WO2009036767A1

WO2009036767A1 - Building panel

Info

Publication number: WO2009036767A1
Application number: PCT/DK2008/050226
Authority: WO
Inventors: Lars Krogh
Original assignee: Lhc Udvikling Aps
Priority date: 2007-09-18
Filing date: 2008-09-18
Publication date: 2009-03-26

Abstract

A building element e.g. for use in partitioning member in animal stables, made of three dimensional curving structures of a solid single layer plate, for example of plastic. In this way a light weight building panel of one layer material is achieved.

Description

Building Panel

Field of the Invention

The present invention concerns a building panel.

Background of the Invention Building panels for use e.g. in building partitionings or roofing or in building constructions necessitate some mechanical strength in order to function optimally.

In addition to having a certain mechanical strength in order to resist the pressure from the animals concerned, partitionings in animal stables are to be cleaning-friendly as well. This means that there must not be joints or openings where cleaning cannot be made efficiently, thus possibly providing a fertile ground for bacteria or similar infectious microorganisms.

EP 0872177 Bl describes such a possible construction of a wall for use in animal stables. In the particular partitioning member there are transverse openings with a convex cross-section. Moreover, within the closed structure there is one or more cavities delimited by ribs. The ribs means that it is possible to cut the given partitioning members into suitable sizes and by means of welding to join these again without opening the cavities to the bacteria-containing environment, or such that cavities are formed which are difficult to clean and in which growth of microorganisms may occur. The transverse openings and the hollow structure enable maintaining a certain strength without the said members becoming too heavy.

However, the present form of production will mean that the partitioning members will have a certain thickness. The partitioning members will thus have a weight and a thickness that make transport and erection cumbersome. By using other production forms, it will be possible to form thinner partitioning members. In order to achieve increased mechanical strength per weight unit, it may be advantageous to apply a three-dimensional curving structure as this structure will increase the strength of a thinner partitioning member. However, the curving structure is to be formed such that cavities that cannot be cleaned are not formed. Moreover, other building panels for use within other areas are also known, where there is a desire of a product with low weight and good structural properties and which at the same time is easy to clean and easy to transport and store. Such products can also be made of different materials.

Object of the Invention

It is the object of the present invention to provide a building element wherein great strength is achieved in relation to the amount of material used, for example for application as partitionings in animal stables, and which is cleaning-friendly, space- saving and easy to mount and transport.

Description of the Invention

Such an object of the invention is achieved by providing a building panel which is made with a three-dimensional curving structure of a solid single-layer plate.

By the expression three-dimensional curving structure as used in the present invention is meant a so-called double-curving surface of the panel.

The building panel is formed of a solid plate with a three-dimensional curving structure. The curving structure is made such that the mechanical strength of the building panel is optimised.

In this way is achieved a building panel that only uses one layer of material, and which thereby is not very heavy in spite of the mechanical strength still being of a magnitude such that the building panel may achieve advantages comparable to other types of building panels used e.g. as partitioning members.

Moreover, the simple design will entail that the building panels become cheaper and more rapid to make, as a smaller amount of material is to be used in order to achieve the same mechanical effect.

The three-dimensional design means larger dimensional volume, but by making plates with the same three-dimensional curving structure, it will be possible to stack the plates such that the three-dimensional structures fit into each other, thereby enabling stacking of the plates, whereby the building panels in total will take up relatively little space during storage and transport.

For use as partitioning members in animal stables, the three-dimensional curving structure of the building panels may be designed in various ways depending on the different animals which they are intended to separate. It will thus be important that the three-dimensional curving structure is formed in a way such that it will not be possible for the animals in question to bite in the curvatures, either biting holes through the member or gnawing unwanted holes at the side of the curvatures. These improper holes will destroy the normal surface and form breeding ground for growth of microorganisms, as small cavities will be difficult to clean. As it may be assumed that e.g. deer, pigs, cows and goats will have different bite forms, it would be logical to design the curving structure individually according to application.

It may also be envisaged that the building panels may be used as other than partitioning members between animals, since it would be possible to use the building panels due to their great mechanical strength for placing around trees, for example, for protection against damage by various types of wildlife.

The building panel can be made of other known materials, including metal as e.g. iron, and aluminium, cellulose/cardboard, gypsum and composites of any type. The building panels of these materials will also be made in various ways depending on the design/production technology which is suited in connection with the used material.

All these materials may be used in widely different products, but they are all based on the same idea of a building panel with a three-dimensional curving structure/double curvature surface. In principle, this structure may impart all materials a considerably higher strength or rigidity than that achieved with a plane building panel.

Building panels of iron may e.g. be used for bedplates for vehicles driving on soft ground where considerable amounts of material can be saved so that more plates can be transported per lorry. Building panels of aluminium may e.g. also be used for bedplates, deck plates, footbridges, stairways and scaffolding where the surface, besides adding strength, also has a non-skid effect. Also in these products are achieved savings in weight and material, which is advantageous in constructions and buildings where weight is desired kept down.

Building panels of cellulose/cardboard may e.g. be used as core layer in sandwich elements in panels where previously corrugated cardboard has been used, and where it may be utilised that the strength is equally great in x- and y-directions. This will mean that cardboard webs from the machines may be utilised in a better way since no regard is to be made where the strength is to be in relation to what is punched out.

Building panels of plasterboard can e.g. be made self-supporting, and will have a sound-attenuating function. Alternatively, the panels can be made of pressed plates of straw material which is also known for use in sound attenuating plates.

This single-layer plate may be a plastic plate and may advantageously be made of bondable or joinable plastic materials, such as polycarbonates (PC) or acryl butadiene styrene (ABS) which furthermore have the advantage that they are transparent.

PC and ABS provide the option of assembling the different building elements by gluing or jointing, which will not be possible with polyethylene (PE) or polypropylene (PP). Moreover, the rigidity factor means that building panels of ABS will have about 50% greater effect than building panels of PE.

The choice of material, such as PC or ABS, will mean that it is not necessary to weld the building panels together in order to achieve joints with a smooth and cleaning- friendly surface. This means that it may be decided to glue and to join the building panels at the site where the panels are wanted to be erected, as e.g. on a construction site, in a home or in an animal stable. The welding process may therefore only be used in places to which it has been specifically adapted in beforehand. In this way is achieved a particular flexibility with regard to places and persons having the possibility of using the building panels efficiently. Moreover, this means that partitioning members for e.g. animal stables may be assembled on site, and may therefor be transported easily and unencumbered as each single member will not be too heavy by itself. This means also, that the customers may be offered standard elements which may be produced to storage, making it cheaper for the customer and providing faster delivery.

According to a further embodiment of the building panel, the elevations in the curving structure are located in the same plane at each their side of a central plane, preferably a centre plane, through the building panel.

By this is meant that if the building panel is seen from each side, elevations may be provided at each their side or just at one side, depending on where the central plane is located. The elevations will be of the equal height as seen in relation to the central plane, whereby equal strength may be achieved throughout the entire plate. By letting the plane go through the middle of the building panel, it will be possible to achieve the same height of the elevations at both sides of the building panel. Hereby is attained a further increase of the mechanical strength.

Under the given conditions, it will, however, be possible to envisage that the elevations will be of different height as seen in relation to the central plane. This may provide alternating mechanical strength properties across the plate.

According to a further embodiment of the building panel, the curving structure provides uniform elevations and depressions as seen from each side of the building panel.

By this is understood that elevations and depressions, respectively, as seen from one side will be depressions and elevations, respectively, when seen from the other side.

The three-dimensional curving structure may be produced in a way such that the three- dimensional curvatures consist of a sinusoidal-like course. Mathematically, it will hereby be possible to adjust height and width of the curving structure, depending on the desired pattern and application. Li that way it will also be possible to adjust the curves depending on a given desired mechanical strength property.

In an additional advantageous embodiment, it may be envisaged that the tops of the curvatures are flattened. Hereby may be achieved many advantages, among others it will, as mentioned above, be more difficult for different types of animals to bite around the curvatures and thereby destroy the curvatures. Furthermore, at flattened top will mean that it will be easier to dispose elements immediately upon the surface and to increase the surface area for a possible fastening.

According to a further embodiment of the building panel, between adjacent elevations and between adjacent depressions curved backs are formed, the curved backs having smaller dimension in direction perpendicular to the plane of the building panel.

An elevation in the building panel does not continue directly into a depression, but are connected by a curving back elevation and elevation as well as depression and depression. The presence of the curving back means that an extra support member for the building panel is provided, as it will act as a reinforcing bridge between elevations and depressions. However, the height of the curving back will be of a magnitude meaning that it will be disposed a distance between the centre plane of the elevations and the depressions and their top and bottom points, respectively, such that the three- dimensional curving structure is not lost due to the height of the curving backs.

According to a further embodiment of the building panel, from an elevation or depression, curved backs are formed in two mutually transverse directions, where between the curved backs depressions and elevations, respectively, are formed.

This means that if the curving backs are formed with perpendicular spacing between each other, there will be elevations perpendicular to each other. Hereby is achieved a considerable mechanical strength in mutually perpendicular directions through the elevations. However, the 45° angle here between will be the weakest area. This means that the weakest area can be displaced according to wish by letting the two transverse directions vary in a given angle such that if the elevations are displaced in an angle not perpendicular to each other.

According to a further embodiment of the building panel, the elevations of the curved backs are disposed in a central plane, preferably a centre plane through the building panel.

Hereby is meant that if the building panel is seen from each their side, elevations of the curving backs may be found at each side. The elevations of the curving backs will be of the same height as seen in relation to the central plane, whereby the same strength may be achieved throughout the entire plate. By letting the plane go through the middle of the building panel, it will be possible to attain the same height of the elevations of the curving backs at both sides of the building panel. Hereby is achieved a further increase of the mechanical strength.

Under the given conditions, it will, however, be possible to envisage that the elevations of the curving backs will be of different height as seen in relation to the central plane. This may provide alternating mechanical strength properties across the plate.

According to a further embodiment of the building panel, mounting holes are provided in the elevations and depressions, respectively, at a position above the plane of the elevations of the curved backs.

Fitting mounting holes in the building panels means that it will be possible to reinforce and secure the building panels with e.g. metal rods, but there may also be envisaged other kinds of fastening and reinforcing elements. In this way, metal rods will be inserted at a given angel in the building panels through the formed mounting holes. The slight angle in the building panel, cf. the transverse direction of the curving backs, may hereby be reinforced by means of the metal rod, or it will be possible to fasten the metal rod to poles, whereby the building panel itself may be secured. The drilling of the mounting holes will not entail opening into cavities which will be difficult to clean, as this is a single-layer plate, preferably a plastic plate. Stabilisation with e.g. metal rods may therefore take place even in the case that the building panel is to be used as partitioning in animal stables where efficient cleaning will be required. The exact disposition of the metal rod will thus be of great significance in general, as there will also be possibility of cavities between the metal rod and the surface of the building panel in case that the distance becomes too short.

According to a further embodiment of the building panel, the building panel is made of a weldable/bondable material, and where it contains a joining edge in the form of a weld edge/glue edge, the joining edge provided at at least one edge of the building panel, the joining edge being without three-dimensional curving structures.

In order to fasten and mount the building panels without producing holes or cavities, it will be a great advantage with an edge area of the building panel which does not contain three-dimensional curving structures, whereby it is achieved that the edge may easily be welded, glued or joined for assembly with another surface at a given angle, without cavities arising which make difficult cleaning the surface in the best way in order to prevent microbial growth.

According to the invention, there is furthermore indicated a method for making a building panel by means of injection moulding.

Making a single-layered plastic building panel by means of injection moulding provides great industrial advantages as it will be possible to produce large standard plates cheaply and rapidly while using traditional and well-known means. This provides great advantages for the customers, as it will be cheaper to produce the building panels in question, since due to their great mechanical strength per weight unit combined with the lesser weight will have the possibility of forming basis for building multiple elements for use in the construction of houses, stables, equipment and so on. Making a single-layer plastic building panel can also be done by using vacuum forming (thermoforming), rotary moulding, embossed design or similar techniques that all will be profitable by small production batches.

According to a further use of the building panel it may be used as core layer in a sandwich element, wherein at least one plate is fitted on the building panel by mounting on the elevations of the curving structure.

This may be advantageous in cases where a plane surface is desired at one or both sides. This may be achieved in that a plate is applied on one or both sides of the building panel, which may be done by means of e.g. glue, joining or welding, depending on the chosen type of material. It may here be of advantage if the elevations have a flattened top, providing the possibility of a greater contact face between the plate and the three-dimensional curving structure. This means that fastening the plate will cause it to rest on a larger contact surface, resulting in better securing of the plate.

By making the building panel of a transparent or translucent plastic, such as PC or ABS, such sandwich construction will be particularly suited as a roof plate.

A further possibility will be that a building panel with a three-dimensional curving structure will be secured at each their side of a plane plate, whereby a series of sandwich elements of building panels between flat plates can be formed. Thus may be constructed a stable mass of varying height according to wish which may be used as stabilising elements in walls, doors, floors and the like.

Description of the Drawing

Fig. 1 illustrates a solid single-layer plate with three-dimensional curving structure secured to a pole by means of a metal rod; Fig. 2 illustrates two examples of designs of solid single-layer plates fastened to pole and floor; and Fig. 3 illustrates three different variations of solid single-layer plates. Detailed Description of the Invention

On Fig. 1 is illustrated a solid single-layered plate 1 with three-dimensional curving structure with elevations 3 and depressions 5, respectively. The shown plate is a plastic plate but it may alternatively be made of one of the above mentioned materials. Moreover, the tops of the elevations appear flattened 7. Mounting holes 9 are formed through the sides of a row of elevations through which a metal rod 11 has been passed and fastened to a pole 13. In this example, the metal rod functions as fastening member to the pole, whereby the solid single-layer plastic plate may be secured at a given position.

Moreover, it may be observed that no cavities are formed, neither along the edges on the plastic plate nor on the plastic plate itself, thus making the plate very cleaning- friendly. The metal rod 11 may be fastened through the solid single-layered plastic plate 1 only, why its fastening will not be necessitated by coupling to a pole 13. A cavity between the solid single-layered plastic plate 1 and a fastening member, as e.g. a pole 13, may be avoided by welding, gluing or joining the solid single-layered plastic plate 1 to the fastening member.

Alternatively, the distance as on Fig. 1 can be made sufficiently large in order to be cleaned efficiently, but in that case this will enable animals to get in contact with each other through the hole between pole 13 and the solid single-layer plastic plate 1, which in some cases may be less desirable due to e.g. danger of infection.

If the solid single-layer plastic plate is to be used as partitioning in e.g. pig stables, it will be necessary with an efficient fastening in order to prevent the animals from destroying the partitioning. A fastening to other than poles, but also to the floor of the solid single-layer plastic plate will thus be advantageous.

An example of this is seen illustrated in Fig. 2. Here it appears how two solid single- layer plastic plates 1 are fastened close to a four-edged pole 15 which also can be fastened to the floor 17, illustrated here in a plane perpendicular to the longitudinal axis 19 of the four-edged pole. The partitioning member is further reinforced by a metal rod 11 running through mounting holes 9 in a row of elevations 3, and continuing from one solid single-layer plastic plate 1 to the next across the four-edges pole 15 without fastening thereto.

The design of the solid single-layer plastic plates with regard to size and number of elevations and depressions influences the strength of the plastic plate and may simply be changed according to desire and need. This means that the pattern may be adapted to the application, i.a. meaning that it may be adapted to which type of animals wanted to be separated, or if the solid single-layer plastic plate is to be used as an element in a door or a floor that are to resist various actions of force.

In Fig. 3 are illustrated three different types of plates which in the shown form are plastic plates. To the left 21 appears a symmetric solid single-layer plastic plate with elevations 3, depressions 5 and curved backs 23 disposed at the same level and with equal spacing. At the centre 25 is illustrated another embodiment of a solid single- layer plastic plate where the central part of the solid single-layer plastic plate is substituted with the elevations 3 and the depressions 5 being phased out in a long sliding path 27 towards the middle of the area 29.

As an alternative, third embodiment, an area without three-dimensional curving structures 31, or possibly of very small height as illustrated here to the right 33 in Fig. 3 may be formed, where the area is located from the centre of the plate and a length downwards. An entire area without three-dimensional curving structures 31 may be placed at a given location on the solid single-layer plastic plate.

Alternatively, the area without three-dimensional curving structures 31 may be disposed at the edge of the plate and act as welding edge in plates made of any kind of weldable material. The solid single-layer plastic plate may thus more readily be fastened to another edge without possibility of formation of small cavities.

In the table below are indicated some values for the relation between load and deflection for plane plates compared with double curving plates according to the present invention. It clearly appears that material savings can be achieved. Measurements are performed on a plate supported at both ends and loaded at the centre of the plate.

Claims

1. A building panel, characterised in that it is made with a three-dimensional curving structure of a solid single-layer plate.

2. Building panel according to claim 1, characterised in that elevations in the curving structure are located in the same plane at each side of a central plane, preferably a centre plane, through the building panel.

3. Building panel according to any preceding claim, characterised in that the curving structure provides uniform elevations and depressions as seen from each side of the building panel.

4. Building panel according to claim 3, characterised in that between adjacent elevations and between adjacent depressions curved backs are formed, the curved backs having smaller dimension in direction perpendicular to the plane of the building panel.

5. Building panel according to claim 4, characterised in that from an elevation or depression, curved backs are formed in two mutually transverse directions, where between the curved backs depressions and elevations, respectively, are formed.

6. Building panel according to claim 5, characterised in that the elevations of the curved backs are disposed in a central plane, preferably a centre plane through the building panel.

7. Building panel according to claim 6, characterised in that mounting holes are provided in the elevations and depressions, respectively, at a position above the plane of the elevations of the curved backs.

8. Building panel according to any preceding claim, characterised in that it is made of a material selected among metals, cellulose, gypsum and composites.

9. Building panel according to any preceding claim, characterised in that the building panel is made of a weldable/bondable material, and that it contains a joining edge in the form of a weld edge/glue edge, the joining edge provided at at least one edge of the building panel, the joining edge being without three-dimensional curving structures.

10. A method for making a building panel according to any preceding claim, characterised in that it is injection moulded in a plastic material.

11. Use of a building panel according to any preceding claim for use as core layer in a sandwich element, wherein at least one plate is fitted on the building panel by mounting on the elevations of the curving structure.