RO117867B1 - Sandwich panel and construction made therewith - Google Patents

Abstract

The invention relates to a sandwich-type panel and to a construction made therewith. The panel having all the elements fireproofed or not fireproofed, with or without cuttings for windows and doors, consisting of a flat or non-flat core, located between two identical or different flat or profiled working sides (2), made of polymeric composites (2a) and/or plates made of metallic or non-metallic materials (2d) or hybrid materials, made of layers of various materials, containing or not containing a finishing layer (2e) of gel-coat or film-forming types with open or closed sides with groove and tongue or male and female profiles (6 a and 6 b) has a multiple-structured core (1) comprising at least 3 structures (1a, 1b and 1g) with open cells, coupled in various combinations so that they can be identical or different, separated from one another by internal thin layers (1c) made of polymeric composite, the elements being bonded to one another with an adhesive film (3).

Description

RO 117867 B2

The present invention refers to a sandwich panel and to a construction made with it, the panel is intended in particular for the creation of walls and floors of civil, industrial and agricultural constructions, but also in other areas and equally.

The well-known sandwich panels, with the core of various structures, by the way they were designed, have as their main fields of use applications involving compression and bending stresses in correlation with low densities. These panels have a light core, made of an open cell structure, most often in the form of a honeycomb, and two working faces of metallic materials, reinforced polymer composites or other materials.

Such sandwich panels are known. Patent FR 2798618 presents a sandwich panel and the method of obtaining it, containing a honeycomb-type core plated on the outside on the two working faces with layers of polymer composite materials. Patent EP1055513 has as its object a sandwich panel consisting of a honeycomb core plated on the two working faces with layers of polymer composite materials and with layers of flame retardant materials. in the patent, WO 0073055, a fireproof sandwich panel is presented, with a honeycomb core plated on the two working faces with layers of reinforced phenolic resin. Patent EP 0722826 A also presents a sandwich panel and the method of obtaining it, consisting of a honeycomb core plated on the two working faces with layers of polymer composite material.

These panels have the disadvantage that in order to have good bending resistance, the cladding layers must be as far apart as possible from the middle area and therefore the honeycomb core must be as thick as possible. On the other hand, the thicker the honeycomb core, the lower the compressive strength. For example, according to the specifications of the FAROM type honeycomb produced at IAR-SA Brașov, if we take as a reference the compressive strength of a 12 mm thick honeycomb, then the compressive strength of a 20 mm honeycomb will be 0.9 times smaller, of a 42 mm thick honeycomb 0.75 times smaller.

Another major drawback is that sandwich panels with a core of a single honeycomb open cell structure cannot be more than 75 mm thick.

The composite panel RO 113329 B, intended for the creation of walls, is also known, which consists of a core in the form of an agglomerated board made of wood particles, and the working surfaces are made of metallic or non-metallic materials. This panel has the disadvantages of not being fireproof, having poor mechanical properties, higher weight than honeycomb core sandwich panels and poor dimensional stability due to the large amount of resin in the core, poor resistance to the action of environmental factors, thermal and sound insulation low, and in order to be used as a wall of a construction, it must have a large thickness (30-50 cm), in addition, it needs to be plastered and painted (whitewashed), which leads to high costs.

A laminated panel and a construction made with it are also known, patent RO 114989 B1. The panel consists of a metal frame, an asbestos-cement board, a polyurethane board and a chipboard board. Such a panel is very heavy, with medium mechanical strength and high price, and to be used in a construction it needs to be plastered and whitewashed (painted). The construction includes a skeleton of metal profiles in which the panels described above are fixed by welding. Such a construction is very heavy, requiring many welds and over long lengths. The welds induce stresses in the frame and panels, requiring stress-relieving heat treatments that cannot be done due to the large dimensions of the construction and due to the components of the panels (stats and polyurethane and PAL) that do not withstand heat treatment temperatures. Because of this, this structure works by deforming over time. Also, at welding temperatures, polyurethane and chipboard layers degrade at least in the vicinity of the welded joint.

RO 117867 Β2

There is also a construction panel (R0111701 B1) made by joining metal bars that constitute a kind of structure that also contains a layer of polyurethane. 50 This structure is encased in a layer of concrete thus forming a construction wall. This construction is very heavy, it requires formwork for pouring concrete, so it has the disadvantages of classic constructions, the walls must be plastered and whitewashed, it requires a lot of labor, the construction price is high.

A prefabricated panel for light anti-seismic constructions is also known (RO 55 115901 B1) which consists of a beam type construction with a lattice made by welding some metal profits to which the insulating and finishing layers are attached. This construction has the welding disadvantage mentioned above. Also, the construction is heavy, requires further finishing, low degrees of thermal and fornic insulation, requires a lot of labor, has high costs. 6 ₀

Another construction is known, patent RO 113264 B1, which consists of a structure made of metal profiles for pillars and floors, prefabricated panels for walls and ceiling. Fixing these elements to the poles is done by welding and by means of wedges. The panels have a metal frame into which insulating layers such as waste biomass and a reed network as reinforcement are inserted, and on the outside, on both sides, they are 65 framed by finishing layers of timber, glass, terraced , earthenware, sandstone, river stone. This construction has a disadvantage related to the welding of the profiles mentioned above, the construction is cumbersome, requires a lot of work, does not remove the classic finishes, in addition, fixing these elements with screws creates additional difficulties. The complete realization of the panel, including the finishing layer, on a flat surface and then mounting it in the 70 strength structure creates great technological difficulties, because the wall is heavy, and the finishing layers can be easily degraded during handling.

A major disadvantage of all laminated or sandwich panels with a core of layers of material (compact strips) as well as sandwich panels with a core of one structure or two structures is that the dew point occurs on one of the working faces. 75 In other words, condensation occurs on that work surface when there is a certain temperature difference on either side of the panel. This aspect means that all the panels mentioned above cannot be used as external walls in the case of certain types of constructions such as those intended as housing, schools, offices, etc. The sandwich panels having the core made of at least three open cell structures for example honeycomb type with the right thicknesses, 80 then the dew point would be inside the middle structure of the core, thus becoming suitable to be used as external walls of constructions of the type those mentioned above. If such a panel is also sealed in the sense that it is closed on all working faces and sides then the condensation that occurs comes only from the humidity of the air inside the middle structure and consequently insignificant. 85

Another common disadvantage of all laminated panels or sandwich panels with a core of layers of material (compact strips), as well as sandwich panels with a core of one structure or two structures, is that of the specific resistance to thermal permeability, together with the low specific (latent) heat, which also makes them unusable for the construction of external walls of buildings such as those intended for housing, schools, 90 offices, etc.

Another common disadvantage of these constructions is that they do not allow door and window frames to be incorporated into the type of panel construction.

The technical problem consists in achieving the dew point inside the panel, in a mid-point of its thickness, increasing the thermal inertia and specific resistance to thermal permeability, increasing the sound and electromagnetic insulation capacity, as well as an increase in resistance to bending and compression to also be used in social buildings and thermally insulated spaces.

RO 117867 B2

The sandwich panel, having a flat or non-flat core arranged between two flat or profiled working faces, identical or different from polymer composite materials, sheets from metallic, non-metallic materials or hybrid materials with structures from different materials, containing or not a type finishing layer gel-coat or pelliculogen, having open or closed side faces with lambda-uluc or mos-baba type profiles and containing thin inner layers of polymer composites, all the elements of the panel being glued together solve the disadvantages mentioned above by the fact that it has a core multiple structured, consisting of at least three structures coupled in various combinations, so that they can be with identical or different open cells, separated from each other by some thin inner layers of polymer composites, contained between the working faces.

The main advantages obtained by applying the invention are:

- the realization of sandwich panels with a large thickness (over 150), which cannot be reached by sandwich panels with a core from one structure or from two structures, thus increasing the range of sizes of sandwich panels, making it possible to use them in bending much larger than sandwich panels with the core of one or two structures with the maintenance of compressive and shear strengths as high as those of a thin-thickness panel with the core of one or two structures;

- the use of cheap cores and very accessible and cheap materials for filling the core structures (soil, sand, glass wool, etc.), which together with the core constitute a very good insulator;

- making a sandwich panel with the diversification of the core structures to be good thermal, electromagnetic insulators, attenuators of x or y radiation, or a panel with good insulating properties against at least three of these factors can be obtained in this way;

- making panels that contain tubes, pipes and electrical conductors, so that when these panels are used as walls or floors of some constructions, they contain the routes of the electrical installation or parts of the sanitary or heating installations;

- creating panels that no longer require painting;

- making fireproof panels;

- making some panels with the dew point inside the core. This aspect makes it possible to use these panels for the construction of external walls of buildings such as those intended for housing, schools, offices, etc.

Below are some examples of implementation with reference to fig. 1-17, which represent:

- fig. 1, structured multi-core sandwich panel consisting of different structures and working faces of reinforced polymer composite materials;

- fig.2, sandwich panel with a multiple core structured from different structures with filling material in one of the structures and working faces from reinforced polymer composite materials containing a layer of high hardness;

- fig.3, sandwich panel with a structured multiple core with filling materials inserted in two of the core structures and work surfaces made of reinforced polymer composite materials imitating sandstone;

- fig.4, sandwich panel with a structured multiple core consisting of different structures with working faces made of metallic or non-metallic semi-finished products;

- fig.5, sandwich panel with a structured multiple core consisting of structures of the same type with one face of reinforced polymeric composite materials and the other of metallic or non-metallic semi-finished products;

- fig.6, sandwich panel with multiple structured core and hybrid faces;

- fig.7, sandwich panel with multiple structured core, with cut-out and profiled side faces;

RO 117867 B2

- fig.8, sandwich panel with multiple structured core and complex geometry;

- fig.9, construction of sandwich panels with a structured multiple core;

- fig. 10, the way of fixing the inner walls to the pillars; 150

- fig. 11, the method of fixing the outer walls to the pillars;

- fig. 12, the method of fixing the floors and the external walls to the beams;

- fig.13, the method of fixing two floors and two interior walls of beams;

- fig.14, section through a wall with a door;

- fig. 15, section through a windowed wall; 155

- fig. 16, section through a panel containing the electrical path and pipes of the heating installation;

- fig.17, industrial construction with double door.

The realization of panels that have properties that no other layered panel or sandwich panel with the core of a structure or of two structures, or other classic 160 construction material, has, in the sense of simultaneously satisfying the four complementary and some antagonistic characteristics regarding thermal comfort, namely: low thermal conductivity coefficient, high specific (latent) heat, low apparent thermal inertia and dew point inside the panel, can only be done with a multi-layered core.

in a first embodiment, according to the invention, the sandwich panel has a multiple structured core 165 1 consisting of three different structures: a structure 1a with open cells such as a honeycomb, a structure 1b of U, I, T profiles , Ω, etc., a structure 1g of alveolar, cellular, porous, non-porous, fibrous, expanded and granular materials, etc., the structures are separated by some inner layers of fiber-reinforced composite materials 1c. The multiple core has the working faces 2 of the layers of fiber reinforced composite materials 170 2a and of a finishing layer 2c. Profiles U, I, T Ω etc. of the structure 1b are made of fiber-reinforced composite materials, metallic or non-metallic materials, all these elements being glued by means of an adhesive film 3. The sandwich panel can be non-fireproof or fireproof, in the latter case, the non-fireproof structures of the multiple structured core 1 are fire retardant by coating with fire retardant resin, and the other resins are used to make 175 polymer composite elements, the finishing or fire retardant layer.

The second embodiment (fig. 2) shows a sandwich panel with a multiple structured core 1 consisting of three structures of which the outer ones are of the same type, for example an open cell structure 1a, and the other structures are of other types, such as U, I, T, Ω profiles, etc. 1b. The structures may contain a granular or particulate filler material 180 such as soil, sand, sawdust, chaff, etc. which improve certain properties, such as the degree of thermal insulation. The inner and adhesive layers are the same as in the previous example, and the working faces additionally have a high hardness layer 2b containing resin and a hard powder such as quartz sand, silica, silicon carbide, boron carbide, other powders metallic or ceramic (in proportion of 0.01-185

90%).

The third embodiment (fig. 3) presents a sandwich panel with a multiple structured core 1 consisting of three structures, of which two adjacent ones are of the same type U, I, T, Ω, etc. 1b. in the voids of one of these structures, a granular or particulate filler material is inserted, such as earth, sand, sawdust, chaff, etc. 1e, 190 and in another, a fibrous filler material 2d, one of the structures also having a finishing layer 2c containing pigments of various colors, and the other, a layer 2e that has patterns imitating: sandstone, faience, river stone, marble, parquet, mosaic, carpet, or other finishes.

RO 117867 Β2

The fourth embodiment (fig. 4) presents a sandwich panel with a multiple structured core 1 consisting of three different structures 1a, 1b and 1g separated from each other by some inner layers of fiber-reinforced composite materials 1c and metal semi-finished products or non-metallic 1f. in open-cell structures such as honeycomb, 1b and profiles II, I, T, Ω, etc., 1b a granular or particulate filler, such as earth, sand, sawdust, has been introduced , chaff, etc. 1e; work surfaces are made of metallic or non-metallic 2d semi-finished products.

The fifth embodiment (fig. 5) presents a sandwich panel with a multiple structured core 1 consisting of four structures, all of the same type, for example with open cells 1a, separated by the inner layers of fiber-reinforced composite materials 1c . The working faces 2 are of different materials, one is of fiber-reinforced composite materials 2a and has a finishing layer 2c, and the other is of metallic or non-metallic blanks 2d.

The sixth embodiment (fig. 6) presents a sandwich panel that has some working surfaces of hybrid materials, formed by the layers of composite materials reinforced with fibers 2a and semi-finished metal or non-metal materials 2d, glued with the adhesive layers 3, one of faces also having a 2c finishing layer.

The seventh embodiment (fig. 7) presents a sandwich panel with a structured multiple core that has a cut-out 4, having the inner side faces 5 suitably profiled, so as to allow the assembly in cut-out of other parts such as door, window, etc., all or only two opposite sides of the side faces containing some profiles 6a and 6b of various shapes to allow the assembly of the panels with each other or the assembly of the panels with other parts. The other elements are the same as in the previous examples.

The eighth embodiment (fig. 8) presents a sandwich panel with a structured multiple core 1 which has a complex geometry, in the sense that it has at least one non-planar working face and/or the non-planar core on at least one face, the other elements already known from previous examples.

The ninth embodiment (fig. 18) shows the sandwich panel with multiple structured core 1 which contains in the working faces 2 some pipes 28, and in the core structures some other pipes 26 and some electrical conductors 27.

The sandwich panels with multiple structured core 1 described above, are used to create constructions with a resistance structure of pillars and beams, for civil, industrial, agricultural, etc. purposes. with external and/or internal walls and/or floors and/or roof. Multi-structured core sandwich panels are fixed to the posts and beams of the resistance structure by bonding with adhesive layers and mechanically with screws and/or rivets by means of T, double T, unequal-wing angle, equal-wing or other shaped profiles proper. The construction has the strength structure of: some concrete or metal posts 7 with solid or hollow polygonal or circular cross-section and some beams 8 in the form of typical profiles, such as I-shaped, fixed to the posts with screws by means of some suitable or classic shaped fasteners. The doors 14 or half-doors and windows 13 (in the case of industrial or agricultural constructions) can be made of structured multi-core panels and have some frames and some frames of polymer composite materials.

With these panels, a construction with a civil, industrial, agricultural, etc. purpose is made, consisting of a classic foundation 11 in which a resistance structure consisting of pillars 7 and beams 8 made of concrete or metallic materials is attached. The beams have the shape of typical profiles such as I-shaped (fig. 15) and are fixed to the posts with screws 23 by means of clamping pieces 19 of an appropriate shape, or they are clamped by classical methods, the clamping pieces being fixed in turn of bolted or welded posts. Walls 9

Claims (13)

RO 117867 B2 exterior 9a or interior 9b, floorboards 10 and roof 12 are made of sandwich panels with a structured multiple core of the type described above. Sandwich panels with a structured multiple core of the type described above. The sandwich panels for the external walls can have a multiple core structured with one or more structures with the role of thermal insulator, and the other 245 or the other structures with a predominantly acoustic, but also thermal role. Structures with a predominantly thermal role can be, for example, U, I, T, Ω profiles, etc. 1b and may contain an additional filler material to improve the degree of thermal insulation, in the form of particles, such as earth, sand, sawdust, chaff, etc. 1e, or fibrous 2d such as glass wool etc. in the case of using earth or sand as additional filling material, 250 it can be inserted into the panel after mounting the panel in the resistance structure of the building. This results in a wall with a high degree of insulation, very cheap, and the construction is very easy because the walls, before the introduction of the filling material, have little mass and are easy to handle. Structures with the role of a predominantly sound insulator can be placed from open cells, such as honeycomb 1a, porous, non-porous, expanded 255 materials 1g such as polyurethane, polystyrene, etc. The structures with the role of sound insulator can be both towards the outside and towards the inside of the building, or only on one of the sides. The inner walls 9b can be made of the same types of sandwich panels as the outer walls. in this case it is recommended to ease the construction, the use of a filling material of low density, such as sawdust, chaff, glass wool, or the 260 filling material can be omitted, or they can be made of sandwich panels with a simple core. Sandwich panels with multi-structured cores for floors, which constitute the floor and also the ceiling, can be of the types shown above, but in this case no more earth or sand is introduced as additional filling material, but a lighter material such as sawdust, chaff , glass wool, the panels may no longer include the structure intended for sound insulation. Fixing the internal or external walls (fig. 10 and fig. 12) is done on some T15, double T 16 or other suitable profiles, which are fixed to these profiles by gluing and mechanically, with some screws and/or some rivets. The walls are fixed to these profiles by gluing and mechanically with some screws and/or some rivets. The construction also contains some doors 14 and some windows 13. The doors are made of panels with a structured multiple core of the types described above, provided with a frame 270 25 made of polymer composites, metallic or non-metallic materials (fig. 16). The sandwich panels in which the doors will be mounted are provided with door frames 20 of suitable shapes for assembly with the door made of polymer composites, and the sandwich panels in which the windows will be assembled are provided with window frames 21 and frames 22 made of polymer composites , metallic or non-metallic materials (fig. 17). The doors and windows can be of the classic 275 type or thermal insulation. Some sandwich panels for the floor (fig. 18) contain some pipes 28 of the heating installation and/or electrical paths formed by some PVC pipes 26 or some electrical conductors 27. Another example of realization presents an industrial construction (fig. 19) which is provided with a large door consisting of two half doors 29a and 29b, one of them also containing 280 an access door for people 14. The half doors are made of sandwich panels of the types described above or of metallic or non-metallic materials. Claims 285 1. Fireproof or non-fireproof sandwich panel, with or without cutouts, made up of a flat or non-flat core arranged between two flat or profiled work faces (2), identical or different, made of polymer composite materials (2a) and/or sheets of metallic or non-metallic materials (2d) or hybrid materials made of layers of different materials and containing RO 117867 Β2 or not a finishing layer (2c) of the gel-coat type or film-forming type, with open or closed side faces with profiles (6a and 6b) of the lamba-uluc or mosh-baba type, containing thin inner layers, from polymer composites, the panel elements being glued together, characterized by the fact that it has a multiple structured core (1) consisting of at least three structures (1a, 1b and 1g) with open cells, coupled in different combinations, so that they can be identical or different, separated from each other by the thin inner layers (1e) of polymer composites, the whole core being contained between the working faces (2a, 2b, 2c and 2d). 2. Sandwich panel, according to claim 1, characterized in that the structure (1a) is made of open honeycomb cells. 3. Sandwich panel, according to claim 1, characterized in that the structure (1b) is made of U, I profiles; T, Ω, etc. 4. Sandwich panel, according to claim 1, characterized in that the structure (1g) is made of a porous, non-porous, fibrous, granular, expanded material. 5. Sandwich panel, according to claims 1-4, characterized in that it has one or more thin inner layers of metallic or non-metallic sheet (1 f). 6. Sandwich panel, according to claims 1-5, characterized in that the multiple structured core (1) contains in one or more of the structures (1a) a filler material (1e and 1d) of granular type or of particles such as eg soil, sand, sawdust, chaff etc. and/or respectively fibrous, such as glass wool. 7. Sandwich panel, according to claims 1-6, characterized in that the working faces (2) contain some pipes (28) and/or in the multiple core some pipes (26) and some electrical conductors (27). 8. Sandwich panel, according to claims 1-7, characterized in that the multiple structured core (1) contains some pipes (26) and some electrical conductors (27). 9. Sandwich panel, according to claims 1-8, characterized in that one or both working faces (2) have a layer of high hardness (2b) consisting of a hard powder such as, for example, quartz sand, silica, carbide , the powder being in a percentage of 0.01-90%. 10. Sandwich panel, according to claims 1-9, characterized in that one or both working faces (2a) of polymer composite materials have a layer (2e) on the outside that has models that imitate sandstone, faience, river stone, marble, parquet, mosaic, carpet or other finishes. 11. Sandwich panel, according to claims 1-10, characterized in that the working face (2a) of polymeric composite material contains pigments of various colors. 12. The use of the sandwich panel, from claims 1-11, for the creation of external walls (9a), internal (9b), floors (10) and/or the roof of a building having the structure of classic elements: pillars and beams, by gluing them elements with some adhesive layers (24) and/or mechanically with screws and rivets, by means of profiles T (15), double T (16), cones with unequal wings (17) or angle with equal wings (18), or other proper form. 13. The use of the sandwich panel, from claims 1-11, for making doors (14) or half doors (29a and 29b) of a construction. The president of the examination committee: Eng. Petrescu loan Cristea Examiner: Eng. Scăunașu Elisabeta