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WO2008155559A1 - Multi-core structural insulated panels - Google Patents

Multi-core structural insulated panels Download PDF

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Publication number
WO2008155559A1
WO2008155559A1 PCT/GB2008/002123 GB2008002123W WO2008155559A1 WO 2008155559 A1 WO2008155559 A1 WO 2008155559A1 GB 2008002123 W GB2008002123 W GB 2008002123W WO 2008155559 A1 WO2008155559 A1 WO 2008155559A1
Authority
WO
WIPO (PCT)
Prior art keywords
structural
core
foam
structural member
board
Prior art date
Application number
PCT/GB2008/002123
Other languages
French (fr)
Inventor
Ian De Haan
Original Assignee
Ian De Haan
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 Ian De Haan filed Critical Ian De Haan
Publication of WO2008155559A1 publication Critical patent/WO2008155559A1/en

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building 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
    • E04C2/34—Building 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
    • E04C2/36—Building 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 transversely-placed strip material, e.g. honeycomb panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building 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
    • E04C2/284—Building 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
    • E04C2/296—Building 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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building 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
    • E04C2/34—Building 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

Definitions

  • the present invention relates to structural insulated panels for use in construction.
  • Structural insulated panels having two facing layers of orientated strand board (OSB) which are adhered together by an insulating core of pressure injected polyurethane foam are well known in the construction industry.
  • SIPs Structural insulated panels
  • OSB orientated strand board
  • These panels have a number of benefits including relatively low production costs and good strength and insulation properties.
  • these advantages can be diminished when openings for doors and windows are included as any such openings must be reinforced by a timber frame and/or lintel in order to maintain the overall strength and integrity of the panel. This can add considerably to build times or, if the openings are pre-cut into the panels during manufacture, to the cost of the panels.
  • Structural panels having multiple layers of OSB separated by layers of rigid foam insulation are also known. Such panels are constructed by gluing the various layers together in a sandwich-like configuration. However, these panels are susceptible to de-lamination under load and therefore have limited application.
  • the present invention provides a multi- core structural member comprising at least three structural board layers, each structural board layer being spaced from at least one other structural board layer by an insulating layer, wherein at least one of the insulating layers comprises a pressure injected foam which bonds the neighbouring structural board layers together.
  • the multi-core construction of the present invention is advantageous as it enables openings for doors and windows to be cut into the structural members without the need for additional reinforcing timber frames or lintels.
  • the pressure injected foam layer ensures the structural integrity of the member even if openings for doors and windows are made.
  • At least one of the insulating layers comprises a sound absorbent foam to provide sound insulation.
  • at least one of the insulating layers comprises a fire resistant foam such as a polyisocyanurate foam.
  • At least one of the insulating layers comprises an environmentally friendly alternative to synthetic insulation materials such as wood fibre or any other natural insulation product such as hemp.
  • each insulating layer comprises a pressure injected foam which bonds the neighbouring structural board layers together.
  • the pressure injected foam is a polyurethane foam or a polyisocyanurate foam.
  • the structural board layers preferably comprise orientated strand board.
  • a coating such as marine epoxy may be applied to the orientated strand board in order to make it more weather resistant.
  • at least one of the structural board layers comprises cement particle board.
  • the present invention provides a multi- core structural member comprising: at least two structural board layers, and a plurality of structural webs which define together with the structural board layers a plurality of insulation compartments, wherein each insulation compartment is arranged to receive at least one insulating rod.
  • the structural webs provide inherent structural integrity to the structural member and therefore also enable openings for doors and windows to be cut into the structural member without the need for reinforcing timber frames or lintels. Furthermore, because of the inherent structural integrity of the member, issues of de-lamination do not arise.
  • At least one of the insulating rods comprises a sound absorbent foam, a fire resistant foam, which may be a polyisocyanurate foam, wood fibre or any other natural insulation product such as hemp.
  • at least one insulating rod comprises a pressure injected foam which bonds the neighbouring structural board layers and structural webs together.
  • each insulating rod comprises a pressure injected foam which bonds the neighbouring structural board layers and structural webs together.
  • the pressure injected foam is a polyurethane foam or a polyisocyanurate foam.
  • the structural board layers preferably comprise orientated strand board. A coating such as marine epoxy may be applied to the orientated strand board in order to make it more weather resistant. Alternatively or additionally, at least one of the structural board layers may comprise cement particle board.
  • the present invention provides a kit for a multi-core structural member comprising: a hollow box structure comprising at least two structural board members and a plurality of structural web members which define together with the structural board layers a plurality of insulation compartments, and a plurality of insulating rods which are arranged to be received in the insulation compartments .
  • Figure 1 is a schematic cross-sectional view through a portion of a two-core structural panel
  • Figure 2 is a schematic cross- sectional view through one edge of the panel of Figure 1;
  • Figure 3 is a schematic cross-sectional view through an alternative edge arrangement to that shown in Figure 2 ;
  • Figure 4 is a schematic cross-sectional view through a portion of a three-core structural panel
  • Figure 5 is a schematic cross-sectional view through a portion of an alternative two-core structural panel
  • Figure 6 is a schematic cross-sectional view through a portion of an alternative multi-core structural panel arrangement ;
  • Figure 7 is an exploded schematic isometric view of a first joint arrangement
  • Figure 8 is an exploded schematic isometric view of a staggered castellated joint arrangement.
  • Figure 1 shows a portion of a two-core structural panel 10 comprising three structural board layers 15a, b,c of orientated strand board (OSB) and two insulating layers 20a, b of CFC free/ODP zero polyurethane foam.
  • the structural board layers 15a, b,c comprise OSB having a thickness of 15mm and the insulating layers 20a, b have a depth of 40mm.
  • the three structural board layers 15a, b,c are bonded together by the polyurethane foam which is pressure injected between the structural board layers during fabrication as described below.
  • Figure 2 shows a schematic cross-sectional view through an example edge arrangement for the panel 10.
  • the panel 10 comprises edge spines 25a, b of engineered wood positioned between the structural board layers 15a, b,c.
  • the edge spines 25a, b are adhered to the adjacent structural board layers 15a, b,c by an adhesive.
  • Figure 3 shows an alternative edge arrangement to that shown in Figure 2.
  • the panel 10 comprises an edge spine core separator 27 formed from a 40mm deep section of laminated veneer lumber such as VERSALAM (RTM) .
  • the edge spine core separator 27 is attached to the structural board layers 15a, b,c by an adhesive.
  • This second edge arrangement is the preferred arrangement as the edge spine core separator 27 serves as a spreading platform which provides equal support along the length of the panel 10.
  • edge spines 25a, b and/or edge spine core separator 27 may be held in place by mechanical fixings such as screws or nails in addition to, or as an alternative to, adhesive.
  • the edge spines 25a, b and edge spine core separator 27 may be made of any suitable material including, but not limited to, engineered wood, laminated veneer lumber or OSB.
  • the structural board layers 15a, b,c are held at a fixed distance apart in a press by rigid supports .
  • These supports may comprise the edge spines 25a, b and/or edge spine core separators 27 described above. Alternatively, the supports may be temporary such that they are removed from the panel once it is complete.
  • the polyurethane foam is pressure injected between the structural board layers 15a, b,c whilst they are supported in the press.
  • the panel 10 is then held in the press until the polyurethane foam has cured and adhered the structural board layers 15a, b,c together.
  • Other types of foam may also be used in this manufacturing process, for example polyisocyanurate (PIR) foam.
  • PIR polyisocyanurate
  • Figure 4 shows a cross-sectional view through a portion of a three-core structural panel 110.
  • the panel 110 comprises four structural board layers 115a,b,c,d and three insulating layers 120a, b,c.
  • the outermost structural board layer 115a comprises 15mm thick cement particle board and each other structural board layer 115b, c,d comprises 10mm thick OSB.
  • the outermost insulating layer 120a has a depth of 40mm and comprises pressure injected CFC free/ODP zero polyurethane foam which bonds the adjacent structural board layers 115a, 115b together.
  • the centremost insulating layer 120b has a depth of 30mm and comprises rigid sound insulating foam which is adhered to the adjacent structural board layers 115b, 115c by an adhesive.
  • the innermost insulating layer 120c has a thickness of 20mm and comprises rigid fire resistant PIR foam which is also attached to the adjacent structural board layers 115c, 115d by an adhesive.
  • Figure 5 shows a second example of a two-core structural panel 210 comprising three structural board layers 215a, b,c, two insulating layers 220a, b and a plurality of structural webs 217.
  • the structural webs 217 are joined to the structural board layers 215a, b,c to form a hollow box structure 230.
  • grooves in the structural board layers 215a, b,c receive the edges of the structural webs 217 to form simple mortise and tenon joints.
  • the structural webs 217 are held in place by an adhesive. Alternatively or additionally, the structural webs 217 may be held in place by mechanical fixings such as screws or nails .
  • the structural webs 217 define a plurality of insulation compartments 235 in the hollow box structure 230.
  • Rods 236 of insulating wood fibre, such as wood wool, are located in the insulation compartments 235 to form the insulating layers 220a, b.
  • the rods 236 are held in place by the structure of the hollow box 230.
  • the rods 236 may be held in place by an adhesive or may consist of a pressure injected foam which bonds the adjacent structural board layers and structural webs together.
  • the panel 210 may be supplied to an end user with the insulating rods 236 already installed.
  • the panel 210 may be supplied as a kit comprising a hollow box structure 230 and rods 236.
  • Figure 6 shows schematic cross-sectional view through an alternative example of a multi-core structural panel 310 comprising a two structural board layers 315a, b, a plurality of structural webs 317 and a plurality of insulating rods
  • the insulating rods 320 comprise pressure injected polyurethane foam which bonds the structural board layers 315a, b and structural webs 317 together.
  • the multi-core structural panels 210, 310 shown in Figures 5 and 6 respectively are suitable for use as floor panels due to the additional rigidity provided by the structural webs 217, 317.
  • all of the multi-core structural panels described above may be repaired if one or more of the layers is damaged.
  • Figure 7 shows an example of a joint arrangement 400 between a multi-core structural panel 410 and a second structural member 411 (which may itself be a multi-core structural panel) .
  • the multi-core structural panel 410 comprises three structural board layers 415a, b,c and two insulating layers 420a, b.
  • a receiving hole 430 has been cut through the first structural board layer 415a and the first insulating layer 420a in order to expose the second structural board layer 415b.
  • the receiving hole 430 has a shape which conforms to that of the second structural member 411 to be joined.
  • the exposed portion of the second structural board layer 415b provides an abutment surface for the second structural member 411. This arrangement therefore provides a joint of great strength.
  • the joint arrangement 400 shown in Figure 7 is only one example of the many joint arrangements possible.
  • the receiving hole 430 my extend through more than one structural board layer and more than one insulating layer .
  • Figure 8 shows an example staggered castellated joint arrangement 500 between a multi-core structural panel 510 and a second structural member 610 (which may itself be a multi-core structural panel as shown) .
  • the first panel 510 comprises three structural board layers 515a, b, c and two insulating layers 520a, b through which two receiving holes 530, 535 have been cut.
  • the first receiving hole 530 is shaped so that it is deepest on the edge of the panel and the second receiving hoe 535 is shaped so that it is shallowest on the edge of the panel.
  • the deep sections of the receiving holes extend through the first and second structural board layers 151a, 515b and both insulating layers 520a, 520b to expose a portion of the third structural board layer 515c. Conversely, the shallow sections of the receiving holes only extend through the first structural board layer 515a and first insulating layer 520a to expose a portion of the second structural board layer 515b.
  • the second structural member 610 comprises tongues 630, 635 which are shaped so to fit within the receiving holes 530, 535.
  • the joint arrangement 500 shown in Figure 8 is illustrative of one type of staggered castellated joint that can be formed between a multi-core panel and another structural member. It will be understood that it is not necessary for the joint to be located at the edge of both panels and that the receiving holes 530, 535 could be located within the borders of the panel. It will also be understood that the shape/depth of the receiving holes/tongues can be varied according to the particular configuration of structural members being joined together.
  • the joint arrangements shown in Figures 7 and 8 may be used with any of the structural panel configurations described above. Each of the structural panels described above are examples only of the plurality of multi-core structural panel arrangements possible.
  • the materials of the structural board layers, structural webs and insulating layers/rods are not limited to the materials described, and that the dimensions of these components may be varied as desired.
  • other types of structural members, such as beams, may be realised in a multi-core configuration.
  • Each of the panels described above may comprise edge members such as edge spines 25a, b and/or edge spine core separators 27. These may be located along every edge of the panel or, alternatively, the panels may be without edge members on one or more of their edges .

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Abstract

A multi-core structural insulated panel (210) comprising at least two structural board layers (215) and a plurality of structural webs (217) is disclosed. The structural board layers and webs define a plurality of insulation compartments (235) which are arranged to receive at least one insulating rod (236). A kit of parts for a multi-core structural insulated panel is also disclosed. Another multi-core structural insulated panel (10) is also disclosed comprising at least three structural board layers (15) spaced from each other by an insulating layer (20). Wherein at least one of the insulating layers comprises a pressure injected foam which bonds the neighbouring structural board layers together.

Description

Multi-Core Structural Insulated Panels
The present invention relates to structural insulated panels for use in construction.
Structural insulated panels (SIPs) having two facing layers of orientated strand board (OSB) which are adhered together by an insulating core of pressure injected polyurethane foam are well known in the construction industry. These panels have a number of benefits including relatively low production costs and good strength and insulation properties. However, these advantages can be diminished when openings for doors and windows are included as any such openings must be reinforced by a timber frame and/or lintel in order to maintain the overall strength and integrity of the panel. This can add considerably to build times or, if the openings are pre-cut into the panels during manufacture, to the cost of the panels.
Structural panels having multiple layers of OSB separated by layers of rigid foam insulation are also known. Such panels are constructed by gluing the various layers together in a sandwich-like configuration. However, these panels are susceptible to de-lamination under load and therefore have limited application.
In a first aspect, the present invention provides a multi- core structural member comprising at least three structural board layers, each structural board layer being spaced from at least one other structural board layer by an insulating layer, wherein at least one of the insulating layers comprises a pressure injected foam which bonds the neighbouring structural board layers together.
The multi-core construction of the present invention is advantageous as it enables openings for doors and windows to be cut into the structural members without the need for additional reinforcing timber frames or lintels.
Furthermore, the pressure injected foam layer ensures the structural integrity of the member even if openings for doors and windows are made.
In a preferred example, at least one of the insulating layers comprises a sound absorbent foam to provide sound insulation. Alternatively or additionally, at least one of the insulating layers comprises a fire resistant foam such as a polyisocyanurate foam.
In another preferred example, at least one of the insulating layers comprises an environmentally friendly alternative to synthetic insulation materials such as wood fibre or any other natural insulation product such as hemp.
In an alternative example, each insulating layer comprises a pressure injected foam which bonds the neighbouring structural board layers together. This arrangement provides a robust structural member which is resistant to de- lamination. Preferably the pressure injected foam is a polyurethane foam or a polyisocyanurate foam.
The structural board layers preferably comprise orientated strand board. A coating such as marine epoxy may be applied to the orientated strand board in order to make it more weather resistant. Alternatively or additionally, at least one of the structural board layers comprises cement particle board.
In a second aspect, the present invention provides a multi- core structural member comprising: at least two structural board layers, and a plurality of structural webs which define together with the structural board layers a plurality of insulation compartments, wherein each insulation compartment is arranged to receive at least one insulating rod.
The structural webs provide inherent structural integrity to the structural member and therefore also enable openings for doors and windows to be cut into the structural member without the need for reinforcing timber frames or lintels. Furthermore, because of the inherent structural integrity of the member, issues of de-lamination do not arise.
Preferably at least one of the insulating rods comprises a sound absorbent foam, a fire resistant foam, which may be a polyisocyanurate foam, wood fibre or any other natural insulation product such as hemp. Alternatively, or additionally, at least one insulating rod comprises a pressure injected foam which bonds the neighbouring structural board layers and structural webs together.
In an alternative example, each insulating rod comprises a pressure injected foam which bonds the neighbouring structural board layers and structural webs together.
Preferably the pressure injected foam is a polyurethane foam or a polyisocyanurate foam. The structural board layers preferably comprise orientated strand board. A coating such as marine epoxy may be applied to the orientated strand board in order to make it more weather resistant. Alternatively or additionally, at least one of the structural board layers may comprise cement particle board.
In a third aspect the present invention provides a kit for a multi-core structural member comprising: a hollow box structure comprising at least two structural board members and a plurality of structural web members which define together with the structural board layers a plurality of insulation compartments, and a plurality of insulating rods which are arranged to be received in the insulation compartments .
Examples of the present invention will now be described with reference to the following drawings in which:
Figure 1 is a schematic cross-sectional view through a portion of a two-core structural panel;
Figure 2 is a schematic cross- sectional view through one edge of the panel of Figure 1;
Figure 3 is a schematic cross-sectional view through an alternative edge arrangement to that shown in Figure 2 ;
Figure 4 is a schematic cross-sectional view through a portion of a three-core structural panel; Figure 5 is a schematic cross-sectional view through a portion of an alternative two-core structural panel;
Figure 6 is a schematic cross-sectional view through a portion of an alternative multi-core structural panel arrangement ;
Figure 7 is an exploded schematic isometric view of a first joint arrangement; and
Figure 8 is an exploded schematic isometric view of a staggered castellated joint arrangement.
Figure 1 shows a portion of a two-core structural panel 10 comprising three structural board layers 15a, b,c of orientated strand board (OSB) and two insulating layers 20a, b of CFC free/ODP zero polyurethane foam. The structural board layers 15a, b,c comprise OSB having a thickness of 15mm and the insulating layers 20a, b have a depth of 40mm. The three structural board layers 15a, b,c are bonded together by the polyurethane foam which is pressure injected between the structural board layers during fabrication as described below.
Figure 2 shows a schematic cross-sectional view through an example edge arrangement for the panel 10. In this example the panel 10 comprises edge spines 25a, b of engineered wood positioned between the structural board layers 15a, b,c. The edge spines 25a, b are adhered to the adjacent structural board layers 15a, b,c by an adhesive. Figure 3 shows an alternative edge arrangement to that shown in Figure 2. In this example the panel 10 comprises an edge spine core separator 27 formed from a 40mm deep section of laminated veneer lumber such as VERSALAM (RTM) . As in the example of Figure 2, the edge spine core separator 27 is attached to the structural board layers 15a, b,c by an adhesive. This second edge arrangement is the preferred arrangement as the edge spine core separator 27 serves as a spreading platform which provides equal support along the length of the panel 10.
The edge spines 25a, b and/or edge spine core separator 27 may be held in place by mechanical fixings such as screws or nails in addition to, or as an alternative to, adhesive. The edge spines 25a, b and edge spine core separator 27 may be made of any suitable material including, but not limited to, engineered wood, laminated veneer lumber or OSB.
During fabrication of the panel 10, the structural board layers 15a, b,c are held at a fixed distance apart in a press by rigid supports . These supports may comprise the edge spines 25a, b and/or edge spine core separators 27 described above. Alternatively, the supports may be temporary such that they are removed from the panel once it is complete. The polyurethane foam is pressure injected between the structural board layers 15a, b,c whilst they are supported in the press. The panel 10 is then held in the press until the polyurethane foam has cured and adhered the structural board layers 15a, b,c together. Other types of foam may also be used in this manufacturing process, for example polyisocyanurate (PIR) foam. Figure 4 shows a cross-sectional view through a portion of a three-core structural panel 110. The panel 110 comprises four structural board layers 115a,b,c,d and three insulating layers 120a, b,c. In this example the outermost structural board layer 115a comprises 15mm thick cement particle board and each other structural board layer 115b, c,d comprises 10mm thick OSB.
The outermost insulating layer 120a has a depth of 40mm and comprises pressure injected CFC free/ODP zero polyurethane foam which bonds the adjacent structural board layers 115a, 115b together. The centremost insulating layer 120b has a depth of 30mm and comprises rigid sound insulating foam which is adhered to the adjacent structural board layers 115b, 115c by an adhesive. Finally, the innermost insulating layer 120c has a thickness of 20mm and comprises rigid fire resistant PIR foam which is also attached to the adjacent structural board layers 115c, 115d by an adhesive.
Figure 5 shows a second example of a two-core structural panel 210 comprising three structural board layers 215a, b,c, two insulating layers 220a, b and a plurality of structural webs 217. The structural webs 217 are joined to the structural board layers 215a, b,c to form a hollow box structure 230. In this example grooves in the structural board layers 215a, b,c receive the edges of the structural webs 217 to form simple mortise and tenon joints. The structural webs 217 are held in place by an adhesive. Alternatively or additionally, the structural webs 217 may be held in place by mechanical fixings such as screws or nails . The structural webs 217 define a plurality of insulation compartments 235 in the hollow box structure 230. Rods 236 of insulating wood fibre, such as wood wool, are located in the insulation compartments 235 to form the insulating layers 220a, b. In this example the rods 236 are held in place by the structure of the hollow box 230. However, in an alternative example, the rods 236 may be held in place by an adhesive or may consist of a pressure injected foam which bonds the adjacent structural board layers and structural webs together.
The panel 210 may be supplied to an end user with the insulating rods 236 already installed. Alternatively, the panel 210 may be supplied as a kit comprising a hollow box structure 230 and rods 236.
Figure 6 shows schematic cross-sectional view through an alternative example of a multi-core structural panel 310 comprising a two structural board layers 315a, b, a plurality of structural webs 317 and a plurality of insulating rods
320. In this example, the insulating rods 320 comprise pressure injected polyurethane foam which bonds the structural board layers 315a, b and structural webs 317 together.
The multi-core structural panels 210, 310 shown in Figures 5 and 6 respectively are suitable for use as floor panels due to the additional rigidity provided by the structural webs 217, 317. In addition, because of the multi core construction which employs multiple structural members, all of the multi-core structural panels described above may be repaired if one or more of the layers is damaged. - S -
Figure 7 shows an example of a joint arrangement 400 between a multi-core structural panel 410 and a second structural member 411 (which may itself be a multi-core structural panel) .
The multi-core structural panel 410 comprises three structural board layers 415a, b,c and two insulating layers 420a, b. A receiving hole 430 has been cut through the first structural board layer 415a and the first insulating layer 420a in order to expose the second structural board layer 415b. The receiving hole 430 has a shape which conforms to that of the second structural member 411 to be joined.
The exposed portion of the second structural board layer 415b provides an abutment surface for the second structural member 411. This arrangement therefore provides a joint of great strength.
The joint arrangement 400 shown in Figure 7 is only one example of the many joint arrangements possible. In particular, for a multi-core panel having more than two cores, the receiving hole 430 my extend through more than one structural board layer and more than one insulating layer .
Figure 8 shows an example staggered castellated joint arrangement 500 between a multi-core structural panel 510 and a second structural member 610 (which may itself be a multi-core structural panel as shown) .
The first panel 510 comprises three structural board layers 515a, b, c and two insulating layers 520a, b through which two receiving holes 530, 535 have been cut. The first receiving hole 530 is shaped so that it is deepest on the edge of the panel and the second receiving hoe 535 is shaped so that it is shallowest on the edge of the panel.
The deep sections of the receiving holes extend through the first and second structural board layers 151a, 515b and both insulating layers 520a, 520b to expose a portion of the third structural board layer 515c. Conversely, the shallow sections of the receiving holes only extend through the first structural board layer 515a and first insulating layer 520a to expose a portion of the second structural board layer 515b.
The second structural member 610 comprises tongues 630, 635 which are shaped so to fit within the receiving holes 530, 535.
The joint arrangement 500 shown in Figure 8 is illustrative of one type of staggered castellated joint that can be formed between a multi-core panel and another structural member. It will be understood that it is not necessary for the joint to be located at the edge of both panels and that the receiving holes 530, 535 could be located within the borders of the panel. It will also be understood that the shape/depth of the receiving holes/tongues can be varied according to the particular configuration of structural members being joined together. The joint arrangements shown in Figures 7 and 8 may be used with any of the structural panel configurations described above. Each of the structural panels described above are examples only of the plurality of multi-core structural panel arrangements possible. In particular it will be understood that the materials of the structural board layers, structural webs and insulating layers/rods are not limited to the materials described, and that the dimensions of these components may be varied as desired. Furthermore, other types of structural members, such as beams, may be realised in a multi-core configuration.
Each of the panels described above may comprise edge members such as edge spines 25a, b and/or edge spine core separators 27. These may be located along every edge of the panel or, alternatively, the panels may be without edge members on one or more of their edges .

Claims

Claims :
1. A multi-core structural member comprising: at least two structural board layers, and a plurality of structural webs which define together with the structural board layers a plurality of insulation compartments , wherein each insulation compartment is arranged to receive at least one insulating rod.
2. A multi-core structural member as claimed in claim 1 wherein at least one of the insulating rods comprises a sound absorbent foam.
3. A multi-core structural member as claimed in claim 1 or 2 wherein at least one of the insulating rods comprises a fire resistant foam.
4. A multi-core structural member as claimed in claim 3 wherein the fire resistant foam is a polyisocyanurate foam.
5. A multi-core structural member as claimed in any one of claims 1 to 4 wherein at least one of the insulating rods comprises wood fibre.
6. A multi-core structural member as claimed in any one of claims 1 to 5 wherein at least one of the insulating rods comprises a pressure injected foam which bonds the neighbouring structural board layers and structural webs together.
7. A multi-core structural member as claimed in claim 1 wherein each insulating rod comprises a pressure injected foam which bonds the neighbouring structural board layers and structural webs together.
8. A multi-core structural member as claimed in claim 6 or 7 wherein the pressure injected foam is a polyurethane foam.
9. A multi-core structural member as claimed in claim 6 or 7 wherein the pressure injected foam is a polyisocyanurate foam.
10. A multi-core structural member as claimed in any one of claims 1 to 9 wherein at least one of the structural board layers comprises orientated strand board.
11. A multi-core structural member as claimed in any one of claims 1 to 10 wherein at least one of the structural board layers comprises cement particle board.
12. A kit for a multi-core structural member comprising: a hollow box structure comprising at least two structural board members and a plurality of structural web members which define together with the structural board layers a plurality of insulation compartments, and a plurality of insulating rods which are arranged to be received in the insulation compartments.
13. A multi-core structural member comprising at least three structural board layers, each structural board layer being spaced from at least one other structural board layer by an insulating layer, wherein at least one of the insulating layers comprises a pressure injected foam which bonds the neighbouring structural board layers together.
14. A multi-core structural member as claimed in claim 13 wherein at least one of the insulating layers comprises a sound absorbent foam.
15. A multi-core structural member as claimed in claim 13 or 14 wherein at least one of the insulating layers comprises a fire resistant foam.
16. A multi-core structural member as claimed in claim 15 wherein the fire resistant foam is a polyisocyanurate foam.
17. A multi-core structural member as claimed in any one of claims 13 to 16 wherein at least one of the insulating layers comprises wood fibre.
18. A multi-core structural member as claimed in claim 13 wherein each insulating layer comprises a pressure injected foam which bonds the neighbouring structural board layers together.
19. A multi-core structural member as claimed in claim 18 wherein the pressure injected foam is a polyurethane foam.
20. A multi-core structural member as claimed in claim 18 wherein the pressure injected foam is a polyisocyanurate foam.
21. A multi-core structural member as claimed in any of claims 10 to 20 wherein at least one of the structural board layers comprises orientated strand board.
22. A multi-core structural member as claimed in any one of claims 13 to 21 wherein at least one of the structural board layers comprises cement particle board.
934187; GLL; GLL
PCT/GB2008/002123 2007-06-20 2008-06-20 Multi-core structural insulated panels WO2008155559A1 (en)

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GB0711954.8 2007-06-20

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GB0711954D0 (en) 2007-08-01

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