WO2021096416A1

WO2021096416A1 - Prefabricated electromagnetically shielded construction element

Info

Publication number: WO2021096416A1
Application number: PCT/SE2020/051089
Authority: WO
Inventors: Hans Marcus ERIKSSON
Original assignee: Sörmländska Invest Ab
Priority date: 2019-11-15
Filing date: 2020-11-13
Publication date: 2021-05-20

Abstract

The invention relates to a prefabricated construction element (1) comprising a bulk element (5) having a front surface (7) and a ack surface (9), extending parallel with each other, defining a thickness (11) thereof, wherein at least one side surface (13) extends between said front and back surfaces (7, 9). The construction element (1) further comprises at least one plate element (5), arranged to cover at least the front surface (7) of the bulk element (5), being in direct contact thereto. Each plate element (15) have a thickness (17) and/or is made of a material that provide electromagnetic shielding to the construction element (1), defining an electromagnetic shielded area (19) thereof. Furthermore, each edge (21) of the at least one plate element (15), which edge (21) is aligned with a circumference (23) of the electromagnetic shielded area (19), comprises at least one flange element (25), extending a predetermined distance (27) from said circumference (23), in a direction away from the electromagnetic shielded area (19) and into the bulk element (5). Wherein an outer surface (29) of said at least one flange element (25) is aligned with a plane defining any surface adjacent the circumference (23) of the electromagnetic shielded area (19). The invention further relates to a method for manufacturing such a construction element (1).

Description

PREFABRICATED ELECTROMAGNETICALLY SHIELDED CONSTRUCTION ELEMENT

TECHNICAL FIELD

The invention relates to a prefabricated electromagnetically shielded construction element, and a method for manufacturing such an element.

BACKGROUND ART

Due to digital technology becoming more and more commonplace in our society, and a large plurality of wireless signals being sent, shielding from such signals have also become a higher priority. Shielding from electromagnetic signals may be of importance for health and environmental reasons, but also for security reasons. As hacking of private and sensitive content being sent wirelessly and server facilities growing bigger and bigger with the expansive digital technical field, the need for shielding and protection of ones signals is growing, and solutions for such shielding needs to be usable for larger and larger facilities and areas.

This in turn puts more strain on the people and companies that provide such services, as shielding of a facility and/or a room thereof desirably should be fast and cost effective. Metals such as copper has been known to provide reliable electromagnetic shielding properties, wherein plates, films or other types of layers of copper have been provided to walls, ceilings and floors of facilities such as server rooms etc. have commonly been a time consuming but effective way of solving shielding of facilities and/or specific rooms.

Prefabricated construction elements may be preferred to speed up building on-site, but is an area that is not yet fully developed in all regards. Thus, there is still a need to further expand the area of prefabricated construction elements that may provide shielding of electromagnetic waves and signals.

SUMMARY OF THE INVENTION

Despite prior art there is a need to develop a prefabricated construction element that provides electromagnetic shielding in a reliable and consistently covering manner. There is also a need to develop such a prefabricated construction element, which is fast and cost effective to manufacture. There is further a need to develop such a prefabricated construction element, which is easily adaptable to manufacture as a large variety of constructional elements of a building, and is versatile with regards to connecting them to each other.

An object of the invention is thus to provide a prefabricated construction element that provides electromagnetic shielding in a reliable and consistently covering manner. Another object is to provide such a refabricated construction element, which is fast and cost effective to manufacture. A further object is to provide such a prefabricated construction element, which is easily adaptable to manufacture as a large variety of constructional elements of a building, and is versatile with regards to connecting them to each other.

According to a first aspect, a prefabricated construction element is provided. The construction element comprises a bulk element having a two-dimensional front surface and a two- dimensional back surface, extending parallel with each other and defining a thickness of the construction element there between. The construction element further comprises at least one side surface, extending between said front and back surfaces. Even further, the construction element further comprises at least one plate element, arranged to cover at least the front surface of the bulk element, being in direct contact thereto. Each plate element have a thickness and/or is made of a material that provides electromagnetic shielding to the construction element, defining an electromagnetic shielded area thereof. Even further, each edge of the at least one plate element, which edge is aligned with a circumference of the electromagnetic shielded area, comprises at least one flange element, extending a predetermined distance from said circumference, in a direction away from the electromagnetic shielded area and into the bulk element. An outer surface of said at least one flange element is aligned with a plane defining any surface of the construction element that may be adjacent the circumference of the electromagnetic shielded area.

This has the advantage that a prefabricated construction element is provided, which prefabricated construction element provides excellent shielding of and/or for electromagnetic waves to said construction element. As the electromagnetic shielded area is positioned at an outer surface of the construction element, it is easier to arrange a plurality of such construction elements adjacent each other and guarantee a fully covered structure and/or room that is electromagnetically shielded, as would not be possible using for example similar elements that comprise a shielding layer arranged within a corresponding bulk thereof. Furthermore, as the flange elements are arranged to sit flush with any surface adjacent the circumference of the electromagnetic shielded area, any such adjacent surface will be completely flat is designed as such, wherein the plate elements and its flanges do not interfere with regular constructional work, such as arranging a plurality of prefabricated construction elements to form a room or similar.

In some examples, the prefabricated construction element may further comprise at least one reinforcement element, arranged in the bulk element, and the at least one flange element may comprise a plurality of receiving surfaces, wherein said reinforcement element is arranged thereto.

This has the advantage that the flange elements may serve a dual functionality of both being used as a fitting means to the bulk element, but also provide a predetermined positioning for such a reinforcement element. When forming the bulk element of any type of material that is casted with regards to its manufacturing, this becomes especially advantageous, as reinforcement elements are commonly used for such structures, and it is beneficial to know beforehand how and where such elements will be distributed within the completed element.

In some examples, the receiving surfaces may be arranged in holes, arranged in each of the at least one flange element.

This has the advantage that the previously mentioned reinforcement elements may be positioned in such holes, wherein a precise and reliable fitting of the two is achieved.

In some examples, the receiving surfaces may be arranged at distance element, arranged to extend from the at least one flange element.

This has the advantage that such distance elements may be used to both serve as said receiving surfaces, but also as a means of fine-tuning the positioning of the reinforcement elements within the structure of the bulk element.

In some examples, each flange element may comprise at least one projecting element, wherein each at least one projecting element extends into the bulk element. This has the advantage that said projecting elements may assist in holding the at least plate element in position towards the bulk element, providing a secure and reliable fitting of the two.

In some examples, each distance element may a portion of the at least one projecting element.

This has the advantage that the multiple advantageous of the separate features may be gained at the same time, while also cutting down on additional elements to provide to the construction element, which makes such a construction element faster, easier and more cost effective to manufacture.

In some examples, the at least one flange element may comprise at least one coupling hole, arranged between the circumference of the electromagnetic shielded area and the predetermined distance.

This has the advantage that each such construction element is prepared in advance for being coupled to an adjacent similar construction element having the same feature. This streamlines assembly of a plurality of such construction elements, which provides a very accurate and reliable assembly process, and also make sure the adjacent electromagnetic shielded areas of the two adjacent construction elements are aligned properly with each other.

In some examples, the prefabricated construction element may comprise at least two plate elements, arranged adjacent each other defining the electromagnetic shielded area and at least one joint therein. Each edge of a plate element, which edge is aligned with said at least one joint, may comprise at least one internal flange element, extending into the bulk element, wherein the at least two internal flange elements are connected to each other within the bulk element.

This has the advantage that the at least two flange elements of the at least two adjacently positioned plate elements may be utilized to both secure a connection between the two, and to further strengthen a coupled to the bulk element.

In some examples, the bulk element may comprise a concrete-type material.

This has the advantage that a robust and commonly used bulk material may be used to manufacture the construction element according to the disclosure. In some examples, the at least one plate element may comprise a metallic material, preferably copper.

This has the advantage that the electromagnetic shielded area is provided in a reliable manner, and a lot of commonly used constructional processes may be used to connect such surfaces to each other, resulting in a secure and reliable construction element as well as ensuring that it has solid shielding properties.

According to a second aspect, a method for manufacturing a construction element according to the disclosure is provided. The method comprises the steps of: a) providing a first plate element comprising at least one flange element, d) arranging at least one sidewall of a mould, flush with the outer surface of said at least one flange element, so as to define a mould, e) filling said mould with a material of the bulk element, and f) removing the at least one sidewall of the mould.

This has the advantage that plate element may serve as a part of the mould as well as an integral part of the final product. This saves resources when it comes to making such a mould, and makes assembly thereof faster, easier and more cost effective. Both these advantages also aid in providing a more environmentally friendly process and product thereof, which may be perceived as universally beneficial. Even further, as the construction element is designed to have its at least one flange element sitting flush with an outer surface of the construction element, sidewalls of a mould may be temporary fixated directly to said flange elements, wherein the intended design is achieved at the same times as the serve a guiding and aligning purpose for the sidewalls of the mould during assembly thereof.

In some examples, the method may further comprise the steps, to be performed between steps a) and c), of: b) arranging at least one additional plate element adjacent to the first plate element, and c) fixating the first and the at least one additional plate element together at flange elements thereof, by means of screws longerthan a combined thickness of said flange elements.

This has the advantage that large construction elements may be prefabricated in this manner, as a plurality of plate members may be used adjacent each other to provide a larger electromagnetic shielded area without using plate elements that are too large to handle without issues. Furthermore, by means of using longer screws than needed only for assembly of two adjacently positioned plate elements, such screws will add the advantage of acting as anchoring elements within the concrete bulk element, wherein a dual purpose and advantage is gained.

BRIEF DESCRIPTION OF THE DRAWINGS Below is a description of, as examples, embodiments with reference to the enclosed drawings, in which:

Figs la-lb show schematic depictions of a prefabricated construction element with an electromagnetically shielded front surface, in a perspective view and a cross-sectional view respectively, according to an embodiment, Figs. 2a-2h show schematic depictions of cross-sectional views of portions of a shielded construction element, according to various embodiments,

Figs. 3a-3b show schematic depictions of cross-sectional views of a shielded construction element, during and after manufacturing thereof, according to an embodiment, and

Fig. 4 shows a flowchart of a method of manufacturing a shielded construction element, according to an embodiment.

DETAILED DESCRIPTION

The description of the various features, and modifications thereof, according to the disclosure will herein be described in more detail with reference to the accompanied drawings. It is thus to be understood that embodiments comprising any of the described feature or a combination of features may be assembled in accordance with the description herein.

Figs la-lb show schematic depictions of a prefabricated construction element 1 with an electromagnetically shielded outer surface 3, in a perspective view and a cross-sectional view respectively, according to a first aspect. The prefabricated construction element 1 according to this first aspect comprises a bulk element 5, having a two-dimensional front surface 7 and a two-dimensional back surface 9. Said two surfaces 7, 9 extend parallel with each other, defining a thickness 11 thereof, wherein at least one side surface 13 extends between said front and back surfaces 7, 9, according to a first aspect. The construction element 1 depicted in figs la- lb comprises four such side surfaces 13, as the construction element 1 is shaped as a cuboid. This may be perceived as the most commonly used shape for a prefabricated construction element 1, and is thus used as a primary example to show the inventive concept. It should however be mentioned and understood that other geometrical forms may be used, wherein if a construction element having round front and back surfaces 7, 9 would only have one side surface 13, extending along a circumference of such round shapes.

The construction element 1 may further comprise at least one plate element 15, wherein the embodiment of figs la-lb comprises one such plate element 15, arranged to cover at least the front surface 7 of the bulk element 5, being in direct contact thereto. Each plate element 15 have a thickness 17 and/or is made of a material that provide electromagnetic shielding to the construction element 1, defining an electromagnetic shielded area 19 thereof. As should be obvious, different types of materials provide more or less shielding for electromagnetic waves, wherein the parameters of thickness 17 and material selection may be varied dependent on each other. That certain types of materials provide such shielding, and that thickness 17 thereof may affect said shielding properties should be perceived as obvious and known to a person skilled in the art. The inventive concept as presented throughout the disclosure is primarily focused at how the construction element 1 is designed and constructed. In some examples, the bulk element 5 may comprise a concrete-type material. In some examples, the at least one plate element 15 comprises a metallic material, preferably copper.

Each edge 21 of the at least one plate element 15, which edge 21 is aligned with a circumference 23 of the electromagnetic shielded area 19, comprise at least one flange element 25, extending a predetermined distance 27 from said circumference 23, in a direction away from the electromagnetic shielded area 19 and into the bulk element 5. Furthermore, an outer surface 29 of the at least one flange element 25 is aligned with a plane defining any side surface 13 adjacent the circumference 23 of the electromagnetic shielded area 19. As is seen in figs la-lb, and especially visible in fig. lb, the outer surface 29 of the flange element is, for the example depicted herein (a cuboid), seen to be aligned and sits flush with a two-dimensional side surface 13 of the construction element 1. The flange element 25 is thus further oriented to extend at a right angle with respect to the flat outer surface of the construction element 1. As is seen in both figs la-lb, such a configuration of the flange elements 25 provide a very accurate fit towards similar and/or additional elements if arranged adjacent each other, which is presented in fig. la by an additional construction element 1 depicted in part, in dashed lines. In whichever manner two such prefabricated construction elements 1 are arranged adjacent each other, their individual electromagnetic shielded areas 19 will be joined together, providing a seamless joint of the two, and thus an uninterrupted shielding when used as a corner of a room as an example. Connection of two such construction elements 1 is then easily achieved by means of, for example, right angled support elements 31, as depicted in dotted lines in fig. la. If assuming the plate elements 1 are made of a metallic material, such an inside corner of a room could also be welded together to achieve a very reliable connection thereof.

As should be obvious, other types of angles of the surfaces 7, 13 and thus the construction elements 1 would easily be manageable to provide to a construction element 1 if desired, without interfering with or deviating from the inventive concept.

Figs. 2a-2h show schematic depictions of cross-sectional views of portions of a shielded construction element 1, according to various embodiments. The variations of the various embodiments according to these figs will illustrate how the construction element 1 may be slightly modified to provide a plurality of specific features to said construction element 1, which in turn may be utilized to achieve a corresponding plurality of functions suitable for different types of constructional work. It should be obvious that the various embodiments herein may be combined in even more ways than is presented, and the depictions of figs. 2a-2h should not be viewed as restrictive with regards to individual features thereof.

Fig. 2a shows an example of the construction element 1, in which the predetermined distance 27 the flange element 25 is extending corresponds to the thickness 11 of the bulk element 5. This may be preferred both with regards to some intended usages of such a construction element 1, and with regards to the manufacturing thereof. By means of having the flange element 25 extending all along the side surface (and thus a sidewall) 13 as depicted in fig. 2a, this exemplary embodiment of the construction element may be used to provide an outside corner of a wall of a construction such as a room, and still provide electromagnetic shielding along said outside corner, as the flange element 25 may provide an additional electromagnetic shielded area 19' connected to the primary electromagnetic shielded area 19 of the construction element 1. When arranged adjacent another construction element 1, which is illustrated with dashed lines, oriented perpendicular to the construction element 1, the electromagnetic shielding provided by these two elements 1 is non-interrupted along the joint there between, which provides a reliable and secure shielding for a room or similar being constructed in this manner with these two types of construction elements 1.

Furthermore, as mentioned, this type of embodiment may provide advantages to a manufacturing method of the construction elements 1 as well. A method of such manufacturing will be expanded upon with reference to figs. 3a-3b and fig. 4, but it will be briefly discussed herein as well. The bulk element 5 may be made in various ways, dependent on the intended application of the construction element 1, but as one example the bulk element 5 may be made of concrete or a similar material and/or compound, which is moulded into its shape. For such cases, the flange element 25 may serve an additional purpose of being used as a mould, or a part thereof, for such a moulding process. The flange element 25 as depicted in fig. 2a, is assumed to extend all around the circumference 23 of the electromagnetic shielded area 19 will thus be able to fully serve the function as a mould that may be filled with concrete, or a similar material, directly. This thus saves on material costs as no additional resources need to be spent on providing a mould to manufacture the bulk element 5 individually. Furthermore, the construction element 1 may, as depicted in fig. 2a, comprise a fastening element 33 such as a screw, to achieve a more secure attachment of the plate element 15 to the bulk element 5 for the final product. Such a screw, or a similar fastener, may then be attached to the flange element 25 before the concrete (or other mouldable material) is added to the mould. When the moulded bulk element 5 has fully cured, such a screw is already in place to perform its function, wherein no pre-drilling and/or insertion of such a screw into a fully cured/hardened material needs to be made, which saves time and effort with regards to the manufacturing of the construction element 1.

Fig. 2b depicts another alternative embodiment of the construction element 1. For the prefabricated construction element 1 according to this example, each flange element 25 comprise at least one projecting element 35, wherein each at least one projecting element 35 extends into the bulk element 5. As the view depicted in fig. 2b is cross-sectional, it is taken through one such projecting element 35, but it should be understood that there may be a plurality of such projecting elements 35 provided, spread out over an edge 37 of the flange elements 25, which edge 37 extends perpendicular to the cross-sectional view. As may be compared to the example depicted in fig. 2a, this embodiment may serve a similar advantage with respect to achieving a shielded outer corner of a structure, as the same type of additional electromagnetic shielded area 19' is provided to the construction element 1 depicted herein, which additional shielded area 19' abuts the circumference 23 of an adjacent additional construction element 1, as depicted in dashed lines.

Furthermore, the provided advantage with regards to manufacturing of the construction element 1 according to fig. 2b may also be perceived as similar to the example according to fig. 2a, as the flange element 25 of the construction element 1 according to fig. 2b also extends along all of the adjacent side surface 13 of the bulk element 5, and may thus similarly be utilized as a mould for the material of the bulk element 5, or at least parts thereof. One difference may be noted however, in that the at least one projecting element 35, extending into the bulk element 5, will provide an alternative way of holding the plate element 15 securely towards the bulk element 5, wherein the screw, or another similar fastening element 33, depicted in fig. 2a may not be needed herein.

Fig. 2c depicts yet another alternative embodiment of the construction element 1. The prefabricated construction element 1 may further comprise at least one reinforcement element 39, arranged in the bulk element 5. The at least one flange element 25 may then comprise a plurality of receiving surfaces 41, wherein said reinforcement element 39 may be arranged thereto. If manufacturing the bulk element 5 of concrete or similar types of material and/or composites, reinforcement elements 39 may not only be beneficial, but crucial for the mechanical stability and integrity of such a bulk element 5. The flange elements 25 may in a plurality of ways provide advantages to the construction element 1, while at the same time serve additional purposes and advantages for interaction with such reinforcement elements 39, wherein non-obvious advantages may be gained.

According to the example depicted in fig. 2c, the receiving surface 41 may be arranged in a hole 43, which is arranged in the at least one flange element 25. The predetermined distance 27 of the flange element 25 is herein shown to extend beyond a centre of the construction element 1, wherein such a hole 43 may be provided aligned with said centre, so as to in a reliable manner provide the reinforcement element 39 in the middle of the construction element 1. Exactly how and where reinforcement elements 39 should be arranged and positioned within a bulk element 5 may of course vary dependent on the size and shape of the bulk element 5, but the example depicted herein, with reinforcement in the middle of such an element 5, is a commonly used practice for a large plurality of construction elements 1, wherein the example according to fig. 2c is highly suitable. If such holes 43 are arranged at opposite sides of the bulk element 5 to be moulded, suitable one-dimensional reinforcement elements 39 may thus be inserted through such a hole 43 from one side, and when it has reached the opposite side and is positioned in an opposite positioned hole 43, alignment of the reinforcement element 39 is achieved. The reinforcement element 39 according to this example also function as an alternative to the screw of fig. 2a, or the projecting element 35 of fig. 2b. As should be obvious, a plurality of such holes 43 may of course be arranged to a single flange element 25. Both as a means of providing a plurality of reinforcement elements 39 along a two-dimensional plane within the bulk element 5, but also to provide a plurality of said reinforcement elements 39 in a plurality of planes therein.

Fig. 2d shows another alternative embodiment of the construction element 1. This embodiment thereof comprises a reinforcement element 39, similar to that of fig. 2c, positioned similarly along the middle of the bulk element 5, but arranged in an alternative manner with respect to the flange element 25. The prefabricated construction element 1 according to this example comprises a receiving surface 41, but it is herein arranged at a distance element 45, arranged to extend from the at least one flange element 25. Such a distance element 45 may be provided to the flange element 25 in various ways, and which way is used may depend other factors related to the bulk element 5, the flange element 25 or other. Fig. 2d depicts one such way and thus one embodiment of the construction element 1, wherein it comprises at least one projecting element 35, extending into the bulk element 5 (similar to fig. 2b), wherein each distance element 45 is a portion of the at least one projecting element 35. Such features may thus be combined in this manner to further streamline a manufacturing process of the construction element 1 in an effective manner. For the depicted embodiment, these two features are shown to also be suitable for positioning of the reinforcement element 39 in the middle of the construction element 1. However, alternatives are also possible dependent on the predetermined distance 27 of the extension of the flange element 25. If the predetermined distance 27 is longer than depicted, the distance element 45 may extend from an inner surface 47 of said flange element 25. Such a longer predetermined distance 27 is illustrated with dotted lines in fig. 2d. The predetermined distance 27 may also be shorter than depicted, wherein the distance element 45 may extend upwards therefrom, which is also illustrated with dotted lines in fig. 2d, more specifically the distance element 45 comprising the receiving surface 41 is herein illustrated to extend upwards at an angle, to show how a reinforcement element 39 may be arranged thereto even if said reinforcement element 39, and the flange element, are comparatively shorter in length.

Fig. 2e shows yet another alternative embodiment of the construction element 1. In this example of the prefabricated construction element 1, the at least one flange element 25 comprises at least one coupling hole 49, arranged between the circumference 23 of the electromagnetic shielded area 19 and the predetermined distance 27 of the flange element 25. The coupling hole 49 may provide a plurality of usages and benefits to the construction element 1 as a whole, and is in this embodiment utilized to anchor a screw 51 there through, extending into the bulk element 5 so as to attach all three said elements 1, 5, 25 together in a secure manner. The coupling hole 49 may be perceived similar to the hole 43 provided in the flange element 25 as described with reference to fig. 2c, and thus also be modified in similar manners with regards to its positioning and/or number thereof within one flange element 25. However, the coupling hole 49 is not primarily intended to receive a reinforcement element 39 therein (note that the coupling hole 49 in fig. 2e is provided with a reinforcement element 39 adjacent thereto, but it is not housed therein), but instead be provided with additional features commonly related to coupling of elements to each other. The coupling hole 49 may thus for example comprise inner threads, wherein it is configured for receiving treaded elements such as screws or threaded rods or similar instead.

Fig. 2f shows an embodiment of the prefabricated construction element 1. This embodiment may be perceived as rather simplistic when compared to the embodiments described with reference to figs. 2a-e, yet this embodiment provide a plurality of features by means of its efficient design. The construction element 1 comprises at least one reinforcement element 39, arranged in the bulk element 5, and wherein the at least one flange element 25 comprises a receiving surface 41, wherein said reinforcement element 39 is arranged thereto. The predetermined distance 27 of the flange element 25 is however in this embodiment designed to align with a positioning of the reinforcement element 39 in its correct positioning, which in this case is the middle of the construction element 1. The receiving surface 41 of the flange element 25 is thus an end portion of the flange element 25 itself. It may also be perceived as if the flange element 25 do not comprise an additional distance element 45, as described with reference to fig. 2d, but that the flange element 25 functions as a distance element 45 itself. If additional fastening of the reinforcement element 39 to the flange element 25 is desired, this may easily be achieved by means of for example spot welding, if the materials of the flange element 25 and the reinforcement element 39 are metallic materials suitable for such welding. By means of such welding, or another similar fastening method, the reinforcement element 39 will be attached to the flange element 25, wherein the plate element 15 is securely attached to the bulk element 5.

Fig. 2g show yet an alternative embodiment of the construction element 1. This embodiment comprises no new features compared to the embodiments described above, otherthan that the side surface 13 extending from the circumference 23 of the electromagnetic shielded area 19 extends at a 45 degree angle instead of the previously described right angle related to cuboid construction elements 1. This mainly serve to illustrate that the construction element 1 may be modified with regards to its geometry without deviating from the inventive concept as presented throughout the disclosure. The construction element 1 herein comprises a reinforcement element 39, arranged to the flange element 25 by means of a receiving surface 41 in the form of a recess, shaped in the flange element 25. An additional construction element 1 is again shown in dashed lines adjacent the construction element 1, to illustrate how non square shapes may be formed by means of a plurality of construction elements 1 by means of simple geometrical modifications, while still maintaining a non-interrupted shielding by means of the joined plate elements 15 of the construction elements 1.

Fig. 2h shows a portion, which is separated from any adjacent side surface, of a prefabricated construction element 1, wherein it comprises at least two plate elements 15, arranged adjacent each other defining a portion of the electromagnetic shielded area 19, and at least one joint therein. Each edge 21 of a plate element, which edge 21 is aligned with said at least one joint, comprises at least one internal flange element 25', extending into the bulk element 5, wherein the at least two internal flange elements 25' are connected to each other within the bulk element 5. The internal flange elements 25' do not have to differ from other flange elements 25 at other edges 21 of the plate elements 15, but as they are arranged within the bulk element 5, they may function in slightly alternative ways compared to exteriorly positioned flange elements 25. The internal flange elements 25', according to the embodiment depicted in fig. 2h, extend a predetermined distance 27 into the bulk element 5, and may be perceived to comprise coupling holes 49 therein, similar to the construction element 1 with reference to fig. 2e. The two aligned coupling holes 49 have then been joined together by means of a screw 55, longer than a combined thickness 17 of said flange elements 25. The screw 55 may as well be perceived as a threaded rod, wherein the functionality is the same. The screw 55 or rod may, as depicted in fig. 2h, be additionally secured by means of nuts 57 or similar, providing a tight fit of the two adjacent flange elements 25, and thus in turn the two adjacent plate elements 15. The screw 55 or rod being longer than the combined thicknesses 17 of the flange elements 25 provides additional securing of the plate elements 15 in the bulk element 5, which is to be perceived as have been poured over the two flange elements 25 of the two adjacent plate elements 15 as described earlier in the disclosure. The at least two plate elements 15 may thus have been joined together in such a manner, providing a desired shape for a mould, wherein the defined mould then is filled with a material of the bulk element 5 such as concrete, so as to manufacture the construction element 1 in the desired shape, with a plurality of plate elements 15 being securely attached at the front surface 7 thereof. As should be obvious, the internal flange elements 25' may instead be provided with projecting elements similar to the one explained with reference to fig. 2d, which may thus replace the screw 55 or threaded rod and the nuts 57, while achieving the same result with regards to holding the plate elements 15 flush with the front surface 7 of the bulk element 5. Such internal flange elements 25' may be welded or screwed together during assembly of the plate elements 15 however if needed, or if additional security is desired. The other features described herein may be combined in further combinations of course, wherein it should be obvious that the internal flange 25' elements as depicted in fig. 2h may extend further into the bulk element 5, and/or be provided with distance elements to which a reinforcement element 39 may be arranged, or if the predetermined distance 27 is suitable with regards to positioning of such a reinforcement element 39 within the bulk element 5, the internal flange elements 25' may function as distance elements on their own.

Figs. 3a-3b show schematic depictions of cross-sectional views of a shielded construction element 1, during and after manufacturing thereof, according to an embodiment. The construction element 1 according to the disclosure may be manufactured in various ways and comprising a plurality of different materials. The embodiment according to fig. 3a-3b should however be perceived as a construction element 1 with a bulk element 5 comprising a material that is made with filling of a mould. A plurality of materials may be used for such processes, such as concrete that cures and hardens, but also a foam-type material that is extruded into a mould and then rapidly hardens and sets in position. For the sake of simplicity, this example will be explained as being made of concrete, which is a preferred constructional material, suitable for a wide variety of constructions, and thus is to be perceived as useful as a prefabricated construction element 1.

Fig. 3a shows a cross-sectional view of a construction material 1 during manufacturing thereof. For an order of process steps for such manufacturing, fig. 4 is also referenced to, wherein the process is explained based on how the various components interact herein. Two plate elements 15 are seen in fig. 3a, which plate elements 15 are to be perceived as having been positioned at a suitable level surface. The plate elements 15 are positioned adjacent each other so as to define the entirety of an electromagnetically shielded area 19 of a construction element 1 to be fabricated. All such plate elements 15 (wherein only two are visible due to the restrictions of a two-dimensional cross-sectional view) are then attached to each other by means of suitable fasteners such as a screw 51, aligned and secured through coupling holes 49 comprised in flange elements 25 of the plate elements 15, which flange elements 25 will become internal flange elements 25' when the construction element 1 is fully assembled. The fasteners may be fasteners as described with reference to fig. 2h, which is used as an example in the illustration in fig. 3a, but other types of fasteners and/or fastening methods may of course be used, dependent of the size and intended usage of the fully prefabricated construction element 1. When the electromagnetic shielded area 19 is established, and all plate elements 15 are securely joined to each other, the circumference 23 thereof is enclosed by board-type elements 59, wherein said board-type elements 59 are connected to any selected plurality of flange elements 25 of any plate element 15 aligned with said circumference 23. Said board-type elements 59 will thus define sidewalls of a mould. In fig. 3a, screws 51 are seen to have been used to secure such a connection. The board-type elements 59 are chosen to extend beyond the predetermined distance 27 of the flange elements 25, at least to a predetermined thickness 11 of the fully fabricated construction element 1, wherein a temporary mould is defined by means of the plate elements 15 and the board-type elements 59, being the sidewalls thereof. Reinforcement elements 39 may then be positioned within said mould, which is seen to have been performed in fig. 3a. The reinforcement element 39 in fig. 3a is seen to have been positioned directly towards the flange elements 25 of the plate elements 15, however other variations are possible within the disclosure, which was explained with reference to figs. 2c-2g. The reinforcement element(s) 39 may or may not be additionally anchored and/or fastened to the flange elements 25 within the mould, dependent on the demands for the fully fabricated construction element 1.

The filling material that is to become the subsequent hardened bulk element 5 is then added to the mould, which is stated prior to be concrete for this example. The concrete will thus be filled in the mould until a desired thickness 11 thereof has been achieved. Said concrete may thus fill the mould, wherein it will bind the previously positioned elements 15, 39 together when it cures and hardens.

Fig. 3b shows the then fully prefabricated construction element 1. When the concrete have hardened fully, the board-type elements are simply removed, wherein as they were attached to the flange elements 25 of the construction element, said flange elements 25 will automatically have their outer surfaces 29 aligned with side surfaces 13 of the bulk element 5, wherein said element 5 is provided with side surfaces 13 in the form of flat surfaces, being readily available for a large variety of assembly work as part of a construction element 1. When comparing figs. 3a and 3b, it may also be seen that the screws 51 used to attach the board-type elements 59 to the flange elements 25 have after de-assembly of said board-type elements been replaced with another screw 51', more suitable to secure the coupling of the flange elements 25 to the bulk element 5, without sticking out past the outer surfaces 29 of the flange elements 25.

Fig. 4 shows a flowchart of a method of manufacturing a shielded construction element, according to an embodiment. The method is intended to be used to manufacture a prefabricated construction element according to the first aspect of the disclosure, wherein such a construction element may be provided with a plurality of additional features as has been thoroughly explained herein. The method comprises the steps of: a) providing a first plate element comprising at least one flange element, d) arranging at least one sidewall of a mould, flush with the outer surface of said at least one flange element, so as to define a mould, e) filling said mould with a material of the bulk element, and f) removing the at least one sidewall of the mould. As was seen in the description of the construction element with reference to figs. 3a-3b, the plate element serves as a part of the mould as well as an integral part of the final product. This flow of the method, as well as the design of the ingoing parts of the construction element provides an extremely streamlined prefabrication method, and thus a cost effective and environmentally friendly product thereof. Ifthe bulkelement is made of concrete orsimilar, the sidewalls of the mould may be provided with simple and readily available material and/or constructional elements such as wooden boards, which may have further uses after being part of a mould in the described manner.

The method depicted in the flowchart according to fig. 4 may be expanded upon with additional method step, dependent on the size and shape of the construction element to be made. Two such additional steps are shown on the right side of fig. 4 wherein it is seen that they may be performed between steps a) and c). Two such additional steps are: b) arranging at least one additional plate element adjacent to the first plate element, and c) fixating the first and the at least one additional plate element together at flange elements thereof, by means of screws longer than a combined thickness of said flange elements.

As should be understood, the mentioned screws, being longer than the combined thickness of the adjacent flange elements corresponds to the assembly depicted and explained with reference to fig. 2h. By means of using screws longer than needed only for assembly of two adjacently positioned plate elements, such screws will thus act as anchoring elements within the bulk element, wherein a dual purpose and advantage is gained.

The construction element 1 and the method for manufacturing such a construction element 1 will thus provide the means of shielding facilities and/or rooms thereof in a very streamlined, fast and effective manner. By means of utilizing such construction elements 1, and in particular prefabricated ones manufacturing in accordance with the defined method, a facility as for example a server room orsimilar may be built in a very cost effective manner. Furthermore, due to the reliable and effective yet versatile design of the construction element 1 and its utilization of its components comprised therein, fully electromagnetic shielding may be provided to walls, ceilings and/or floors of a room or a building, without any weak areas where shielding will be lacking due to inconsistencies of the shielding provided to the construction element 1. The foregoing description of the embodiments has been furnished for illustrative and descriptive purposes. It is not intended to be exhaustive, or to limit the embodiments to the variations described. Many modifications and variations will obviously be apparent to one skilled in the art. The embodiments have been chosen and described in order to best explicate principles and practical applications, and to thereby enable one skilled in the arts to understand the invention in terms of its various embodiments and with the various modifications that are applicable to its intended use. The components and features specified above may, within the framework of the disclosure, be combined between different embodiments specified.

Claims

1. A prefabricated construction element (1) comprising a bulk element (5) having a two- dimensional front surface (7) and a two-dimensional back surface (9), extending parallel with each other, defining a thickness (11) thereof, wherein at least one side surface (13) extends between said front and back surfaces (7, 9), the construction element (1) further comprises at least one plate element (5), arranged to cover at least the front surface (7) of the bulk element (5), being in direct contact thereto, each plate element (15) having a thickness (17) and/or being made of a material that provide electromagnetic shielding to the construction element (1), defining an electromagnetic shielded area (19) thereof, wherein each edge (21) of the at least one plate element (15), which edge (21) is aligned with a circumference (23) of the electromagnetic shielded area (19), comprises at least one flange element (25), extending a predetermined distance (27) from said circumference (23), in a direction away from the electromagnetic shielded area (19) and into the bulk element (5), and wherein an outer surface (29) of said at least one flange element (25) being aligned with a plane defining any surface adjacent the circumference (23) of the electromagnetic shielded area (19).

2. The prefabricated construction (1) element according to claim 1, wherein it further comprises at least one reinforcement element (39), arranged in the bulk element (5), and wherein the at least one flange element (25) comprises a plurality of receiving surfaces (41), wherein said reinforcement element (39) is arranged thereto.

3. The prefabricated construction element (1) according to claim 2, wherein the receiving surfaces (41) are arranged in holes (43), arranged in each of the at least one flange element (25).

4. The prefabricated construction element (1) according to claim 2, wherein the receiving surfaces (41) are arranged at distance elements (45), arranged to extend from the at least one flange element (25).

5. The prefabricated construction element (1) according to any of the preceding claims, wherein each flange element (25) comprises at least one projecting element (35), wherein each at least one projecting element (35) extends into the bulk element 5.

6. The prefabricated construction element (1) according to claim 4 and 5, wherein each distance element (45) is a portion of the at least one projecting element (35).

7. The prefabricated construction element (1) according to any of the preceding claims, wherein the at least one flange element (25) comprises at least one coupling hole (49), arranged between the circumference (23) of the electromagnetic shielded area (19) and the predetermined distance (27).

8. The prefabricated construction element (1) according to any of the preceding claims, wherein it comprises at least two plate elements (15), arranged adjacent each other defining the electromagnetic shielded area (19) and at least one joint therein, wherein each edge (21) of a plate element , which edge (21) is aligned with said at least one joint, comprises at least one internal flange element (25'), extending into the bulk element (5), wherein the at least two internal flange elements (25') are connected to each other within the bulk element (5).

9. The prefabricated construction (1) element according to any of the preceding claims, wherein the bulk element (5) comprises a concrete-type material.

10. The prefabricated construction element (1) according to any of the preceding claims, wherein the at least one plate element (15) comprises a metallic material, preferably copper.

11. A method of manufacturing a construction element (1) according to any of the claims 1-10, said method comprising the steps of: a) providing a first plate element (15) comprising at least one flange element (25), d) arranging at least one sidewall of a mould, flush with the outer surface (29) of said at least one flange element (25), so as to define a mould, e) filling said mould with a material of the bulk element (5), and f) removing the at least one sidewall of the mould.

12. The method of manufacturing a construction element (1) according to claim 11, wherein said method further comprises the steps, to be performed between steps a) and c), of: b) arranging at least one additional plate element (15) adjacent to the first plate element (15), and c) fixating the first and the at least one additional plate element (15) together at flange elements (25) thereof, by means of screws longer than a combined thickness (17) of said flange elements (25).