A number of material systems could be used in inflating and optionally stabilizing the wall unit. In a first inflation mechanism, the wall unit can be filled with pressurized gas (e.g., air or an inert gas) or a liquid or with solid particles and then totally sealed. Although having the advantage of simplicity, this mechanism runs the risk of deflation due to leakage.

In a second inflation mechanism, the wall unit can be filled with a material that solidifies after being injected into the interior of the wall unit, so that the wall unit is then stabilised. The material preferably also expands upon entry so that it can be more quickly injected and is less bulky to carry to the site of the inflation. A preferred material is a light foam. The foam could include materials intended to enhance the non-structural properties of the wall.

In a third inflation mechanism, the wall unit can be filled with a pressurized material and, while pressurized, subjected to a treatment that causes its shape to be stabilized in inflated form. For example, the honeycomb structure could be formed of thermosetting fibres or fibres coated with a heat- curable resin. The wall unit could then be inflated with steam that cures the fibres during inflation so as to set them in the inflated configuration. Then the pressure could be removed and the wall unit would stay in its inflated form.

In a fourth inflation mechanism, the wall unit itself could be activatable to expand without pressurisation. For example, it could include struts of shape memory material that could be activated to expand by directing a heat gun at the wall. Alternatively, the wall could contain springs for biasing the outer sheets away from each other. The springs could be initially held in a compressed state by a low melting point thermoplastic material which could release the springs on being exposed to heat.

The wall unit could be sealed, and could contain a source of gas or foam that can be activated from outside the wall unit by, e.g., exposure to heat from a heat gun. This has the advantages that a precisely chosen amount of gas/foam will be used for inflation, and there is no need for a separate inflation source at the location where the wall is to be erected.

To allow the air inside the wall unit to escape when it is being inflated with another material, vent holes 55 (see Fig. 3) could be provided opposite the inflation points. These holes are preferably small enough that although air can escape through them, the wall unit can still hold the desired pressure. One-way valves could be included in holes 55.

To inflate the wall unit, an inflation device can be fixed to inflation tubes 10. The inflation device can be, for instance, a pump, compressed gas, steam supply, or foam canister. Once the wall unit is correctly in place, the inflation device is activated. There could conveniently be a pressure relief valve between the inflation device and the inflation tube to avoid over-pressurization of the wall unit. The inflation device could be connected to more than one inflation tube at once and could inflate more than one wall unit simultaneously. Depending on the material with which the wall unit is inflated and on the interior design of the wall unit, it may be advantageous to inflate the wall unit from the top, bottom, side, or a combination of points. When the wall unit is being injected with a material that is to solidify, such as a foam, it may be advantageous to overfill the wall unit so that foam begins to escape from the wall unit through holes 55; this can help to ensure that the wall unit is properly filled. The vents could be located so that they open into cavities 51 in the frame members so that foam leaking through them could help seal the wall unit to the frame.

A wall formed as described herein may have useful fire retardant and/or acoustic shielding properties that can be enhanced by good sealing between the wall units and the frame. The wall unit can be provided with components intended to enhance its non-structural properties. These components could be integrated with the wall unit before inflation or could be included in the material (e.g., foam) with which the wall unit is inflated. Examples include phase change materials such as hydrated magnesium/aluminium chloride to help stabilise the temperature of spaces adjoining the wall; fire retardant or intumescent materials; and acoustically absorbent materials.

The walling system has special advantages in some specific situations. First, the wall unit can be long enough to extend through several floors. Such a wall unit could be used for lining shafts for lifts (i.e., elevators). Such shafts are normally subject to special fire regulations and are conventionally lined with layers of fire-retardant plasterboard. Fixing the plasterboard in place in a lift shaft is a difficult and time consuming job because of the limited size of plasterboard sheets. With an extended wall unit the lift shaft could be lined straightforwardly with far fewer pieces. Second, the wall units could be linked together by joints or by a frame so as to form a small building. This can be useful when a building must be erected rapidly. Third, wall units of a suitable shape and with suitable fitments could be used as personal shields, for instance police riot shields. The shield could be stored in a rolled state together with a canister of pressurised foam with which it can be inflated. Such a system can be transported (e.g., in a car) much more easily than a conventional shield.

The wall units could be used for other structural components such as interior or exterior walls, roofs, ceilings, floors, partitions, and the like.

In an alternative embodiment, the frame can be omitted. The wall units could be inflated and then attached by adhesive or, if the wall units were filled with stable foam, even nailed to an existing structure such as another wall. This could be useful, for instance, if the wall unit were fire retardant. Optionally, it could be attached to an existing wall to provide additional protection.

Claims

CLAIMS We claim:

1. An inflatable panel comprising a front sheet and a rear sheet, said front and rear sheets being connected around their peripheries, and an expandable member for limiting inflation of the wall panel, said member being located between and connected to said front and rear sheets.

2. A process for forming a panel comprising inflating an inflatable panel that comprises a front sheet and a rear sheet, said front and rear sheets being connected around their peripheries, and an expandable member for limiting inflation of the wall panel, said member being located between and connected to said front and rear sheets.

3. A method for forming a wall, comprising: a) assembling a frame comprising a plurality of linear members arranged to define apertures therebetween; b) arranging an inflatable panel in each of said apertures; and c) inflating each of the panels to occupy each of the apertures.

4. The method of claim 3 wherein said inflatable panel comprises a front sheet and a rear sheet, said front and rear sheets being connected around their peripheries, and an expandable member for limiting inflation of the wall panel, said member being located between and connected to said front and rear sheets.

5. The panel of claim 1 , the process of claim 2, or the method of claim 4 wherein said front and rear sheets are substantially impermeable.

6. The panel of any of claims 1 and 5, the process of any of claims 2 and 5, or the method of any of claims 4 to 5 wherein said front and rear sheets are connected by a substantially impermeable seal around their peripheries with at least one inflation duct passing through said seal.

7. The panel of any of claims 1 and 5 to 6, the process of any of claims 2 and 5 to 6, or the method of any of claims 4 to 6 wherein said front and rear sheets are connected by a substantially impermeable seal around their entire peripheries and said wall panel further comprises a source of inflatant, activatable from outside said wall panel, located between said sheets.

8. The panel of any of claims 1 and 5 to 7, the process of any of claims 2 and 5 to 7, or the method of any of claims 4 to 7 wherein at least one of the following is true about said expandable member: it is in the form of a honeycomb; it is in the form of a sheet and is bonded to said front and rear sheets across its entire major surfaces; and it comprises a flexible material that can be set in shape upon exposure to heat.

9. The panel of any of claims 1 and 5 to 8, the process of any of claims 2 and 5 to 8, or the method of any of claims 4 to 8 wherein the panel is inflated with at least one of a curable foam and a gas.

10. The panel of any of claims 1 and 5 to 9, the process of any of claims 2 and 5 to 9, or the method of any of claims 4 to 9 wherein said expandable member comprises a flexible material that can be set in shape upon exposure to heat and said panel is inflated with a material that is at a temperature sufficiently high to cause said flexible material to set.