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WO2017167634A1 - A panel for mounting in a building structure and a method of manufacturing such panel - Google Patents

A panel for mounting in a building structure and a method of manufacturing such panel Download PDF

Info

Publication number
WO2017167634A1
WO2017167634A1 PCT/EP2017/056918 EP2017056918W WO2017167634A1 WO 2017167634 A1 WO2017167634 A1 WO 2017167634A1 EP 2017056918 W EP2017056918 W EP 2017056918W WO 2017167634 A1 WO2017167634 A1 WO 2017167634A1
Authority
WO
WIPO (PCT)
Prior art keywords
panel
edge regions
core material
panels
mineral wool
Prior art date
Application number
PCT/EP2017/056918
Other languages
French (fr)
Inventor
Michael EMBORG
Lars Levin-Jensen
Original Assignee
Rockwool International A/S
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 Rockwool International A/S filed Critical Rockwool International A/S
Publication of WO2017167634A1 publication Critical patent/WO2017167634A1/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
    • E04C2/02—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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/04—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material
    • B32B19/041—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material of metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/04—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material
    • B32B19/042—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material of wood
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/06—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/18—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by an internal layer formed of separate pieces of material which are juxtaposed side-by-side
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/78—Heat insulating elements
    • E04B1/80—Heat insulating elements slab-shaped
    • 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
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/16—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of fibres, chips, vegetable stems, or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/44—Number of layers variable across the laminate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Definitions

  • the present invention relates to a panel for mounting in a building structure and a method of manufacturing such panel.
  • WO 2013/064150 Temporary building structures or building structures that are simple and fast to erect by using suitable panels are well known from e.g. WO 2013/064150.
  • a shelter construction is disclosed which comprises premade shells, i.e. preformed panels of e.g. polyurethane or polystyrene concrete for providing insulation. This is advantageous over the shelter constructions disclosed in GB 1 ,178,261 where the shells are made of glass fibre.
  • US 8,615,934 another example of a panelised portable shelter is known.
  • Such shelters are building structures of a portable kind are used in addition or instead of tents to provide immediate shelter for refugees, victims of a natural disaster or the like where people are made home-less and are therefore in need for accommodation.
  • a requirement for such shelters is therefore that it is easy to transport to a sometimes remote geographical area in which it is needed and that it is easy to erect.
  • Tents have been widely used as a tent fulfils these criteria, but a drawback for tents is that there is no thermal insulation. A further drawback is the relatively short life time of tents.
  • the building structure could also be a low cost or semi-permanent building, i.e. in regions with poverty or in situations where the building is needed for a limited number of years, e.g. for housing children or as a hunting lodge.
  • a building structure such as a shelter of the above-identified kind
  • a building panel with good insulation properties besides the above-mentioned properties.
  • the panels should also allow for construction that facilitates a quick, simple and easy construction of such a shelter. It is therefore an object of the present invention to provide a panel.
  • a panel for mounting in a building structure said panel being a generally rectangular sandwich panel having a set of side edge regions and a set of end edge regions, the panel comprising a core material layer of low density mineral wool, exterior layers of high density on each side of the core material layer, wherein the core material extends beyond the exterior layers at at least one of the edge regions, preferably the side edge regions, thereby providing a compressible seal between adjacent panels when mounted in the building structure.
  • This seal will generally provide adequate weatherproofing so separate sealing means or tarpaulin may be dispensed with.
  • the core material may extend beyond the exterior layers at both side edge regions, however it is preferred the core material extends beyond the exterior layers at one side edge only.
  • the advantage is primarily that manufacture is easier with one side edge being flush for both core material and exterior layers.
  • a panel of such kind is found advantageous since the building structure constructed by such panels is simple to erect and the amount of fittings for the building structure to be mounted can be reduced.
  • the mineral wool fibre material since mineral wool fibre material can be made water repellent using limited amounts of added oil. So by utilising this property and by "oversizing" the core material at the edges, a compressible seal, which is water tight, is thereby achieved. The extension of approx. 5 mm is found adequate in order to achieve such seal.
  • the mineral wool fibre boards are known to have good thermal and acoustic insulation characteristics as well as being fireproof and thereby provide the building structure with fire-preventing properties.
  • the exterior layers may be made of any material providing strength and robustness to the panel. Suitable materials may include metal or fiber cement boards, and in some cases even wood fibre boards could be a relevant solution do to availability or price even though it is preferred that the materials are inorganic.
  • at least one of the exterior layers is made of high density mineral wool. Mineral wool has favourable properties in relation to thermal insulation properties, and the risk delamination of the panel is minimized by using same materials for the core and the exterior layers as any difference in thermal expansion is limited.
  • the low density mineral wool fibre has a density between 30-100 kg/m 3 .
  • the high density exterior layers are preferably provided with a density between 400-500 kg/m 3 .
  • the panel will be provided with a hard outer shell, which is water repellent and resistant to absorbing moisture, and provides a good strength of the resultant sandwich panel.
  • the softer core material in the low-density range of 30-100 kg/m 3 ensures a light product with good insulation characteristics and which is easily compressible for the provision of sealing between two panels.
  • the core may be provided as a unitary mineral wool element, which may be provided as a web in roll form, allowing easy shipment and manufacture of the panels.
  • mineral wool webs have an uneven surface structure, e.g. as a result of curing in a curing oven between belts having an open structure leaving a pattern on the cured mineral wool web surface.
  • Such an uneven surface structure can provide difficulties in manufacture of sandwich panels, and in this case the surface is often machined to achieve an even surface.
  • the core is made of a plurality of mineral wool fibre lamella.
  • said lamella are provided with different densities.
  • the fibre orientation of the core material is preferably perpendicular to the external surfaces of the panel so that the compression resistance in the orthogonal direction is high and the compressibility of the edge regions i.e. in a direction generally parallel to the exterior panel surfaces is ensured.
  • the lamellae making up the end edge sections are provided with in a density within the range of 60-500 kg/m 3 .
  • the panels may be provided with an edge geometry adapted for assembly with other building components, such as a sub-frame, a floor or the like.
  • Connection of neighbouring panels can be achieved in a number of ways, such as by through-going tension rods or wires through the panels. Such tension rods could simply be forced through the mineral wool core layer, but it may be difficult in practice.
  • one or more mounting tubes are provided substantially perpendicular to the side edge regions of the panels for guiding such tension rods or wires, preferably between two neighbouring lamellae in the core material layer.
  • a method of mounting a plurality of panels according to the above described aspect of the invention in a building structure whereby a first panel is provided adjacent a second panel such that the two panels have abutting side edge regions, and then the first and second panels are then mounted to each other thereby compressing the abutting side edge regions for providing a seal being the two panels.
  • the panel according to the invention may be flat or the panel may be provided with a predefined curvature.
  • any one of the preceding claims comprising the steps of providing a first exterior board of high-density mineral wool fibre on a panel support member having a predefined shape, providing a core material layer of low-density mineral wool fibre, said core layer consisting of plurality of mineral wool fibre lamellae, and then providing a second exterior board of high-density mineral wool fibre on said core material layer, whereby the core material layer is provided such that extends beyond the exterior layers at at least one of the sets of edge regions, preferably the side edge regions, thereby providing a compressible seal between adjacent panels when mounted in the building structure.
  • the predefined shape of the panel support member may be planar such that the resulting panel is flat or the predefined shape of the panel support member may be provided with a curvature such that the resulting panel is provided with a predefined curvature.
  • Fig. 1 is a schematic cross-sectional view of a sandwich panel according to the
  • FIG. 2 is a schematic drawing of two panels of fig. 1 assembled together;
  • Fig. 3 is a detailed view of the side edge region of a panel according to a preferred embodiment of the invention.
  • Fig. 4 is a side view of a panel according to a preferred embodiment of the
  • Fig. 5 is a side view of a panel in the panel support member during manufacture.
  • a panel according to the invention comprises a top and bottom exterior skin layers 1 , 3 sandwiching a core material 2.
  • the panels are made as a sandwich of skin layers 1 , 3 of high-density mineral wool, such as 400-500 kg/m 3 , and a core 2 of low-density mineral wool, such as 30-100 kg/m 3 .
  • the core material 2 extends a little (approx. 5 mm) beyond the skin layers 1 , 3 at the side edge and this extension 21 act as a compressible seal between adjacent panels, since the mineral wool is water-repellent by minor amounts of added oil as is common.
  • two adjacent panels are shown mounted together and the adjacent top layers 1 , 1 ' and two bottom exterior layers 3, 3' abutting each other and then the extensions 21 , 21 ' are compressed.
  • the side edge region of a panel is shown.
  • the skin layers 1 , 3 are provided as high-density mineral wool fibre boards glued onto each side of a low-density mineral wool core material 2 including the extension 21 protruding beyond the side edges of the skin layers 1 , 3.
  • the fibre orientation of the core material 2 is oriented generally perpendicular to the top and bottom surfaces of the panel.
  • the dimensions of the panels are: 600 mm wide, 45 mm thick (the two exterior skin layers of 5 mm, and core 35 mm). At present it is considered that the skin layers should be minimum 3 mm and max. 15 mm, and for the core material 20 mm is considered a minimum value.
  • the core material is preferably made of mineral wool lamellae 2a-2f, which are turned 90° and glued together to form the core material 2.
  • the fibre direction is more or less at right angles to the skin layers 1 , 3. This is beneficial for gluing the skin layers 1 , 3 to the core material and for compression strength of the panels.
  • a high density element 22 may be provided with a cut-out for engagement with a rail of the building structure foundation.
  • a high density element may be provided with a cut-out for receiving assembly means such as a mounting tube for alignment of the panels.
  • each panel is provided with a plurality of mounting tubes 4 between elements 2a-2f of the core 2 providing a channel for insertion of threaded rods (not shown) or the like of the mounting system for the building structure.
  • the panel according to the invention is produced in a form 5 having a support surface 6.
  • the first exterior skin layer 3 is placed on the support surface 6 in the form 5.
  • the lamellae 2a-2f are then glued onto the inner surface of the exterior skin layer 3.
  • Suitable mounting tubes 4 are provided as well and the ends 22 are also placed and adhesively bonded to the exterior skin layer 3.
  • the ends 22 may be covered on both sides by the exterior skin layer 3.
  • the second exterior skin layer 1 is provided and glued onto the lamellae 2a-2f to finish the manufacture of the panel.
  • a second moulding part (not shown) may be provided to hold the mineral wool fibre elements 1 , 2, 3 in place while the adhesive is being cured.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Civil Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Panels For Use In Building Construction (AREA)
  • Building Environments (AREA)

Abstract

The present invention concerns a panel for mounting in a building structure, said panel being a generally rectangular sandwich panel having a set of side edge regions and a set of end edge regions, the panel comprising a core material layer of low density mineral wool, exterior layers of high density mineral wool on each side of the core material layer, wherein the core material extends beyond the exterior layers at at least one of the sets of edge regions, preferably the side edge regions, thereby providing a compressible seal between adjacent panels when mounted in the building structure.

Description

A panel for mounting in a building structure and a method of manufacturing such panel
The present invention relates to a panel for mounting in a building structure and a method of manufacturing such panel.
Temporary building structures or building structures that are simple and fast to erect by using suitable panels are well known from e.g. WO 2013/064150. In WO 2013/064150 a shelter construction is disclosed which comprises premade shells, i.e. preformed panels of e.g. polyurethane or polystyrene concrete for providing insulation. This is advantageous over the shelter constructions disclosed in GB 1 ,178,261 where the shells are made of glass fibre. In US 8,615,934 another example of a panelised portable shelter is known.
Such shelters are building structures of a portable kind are used in addition or instead of tents to provide immediate shelter for refugees, victims of a natural disaster or the like where people are made home-less and are therefore in need for accommodation. A requirement for such shelters is therefore that it is easy to transport to a sometimes remote geographical area in which it is needed and that it is easy to erect. Tents have been widely used as a tent fulfils these criteria, but a drawback for tents is that there is no thermal insulation. A further drawback is the relatively short life time of tents.
The building structure could also be a low cost or semi-permanent building, i.e. in regions with poverty or in situations where the building is needed for a limited number of years, e.g. for housing children or as a hunting lodge.
For a building structure, such as a shelter of the above-identified kind, it is desirable to obtain a building panel with good insulation properties besides the above-mentioned properties. The panels should also allow for construction that facilitates a quick, simple and easy construction of such a shelter. It is therefore an object of the present invention to provide a panel.
Accordingly, this object is achieved by a panel for mounting in a building structure, said panel being a generally rectangular sandwich panel having a set of side edge regions and a set of end edge regions, the panel comprising a core material layer of low density mineral wool, exterior layers of high density on each side of the core material layer, wherein the core material extends beyond the exterior layers at at least one of the edge regions, preferably the side edge regions, thereby providing a compressible seal between adjacent panels when mounted in the building structure. This seal will generally provide adequate weatherproofing so separate sealing means or tarpaulin may be dispensed with.
The core material may extend beyond the exterior layers at both side edge regions, however it is preferred the core material extends beyond the exterior layers at one side edge only. The advantage is primarily that manufacture is easier with one side edge being flush for both core material and exterior layers.
A panel of such kind is found advantageous since the building structure constructed by such panels is simple to erect and the amount of fittings for the building structure to be mounted can be reduced. Particularly, it is found advantageous to use the mineral wool fibre material, since mineral wool fibre material can be made water repellent using limited amounts of added oil. So by utilising this property and by "oversizing" the core material at the edges, a compressible seal, which is water tight, is thereby achieved. The extension of approx. 5 mm is found adequate in order to achieve such seal.
Moreover, the mineral wool fibre boards are known to have good thermal and acoustic insulation characteristics as well as being fireproof and thereby provide the building structure with fire-preventing properties. The exterior layers may be made of any material providing strength and robustness to the panel. Suitable materials may include metal or fiber cement boards, and in some cases even wood fibre boards could be a relevant solution do to availability or price even though it is preferred that the materials are inorganic. However according to an embodiment at least one of the exterior layers is made of high density mineral wool. Mineral wool has favourable properties in relation to thermal insulation properties, and the risk delamination of the panel is minimized by using same materials for the core and the exterior layers as any difference in thermal expansion is limited.
In the preferred embodiments of the invention, the low density mineral wool fibre has a density between 30-100 kg/m3. Further, the high density exterior layers are preferably provided with a density between 400-500 kg/m3. By providing the exterior layers of the panel in such high density the panel will be provided with a hard outer shell, which is water repellent and resistant to absorbing moisture, and provides a good strength of the resultant sandwich panel. Likewise, the softer core material in the low-density range of 30-100 kg/m3 ensures a light product with good insulation characteristics and which is easily compressible for the provision of sealing between two panels.
The core may be provided as a unitary mineral wool element, which may be provided as a web in roll form, allowing easy shipment and manufacture of the panels. Often mineral wool webs have an uneven surface structure, e.g. as a result of curing in a curing oven between belts having an open structure leaving a pattern on the cured mineral wool web surface. Such an uneven surface structure can provide difficulties in manufacture of sandwich panels, and in this case the surface is often machined to achieve an even surface.
In a preferred embodiment of the invention, the core is made of a plurality of mineral wool fibre lamella. Hereby, flexibility in the size and dimensional shape of the panels is achieved, just as a structural stiffness in the panel may be achieved. In an embodiment of the invention, said lamella are provided with different densities. Moreover, the fibre orientation of the core material is preferably perpendicular to the external surfaces of the panel so that the compression resistance in the orthogonal direction is high and the compressibility of the edge regions i.e. in a direction generally parallel to the exterior panel surfaces is ensured. Preferably, the lamellae making up the end edge sections are provided with in a density within the range of 60-500 kg/m3. This ensures a form stability for the panel edge geometry so that the panels may be provided with an edge geometry adapted for assembly with other building components, such as a sub-frame, a floor or the like. Connection of neighbouring panels can be achieved in a number of ways, such as by through-going tension rods or wires through the panels. Such tension rods could simply be forced through the mineral wool core layer, but it may be difficult in practice. In the preferred embodiment, one or more mounting tubes are provided substantially perpendicular to the side edge regions of the panels for guiding such tension rods or wires, preferably between two neighbouring lamellae in the core material layer. Hereby, the panels according to the invention are well adapted for being mounted together using the assembly method described in WO 2013/064150.
To dispense of the requirement of a separate sealing arrangement between the panels, according to another aspect of the invention there is provided a method of mounting a plurality of panels according to the above described aspect of the invention in a building structure, whereby a first panel is provided adjacent a second panel such that the two panels have abutting side edge regions, and then the first and second panels are then mounted to each other thereby compressing the abutting side edge regions for providing a seal being the two panels.
By the invention it is realised that the panel according to the invention may be flat or the panel may be provided with a predefined curvature. In a further aspect of the present invention, there is provided a method of
manufacturing a panel according to any one of the preceding claims, said method comprising the steps of providing a first exterior board of high-density mineral wool fibre on a panel support member having a predefined shape, providing a core material layer of low-density mineral wool fibre, said core layer consisting of plurality of mineral wool fibre lamellae, and then providing a second exterior board of high-density mineral wool fibre on said core material layer, whereby the core material layer is provided such that extends beyond the exterior layers at at least one of the sets of edge regions, preferably the side edge regions, thereby providing a compressible seal between adjacent panels when mounted in the building structure.
In accordance with this method, the predefined shape of the panel support member may be planar such that the resulting panel is flat or the predefined shape of the panel support member may be provided with a curvature such that the resulting panel is provided with a predefined curvature.
The invention is described in further details with reference to the accompanying drawings, in which
Fig. 1 is a schematic cross-sectional view of a sandwich panel according to the
invention; Fig. 2 is a schematic drawing of two panels of fig. 1 assembled together;
Fig. 3 is a detailed view of the side edge region of a panel according to a preferred embodiment of the invention;
Fig. 4 is a side view of a panel according to a preferred embodiment of the
invention; and
Fig. 5 is a side view of a panel in the panel support member during manufacture.
With reference to fig. 1 , a panel according to the invention comprises a top and bottom exterior skin layers 1 , 3 sandwiching a core material 2.
The panels are made as a sandwich of skin layers 1 , 3 of high-density mineral wool, such as 400-500 kg/m3, and a core 2 of low-density mineral wool, such as 30-100 kg/m3. The core material 2 extends a little (approx. 5 mm) beyond the skin layers 1 , 3 at the side edge and this extension 21 act as a compressible seal between adjacent panels, since the mineral wool is water-repellent by minor amounts of added oil as is common. In fig. 2 two adjacent panels are shown mounted together and the adjacent top layers 1 , 1 ' and two bottom exterior layers 3, 3' abutting each other and then the extensions 21 , 21 ' are compressed. In fig. 3, the side edge region of a panel is shown. The skin layers 1 , 3 are provided as high-density mineral wool fibre boards glued onto each side of a low-density mineral wool core material 2 including the extension 21 protruding beyond the side edges of the skin layers 1 , 3. The fibre orientation of the core material 2 is oriented generally perpendicular to the top and bottom surfaces of the panel.
In a specific embodiment of a panel for a specific shelter design, the dimensions of the panels are: 600 mm wide, 45 mm thick (the two exterior skin layers of 5 mm, and core 35 mm). At present it is considered that the skin layers should be minimum 3 mm and max. 15 mm, and for the core material 20 mm is considered a minimum value. As shown in fig. 4, the core material is preferably made of mineral wool lamellae 2a-2f, which are turned 90° and glued together to form the core material 2. Hereby, the fibre direction is more or less at right angles to the skin layers 1 , 3. This is beneficial for gluing the skin layers 1 , 3 to the core material and for compression strength of the panels. At the foot of the panels a high density element 22 may be provided with a cut-out for engagement with a rail of the building structure foundation. Similarly at the apex of the building structure a high density element may be provided with a cut-out for receiving assembly means such as a mounting tube for alignment of the panels. Further each panel is provided with a plurality of mounting tubes 4 between elements 2a-2f of the core 2 providing a channel for insertion of threaded rods (not shown) or the like of the mounting system for the building structure. When all panels in the building structure are positioned the panels are compressed the soft core material 2 extending between adjacent panels will be compressed and form a weatherproof seal between adjacent panels, such as schematically shown in fig. 2.
As shown in fig. 5, the panel according to the invention is produced in a form 5 having a support surface 6. The first exterior skin layer 3 is placed on the support surface 6 in the form 5. The lamellae 2a-2f are then glued onto the inner surface of the exterior skin layer 3. Suitable mounting tubes 4 are provided as well and the ends 22 are also placed and adhesively bonded to the exterior skin layer 3. As an alternative the embodiment shown in fig. 4 and 5 the ends 22 may be covered on both sides by the exterior skin layer 3. Hereby the need for machining of the ends 22 is limited and anchoring of the ends 22 to the exterior layers optimized. Finally, the second exterior skin layer 1 is provided and glued onto the lamellae 2a-2f to finish the manufacture of the panel. A second moulding part (not shown) may be provided to hold the mineral wool fibre elements 1 , 2, 3 in place while the adhesive is being cured.
Above an embodiment of the invention is described. However, it is by the invention realised that other variants and embodiments may be provided without departing from the scope of the invention as defined in the accompanying claims.

Claims

Claims
1 . A panel for mounting in a building structure, said panel being a generally rectangular sandwich panel having a set of side edge regions and a set of end edge regions, the panel comprising
a core material layer of low density mineral wool,
exterior layers on each side of the core material layer,
wherein the core material extends beyond the exterior layers at at least one of the edge regions, preferably the side edge regions, thereby providing a compressible seal between adjacent panels when mounted in the building structure.
2. A panel according to claim 1 , wherein the low density mineral wool has a density between 30-100 kg/m3.
3. A panel according to claim 1 or 2, wherein at least one of the exterior layers is made of high density mineral wool.
4. A panel according to any one of the preceding claims, wherein the high density exterior layers are provided with a density between 400-500 kg/m3.
5. A panel according to any one of the preceding claims, wherein the core is made of a plurality of mineral wool fibre lamellae.
6. A panel according to any one of the preceding claims, wherein said lamellae are provided with different densities.
7. A panel according to any one of the preceding claims, wherein the lamellae making up the end edge sections are provided with in a density within the range of 60-500 kg/m3.
8. A panel according to any one of the preceding claims, wherein one or more mounting tubes are provided substantially perpendicular to the side edge regions.
9. A panel according to any one of the preceding claims, wherein the panel is flat.
10. A panel according to any one of the claims 1 to 8, wherein the panel is provided with a predefined curvature.
1 1 . A building structure comprising a panel according to any one of the claims above.
12. A method of manufacturing a panel according to any one of the preceding claims, said method comprising the steps of:
- providing a first exterior board on a panel support member having a predefined shape,
- providing a core material layer of low-density mineral wool fibre, said core layer consisting of plurality of mineral wool fibre lamellae, - providing a second exterior board on said core material layer, whereby the core material layer is provided such that extends beyond the exterior layers at at least one of the edge regions, preferably the side edge regions, thereby providing a compressible seal between adjacent panels when mounted in the building structure.
13. A method according to claim 12, whereby one or more mounting tubes are provided substantially perpendicular to the side edge regions, preferably between the lamellae.
14. A method according to claim 12 or 13, whereby the predefined shape of the panel support member is planar such that the resulting panel is flat.
15. A method according to claim 12 or 13, whereby the predefined shape of the panel support member is provided with a curvature such that the resulting panel is provided with a predefined curvature.
16. A method of mounting a plurality of panels according to any of the claims 1 to 10 in a building structure, whereby
a first panel is provided adjacent a second panel such that the two panels have abutting side edge regions, and then the first and second panels are then mounted to each other thereby compressing the abutting side edge regions for providing a seal being the two panels.
PCT/EP2017/056918 2016-03-31 2017-03-23 A panel for mounting in a building structure and a method of manufacturing such panel WO2017167634A1 (en)

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EP16163202.1 2016-03-31

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Publication number Priority date Publication date Assignee Title
WO2019141678A1 (en) 2018-01-19 2019-07-25 Rockwool International A/S A panel for a building structure having a predefined curvature and a method of manufacturing such panel

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GB1178261A (en) 1966-01-25 1970-01-21 English Electric Co Ltd Improvements in or relating to Building Structures.
GB2017885A (en) * 1978-03-30 1979-10-10 Krupp Koppers Gmbh Furnace expansion joint
CH648630A5 (en) * 1981-02-23 1985-03-29 Zuercher Ziegeleien Roof-substructure panel for an insulating roof substructure
AU731419B2 (en) * 1997-03-26 2001-03-29 Paroc Group Oy Ab Method for pressing of sandwich panels
WO2002092342A1 (en) * 2001-05-11 2002-11-21 Paroc Group Oy Ab Method for manufacturing a sandwich building element
WO2003095756A1 (en) * 2002-04-25 2003-11-20 Sircelj, D.O.O. Thermal insulating fiberboard with lap or grooved seams
EP2141303A2 (en) * 2008-07-02 2010-01-06 Knauf Insulation GmbH Load-bearing structural building panel
WO2013064150A1 (en) 2011-11-02 2013-05-10 Evershelter Aps Construction-unit for immediate or permanent shelter
US8615934B1 (en) 2011-10-07 2013-12-31 Stephen C. Webb Panelized portable shelter

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1178261A (en) 1966-01-25 1970-01-21 English Electric Co Ltd Improvements in or relating to Building Structures.
GB2017885A (en) * 1978-03-30 1979-10-10 Krupp Koppers Gmbh Furnace expansion joint
CH648630A5 (en) * 1981-02-23 1985-03-29 Zuercher Ziegeleien Roof-substructure panel for an insulating roof substructure
AU731419B2 (en) * 1997-03-26 2001-03-29 Paroc Group Oy Ab Method for pressing of sandwich panels
WO2002092342A1 (en) * 2001-05-11 2002-11-21 Paroc Group Oy Ab Method for manufacturing a sandwich building element
WO2003095756A1 (en) * 2002-04-25 2003-11-20 Sircelj, D.O.O. Thermal insulating fiberboard with lap or grooved seams
EP2141303A2 (en) * 2008-07-02 2010-01-06 Knauf Insulation GmbH Load-bearing structural building panel
US8615934B1 (en) 2011-10-07 2013-12-31 Stephen C. Webb Panelized portable shelter
WO2013064150A1 (en) 2011-11-02 2013-05-10 Evershelter Aps Construction-unit for immediate or permanent shelter

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019141678A1 (en) 2018-01-19 2019-07-25 Rockwool International A/S A panel for a building structure having a predefined curvature and a method of manufacturing such panel
CN111630234A (en) * 2018-01-19 2020-09-04 洛科威国际有限公司 Panel for building structures having a predetermined curvature and method of manufacturing the panel
US11566435B2 (en) 2018-01-19 2023-01-31 Rockwool International A/S Panel for a building structure having a predefined curvature and a method of manufacturing such panel

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