WO2009145621A1

WO2009145621A1 - Wall element

Info

Publication number: WO2009145621A1
Application number: PCT/NL2009/050285
Authority: WO
Inventors: Wilhelmus Jan Reinier Karel Snel
Original assignee: Unda Maris Holding N.V.
Priority date: 2008-05-29
Filing date: 2009-05-25
Publication date: 2009-12-03
Also published as: EP2307630A1; NL2001634C2; WO2009145621A9; EP2307630B9; ATE542962T1; EP2307630B1

Abstract

A wall element comprising two outer layers extending at least substantially parallel to each other with at least one intermediate layer present there between, characterised in that the intermediate layer is at least substantially made of a metal plate-shaped material, wherein a profile is formed in the plane of the plate-shaped material, and wherein the intermediate layer defines a compartment which contains an insulation material. In particular, opposing edges of the intermediate layer are flanged at least twice, said insulation material being contained between flanged parts of the edges of the intermediate layer.

Description

WALL ELEMENT

The invention relates to a wall element comprising two outer layers extending at least substantially parallel to each other with at least one intermediate layer present therebetween.

Such a wall element is described in German patent No. 23 49 436 (Baltzer) .

The object of the invention is to improve the wall element that is known from the aforesaid German patent publication, in the sense that a wall element is provided which has an optimal constructional stiffness for serving as (part of a) wall panel, for example a partition wall etc, and which at the same time is light in weight. It is noted that the term "wall panel" is understood to include an element for use in a wall, floor, ceiling, roof etc.

In order to accomplish that object, a wall element of the kind referred to in the introduction is according to the invention characterised in that the intermediate layer is at least substantially made of a metal plate-shaped material, wherein a profile is formed in the plane of the plate-shaped material, and wherein the intermediate layer defines a compartment which contains an insulation material. The insulation material is preferably a sound-insulating and/or thermally insulating material. In particular, opposing edges of the intermediate layer are flanged at least twice, with the insulation material being contained between flanged parts of the edges of the intermediate layer.

In a preferred embodiment of a wall element according to the invention, the intermediate layer is connected to one outer layer on its side remote from the insulation material, whilst the intermediate layer is connected to the other outer layer at the flanged parts of the edges of the intermediate layer. In another preferred variant, the intermediate layer is connected to one outer layer on its side remote from the insulation material, whilst the intermediate layer is connected to the other outer layer via another, second intermediate layer. The second intermediate layer preferably has an at least substantially U-shaped cross-section, with the second intermediate layer engaging the first intermediate layer with legs of said U-shaped cross-section. In another preferred variant, the second intermediate layer has an at least substantially L-shaped cross-section, with the second intermediate layer engaging the first intermediate layer with legs of said L-shaped cross-section.

Research has shown that the present construction results in an unexpectedly high constructional stiffness of the wall element, so that the wall element can be loaded with large forces without losing any of its shape stability. At the same time a surprisingly light-weight construction is obtained, which makes the element easier to handle.

Experiments have furthermore shown that the metal intermediate layer comprising the (thermal) insulation material is resistant to very high temperatures, as high as 1000 ⁰C and higher. In addition, said experiments have shown that warping of the intermediate layer due to expansion of the metal is hardly possible at the aforesaid temperatures, if at all, since the profile is capable of compensating said expansion in various directions, viz. both in the longitudinal direction and in the transverse direction of the profile. The present wall element is for example quite suitable for use as a (part of a) partition wall in a building, for example a hospital, since the metal intermediate layer is capable of stopping electromagnetic radiation that is used in the hospital.

In another preferred embodiment of a wall element according to the invention, the profile is a profile of corrugated cross-section formed in the plane of the plate-shaped material. Preferably, corrugations of the profile extend in meandering fashion in the plane of the plate-shaped material. It is noted that within the framework of the invention the term "in meandering fashion" is understood to mean any manner of meandering (from left to right) . Preferably, the corrugations extend in zigzag fashion in the plane of the plate-shaped material, so that corrugations alternately make a more or less acute angle to the left and to the right. In another preferred embodiment, the corrugations extend in snake-like fashion in the plane of the plate-shaped material. The corrugations preferably extend parallel to each other in the plane of the plate-shaped material rather than converge or diverge. The profile is in particular provided along at least substantially the entire length of the plate-shaped material and extends over all the first parts of the intermediate layer.

In another preferred embodiment of a wall element according to the invention, the corrugations extend sinusoidally in the plane of the plate-shaped material. The distance between two adjacent crests of the sine shape preferably ranges between 0.25 and 2 times the amplitude of the sine shape. In particular, the distance between two adjacent crests of the sine shape at least substantially equals the amplitude of the sine shape. Tests have shown that in this way a construction having an optimum constructional stiffness is obtained, whilst at the same time said construction is light in weight. In another preferred embodiment of a wall element according to the invention, the plate-shaped material is made of a metal selected from the group consisting of iron, steel, copper and aluminium, or of an alloy of one or more of said metals. The profile is preferably rolled in the plate-shaped material, as will be explained in more detail yet hereinafter.

In another preferred embodiment of a wall element according to the invention, the outer layers are glued together with the intermediate layer/layers. The adhesive that is used is preferably a swellable adhesive, in particular a foamable adhesive, more in particular a polyurethane-based foamable adhesive .

In another preferred embodiment of a wall element according to the invention, the outer layers are at least substantially made of a material selected from the group consisting of fibre material, plastic, rubber, metal, paper/cardboard and wood. In another preferred variant, plaster boards are used as the outer layers .

The fibre material in particular contains glass fibres, carbon fibres, mineral fibres and/or synthetic fibres. Fibres of the type known under the trade names "Kevlar" or "Twaron" may for example be used as synthetic fibres.

The layer of plastic material is preferably selected from the group consisting of PVC-U, PP, PE, ABS, PVC-C and PVDF. It is noted that the material abbreviations used above relate to the following (plastic) materials:

PVC-U Polyvinyl fluoride (without plasticiser) PP Polypropylene

PE Polyethylene

ABS Acrylonitrile Butadiene Styrene

PVC-C Polyvinyl chloride (rechlorinated) PVDF Polyvinylidene fluoride

The rubber layer is in particular selected form the group consisting of EPDM or NBR. In another preferred variant, the outer layers are made of a metal, in particular stainless steel or wood, such as two-ply or three-ply wood.

In another preferred embodiment of a wall element according to the invention, the outer layers are at least substantially made of layers of paper/cardboard, each layer at least substantially being made up of a corrugated sub-layer and a flat sub-layer provided on one side thereof, with the paper/cardboard layers being bonded together by means of an adhesive applied to the corrugations of the corrugated sub-layers. It is noted that the term "paper" is commonly used for lighter paper types, whilst the term "cardboard" is frequently used for heavier paper types. Within the framework of the present invention no limitation is intended as regards the type of material when the terms "paper" or "cardboard" are used.

The outer layers are preferably impregnated, in particular with a resinous material, such as polyurethane or polyester resin. It is noted that impregnation with a resinous material, for example, not only has the advantage of increasing the constructional stiffness, but also of providing protection against external influences, such as moisture. Because of the additional stiffness, fewer layers of corrugated paper/cardboard are in principle required for imparting the required stiffness to the flat wall panel. Impregnation preferably takes place by vapour deposition, spraying or otherwise, with vapour deposition or spraying taking place in a direction parallel to the direction of the "cell structure" of the corrugated paper/cardboard that is used. Impregnation can also take place mechanically, in which case toothed and/or flat rollers are used for forcing the impregnation agent into the paper/cardboard.

In another preferred embodiment of a wall element according to the invention, the intermediate layer/layers is/are staggered relative to the outer layers, said wall element being profiled along a first part of the circumferential edge and being provided with at least one outwardly extending lip along a second part of the circumferential edge, with a lip of one wall element being inserted into a corresponding profile of the upper wall element in the connected condition of adjacent wall elements. Such a staggered position of the intermediate layer/layers makes it possible to effect a solid connection between several wall elements in a simple manner.

In an alternative preferred embodiment, the wall element is profiled along a first part of the circumferential edge at both ends, and the wall element is provided with at least one outwardly extending lip along an adjacent part of the circumferential edge, with a lip of one wall element being inserted into a corresponding profile of the upper wall element in the connected condition of adjacent wall elements.

Preferably, said intermediate layer/layers is/are flanged in a direction transversely to the outer layers, parallel to the flanged portions of the intermediate layer/layers, at at least one edge of the wall element. The invention will now be explained in more detail with reference to figures of embodiments of the invention shown in a drawing, in which like parts are provided with the same numerals and in which:

- Figure 1 shows a wall element according to the invention;

- Figures 2 and 3 show a part of the wall element of figure 1 in the direction indicated at II;

- Figures 4 and 5 correspond to figures 2 and 3 but relate to another variant of the wall element of figure 1;

- Figure 6 schematically shows a plate-shaped material for use as an intermediate layer in the wall element of figure 1; and

- Figure 7 corresponds to figure 6, but makes use of the plate-shaped material of figure 6.

In figure 1, a wall element 1 according to the invention is shown. The wall element 1 is substantially plate-shaped, being built up of two parallel outer layers 2 and 3 of gypsum. Disposed between said outer layers 2 and 3 is an intermediate layer 4, which extends between the outer layers 2 and 3.

Figure 2 shows part of the wall element 1, seen in the direction II shown in figure 1. The intermediate layer 4 comprises a first intermediate layer 4' consisting of a plate-shaped material which is flanged three times (inter alia) for forming first parts 5a, second parts 5b and third parts 5c. The first parts 5a, which extend perpendicularly to the outer layers 2 and 3, and the second parts 5b, which extend parallel to the outer layers 2 and 3, may be connected (in particular glued) to a second intermediate layer 4' ' likewise made of a plate-shaped material. The plate-shaped material of the second intermediate layer 4 ' ' is flanged once for forming parts 6, which extend perpendicularly to the outer layers 2 and 3. The parts 6 of the second intermediate layer 4' ' engage round the first intermediate layer 4', viz. at the location of the first parts 5a. As figure 3 shows, the intermediate layers 4' and 4'' form a compartment 7, in which strip-shaped sound-insulating and/or thermally insulating material can be contained. The material 8 is partially held in place by the third parts 5c of the first intermediate layer 4' . The intermediate layers 4 ' and 4 ' ' are connected, preferably glued, to the outer layers 2 on their sides remote from the insulation material 8.

Figures 4 and 5 correspond to figures 2 and 3, with this difference that the second intermediate layer 4' ' (which is more or less L-shaped) is flanged twice on one side for forming parts 9a and 9b, part 9a extending perpendicularly to the outer layers 2 a 3 and part 9b extending parallel thereto. The part 5c of the first intermediate layer 4 ' engages the second part 9b of the second intermediate layer 4''.

To make it possible to connect wall elements 1 together so as to create a wall, for example, the intermediate layer 4 is slightly staggered relative to the outer layers 2 and 3, as is indicated at x. One part of the intermediate layer, which projects outside the outer layers 2 and 3, forms a lip 10 along a circumferential edge of the wall element 1, whilst the other part of the intermediate layer, which extends within the outer layers 2 and 3, forms a profile 11 in said circumferential edge. In connected condition, a lip 10 can be inserted into a profile 11 of an adjacent wall element. The end of one wall element 1 comes to abut against the end of an adjacent wall element 1 in that case.

As figures 1 - 5 show, a profile of corrugated cross-section comprising crests 12 and valleys 13 is formed in the intermediate layers 4 ' and 4 ' ' .

In figure 6, the plate-shaped material for use in the intermediate layer 4 of figure 7 is shown. A profile of corrugated cross-section comprising crests 12 and valleys 13 is formed in the plane of the plate-shaped material, with the corrugations 14 of the profile extending sinusoidally and parallel to each other in the plane of the plate-shaped material.

Figure 7 corresponds to figure 5, with this difference that a corrugated profile as shown in figure 6 is formed in the intermediate layers 4 ' and 4 ' ' .

It is noted that the invention is not limited to the embodiments as shown and described herein, but it also extends to other preferred variants that fall within the scope of the appended claims.

Claims

1. A wall element comprising two outer layers extending at least substantially parallel to each other with at least one intermediate layer present therebetween, characterised in that the intermediate layer is at least substantially made of a metal plate-shaped material, wherein a profile is formed in the plane of the plate-shaped material, and wherein the intermediate layer defines a compartment which contains an insulation material.

2. A wall element according to claim 1, wherein opposing edges of the intermediate layer are flanged at least twice, and wherein the insulation material is contained between flanged parts of the edges of the intermediate layer.

3. A wall element according to claim 1 or 2, wherein the intermediate layer is connected to one outer layer on its side remote from the insulation material, and wherein the intermediate layer is connected to the other outer layer at the flanged parts of the edges of the intermediate layer.

4. A wall element according to claim 1 or 2, wherein the intermediate layer is connected to one outer layer on its side remote from the insulation material, and wherein the intermediate layer is connected to the other outer layer via another, second intermediate layer.

5. A wall element according to claim 4, wherein the second intermediate layer has an at least substantially U-shaped cross-section, and wherein the second intermediate layer engages the first intermediate layer with legs of said U-shaped cross-section.

6. A wall element according to claim 4, wherein the second intermediate layer has an at least substantially L-shaped cross-section, and wherein the second intermediate layer engages the first intermediate layer with legs of said L-shaped cross-section.

7. A wall element according to claim 4, 5 or 6, wherein the second intermediate layer is at least substantially made of a metal plate-shaped material, wherein a profile is formed in the plane of the plate-shaped material.

8. A wall element according to any one of the preceding claims 1 - 6, wherein the profile is a profile of corrugated cross-section formed in the plane of the plate-shaped material.

9. A wall element according to claim 8, wherein corrugations of the profile extend in meandering fashion in the plane of the plate-shaped material.

10. A wall element according to claim 9, wherein said corrugations extend parallel to each other in the plane of the plate-shaped material.

11. A wall element according to claim 9 or 10, wherein the corrugations extend in zigzag fashion in the plane of the plate-shaped material.

12. A wall element according to claim 9 or 10, wherein the corrugations extend in snake-like fashion in the plane of the plate-shaped material.

13. A wall element according to claim 12, wherein the corrugations extend sinusoidally in the plane of the plate-shaped material.

14. A wall element according to claim 13, wherein the distance between two adjacent crests of the sine shape preferably ranges between 0.25 and 2 times the amplitude of the sine shape.

15. A wall element according to claim 14, wherein the distance between two adjacent crests of the sine shape at least substantially equals the amplitude of the sine shape.

16. A wall element according to any one of the preceding claims 1 - 15, wherein the profile is provided along at least substantially the entire length of the plate-shaped material .

17. A wall element according to any one of the preceding claims 1 - 16, wherein the plate-shaped material is made of a metal selected from the group consisting of iron, steel, copper and aluminium, or of an alloy of one or more of said metals.

18. A wall element according to any one of the preceding claims 1 - 17, wherein the outer layers are glued together with the intermediate layer/layers.

19. A wall element according to any one of the preceding claims 1 - 18, wherein the outer layers are at least substantially made of a material selected from the group consisting of fibre material, plastic, rubber, metal, gypsum, paper/cardboard and wood.

20. A wall element according claim 19, wherein the fibre material contains glass fibres, carbon fibres, mineral fibres and/or synthetic fibres.

21. A wall element according to claim 19, wherein the outer layers are at least substantially made of layers of paper/cardboard, each layer at least substantially being made up of a corrugated sub-layer and a flat sub-layer provided on one side thereof, with the paper/cardboard layers being bonded together by means of an adhesive applied to the corrugations of the corrugated sub-layers.

22. A wall element according to claim 21, wherein the outer layers are preferably impregnated, in particular with a resinous material.

23. A wall element according to claim 19, wherein the outer layers are at least substantially made of two-ply or three-ply wood.

24. A wall element according to any one of the preceding claims 1 - 23, wherein the intermediate layer/layers is/are staggered relative to the outer layers, said wall element being profiled along a first part of the circumferential edge and being provided with at least one outwardly extending lip along a second part of the circumferential edge, with a lip of one wall element being inserted into a corresponding profile of the upper wall element in the connected condition of adjacent wall elements.

25. A wall element according to any one of the preceding claims 1 - 24, wherein said intermediate layer/layers is/are flanged in a direction transversely to the outer layers, parallel to the flanged portions of the intermediate layer/layers, at at least one edge of the wall element.

26. A wall element according to any one of the preceding claims 1 - 25, wherein the wall element is profiled along a first part of the circumferential edge at both ends, and the wall element is provided with at least one outwardly extending lip along an adjacent part of the circumferential edge, with a lip of one wall element being inserted into a corresponding profile of the upper wall element in the connected condition of adjacent wall elements.