WO2023248245A1 - Plastic construction panels - Google Patents

Plastic construction panels Download PDF

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Publication number
WO2023248245A1
WO2023248245A1 PCT/IN2023/050590 IN2023050590W WO2023248245A1 WO 2023248245 A1 WO2023248245 A1 WO 2023248245A1 IN 2023050590 W IN2023050590 W IN 2023050590W WO 2023248245 A1 WO2023248245 A1 WO 2023248245A1
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WO
WIPO (PCT)
Prior art keywords
panel
construction
sheet
channel
core
Prior art date
Application number
PCT/IN2023/050590
Other languages
French (fr)
Inventor
Madipakam Parasuram NARENDRA
Original Assignee
Narendra Madipakam Parasuram
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Narendra Madipakam Parasuram filed Critical Narendra Madipakam Parasuram
Publication of WO2023248245A1 publication Critical patent/WO2023248245A1/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/296Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/44Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
    • E04C2/52Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
    • E04C2/521Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits serving for locating conduits; for ventilating, heating or cooling
    • E04C2/523Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits serving for locating conduits; for ventilating, heating or cooling for ventilating
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2002/3488Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by frame like structures

Definitions

  • Walls, floors and roofs for buildings in the present world are generally constructed using one of these following methods.
  • FIG. 1 illustrates a perspective view of a construction panel, in accordance with an implementation of the present subject matter
  • FIG. 2 illustrates an exploded view of a construction panel, in accordance with an implementation of the present subject matter
  • FIG. 3a illustrates a schematic view of a core panel, in accordance with an implementation of the present subject matter
  • FIG. 3b illustrates a schematic view of a core panel, in accordance with another implementation of the present subject matter
  • FIG. 4 illustrates a schematic view of a construction panel assembly having two construction panels, in accordance with another implementation of the present subject matter
  • FIG. 5 illustrates a schematic view of a construction panel assembly having inlet and outlet positioned at different positions, in accordance with another implementation of the present subject matter; [0009] FIGS. 5a-i illustrate different positions of inlets and outlets in a construction panel assembly in accordance with another implementation of the present subject matter; and
  • FIG. 6 illustrates a schematic view of a construction panel with different temperature zones, in accordance with an implementation of the present subject matter.
  • slabs of precast concrete are formed, tilted upright, and joined together to form a wall of a building.
  • slabs may be precast offsite and transported to a construction site for erection, which increases transportation costs and difficulty in handling large and extremely heavy concrete slabs into position with associated risk of injury to personnel and need for heavy lifting equipment.
  • the slabs may be casted onsite.
  • the onsite casting may be affected due to bad weather, because the casted slabs must be fully dried before usage and the bad weather may delay the slab drying or may also damage the slabs.
  • the slabs need special lifting lugs and heavy lifting equipment to move them into position or tilt them upright.
  • the buildings constructed using the conventional procedures, such as concrete panels, etc. do not provide any provision for natural air conditioning. Therefore, to keep the room temperature inside the building optimal, generally air-conditioning systems are used.
  • the usage of the air-conditioning systems requires a high energy consumption, which comes at an additional cost.
  • the air-conditioning systems need regular maintenance and repairs which can lead to further additional costs.
  • the present subject matter describes example construction panels for use in building construction. Using the example construction panel described herein, optimal internal temperature may be maintained within the building without using any air-conditioning system and thus better environmental sustainability is provided.
  • the example construction panel described herein is light weight and cost-effective as compared to construction materials used in conventional construction techniques.
  • a construction panel may include a first sheet panel, a second sheet panel, and a core panel.
  • the core panel may be interposed between the first and second sheet panels.
  • the first sheet panel may be a sheet made of a lightweight material, such as plastic.
  • the first sheet panel may include a vent to receive air.
  • the second sheet panel may be a sheet made of a lightweight material, such as plastic.
  • the core panel is a corrugated structure made of a lightweight material that provides structural strength to the construction panel when interposed between the first and second sheet panels.
  • the core panel may include a channel. The channel may be disposed within the core panel and extends from one end of the core panel to another end of the core panel.
  • the channel is a structure that provides a through passage to a fluid, such as ambient air.
  • the channel ensures upward movement of the air from one end of the channel to another end of the channel.
  • the channel may include a channel inlet and a channel outlet.
  • the channel inlet may receive air from ambience surrounding if the construction panel is the lowermost construction panel of a building.
  • the channel inlet may receive air from a channel of another construction panel if the construction panel is not the lowermost construction panel of the building.
  • the channel inlet may receive air from the vent disposed in the first sheet panel.
  • the channel outlet may vent out the received air.
  • the channel outlet may vent out the received air to the ambience surrounding if the construction panel does not have another construction panel connected to it.
  • the channel outlet may vent out the received air to a channel of another construction panel if the construction panel have another construction panel connected to it.
  • the ambience surrounding may be environmental condition exposed to the constructional panel.
  • the ambience surrounding may be atmospheric surrounding.
  • the ambience surrounding may be inner surrounding of the building.
  • the received air may travel within the channel from the channel inlet to the channel outlet such that the air absorbs heat from the ambient surrounding in contact with an external surface of the construction panel.
  • the hot air rises above within the channel and vents out on finding any outlet, such as the channel outlet.
  • the channel of the construction panel of the present subject matter allows upward movement of the hot air and thereby ensures that internal temperature of the building is optimally maintained.
  • the internal temperature of the building is optimally maintained because the construction panel of the present subject matter allows a very low thermal transmission between the interior and the exterior of the construction panels.
  • the construction panel saves on the cost which would have otherwise incurred on installation and usage of an air- conditioning system.
  • the construction panel assembly may be an arrangement of multiple construction panel assemblies.
  • the construction panel assembly may include a plurality of constructions panels interlockable with each other to form the construction panel assembly.
  • each of the plurality of constructions panels may be interlockable via male and female configurations.
  • Each of the plurality of constructions panels may include a first sheet panel, a second sheet panel, and a core panel interposed between the first sheet panel and the second sheet panel.
  • the core panel may include a channel disposed within the core panel and that extends from one end of the core panel to another end of the core panel.
  • the channel includes a channel inlet to receive air and a channel outlet to dispense air.
  • the air travels within the channel from the channel inlet to the channel outlet such that heat is absorbed from the ambient surrounding in contact with an external surface of the construction panel air.
  • the channel allows upward movement of the hot air and thereby ensures that internal temperature of the building is optimally maintained.
  • the channel receives air from one of an air vent of the construction panel and a channel of another adjoining construction panel.
  • the channel vents out received air to one of ambient surrounding and a channel of another adjoining construction panel.
  • the construction panel of the present subject matter can be fabricated in various sizes, dimensions and various thicknesses depending on the construction requirement of the building. Also, the construction panel ensures a dry construction that substantially reduces the use of water in the construction.
  • the construction panel of the present subject matter ensures that the amount of cement used is much lower which would have otherwise used in the conventional building construction.
  • the construction panel of the present subject matter uses less than 15% amount of cement which would have been used in the conventional building construction using concrete panels raised in situ or clay bricks.
  • the construction panel can be fabricated using the recycled material.
  • the construction panel is eco-friendly.
  • the construction panel possesses excellent load bearing capacity. Therefore, the use of the construction panel is not restricted for rapid construction, semi-permanent or temporary buildings, and can be readily used for industrial or commercial construction purposes with a life span of more than 50 years.
  • the plastic construction panel is light weight and therefore, heavy machinery is not required during the building construction. Also, after the building demolition, the material of the construction panel can be recycled to fabricate new construction panels. Also, the construction panel enables faster speed of construction when compared to conventional construction techniques. In addition, the plastic construction panel is rust/corrosion free and thus have prolonged life span.
  • the components of the construction panel are substantially made of environmentally friendly and recycled materials which are nontoxic, odourless and long-lasting.
  • the construction panel can advantageously have its size and capacity for withstanding the structural stresses of compression, tension and bending mathematically increased or decreased by selectively specifying the various parameters of the components of the construction panel.
  • the modularity of the construction panel advantageously provides a building material which is inexpensive and easily repaired/replaced when damaged.
  • FIG. 1 illustrates a perspective view of a construction panel 100, in accordance with an implementation of the present subject matter.
  • the construction panel 100 is a building block used for the construction of a structure, such as a building.
  • the construction panel 100 includes a first sheet panel 102, a second sheet panel 104, and a core panel 106 disposed between the first sheet panel 102 and the second sheet panel 104.
  • the first sheet panel 102 may be a sheet made of a lightweight material.
  • the lightweight material may be plastic.
  • the first sheet panel 102 may include a vent (not shown in FIG. 1 ) to receive air.
  • the second sheet panel 104 may be a sheet made of a lightweight material.
  • the lightweight material may be plastic.
  • the core panel 106 is a corrugated structure made of a lightweight material that provides structural strength to the construction panel 100 when interposed between the first and second sheet panels 102, 104.
  • the lightweight material may be plastic. Any other material having properties similar to plastic can be used.
  • the structure of the core panel 106 is one of a honeycomb structure, a grid structure, an aerated grid structure, and a corrugated structure.
  • the first sheet panel 102 defines the dimension of the construction panel 100 and may include an inner surface and an outer surface.
  • the inner surface of the first sheet panel 102 may be attached to the core panel 106.
  • the outer surface of the first sheet panel 102 may be provided with a surface finishing material.
  • the surface finishing material is selected from, but is not limited to, one of a cement bonded particle board, a plywood, a medium density fiberboard, and an aluminum composite board.
  • the second sheet panel 104 includes an inner surface and an outer surface and defines the dimension of the construction panel 100 as the first sheet panel 102 does.
  • the inner surface of the second sheet panel 104 may be attached to the core panel 106.
  • the outer surface of the second sheet panel 104 may be provided with the surface finishing material.
  • the surface finishing material provides primary safety or be a sacrificial layer to the construction panel 100.
  • any inlet and outlet for air is not shown in the construction panel 100, but the construction panel 100 may include an inlet and outlet to let in the air inside the construction panel 100 and then vent out the air outside the construction panel 100.
  • FIG. 2 illustrates an exploded view of a construction panel 200, in accordance with an implementation of the present subject matter.
  • the construction panel 200 includes a first sheet panel 202, a second sheet panel 204, and a core panel 206 disposed between the first sheet panel 202 and the second sheet panel 204.
  • the first sheet panel 202 may be similar to the first sheet panel of FIG. 1 .
  • the second sheet panel 204 may be similar to the second sheet panel of FIG. 1 .
  • the structure of the core panel 206 may be one of a honeycomb structure, a grid structure, an aerated grid structure, and a corrugated structure.
  • the core panel 206 as shown in FIG. 2 includes a channel 208 disposed within the core panel 206 and extending from one end of the core panel 206 to another end of the core panel 206.
  • the channel is a structure that provides a through passage to a fluid, such as ambient air.
  • a plurality of channels may be provided in the core panel 206. Each of the plurality of channels may be interconnected via conventional joining techniques.
  • the plurality of channels may have intermediatory holes across the channels to provide an expanded through passage to the fluid.
  • the channel 208 may be a hollow grid having intermediatory holes across the hollow grid.
  • the channel 208 provides an upward movement of the air from one end of the channel 208 to another end of the channel 208. In an example, the channel 208 provides a sideways movement of the air from one side end of the channel 208 to another side end of the channel 208.
  • the channel 208 may include a channel inlet 210 and a channel outlet 212.
  • the channel inlet 210 may receive air from ambience surrounding if the construction panel is the lowermost construction panel of a building. In an example, the channel inlet 210 may receive air from the ambience surrounding despite the positioning of the construction panel in the building. In an example, the channel inlet 210 may receive air from a channel of another construction panel if the construction panel 200 is not the lowermost construction panel of the building.
  • the channel inlet 210 may receive air from a vent 214 disposed in the first sheet panel 202.
  • the vent 214 may be disposed at any location in the first sheet panel 202.
  • the vent 214 may be disposed at a lowermost edge of the first sheet panel 202.
  • the first sheet panel 202 may include a first plastic sheet 216 adjacent to the core panel 206 and a first cement sheet 218 adjacent to the first plastic sheet 216.
  • the first plastic sheet 216 may include the vent 214 and the first cement sheet 218 may include another vent (not shown) fluidly connected to the vent 214 and the channel inlet 210 so that the ambient air can pass from the vent 214 via the other vent to the channel inlet 210.
  • the second sheet panel 204 may include a second plastic sheet 220 adjacent to the core panel 206 and a second cement sheet 222 adjacent to the second plastic sheet 220.
  • the first cement sheet 218 and the second cement sheet 222 are to provide additional strength to the construction panel 200 and to enable the exterior finishing of the construction panel 200 for which cement material is a requirement, for example, plastering of the walls of the building.
  • the channel outlet 212 may vent out the received air.
  • the channel outlet 212 may vent out the received air to the ambience surrounding if the construction panel 200 does not have another construction panel connected to it.
  • the channel outlet 212 may vent out the received air to a channel of another construction panel if the construction panel 200 have another construction panel connected to it.
  • the ambience surrounding may be environmental condition exposed to the constructional panel.
  • the ambience surrounding may be atmospheric surrounding.
  • the ambience surrounding may be inner surrounding of the building but external to the room.
  • the core panel 206 may include a third sheet panel 224 disposed between the first sheet panel 202 and the second sheet panel 204.
  • the third sheet panel 224 may be made of a plastic material.
  • the plastic material can be recyclable.
  • the recycled plastic sheets are made from heterogeneous waste plastic that is shredded, cleaned and heat pressed to form the sheets.
  • the plastic material can be virgin plastic.
  • the core panel 206 may further includes a first core panel 226 having the channel 208 extending from one end of the first core panel 226 to another end of the first core panel 226.
  • the first core panel 226 is interposed between the first sheet panel 202 and the third sheet panel 224.
  • the first core panel 226 may be made of a plastic material.
  • the plastic material may be recyclable.
  • the recycled plastic sheets are made from heterogeneous waste plastic that is shredded, cleaned and heat pressed to form the sheets.
  • the plastic material may be a virgin plastic.
  • the structure of the first core panel 226 may be one of a honeycomb structure, a grid structure, an aerated grid structure, and a corrugated structure.
  • the core panel 206 may include a second core panel 228 interposed between the second sheet panel 204 and the third sheet panel 224.
  • the second core panel 228 may be made of a plastic material.
  • the plastic material can be recyclable.
  • the recycled core panel may be made from heterogeneous waste plastic that is shredded and cleaned to form the core panel.
  • the plastic material can be virgin plastic.
  • the structure of the second core panel 228 may be one of a honeycomb structure, a grid structure, an aerated grid structure, and a corrugated structure.
  • the third sheet panel 224 may include a third plastic sheet 230 and a fourth plastic sheet 232.
  • the third plastic sheet 230 may be placed adjacent to the first core panel 226 and fourth plastic sheet 232 may be placed adjacent to the second core panel 228.
  • the third plastic sheet 230 and the fourth plastic sheet 232 may be adjacent to each other.
  • the third plastic sheet 230 and the fourth plastic sheet 232 may be bonded to each other to a form a single sheet.
  • the first sheet panel 202, the second sheet panel 204, the third sheet panel 224, the core panel 206, the first core panel 226, and the second core panel 228 are made of the same plastic material.
  • the first sheet panel 202, the second sheet panel 204, the third sheet panel 224, the core panel 206, the first core panel 226, and the second core panel 228 are made of different plastic materials. Since the construction panel 200 is made of the plastic material, the customization of the construction panel 200, as per the application/requirement during the construction, is easier. Also, the fire retardancy of the construction panel 200 is rated as per strict building bylaws.
  • the construction panel 200 provides numerous desirable properties making it suitable for building and construction such as substantial structural strength for bearing loads.
  • the core panel 206 further includes a plurality of cells.
  • one or more of the plurality of cells are fillable with one of polyurethane, cellulose fiber, ash, or cementconcrete mixture or a combination.
  • the cells are filled for enhancing the strength of the construction panel 200 along with other enhancements like sound proofing, improved thermal behavior, reduced knocking sound, and for withstanding wind speed.
  • metals sheets can also be filled in the cells. Further, the size of the cells may be calibrated for specific applications.
  • the construction panel 200 uses recycled plastic for adapting to the elasticity property of the plastic to its maximum advantage and that too in a cost-effective matter.
  • the combination of recycled plastic sheets to cement sheets enhances the load bearing physical property of the construction panel 200.
  • the recycled plastic may be used as I-Beam support sandwiched between the two sheets of the construction panel 200 for producing the required cantilevered support to the construction panel 200.
  • the construction panel 200 may have a horizontal flat compression formulated from 5 Tons/SqMt 15 up to 20 Tons/SqMt and a vertical compression designed for 1.2 to 2.4 Tons for every running foot of 8 feet high wall. Also, the puncher resistance of the construction panel 200 can be altered for high security areas.
  • the construction panel 200 has inherent thermal insulting property because of the air trapped within the construction panel 200.
  • the construction panel 200 allows for two different face materials on either side, such as a glass sheet for the exterior and plywood sheet for the interiors.
  • the construction panel 200 has light weight property that allows easy material handling and transportation. Also, the construction panel 200 may not be damaged during transportation due to the use of plastic material.
  • the construction panel 200 has waterproof property and thus acts as a moisture barrier.
  • the construction panel 200 ensures ease of installing electrical wiring and plumbing lines into the panels.
  • the construction panel 200 of the present subject matter is breakage resistant, puncture resistant, water and fire-resistant, long-life span comparable to brick and cement structure, modular construction convenience, versatile applications, and swappable fascia based on the application.
  • the first core panel may be fused to the first sheet panel and the third sheet panel either by thermal fusion or stuck with adhesive or fixed with steel fixtures.
  • the second core panel may be fused to the second sheet panel and the third sheet panel either by thermal fusion, stuck with adhesive or fixed with steel fixtures.
  • the construction panel 200 is finally layered on one of a cement fiber board, a particle board, a gypsum board, a plywood, a medium density fiber board, glass, metal sheets etc. Outer skin used for cladding the plastic construction panel depends on the final application.
  • each of the first, second, third, and fourth plastic sheets 216, 220, 230, 232 may have a thickness ranging from 4mm to 18mm.
  • each of the first core panel 226 and the second core panel 228 may have a thickness ranging from 4mm to 36mm and may be interlocked/ fused/ riveted to form a grid of varying dimensions and shapes.
  • the first core panel 226 and the second core panel 228 provide strength and load distribution properties to the construction panel 200.
  • the core panel 206 includes a plurality of cells 300.
  • the core panel 206 has a honeycomb structure.
  • the cell size of the plurality of cells 300 can be calibrated for specific applications.
  • cavities are formed between the cells 300 of the core panel 206 and the inner surfaces of the first sheet panel 202 and the second sheet panel 204.
  • cavities are filled with one of polyurethane, cellulose fiber, ash, or cement-concrete mixture or a combination of these.
  • the cavity filling is done for enhancing the strength of the construction panel 200 along with other enhancements like sound proofing, improved thermal behavior, reduces knocking sound, and withstand wind speed.
  • metals sheets can be filled in the cavities.
  • the construction panels can be put together by various means like welding, fusing, using an adhesive, riveting etc. based on the intended application of the construction panel. After putting the construction panels together, the building can withstand very high wind speeds, for example, up to 150-180 Kilometers/hour wind speed.
  • the construction panel 100, 200 may have a thickness in a range of 3 to 12 inches. Though a range is specified, however, the construction panel 100 may have any thickness depending on the requirement.
  • the construction panel 100, 200 may have a dimension of 8 feet by 4 feet. In an example, the construction panel 100, 200 may have a dimension of 10 feet by 4 feet. Though a dimension is specified, however, the construction panel 100, 200 may have any dimension depending on the requirement.
  • the construction panel 100, 20 may be adaptable to any climatic situation across the world, i.e., it can be used in an ambient temperature range of -25 degrees Celsius to +55 degrees Celsius.
  • special adhesives, fixtures and a super strong grid pattern may be used for the fabrication of the construction panel 100, 200.
  • the core panel 206 includes a plurality of cells 302.
  • the core panel 206 has a grid structure.
  • the cell size of the plurality of cells 302 can be calibrated for specific applications.
  • cavities are formed between the cells 302 of the core panel 206 and the inner surfaces of the first sheet panel 202 and the second sheet panel 204.
  • cavities are filled with one of polyurethane, cellulose fiber, ash, or cement-concrete mixture or a combination of these.
  • the cavity filling is done for enhancing the strength of the construction panel 200 along with other enhancements like sound proofing, improved thermal behavior, reduces knocking sound, and withstand wind speed.
  • metals sheets can be filled in the cavities.
  • the structure of the first core panel 226 may be one of a honeycomb structure, a grid structure, an aerated grid structure, and a corrugated structure.
  • the structure of the second core panel 228 may be one of a honeycomb structure, a grid structure, an aerated grid structure, and a corrugated structure.
  • the first core panel 226 may be fused to the first sheet panel 202 and the third sheet panel 224 either by thermal fusion, stuck with adhesive or fixed with steel fixtures.
  • the second core panel 228 may be fused to the second sheet panel 204 and the third sheet panel 224 either by thermal fusion, stuck with adhesive or fixed with steel fixtures.
  • FIG. 4 illustrates a schematic view of a construction panel assembly 400 having two construction panels 402, 404, in accordance with another implementation of the present subject matter.
  • construction panel assembly 400 may include intermediary panels (now shown) interposed between the two construction panels 402, 404 to form construction panel assembly 400.
  • the construction panel assembly 400 may include a plurality of constructions panels interlockable with each other to form the construction panel assembly 400.
  • the constructions panels interlockable by means of conventionally known techniques. For example, one construction panel may have a male fitment and another construction panel may have a female fitment. A male-female joint may be formed between the construction panels to form the construction panel assembly.
  • the constructions panels may be riveted to each other for interlocking with each other to form the construction panel assembly.
  • the construction panel 402 may include a first sheet panel 406, a second sheet panel 408, and a core panel (not shown) interposed between the first sheet panel 406 and the second sheet panel 408.
  • the core panel may include a channel 410 disposed within the core panel and extending from one end of the core panel to another end of the core panel.
  • the channel 410 may include a channel inlet 412 to receive air and a channel outlet 414 to dispense air. When the air travels within the channel 410 from the channel inlet 412 to the channel outlet 414 to absorb heat from the ambient surrounding in contact with an external surface of the construction panel 402.
  • the channel 410 may receive air from one of an inlet 416 of the construction panel 402 and a channel (not shown in FIG. 4) of another adjoining construction panel.
  • the channel may vent out the received air to ambient surrounding if not assembled with another construction panel.
  • the channel may vent out the received air to a channel of another adjoining construction panel if assembled with another construction panel.
  • the construction panel 404 may have similar structure to that of the construction panel 402. Only difference is that the construction panel 404 does not have any inlet at the first sheet panel to receive the air. Instead, the channel inlet of the construction panel 404 receives the air from the channel outlet of the construction panel 402.
  • the construction panel assembly 400 is a monolith-like structure having a first construction panel 402, a second construction panel 404, and one or more intermediary constructions panels.
  • the channel of two adjoining construction panels may be fluidly coupled to each other.
  • the channel 410 of the first construction panel 402 is disposed within the core panel of the first construction panel 402 to receive the air from the inlet 416 of the first construction panel 402.
  • the second construction panel 404 may include the channel 410 disposed within the core panel of the second construction panel 404 to receive air from the channel 410 of one of the first construction panel 402 and the one or more intermediary construction panels.
  • the channel 410 of the second construction panel 404 vent out air to the ambient surrounding.
  • the temperature of the air vent out by the second construction panel 404 is higher than the temperature of the air received by the first construction panel 402 from the ambient surrounding.
  • FIG. 5 illustrates a schematic view of a construction panel assembly 500 having inlet and outlet positioned at different positions, in accordance with an implementation of the present subject matter.
  • the construction panel assembly 500 may have a first construction panel 502 and a second construction panel 504 as shown.
  • the first construction panel 502 may have a first face 506, a second face 508, a third face 510, a fourth face 512, and fifth face 514.
  • the second construction panel 504 may have a first face 516, a second face 518, a third face 520, and a fourth face 522.
  • the first face 506 of the first construction panel 502 may include one or more inlet 506a for air.
  • the second face 508 of the first construction panel 502 may include one or more inlet 506b for air.
  • the third face 510 of the first construction panel 502 may include one or more inlet 510c for air when another construction panel is adjoined adjacent to the first construction panel 502.
  • the fourth face 512 of the first construction panel 502 may include one or more outlet 512d for air when another construction panel is adjoined adjacent to the first construction panel 502.
  • the fifth face 514 of the first construction panel 502 may include one or more outlet 514e for air when another construction panel is adjoined above the first construction panel 502.
  • the first face 516 of the second construction panel 504 may include one or more inlet 516f for air when the first construction panel 502 is adjoined below the second construction panel 504.
  • the second face 518 of the second construction panel 504 may include one or more outlet 518g for air when the second construction panel 504 is exposed to the ambience surrounding.
  • the third face 520 of the second construction panel 504 may include one or more inlet 520h for air when another construction panel is adjoined adjacent to the second construction panel 504.
  • FIG. 6 illustrates a schematic view of the construction panel 200 with different temperature zones, in accordance with an implementation of the present subject matter.
  • the construction panel 200 is similar to the construction panel described in FIG. 2.
  • the different temperature zones are due to an experimental setup of the construction panel assembly (not shown in FIG. 6) to determine the temperature inside a room when ambient temperature is about 50 (°C).
  • the construction panel assembly may be an arrangement of multiple construction panel assemblies.
  • the construction panel assembly includes a plurality of constructions panels interlockable with each other to form the construction panel assembly.
  • each of the plurality of constructions panels may be interlockable via male and female configuration between a construction panel to the adjacent construction panel.
  • ultra-violet (UV) bulbs (not shown) are placed on a side of the constructional panel facing an external surface of a target zone.
  • the bottommost constructional panel of the construction panel assembly receives the heat produced from ambient surrounding, i.e., UV bulbs via the air vent.
  • the received air travels within the channel from the channel inlet to the channel outlet.
  • the channel of the intermediate construction panel receives air from one of the air vent of the bottommost construction panel and a channel of another adjoining panel.
  • the channel of either one of the intermediate construction panel or the topmost construction panel vents out received air to one of ambient surrounding and a channel of another adjoining construction panel.
  • the hot air absorbed from the ambient surroundings in contact with the external surface of the bottommost construction panel rises above to the topmost construction panel via the channels of the intermediate construction panel. Thereby, internal temperature of the building does not increase.
  • the temperature of the air vent out by a second construction panel i.e., intermediate construction panel is observed to be higher than the temperature of the air received by a first construction panel, i.e., bottommost construction panel from the ambient surrounding.
  • temperature T1 at UV bulbs was observed to be 108.1 (°C)
  • temperature T2 at air vent was observed to be 25.9 (°C)
  • temperature T3 at channel outlet was observed to be 52.7 (°C)
  • temperature T4 at target zone T4 was observed to be 31 .0 (°C).
  • the temperature of the air vent out by the second construction panel is higher than the temperature of the air received by the first construction panel from the ambient surrounding. Further, the air temperature difference, i.e., T3-T2 to be 26.8 (°C) and the room temperature difference T1 -T4 was observed to be 77.1 (°C).
  • temperature T1 at UV bulbs was observed to be 75.2 (°C)
  • temperature T2 at air vent was observed to be 29.1 (°C)
  • temperature T3 at channel outlet was observed to be 29.7 (°C)
  • temperature T4 at target zone T4 was observed to be 25.5 (°C).
  • the temperature of the air vent out by the second construction panel is higher than the temperature of the air received by the first construction panel from the ambient surrounding.
  • the air temperature difference, i.e., T3-T2 to be 0.6 (°C) and the room temperature difference T1 -T4 was observed to be 49.7 (°C).
  • temperature T1 at UV bulbs was observed to be 84.4 (°C)
  • temperature T2 at air vent was observed to be 30.7 (°C)
  • temperature T3 at channel outlet was observed to be 41 .6 (°C)
  • temperature T4 at target zone T4 was observed to be 28.8 (°C).
  • the temperature of the air vent out by the second construction panel is higher than the temperature of the air received by the first construction panel from the ambient surrounding.
  • the air temperature difference, i.e., T3-T2 to be 10.9 (°C) and the room temperature difference T1 -T4 was observed to be 55.6 (°C).

Abstract

The present subject matter relates to a construction panel (200) and a construction panel assembly (400). In an example, a construction panel (200) includes a first sheet panel (202), a second sheet panel (204), and a core panel (206) interposed between the first sheet panel (202) and the second sheet panel (204). The core panel (206) comprises a channel (208) disposed within the core panel (206) to receive air and further to vent out the received air.

Description

PLASTIC CONSTRUCTION PANELS
BACKGROUND
[0001] Walls, floors and roofs for buildings in the present world are generally constructed using one of these following methods. A) Concrete bricks with cement plastering, B) Clay bricks with cement plastering, C) Steel frame structures, D) Wood stick frame structures, E) Timber frame structures, and F) Structurally insulated panels.
BRIEF DESCRIPTION OF DRAWINGS
[0002] The features, aspects, and advantages of the subject matter will be better understood with regard to the following description and accompanying figures. The use of the same reference number in different figures indicates similar or identical features and components.
[0003] FIG. 1 illustrates a perspective view of a construction panel, in accordance with an implementation of the present subject matter; and
[0004] FIG. 2 illustrates an exploded view of a construction panel, in accordance with an implementation of the present subject matter;
[0005] FIG. 3a illustrates a schematic view of a core panel, in accordance with an implementation of the present subject matter;
[0006] FIG. 3b illustrates a schematic view of a core panel, in accordance with another implementation of the present subject matter;
[0007] FIG. 4 illustrates a schematic view of a construction panel assembly having two construction panels, in accordance with another implementation of the present subject matter;
[0008] FIG. 5 illustrates a schematic view of a construction panel assembly having inlet and outlet positioned at different positions, in accordance with another implementation of the present subject matter; [0009] FIGS. 5a-i illustrate different positions of inlets and outlets in a construction panel assembly in accordance with another implementation of the present subject matter; and
[0010] FIG. 6 illustrates a schematic view of a construction panel with different temperature zones, in accordance with an implementation of the present subject matter.
DETAILED DESCRIPTION
[0011] Construction of walls for buildings using concrete panels raised in situ or clay bricks is relatively lengthy and labour-intensive procedure. Such a construction requires a lot of water for the installation of the concrete panels or the clay bricks. In case wooden frames are used for the construction, suitability for wooden frames usage is limited to certain types of building and locations. In addition, modular structural insulated panels are also used for rapid construction, semi-permanent or temporary buildings construction. Thus, the modular structural insulated panels are not designed for industrial or commercial uses.
[0012] In another conventional construction procedure, slabs of precast concrete are formed, tilted upright, and joined together to form a wall of a building. However, such slabs may be precast offsite and transported to a construction site for erection, which increases transportation costs and difficulty in handling large and extremely heavy concrete slabs into position with associated risk of injury to personnel and need for heavy lifting equipment. Alternatively, the slabs may be casted onsite. However, the onsite casting may be affected due to bad weather, because the casted slabs must be fully dried before usage and the bad weather may delay the slab drying or may also damage the slabs. In addition, the slabs need special lifting lugs and heavy lifting equipment to move them into position or tilt them upright. [0013] Further, the buildings constructed using the conventional procedures, such as concrete panels, etc. do not provide any provision for natural air conditioning. Therefore, to keep the room temperature inside the building optimal, generally air-conditioning systems are used. The usage of the air-conditioning systems requires a high energy consumption, which comes at an additional cost. In addition, the air-conditioning systems need regular maintenance and repairs which can lead to further additional costs.
[0014] The present subject matter describes example construction panels for use in building construction. Using the example construction panel described herein, optimal internal temperature may be maintained within the building without using any air-conditioning system and thus better environmental sustainability is provided. The example construction panel described herein is light weight and cost-effective as compared to construction materials used in conventional construction techniques.
[0015] In an example, a construction panel may include a first sheet panel, a second sheet panel, and a core panel. The core panel may be interposed between the first and second sheet panels. The first sheet panel may be a sheet made of a lightweight material, such as plastic. In an example, the first sheet panel may include a vent to receive air. The second sheet panel may be a sheet made of a lightweight material, such as plastic. The core panel is a corrugated structure made of a lightweight material that provides structural strength to the construction panel when interposed between the first and second sheet panels. Further, the core panel may include a channel. The channel may be disposed within the core panel and extends from one end of the core panel to another end of the core panel. The channel is a structure that provides a through passage to a fluid, such as ambient air. The channel ensures upward movement of the air from one end of the channel to another end of the channel. The channel may include a channel inlet and a channel outlet. In an example, the channel inlet may receive air from ambience surrounding if the construction panel is the lowermost construction panel of a building. In an example, the channel inlet may receive air from a channel of another construction panel if the construction panel is not the lowermost construction panel of the building. In an example, the channel inlet may receive air from the vent disposed in the first sheet panel.
[0016] Further, the channel outlet may vent out the received air. In an example, the channel outlet may vent out the received air to the ambience surrounding if the construction panel does not have another construction panel connected to it. In an example, the channel outlet may vent out the received air to a channel of another construction panel if the construction panel have another construction panel connected to it. The ambience surrounding may be environmental condition exposed to the constructional panel. In an example, the ambience surrounding may be atmospheric surrounding. In another example, if the construction panel is used to construct a room inside a building, the ambience surrounding may be inner surrounding of the building.
[0017] The received air may travel within the channel from the channel inlet to the channel outlet such that the air absorbs heat from the ambient surrounding in contact with an external surface of the construction panel. As per the general principle, the hot air rises above within the channel and vents out on finding any outlet, such as the channel outlet. Thus, unlike conventional construction materials, the channel of the construction panel of the present subject matter allows upward movement of the hot air and thereby ensures that internal temperature of the building is optimally maintained. The internal temperature of the building is optimally maintained because the construction panel of the present subject matter allows a very low thermal transmission between the interior and the exterior of the construction panels. Thus, the construction panel saves on the cost which would have otherwise incurred on installation and usage of an air- conditioning system. [0018] In another example of the present subject matter, a construction panel assembly is described. The construction panel assembly may be an arrangement of multiple construction panel assemblies. The construction panel assembly may include a plurality of constructions panels interlockable with each other to form the construction panel assembly. In an example, each of the plurality of constructions panels may be interlockable via male and female configurations. Each of the plurality of constructions panels may include a first sheet panel, a second sheet panel, and a core panel interposed between the first sheet panel and the second sheet panel. The core panel may include a channel disposed within the core panel and that extends from one end of the core panel to another end of the core panel. The channel includes a channel inlet to receive air and a channel outlet to dispense air. The air travels within the channel from the channel inlet to the channel outlet such that heat is absorbed from the ambient surrounding in contact with an external surface of the construction panel air. The channel allows upward movement of the hot air and thereby ensures that internal temperature of the building is optimally maintained. Furthermore, the channel receives air from one of an air vent of the construction panel and a channel of another adjoining construction panel. In addition, the channel vents out received air to one of ambient surrounding and a channel of another adjoining construction panel.
[0019] The construction panel of the present subject matter can be fabricated in various sizes, dimensions and various thicknesses depending on the construction requirement of the building. Also, the construction panel ensures a dry construction that substantially reduces the use of water in the construction.
[0020] The construction panel of the present subject matter ensures that the amount of cement used is much lower which would have otherwise used in the conventional building construction. In an example, the construction panel of the present subject matter uses less than 15% amount of cement which would have been used in the conventional building construction using concrete panels raised in situ or clay bricks. The construction panel can be fabricated using the recycled material. Thus, the construction panel is eco-friendly.
[0021] The construction panel possesses excellent load bearing capacity. Therefore, the use of the construction panel is not restricted for rapid construction, semi-permanent or temporary buildings, and can be readily used for industrial or commercial construction purposes with a life span of more than 50 years.
[0022] The plastic construction panel is light weight and therefore, heavy machinery is not required during the building construction. Also, after the building demolition, the material of the construction panel can be recycled to fabricate new construction panels. Also, the construction panel enables faster speed of construction when compared to conventional construction techniques. In addition, the plastic construction panel is rust/corrosion free and thus have prolonged life span.
[0023] The components of the construction panel are substantially made of environmentally friendly and recycled materials which are nontoxic, odourless and long-lasting. The construction panel can advantageously have its size and capacity for withstanding the structural stresses of compression, tension and bending mathematically increased or decreased by selectively specifying the various parameters of the components of the construction panel. The modularity of the construction panel advantageously provides a building material which is inexpensive and easily repaired/replaced when damaged.
[0024] The description hereinafter describes the construction panel as per the present subject matter. The manner in which the construction panel of the present subject matter shall be implemented has been explained in detail with respect to FIGS. 1 to 6. [0025] It should be noted that the description and figures merely illustrate the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope. Furthermore, all examples recited herein are intended only to aid the reader in understanding the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects and implementations of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.
[0026] FIG. 1 illustrates a perspective view of a construction panel 100, in accordance with an implementation of the present subject matter. The construction panel 100 is a building block used for the construction of a structure, such as a building. The construction panel 100 includes a first sheet panel 102, a second sheet panel 104, and a core panel 106 disposed between the first sheet panel 102 and the second sheet panel 104. The first sheet panel 102 may be a sheet made of a lightweight material. In an example, the lightweight material may be plastic. In an example, the first sheet panel 102 may include a vent (not shown in FIG. 1 ) to receive air. The second sheet panel 104 may be a sheet made of a lightweight material. In an example, the lightweight material may be plastic. The core panel 106 is a corrugated structure made of a lightweight material that provides structural strength to the construction panel 100 when interposed between the first and second sheet panels 102, 104. In an example, the lightweight material may be plastic. Any other material having properties similar to plastic can be used. In an example, the structure of the core panel 106 is one of a honeycomb structure, a grid structure, an aerated grid structure, and a corrugated structure.
[0027] The first sheet panel 102 defines the dimension of the construction panel 100 and may include an inner surface and an outer surface. The inner surface of the first sheet panel 102 may be attached to the core panel 106. The outer surface of the first sheet panel 102 may be provided with a surface finishing material. In an example, the surface finishing material is selected from, but is not limited to, one of a cement bonded particle board, a plywood, a medium density fiberboard, and an aluminum composite board. Further, the second sheet panel 104 includes an inner surface and an outer surface and defines the dimension of the construction panel 100 as the first sheet panel 102 does. The inner surface of the second sheet panel 104 may be attached to the core panel 106. The outer surface of the second sheet panel 104 may be provided with the surface finishing material. In an example, the surface finishing material provides primary safety or be a sacrificial layer to the construction panel 100.
[0028] Although in FIG. 1 , any inlet and outlet for air is not shown in the construction panel 100, but the construction panel 100 may include an inlet and outlet to let in the air inside the construction panel 100 and then vent out the air outside the construction panel 100.
[0029] FIG. 2 illustrates an exploded view of a construction panel 200, in accordance with an implementation of the present subject matter. The construction panel 200 includes a first sheet panel 202, a second sheet panel 204, and a core panel 206 disposed between the first sheet panel 202 and the second sheet panel 204. The first sheet panel 202 may be similar to the first sheet panel of FIG. 1 . The second sheet panel 204 may be similar to the second sheet panel of FIG. 1 . In an example, the structure of the core panel 206 may be one of a honeycomb structure, a grid structure, an aerated grid structure, and a corrugated structure.
[0030] Further, the core panel 206 as shown in FIG. 2 includes a channel 208 disposed within the core panel 206 and extending from one end of the core panel 206 to another end of the core panel 206. The channel is a structure that provides a through passage to a fluid, such as ambient air. In an example, a plurality of channels may be provided in the core panel 206. Each of the plurality of channels may be interconnected via conventional joining techniques. In an example, the plurality of channels may have intermediatory holes across the channels to provide an expanded through passage to the fluid. In an example, the channel 208 may be a hollow grid having intermediatory holes across the hollow grid. In an example, the channel 208 provides an upward movement of the air from one end of the channel 208 to another end of the channel 208. In an example, the channel 208 provides a sideways movement of the air from one side end of the channel 208 to another side end of the channel 208. Further, the channel 208 may include a channel inlet 210 and a channel outlet 212. In an example, the channel inlet 210 may receive air from ambience surrounding if the construction panel is the lowermost construction panel of a building. In an example, the channel inlet 210 may receive air from the ambience surrounding despite the positioning of the construction panel in the building. In an example, the channel inlet 210 may receive air from a channel of another construction panel if the construction panel 200 is not the lowermost construction panel of the building. In an example, the channel inlet 210 may receive air from a vent 214 disposed in the first sheet panel 202. In an example, the vent 214 may be disposed at any location in the first sheet panel 202. In an example, the vent 214 may be disposed at a lowermost edge of the first sheet panel 202. In an example, the first sheet panel 202 may include a first plastic sheet 216 adjacent to the core panel 206 and a first cement sheet 218 adjacent to the first plastic sheet 216. In an example, the first plastic sheet 216 may include the vent 214 and the first cement sheet 218 may include another vent (not shown) fluidly connected to the vent 214 and the channel inlet 210 so that the ambient air can pass from the vent 214 via the other vent to the channel inlet 210. In an example, the second sheet panel 204 may include a second plastic sheet 220 adjacent to the core panel 206 and a second cement sheet 222 adjacent to the second plastic sheet 220. The first cement sheet 218 and the second cement sheet 222 are to provide additional strength to the construction panel 200 and to enable the exterior finishing of the construction panel 200 for which cement material is a requirement, for example, plastering of the walls of the building.
[0031] Further, the channel outlet 212 may vent out the received air. In an example, the channel outlet 212 may vent out the received air to the ambience surrounding if the construction panel 200 does not have another construction panel connected to it. In an example, the channel outlet 212 may vent out the received air to a channel of another construction panel if the construction panel 200 have another construction panel connected to it. The ambience surrounding may be environmental condition exposed to the constructional panel. In an example, the ambience surrounding may be atmospheric surrounding. In another example, if the construction panel 200 is used to construct a room inside a building, the ambience surrounding may be inner surrounding of the building but external to the room.
[0032] In an example implementation, the core panel 206 may include a third sheet panel 224 disposed between the first sheet panel 202 and the second sheet panel 204. The third sheet panel 224 may be made of a plastic material. In an example, the plastic material can be recyclable. In an example, the recycled plastic sheets are made from heterogeneous waste plastic that is shredded, cleaned and heat pressed to form the sheets. In an example, the plastic material can be virgin plastic. The core panel 206 may further includes a first core panel 226 having the channel 208 extending from one end of the first core panel 226 to another end of the first core panel 226. The first core panel 226 is interposed between the first sheet panel 202 and the third sheet panel 224. The first core panel 226 may be made of a plastic material. In an example, the plastic material may be recyclable. In an example, the recycled plastic sheets are made from heterogeneous waste plastic that is shredded, cleaned and heat pressed to form the sheets. In an example, the plastic material may be a virgin plastic. In an example, the structure of the first core panel 226 may be one of a honeycomb structure, a grid structure, an aerated grid structure, and a corrugated structure. Furthermore, the core panel 206 may include a second core panel 228 interposed between the second sheet panel 204 and the third sheet panel 224. The second core panel 228 may be made of a plastic material. In an example, the plastic material can be recyclable. In an example, the recycled core panel may be made from heterogeneous waste plastic that is shredded and cleaned to form the core panel. In an example, the plastic material can be virgin plastic. In an example, the structure of the second core panel 228 may be one of a honeycomb structure, a grid structure, an aerated grid structure, and a corrugated structure.
[0033] In an example, the third sheet panel 224 may include a third plastic sheet 230 and a fourth plastic sheet 232. The third plastic sheet 230 may be placed adjacent to the first core panel 226 and fourth plastic sheet 232 may be placed adjacent to the second core panel 228. In an example, the third plastic sheet 230 and the fourth plastic sheet 232 may be adjacent to each other. In an example, the third plastic sheet 230 and the fourth plastic sheet 232 may be bonded to each other to a form a single sheet.
[0034] In an example, the first sheet panel 202, the second sheet panel 204, the third sheet panel 224, the core panel 206, the first core panel 226, and the second core panel 228 are made of the same plastic material. In an example, the first sheet panel 202, the second sheet panel 204, the third sheet panel 224, the core panel 206, the first core panel 226, and the second core panel 228 are made of different plastic materials. Since the construction panel 200 is made of the plastic material, the customization of the construction panel 200, as per the application/requirement during the construction, is easier. Also, the fire retardancy of the construction panel 200 is rated as per strict building bylaws. The construction panel 200 provides numerous desirable properties making it suitable for building and construction such as substantial structural strength for bearing loads. [0035] In an example implementation, the core panel 206 further includes a plurality of cells. In an example, one or more of the plurality of cells are fillable with one of polyurethane, cellulose fiber, ash, or cementconcrete mixture or a combination. The cells are filled for enhancing the strength of the construction panel 200 along with other enhancements like sound proofing, improved thermal behavior, reduced knocking sound, and for withstanding wind speed. In an example, metals sheets can also be filled in the cells. Further, the size of the cells may be calibrated for specific applications.
[0036] The construction panel 200 uses recycled plastic for adapting to the elasticity property of the plastic to its maximum advantage and that too in a cost-effective matter. The combination of recycled plastic sheets to cement sheets enhances the load bearing physical property of the construction panel 200.
[0037] In an example implementation, the recycled plastic may be used as I-Beam support sandwiched between the two sheets of the construction panel 200 for producing the required cantilevered support to the construction panel 200.
[0038] In an example implementation, the construction panel 200 may have a horizontal flat compression formulated from 5 Tons/SqMt 15 up to 20 Tons/SqMt and a vertical compression designed for 1.2 to 2.4 Tons for every running foot of 8 feet high wall. Also, the puncher resistance of the construction panel 200 can be altered for high security areas.
[0039] Also, the construction panel 200 has inherent thermal insulting property because of the air trapped within the construction panel 200. In an example, the construction panel 200 allows for two different face materials on either side, such as a glass sheet for the exterior and plywood sheet for the interiors.
[0040] The construction panel 200 has light weight property that allows easy material handling and transportation. Also, the construction panel 200 may not be damaged during transportation due to the use of plastic material. The construction panel 200 has waterproof property and thus acts as a moisture barrier.
[0041] In an example, to connect or join the construction panels with each other during the construction of the building, portable generator and regular electric hand tools are sufficient. The construction panel 200 ensures ease of installing electrical wiring and plumbing lines into the panels. The construction panel 200 of the present subject matter is breakage resistant, puncture resistant, water and fire-resistant, long-life span comparable to brick and cement structure, modular construction convenience, versatile applications, and swappable fascia based on the application.
[0042] In an example, the first core panel may be fused to the first sheet panel and the third sheet panel either by thermal fusion or stuck with adhesive or fixed with steel fixtures. In an example, the second core panel may be fused to the second sheet panel and the third sheet panel either by thermal fusion, stuck with adhesive or fixed with steel fixtures. The construction panel 200 is finally layered on one of a cement fiber board, a particle board, a gypsum board, a plywood, a medium density fiber board, glass, metal sheets etc. Outer skin used for cladding the plastic construction panel depends on the final application.
[0043] In an example, each of the first, second, third, and fourth plastic sheets 216, 220, 230, 232 may have a thickness ranging from 4mm to 18mm.
[0044] In an example, each of the first core panel 226 and the second core panel 228 may have a thickness ranging from 4mm to 36mm and may be interlocked/ fused/ riveted to form a grid of varying dimensions and shapes. The first core panel 226 and the second core panel 228 provide strength and load distribution properties to the construction panel 200.
[0045] In the example implementation of FIG. 3a illustrating a schematic view of the core panel 206, in accordance with an implementation of the present subject matter, the core panel 206 includes a plurality of cells 300. In an example, the core panel 206 has a honeycomb structure. The cell size of the plurality of cells 300 can be calibrated for specific applications. Between the cells 300 of the core panel 206 and the inner surfaces of the first sheet panel 202 and the second sheet panel 204, cavities are formed. Such cavities are filled with one of polyurethane, cellulose fiber, ash, or cement-concrete mixture or a combination of these. The cavity filling is done for enhancing the strength of the construction panel 200 along with other enhancements like sound proofing, improved thermal behavior, reduces knocking sound, and withstand wind speed. In an example, metals sheets can be filled in the cavities.
[0046] During the construction of the building, the construction panels can be put together by various means like welding, fusing, using an adhesive, riveting etc. based on the intended application of the construction panel. After putting the construction panels together, the building can withstand very high wind speeds, for example, up to 150-180 Kilometers/hour wind speed.
[0047] In an example, the construction panel 100, 200 may have a thickness in a range of 3 to 12 inches. Though a range is specified, however, the construction panel 100 may have any thickness depending on the requirement.
[0048] In an example, the construction panel 100, 200 may have a dimension of 8 feet by 4 feet. In an example, the construction panel 100, 200 may have a dimension of 10 feet by 4 feet. Though a dimension is specified, however, the construction panel 100, 200 may have any dimension depending on the requirement.
[0049] In an example, the construction panel 100, 20 may be adaptable to any climatic situation across the world, i.e., it can be used in an ambient temperature range of -25 degrees Celsius to +55 degrees Celsius. [0050] In an example, special adhesives, fixtures and a super strong grid pattern may be used for the fabrication of the construction panel 100, 200.
[0051] In the example implementation of FIG. 3b illustrating a schematic view of a core panel, in accordance with another implementation of the present subject matter, the core panel 206 includes a plurality of cells 302. In the example implementation of FIG. 3b, In an example, the core panel 206 has a grid structure. The cell size of the plurality of cells 302 can be calibrated for specific applications. Between the cells 302 of the core panel 206 and the inner surfaces of the first sheet panel 202 and the second sheet panel 204, cavities are formed. Such cavities are filled with one of polyurethane, cellulose fiber, ash, or cement-concrete mixture or a combination of these. The cavity filling is done for enhancing the strength of the construction panel 200 along with other enhancements like sound proofing, improved thermal behavior, reduces knocking sound, and withstand wind speed. In an example, metals sheets can be filled in the cavities.
[0052] In an example, the structure of the first core panel 226 may be one of a honeycomb structure, a grid structure, an aerated grid structure, and a corrugated structure. In an example, the structure of the second core panel 228 may be one of a honeycomb structure, a grid structure, an aerated grid structure, and a corrugated structure. In an example, the first core panel 226 may be fused to the first sheet panel 202 and the third sheet panel 224 either by thermal fusion, stuck with adhesive or fixed with steel fixtures. In an example, the second core panel 228 may be fused to the second sheet panel 204 and the third sheet panel 224 either by thermal fusion, stuck with adhesive or fixed with steel fixtures.
[0053] FIG. 4 illustrates a schematic view of a construction panel assembly 400 having two construction panels 402, 404, in accordance with another implementation of the present subject matter. In an example, construction panel assembly 400 may include intermediary panels (now shown) interposed between the two construction panels 402, 404 to form construction panel assembly 400. In an example, the construction panel assembly 400 may include a plurality of constructions panels interlockable with each other to form the construction panel assembly 400. The constructions panels interlockable by means of conventionally known techniques. For example, one construction panel may have a male fitment and another construction panel may have a female fitment. A male-female joint may be formed between the construction panels to form the construction panel assembly. In another example, the constructions panels may be riveted to each other for interlocking with each other to form the construction panel assembly.
[0054] Further, the construction panel 402 may include a first sheet panel 406, a second sheet panel 408, and a core panel (not shown) interposed between the first sheet panel 406 and the second sheet panel 408. Further, the core panel may include a channel 410 disposed within the core panel and extending from one end of the core panel to another end of the core panel. The channel 410 may include a channel inlet 412 to receive air and a channel outlet 414 to dispense air. When the air travels within the channel 410 from the channel inlet 412 to the channel outlet 414 to absorb heat from the ambient surrounding in contact with an external surface of the construction panel 402. In an example, the channel 410 may receive air from one of an inlet 416 of the construction panel 402 and a channel (not shown in FIG. 4) of another adjoining construction panel. The channel may vent out the received air to ambient surrounding if not assembled with another construction panel. The channel may vent out the received air to a channel of another adjoining construction panel if assembled with another construction panel.
[0055] Further, the construction panel 404 may have similar structure to that of the construction panel 402. Only difference is that the construction panel 404 does not have any inlet at the first sheet panel to receive the air. Instead, the channel inlet of the construction panel 404 receives the air from the channel outlet of the construction panel 402.
[0056] In an example, the construction panel assembly 400 is a monolith-like structure having a first construction panel 402, a second construction panel 404, and one or more intermediary constructions panels. The channel of two adjoining construction panels may be fluidly coupled to each other. Further, the channel 410 of the first construction panel 402 is disposed within the core panel of the first construction panel 402 to receive the air from the inlet 416 of the first construction panel 402. Further, the second construction panel 404 may include the channel 410 disposed within the core panel of the second construction panel 404 to receive air from the channel 410 of one of the first construction panel 402 and the one or more intermediary construction panels. Further, the channel 410 of the second construction panel 404 vent out air to the ambient surrounding. In an example, the temperature of the air vent out by the second construction panel 404 is higher than the temperature of the air received by the first construction panel 402 from the ambient surrounding.
[0057] FIG. 5 illustrates a schematic view of a construction panel assembly 500 having inlet and outlet positioned at different positions, in accordance with an implementation of the present subject matter. In an example, the construction panel assembly 500 may have a first construction panel 502 and a second construction panel 504 as shown. The first construction panel 502 may have a first face 506, a second face 508, a third face 510, a fourth face 512, and fifth face 514. Similarly, the second construction panel 504 may have a first face 516, a second face 518, a third face 520, and a fourth face 522.
[0058] As shown in FIG. 5a, the first face 506 of the first construction panel 502 may include one or more inlet 506a for air. [0059] As shown in FIG. 5b, the second face 508 of the first construction panel 502 may include one or more inlet 506b for air.
[0060] As shown in FIG. 5c, the third face 510 of the first construction panel 502 may include one or more inlet 510c for air when another construction panel is adjoined adjacent to the first construction panel 502.
[0061] As shown in FIG. 5d, the fourth face 512 of the first construction panel 502 may include one or more outlet 512d for air when another construction panel is adjoined adjacent to the first construction panel 502.
[0062] As shown in FIG. 5e, the fifth face 514 of the first construction panel 502 may include one or more outlet 514e for air when another construction panel is adjoined above the first construction panel 502.
[0063] As shown in FIG. 5f, the first face 516 of the second construction panel 504 may include one or more inlet 516f for air when the first construction panel 502 is adjoined below the second construction panel 504.
[0064] As shown in FIG. 5g, the second face 518 of the second construction panel 504 may include one or more outlet 518g for air when the second construction panel 504 is exposed to the ambience surrounding.
[0065] As shown in FIG. 5h, the third face 520 of the second construction panel 504 may include one or more inlet 520h for air when another construction panel is adjoined adjacent to the second construction panel 504.
[0066] As shown in FIG. 5i, the fourth face 522 of the second construction panel 504 may include one or more outlet 522i for air when another construction panel is adjoined adjacent to the second construction panel 504. [0067] FIG. 6 illustrates a schematic view of the construction panel 200 with different temperature zones, in accordance with an implementation of the present subject matter. The construction panel 200 is similar to the construction panel described in FIG. 2. The different temperature zones are due to an experimental setup of the construction panel assembly (not shown in FIG. 6) to determine the temperature inside a room when ambient temperature is about 50 (°C). The construction panel assembly may be an arrangement of multiple construction panel assemblies. The construction panel assembly includes a plurality of constructions panels interlockable with each other to form the construction panel assembly. In an example, each of the plurality of constructions panels may be interlockable via male and female configuration between a construction panel to the adjacent construction panel. To conduct the experiment using the above described construction panel assembly, ultra-violet (UV) bulbs (not shown) are placed on a side of the constructional panel facing an external surface of a target zone. The bottommost constructional panel of the construction panel assembly receives the heat produced from ambient surrounding, i.e., UV bulbs via the air vent. The received air travels within the channel from the channel inlet to the channel outlet. The channel of the intermediate construction panel receives air from one of the air vent of the bottommost construction panel and a channel of another adjoining panel. The channel of either one of the intermediate construction panel or the topmost construction panel vents out received air to one of ambient surrounding and a channel of another adjoining construction panel. Thus, the hot air absorbed from the ambient surroundings in contact with the external surface of the bottommost construction panel rises above to the topmost construction panel via the channels of the intermediate construction panel. Thereby, internal temperature of the building does not increase.
[0068] Based on the results of the experiment, the temperature of the air vent out by a second construction panel, i.e., intermediate construction panel is observed to be higher than the temperature of the air received by a first construction panel, i.e., bottommost construction panel from the ambient surrounding. In the experiment conducted using natural convection via air outlet for 3 hours, temperature T1 at UV bulbs was observed to be 108.1 (°C), temperature T2 at air vent was observed to be 25.9 (°C), temperature T3 at channel outlet was observed to be 52.7 (°C), and temperature T4 at target zone T4 was observed to be 31 .0 (°C). Based on the above results of the experiment, the temperature of the air vent out by the second construction panel is higher than the temperature of the air received by the first construction panel from the ambient surrounding. Further, the air temperature difference, i.e., T3-T2 to be 26.8 (°C) and the room temperature difference T1 -T4 was observed to be 77.1 (°C).
[0069] In the experiment using natural convection via air outlet for 1 hour, temperature T1 at UV bulbs was observed to be 75.2 (°C), temperature T2 at air vent was observed to be 29.1 (°C), temperature T3 at channel outlet was observed to be 29.7 (°C), and temperature T4 at target zone T4 was observed to be 25.5 (°C). Based on the above results of the experiment, the temperature of the air vent out by the second construction panel is higher than the temperature of the air received by the first construction panel from the ambient surrounding. Further, the air temperature difference, i.e., T3-T2 to be 0.6 (°C) and the room temperature difference T1 -T4 was observed to be 49.7 (°C).
[0070] In the experiment using forced convection via air outlet for 3 hours, temperature T1 at UV bulbs was observed to be 84.4 (°C), temperature T2 at air vent was observed to be 30.7 (°C), temperature T3 at channel outlet was observed to be 41 .6 (°C), and temperature T4 at target zone T4 was observed to be 28.8 (°C). Based on the above results of the experiment, the temperature of the air vent out by the second construction panel is higher than the temperature of the air received by the first construction panel from the ambient surrounding. Further, the air temperature difference, i.e., T3-T2 to be 10.9 (°C) and the room temperature difference T1 -T4 was observed to be 55.6 (°C).
[0071] In the experiment using conditioned air via air outlet for 3 hours, temperature T1 at UV bulbs was observed to be 65.3 (°C), temperature T2 at air vent was observed to be 26.9 (°C), temperature T3 at channel outlet was observed to be 33.3 (°C), and temperature T4 at target zone T4 was observed to be 21.8 (°C). Based on the above results of the experiment, the temperature of the air vent out by the second construction panel is higher than the temperature of the air received by the first construction panel from the ambient surrounding. Further, the air temperature difference, i.e., T3-T2 to be 6.4 (°C) and the room temperature difference T1 -T4 was observed to be 43.5 (°C). Thus, it is proved that the room is naturally cooled without using any external or additional air conditioning system.
[0072] Although examples for the present disclosure have been described in language specific to structural features and/or methods, it is to be understood that the appended claims are not necessarily limited to the specific features or methods described. Rather, the specific features and methods are disclosed and explained as examples of the present disclosure.

Claims

We claim:
1. A construction panel (200) comprising: a first sheet panel (202); a second sheet panel (204); and a core panel (206) interposed between the first sheet panel (202) and the second sheet panel (204), the core panel (206) comprising; at least one channel (208) disposed within the core panel (206) and extending from one end of the core panel (206) to another end of the core panel (206), wherein the at least one channel (208) comprises: a channel inlet (210) to receive air from one of ambience surrounding and a channel of another construction panel; and a channel outlet (212) to vent out the received air to at least one of the ambience surrounding and a channel of another construction panel, and wherein the air travels within the at least one channel (208) from the channel inlet (210) to the channel outlet (212) to absorb heat from the ambient surrounding in contact with an external surface of the construction panel (200).
2. The construction panel (200) as claimed in claim 1 , wherein the core panel (206) comprises: a third sheet panel (224) disposed between the first sheet panel (202) and the second sheet panel (204); a first core panel (226) having the at least one channel (208) extending from one end of the first core panel (226) to another end of the first core panel (226), wherein the first core panel (226) is interposed between the first sheet panel (202) and the third sheet panel (224); and a second core panel (228) interposed between the second sheet panel (204) and the third sheet panel (224).
3. The construction panel (200) as claimed in claim 2, wherein the structure of the first core panel (226) and the second core panel (228) is one of a honeycomb structure, a grid structure, an aerated grid structure, and a corrugated structure.
4. The construction panel (200) as claimed in claim 2, wherein the first core panel (226) and the second core panel (228) are made of a plastic material.
5. The construction panel (200) as claimed in claim 1 , wherein the first sheet panel (202) comprises a first plastic sheet (216) adjacent to the core panel (206) and a first cement sheet (218) adjacent to the first plastic sheet (216).
6. The construction panel (200) as claimed in claim 1 , wherein the second sheet panel (204) comprises a second plastic sheet (220) adjacent to the core panel (206) and a second cement sheet (222) adjacent to the second plastic sheet (220).
7. The construction panel (200) as claimed in claim 2, wherein the third sheet panel (224) comprises a third plastic sheet (230) and a fourth plastic sheet (232), wherein the third plastic sheet (230) is adjacent to the first core panel (226) and the fourth plastic sheet (232) is adjacent to the second core panel (228), and wherein the third plastic sheet (230) and the fourth plastic sheet (232) are adjacent to each other.
8. The construction panel (200) as claimed in claim 1 , wherein the first sheet panel (202) comprises at least one vent (214), fluidly coupled to the channel inlet (210) of the at least one channel (208), to receive the air.
9. The construction panel (200) as claimed in claim 1 , wherein the core panel (206) comprises a plurality of cells (300, 302), and wherein one or more of the plurality of cells (300, 302) are fillable with one of polyurethane, cellulose fiber, ash, or cement-concrete mixture or a combination of these.
10. The construction panel (200) as claimed in claim 1 , wherein at least one of the first sheet panel (202) and the second sheet panel (204) comprises a surface finishing material selected from one of a cement bonded particle board, a plywood, a medium density fiberboard, and an aluminum composite board.
1 1 . A construction panel assembly (400) comprising: a plurality of constructions panels interlockable with each other to form the construction panel assembly (400), wherein each construction panel comprises: a first sheet panel (406); a second sheet panel (408); and a core panel interposed between the first sheet panel (406) and the second sheet panel (408), the core panel comprising; at least one channel (410) disposed within the core panel and extending from one end of the core panel to another end of the core panel, the at least one channel (410) comprising: a channel inlet (412) to receive air; and a channel outlet (414) to dispense air, wherein the air travels within the at least one channel (410) from the channel inlet (412) to the channel outlet (414) to absorb heat from the ambient surrounding in contact with an external surface of the construction panel, wherein the at least one channel (410) is to receive air from one of an inlet (416) of the construction panel and a channel of another adjoining construction panel; and wherein the at least one channel (410) is to vent out the received air to at least one of ambient surrounding and a channel of another adjoining construction panel.
12. The construction panel assembly (400) as claimed in claim 11 , wherein the construction panel assembly (400) is a monolith-like structure comprising a first construction panel (402), a second construction panel (404), and one or more intermediary constructions panels, wherein the at least one channel (410) of two adjoining construction panels are fluidly coupled to each other, and wherein the first construction panel (402) comprises the at least one channel (410) disposed within the core panel of the first construction panel (402) to receive the air from the inlet (416) of the first construction panel (402); and the second construction panel (404) comprises the at least one channel (410) disposed within the core panel of the second construction panel (404) to: receive air from the at least one channel (410) of one of the first construction panel (402) and the one or more intermediary construction panels, and vent out air to the ambient surrounding.
13. The construction panel assembly (400) as claimed in claim 11 , wherein the temperature of the air vent out by the second construction panel (404) is higher than the temperature of the air received by the first construction panel (402) from the ambient surrounding.
PCT/IN2023/050590 2022-06-21 2023-06-21 Plastic construction panels WO2023248245A1 (en)

Applications Claiming Priority (2)

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IN202241035634 2022-06-21
IN202241035634 2022-06-21

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2507090A1 (en) * 1975-02-19 1976-09-09 Star Mfg Co Prefabricated panel for roofs-wall - having corrugated metal core plate, hard smooth facing plate, outer flapped membrane
WO2011010115A1 (en) * 2009-07-24 2011-01-27 Viig Limited Improved panel
US10392802B2 (en) * 2017-10-18 2019-08-27 Kenneth R. Kreizinger Polyurethane foam backed panel

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2507090A1 (en) * 1975-02-19 1976-09-09 Star Mfg Co Prefabricated panel for roofs-wall - having corrugated metal core plate, hard smooth facing plate, outer flapped membrane
WO2011010115A1 (en) * 2009-07-24 2011-01-27 Viig Limited Improved panel
US10392802B2 (en) * 2017-10-18 2019-08-27 Kenneth R. Kreizinger Polyurethane foam backed panel

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