U.S. patent application number 10/961332 was filed with the patent office on 2005-06-30 for flat wall panel at least substantially made of cellulose material.
This patent application is currently assigned to Unda Maris B.V.. Invention is credited to Snel, Wilhelmus Jan Reinier Karel.
Application Number | 20050138879 10/961332 |
Document ID | / |
Family ID | 33448539 |
Filed Date | 2005-06-30 |
United States Patent
Application |
20050138879 |
Kind Code |
A1 |
Snel, Wilhelmus Jan Reinier
Karel |
June 30, 2005 |
Flat wall panel at least substantially made of cellulose
material
Abstract
A flat wall panel at least substantially made of cellulose
material, a special feature being the fact that the wall panel is
at least substantially made of layers of paper/cardboard, each
layer at least substantially being made up of a corrugated sublayer
and a flat sublayer provided on one side thereof, which layers of
paper/cardboard are interconnected via an adhesive applied to the
corrugations of the corrugated sublayers, wherein the wall panel is
impregnated, in particular with a resinous material, and wherein at
least one strengthening layer having a greater elasticity modulus
than the layers of paper/cardboard is provided, which strengthening
layer is connected to a layer of paper/cardboard on one side of the
wall panel via an adhesive.
Inventors: |
Snel, Wilhelmus Jan Reinier
Karel; (Zwaag, NL) |
Correspondence
Address: |
FLIESLER MEYER, LLP
FOUR EMBARCADERO CENTER
SUITE 400
SAN FRANCISCO
CA
94111
US
|
Assignee: |
Unda Maris B.V.
Zwaag
NL
|
Family ID: |
33448539 |
Appl. No.: |
10/961332 |
Filed: |
October 8, 2004 |
Current U.S.
Class: |
52/506.01 |
Current CPC
Class: |
E04C 2002/345 20130101;
E04C 2/3405 20130101 |
Class at
Publication: |
052/506.01 |
International
Class: |
E04B 002/00 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 10, 2003 |
NL |
1024505 |
Claims
1. A wall panel comprising: at least one layer including a
corrugated sublayer and a flat sub layer wherein flat sublayer is
connected with corrugated sublayer; and wherein the corrugated
sublayer(s) and the flat sub layer(s) are composed of paper,
cardboard or other material containing a high cellulose content;
and a strengthening layer adhesively connected to the
paper/cardboard layer wherein the wall panel is impregnated with
resinous material; and wherein the strengthening layer has a
greater elasticity modulus than the paper/cardboard layer.
2. A wall panel according to claim 1, wherein a second
strengthening layer is adhesively connected to the paper/cardboard
layer thereby sandwiching the paper/cardboard layer between the two
strengthening layers.
3. A wall panel according to claim 1 wherein the said strengthening
layer is made of wood.
4. A wall panel according to claim 2 wherein the said strengthening
layers are made of wood.
5. A wall panel according to claim 1 wherein the said strengthening
layer is made of metal.
6. A wall panel according to claim 2 wherein the said strengthening
layers are made of metal.
7. A wall panel according to claim 1 wherein the said strengthening
layer is made of a fibre material.
8. A wall panel according to claim 2 wherein the said strengthening
layers are made of a fibre material.
9. A wall panel according to claim 6 wherein the fibre material is
selected from the group of glass fibres, carbon fires, mineral
fibres, synthetic fibres.
10. A wall panel according to claim 7 wherein the fibre material is
selected from the group of glass fibres, carbon fires, mineral
fibres, synthetic fibres.
11. A wall panel according to claim 1, wherein the said
strengthening layer includes a layer of plastic material.
12. A wall panel according to claim 2, wherein the said
strengthening layer includes a layer of plastic material.
13. A wall panel according to claim 3, wherein the said
strengthening layer includes a layer of plastic material.
14. A wall panel according to claim 4, wherein the said
strengthening layer includes a layer of plastic material.
15. A wall panel according to claim 5, wherein the said
strengthening layer includes a layer of plastic material.
16. A wall panel according to claim 6, wherein the said
strengthening layer includes a layer of plastic material.
17. A wall panel according to claim 7, wherein the said
strengthening layer includes a layer of plastic material.
18. A wall panel according to claim 8, wherein the said
strengthening layer includes a layer of plastic material.
19. A wall panel according to claim 9, wherein the said
strengthening layer includes a layer of plastic material.
20. A wall panel according to claim 1, wherein the said
strengthening layer includes a layer of rubber.
21. A wall panel according to claim 2, wherein the said
strengthening layer includes a layer of rubber.
22. A wall panel according to claim 3, wherein the said
strengthening layer includes a layer of rubber.
23. A wall panel according to claim 4, wherein the said
strengthening layer includes a layer of rubber.
24. A wall panel according to claim 5, wherein the said
strengthening layer includes a layer of rubber.
25. A wall panel according to claim 6, wherein the said
strengthening layer includes a layer of rubber.
26. A wall panel according to claim 7, wherein the said
strengthening layer includes a layer of rubber.
27. A wall panel according to claim 8, wherein the said
strengthening layer includes a layer of rubber.
28. A wall panel according to claim 9, wherein the said
strengthening layer includes a layer of rubber.
29. A wall panel according to claim 10, wherein the said
strengthening layer includes a layer of rubber.
30. A wall panel according to claim 11, wherein the said
strengthening layer includes a layer of rubber.
31. A wall panel according to claim 12, wherein the said
strengthening layer includes a layer of rubber.
32. A wall panel according to claim 13, wherein the said
strengthening layer includes a layer of rubber.
33. A wall panel according to claim 14, wherein the said
strengthening layer includes a layer of rubber.
34. A wall panel according to claim 15, wherein the said
strengthening layer includes a layer of rubber.
35. A wall panel according to claim 16, wherein the said
strengthening layer includes a layer of rubber.
36. A wall panel according to claim 17, wherein the said
strengthening layer includes a layer of rubber.
37. A wall panel according to claim 18, wherein the said
strengthening layer includes a layer of rubber.
38. A wall panel according to claim 19, wherein the said
strengthening layer includes a layer of rubber
39. A wall panel according to claim 2, wherein the wall panel
comprises an even number of layers.
40. A wall panel according to claim 39, wherein the wall panel is
mirror symmetrical with respect to a central longitudinal plane of
the wall panel.
41. A method for manufacturing the wall panel comprising:
interconnecting layers including a corrugated paper/cardboard
sublayer and a flat paper/cardboard sublayer, wherein the layers
are interconnected via adhesive applied to the corrugations of the
corrugated sublayers, connecting at least one strengthening layer
having a greater elasticity modulus than the layers of
paper/cardboard is connected to the paper/cardboard layer via an
adhesive, wherein the wall is impregnated with a resinous material.
Description
CLAIM OF PRIORITY
[0001] This application claims priority to the Netherlands Patent
Application No. NL 1024505, entitled FLAT WALL PANEL AT LEAST
SUBSTANTIALLY MADE OF CELLULOSE MATERIAL, by Snel, filed 10 Oct.,
2003, incorporated herein by reference.
TECHICAL FIELD
[0002] The present invention relates to a flat wall panel at least
substantially made of cellulose material. The invention also
relates to a method for manufacturing said wall panel.
BACKGROUND
[0003] Such a wall panel is known from German patent No. 2 026 768.
Said patent describes a building that is built up of a great many
different construction elements, such as a concrete floor, roof and
side wall panels made of an intermediate layer of corrugated
cardboard sandwiched between two flat outer layers, as well as
cramps and corner elements. In practice, the constructional
strength of the roof and side wall panels appears to be
insufficient to give the building sufficient strength.
SUMMARY
[0004] The object of the invention is to improve the wall panel
that is known from the aforesaid German patent publication, in the
sense that a wall panel having an optimum constructional stiffness
is provided for use as a construction element of a building, as a
wall panel in, for example, a separation wall, etc. It is noted
that the term wall panel is understood to include an element for
use in a wall, a floor, a ceiling, a roof, etc.
[0005] According to the invention, a wall panel of the kind
referred to in the introduction is characterized in that the wall
panel is at least substantially made of layers of paper/cardboard,
each layer at least substantially being made up of a corrugated
sublayer and a flat sublayer provided on one side thereof, which
layers of paper/cardboard are interconnected via an adhesive
applied to the corrugations of the corrugated sublayers, wherein
the wall panel is impregnated, in particular with a resinous
material, and wherein at least one strengthening layer having a
greater elasticity modulus than the layers of paper/cardboard is
provided, which strengthening layer is connected to a layer of
paper/cardboard on one side of the wall panel via an adhesive.
[0006] In other words, the sum of a number of adhered-together
layers of paper/cardboard are connected on at least one flat
(outer) side thereof to the less elastic strengthening layer.
Experiments have shown that the present construction leads to an
unexpectedly great constructional stiffness of the wall panel, so
that it is possible to subject the wall panel to large forces
without the dimensional stability being affected. The
constructional stiffness is increased even further by using a
strengthening layer having an elasticity modulus greater than or
equal to 50 GPA, in particular greater than or equal to 100 GPA,
more in particular greater than or equal to 150 GPA, more in
particular greater than or equal to 200 GPA, more in particular
greater than or equal to 300 GPA, more in particular greater than
or equal to 400 GPA.
[0007] In a preferred embodiment of a wall panel according to the
invention, the wall panel comprises two strengthening layers, which
are connected to a layer of paper/cardboard on either side of the
wall panel via an adhesive. Thus a sandwich construction is
obtained, in which the whole of various adhered-together layers of
paper/cardboard is connected to a less elastic strengthening layer
on both flat outer sides. The result is an even greater
constructional stiffness having a corresponding dimensional
stability.
[0008] It is noted that impregnating the wall panel with, for
example, a resinous material not only has the advantage of
providing a greater constructional stiffness, but also of providing
protection against external influences, such as moisture. As a
result of said additional stiffness, fewer layers of corrugated
paper/cardboard are in principle needed in order to give the flat
panel the required stiffness. Said impregnation preferably takes
place by means of vapour deposition, spraying or otherwise, said
vapour deposition or spraying taking place in a direction parallel
to the direction of the "cell structure" of the corrugated
paper/cardboard that is used. Said impregnation may also be
effected with mechanical means, wherein toothed and/or flat rollers
are used for pressing the impregnating medium into the
paper/cardboard.
[0009] In another preferred embodiment of a wall panel according to
the invention, the strengthening layer is comprised of a fibre
material. In particular, the fibre material consists of glass
fibres, carbon fibres, mineral fibres and/or synthetic fibres. Said
synthetic fibres may e.g. be fibres of the type known under the
brand names "Kevlar" or "Twaron".
[0010] In another preferred embodiment the strengthening layer
comprises a layer of a plastic material. The plastic of said layer
of plastic material is preferably selected from the group
consisting of PVC-U, PP, PE, ABS, PVC-C and PVDF. It is noted that
the above abbreviations relate to the following (plastic)
materials.
[0011] PVC-U Polyvinyl chloride (without plasticizer)
[0012] PP Polypropylene
[0013] PE Polyethylene
[0014] ABS Acrylonitrile-Butadiene-Styrene
[0015] PVC-C Polyvinyl chloride (post-chlorinated)
[0016] PVDF Polyvinylydene fluoride
[0017] In another preferred embodiment of the wall panel according
to the invention, the strengthening layer comprises a layer of
rubber. The rubber of said layer of rubber is preferably selected
from the group consisting of EPDM or NBR. In another preferred
variant, the strengthening layer is made of a metal, in particular
stainless steel or wood.
[0018] In another preferred embodiment of a wall panel according to
the invention, the wall panel is at least substantially made of an
even number of layers of paper/cardboard. In combination with the
strengthening layer, this provides a plate-shaped material which is
hardly deformable, if at all. Preferably, the wall panel is mirror
symmetrical with respect to a central longitudinal plane of the
wall panel so as to increase the dimension all stability thereof,
so that "warping" is prevented at all times.
[0019] The invention also relates to a method for manufacturing a
wall panel according to the specifications of the invention,
wherein the wall panel is at least substantially made of layers of
paper/cardboard, each layer at least substantially being made up of
a corrugated sublayer and a flat sublayer provided on one side
thereof, which layers of paper/cardboard are interconnected via an
adhesive applied to the corrugations of the corrugated sublayers,
wherein the wall panel is impregnated, in particular with a
resinous material, and wherein at least one strengthening layer
having a greater elasticity modulus than the layers of
paper/cardboard is provided, which strengthening layer is connected
to a layer of paper/cardboard on one side of the wall panel via an
adhesive.
[0020] It is noted that the term paper is usually used for lighter
types of paper; in the case of a heavier quality, the term
cardboard is frequently used. Within the framework of the
invention, the terms paper, cardboard and weight are not intended
to be limitations as regards the type of material to be used.
[0021] The aforesaid resinous material with which the wall panel
according to the invention is impregnated, is preferably an epoxy
resin, a polyurethane resin, a polyester resin or a phenol resin.
Fire-resistant and/or fire-retarding agents may be added thereto.
Preferably, the resinous material with which the wall panel
according to the invention is impregnated also functions as an
adhesive for adhering two layers of paper/cardboard together, so
that a separate adhesive, such as a glue, is not required. To that
end, sets consisting of a corrugated sublayer and a flat sublayer
provided on one side thereof, which sublayers are already
impregnated with the resinous material, can be placed on top of
each other so as to be adhered together (after the resinous
material has dried).
BRIEF DESCRIPTION OF THE FIGURES
[0022] The invention will now be explained in more detail with
reference to figures illustrating a preferred variant of the
invention.
[0023] FIG. 1 shows a schematic, perspective view of the present
wall panel.
[0024] FIG. 2 shows a schematic, detail view of the wall panel in
FIG. 1.
[0025] FIG. 3 shows a schematic, exploded view of the wall panel in
FIG. 1.
DETAILED DESCRIPTION
[0026] FIG. 1-3 shows a flat wall panel I according to the
invention in the form of a "sandwich", in the sense that a core 2
built up of several layers of corrugated cardboard is connected on
either side to a less elastic strengthening layer 3 of a thin
material having an elasticity modulus of about 400 Gpa.
[0027] In this case, four layers of corrugated cardboard are
provided, which are each built up of corrugated sublayer 4 and a
flat sublayer 5 glued to one side thereof, using a glue applied to
the corrugations 6 of the corrugated sublayer 4. The core 2 is
impregnated with a resinous material. As already said before, the
strengthening layers 3 are glued to both sides of the core 2.
[0028] The wall panel 1 is mirror symmetrical with respect to a
central longitudinal plane 7 of the wall panel 1.
[0029] It is noted that the invention is not limited to the
embodiment as shown in the figures, but that it also extends to
other variants that fall within the scope of the appended claims.
Thus it will be apparent to those skilled in the art that the wall
panel may exhibit a (slight) curvature, whilst the wall panel may
also comprise a curved longitudinal edge.
* * * * *