U.S. patent application number 11/883735 was filed with the patent office on 2009-02-19 for building board, building element or the like.
Invention is credited to Johann Berger.
Application Number | 20090044484 11/883735 |
Document ID | / |
Family ID | 35149448 |
Filed Date | 2009-02-19 |
United States Patent
Application |
20090044484 |
Kind Code |
A1 |
Berger; Johann |
February 19, 2009 |
Building Board, Building Element or the Like
Abstract
The invention relates to a building board or a building element
having a multilayer structure, preferably wood-based and consisting
of at least three bonded to each other layers, wherein a layer (5)
is made of a material, preferably wood-based, which consists of
vertically oriented (fv) vertical fibres (50) and is formed as a
core layer between two covering layers (3, 4) made of a layer,
preferably wood-based, material, the vertical fibres (50) are
oriented substantially in a vertical direction with respect to the
main extension (ed) of the covering layers (3, 4), in the preferred
embodiment, the vertical fibre layer (50) comprises a plurality of
vertical cavities (6) which completely transverse said layer and
are oriented in a direction (hv) in conformity with the vertical
orientation (fv) of the vertical fibres (50) of the material,
preferably wood, of which said layer (5) is made. A method for
producing the inventive building boards and elements is also
disclosed.
Inventors: |
Berger; Johann; (Neustadtl
an der Donau, AT) |
Correspondence
Address: |
TOWNSEND AND TOWNSEND AND CREW, LLP
TWO EMBARCADERO CENTER, EIGHTH FLOOR
SAN FRANCISCO
CA
94111-3834
US
|
Family ID: |
35149448 |
Appl. No.: |
11/883735 |
Filed: |
April 26, 2005 |
PCT Filed: |
April 26, 2005 |
PCT NO: |
PCT/AT05/00141 |
371 Date: |
May 15, 2008 |
Current U.S.
Class: |
52/783.1 ;
156/182 |
Current CPC
Class: |
E04C 2/12 20130101 |
Class at
Publication: |
52/783.1 ;
156/182 |
International
Class: |
E04C 2/00 20060101
E04C002/00 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 4, 2005 |
AT |
A 190/2005 |
Claims
1. A new building board or a new building element, in particular a
structural element, wall element, facing element, support element
or the like, having a multilayer structure, preferably wood-based
or consisting of wood materials, which consist(s) of at least three
bonded layers, layers, boards, sheets or the like, preferably
having two covering layers which are spaced from one another and
parallel to one another and having a core layer between them and
connected with them, characterized in that covering layers (3, 4),
optionally multilayer, are formed between two, each with a flat,
preferably compact, laminated, plate or sheet material, in
particular from the group comprised of wood, wood materials, such
as laminated wood, layerwood, wood chip material, metals, textiles
and fibrous materials, cardboard, papers, plastics,
fibre-reinforced plastics, mineral-based building materials, stone,
artificial stone and composites of two or more of the
aforementioned materials, as a core layer, containing a vertical
fibre layer (5) comprised of vertical fibres (50), vertical
filaments or the like with an essentially uniform vertical
orientation (fv) or formed with them or a material of this type
having a grain or fibre structure of this type, preferably of wood,
whereby the vertical fibres (50) or the grains of the vertical
fibre layer (5), preferably wood vertical fibre layer, is or are
oriented essentially vertically or at a right angle to the main
extension (ed) of the two covering layers (3, 4), and wherein it is
preferably provided, that the vertical fibre layer (50), preferably
a wood vertical fibre layer, is formed with a plurality thereof
fully traversing them, with the vertical orientation (fv) of the
vertical fibres (50) or grains of the material forming this layer
(5), preferably wood, vertical cavities (6), recesses, millings,
bores or the like having essentially corresponding or vertical
orientation (hv) thereto or parallel to one another.
2. The building board or building element or the like according to
claim 1, characterized in that the vertical cavities in the
vertical fibre layer (5) have the same area and/or cavity cross
sections (Qh) having a geometric form.
3. The building board or building element or the like according to
claim 1, characterized in that the vertical cavities (6) in the
vertical fibre layer (5) or in the vertical fibre bodies (51)
forming them, are arranged in a matrix or grid-like manner and are
preferably uniformly distributed.
4. The building board or building element or the like according to
claim 1, characterized in that the ratio of the totality of the
cross-sectional areas (Qh) of the vertical cavities (6) in the
vertical fibre layer (5) to the totality of the cross-sectional
area(s) (Qm) of the vertical fibre material, preferably wood,
forming the same, is between 5:1 and 1:5, preferably between 2:1
and 1:2.
5. The building board or building element or the like according to
claim 1, characterized in that the inner walls, and preferably also
the base, of the vertical cavities (6) of the vertical fibre layer
(5) are coated with an intumescent fireproof or fire-propagation
retarding polymer substance, e.g. based on silicates containing
structure water, which expand under the effect of heat in the case
of fire and fill the vertical cavities (6).
6. The building board or building element or the like according to
claim 1, characterized in that the covering layers (3, 4) are
formed with the same materials between them, preferably with
identical wood and/or with the same material thicknesses (dd3,
dd4), or that the covering layers (3, 4) are formed with various
materials, as in particular with various types of wood and/or with
various material thicknesses (dd3, dd4), however with essentially
the same, physical, optionally orientation-controlled, same
variation behaviour or the like when environmental conditions
change, as e.g. with changes in temperature, humidity or the
like.
7. The building board or building element or the like according to
claim 1, characterized in that the vertical fibre layer (5) is
formed with a plurality of vertical fibre bodies (51), preferably
of wood, which are arranged adjacent to one another with at least
two of their flank surfaces (55) having an orientation that
corresponds to the vertical orientation (fv) of its vertical fibres
(5) or grains and preferably bonded together so as to seal the
material.
8. The building board or building element or the like according to
claim 1, characterized in that the vertical fibre bodies (51)
formed with the vertical cavities (6) in the vertical fibre layer
(5) are designed as vertical fibre body molds or strips (51) which
are arranged in a row in a linear straight manner, preferably
having the same width (bv), which are arranged so as to be either
directly longitudinally adjacent to one another and preferably
bonded to one another, whereby it is preferred in this case that
the two covering layers (3, 3) are formed from compact wood
chipboards or homogeneous boards without a distinct grain
orientation, or that, between adjacent strips (510) of this type,
reinforcing or stiffening strips (7) are each arranged, adjoining
their vertical longitudinal flank sides (511) facing one another,
preferably bonded to them, and extending parallel to one another,
whereby, in this latter case, it is preferred if the two covering
layers (3, 4) made of wood, whose grain or fibres is or are
oriented parallel to one another, yet at a right angle to the
direction of the grains extending in longitudinal direction (II) of
the reinforcing strips (7).
9. The building board or building element or the like according to
claim 1, characterized in that the reinforcing or stiffening strips
(7) have an elongated rectangular cross section and, in the event
that they essentially have the same physical property-varying
behaviour when the environmental conditions change in a direction
at a right angle to the main extension (ed) of the covering
surfaces (3, 4) as the vertical fibre body strips (510) or the
vertical fibre layer (5) formed with them are bonded to the
covering layers (3, 4) so as to seal the material with their upper
and lower narrow edges (72).
10. The building board or building element or the like according to
claim 1, characterized in that the reinforcing or stiffening strips
(7) have an elongated rectangular cross section and, in the event
that they have the physical property-varying behaviour when the
environmental conditions change in a direction at a right angle to
the main extension (ed) of the covering surfaces (3, 4) or to their
grains (70) other than the vertical fibre bodies (51) or the
vertical fibre strips (510) or the vertical fibre layer (5) formed
with them, they do adjoin the vertical fibre body strips (510) on
both sides with their longitudinal side surfaces and are preferably
bonded to them, however, they do not adjoin the covering surfaces
(3, 4) on the inside with their two narrow side surfaces (72) and
are not bonded to them and their narrow side surfaces (72) are
spaced from the covering surfaces (3, 4) to such an extent in the
diagonal to the grain expansion or the like when environmental
conditions change to an extent corresponding to said strips.
11. The building board or building element or the like according to
claim 1, characterized in that the reinforcing or stiffening strips
(7) are formed from a material, preferably wood, having fibres (70)
or grains with an essentially uniform orientation (fl) in direction
of the longitudinal extension (II), formed with said orientation of
its grains, which is essentially at a right angle to the direction
of the fibres or grains of the vertical fibre layer (5).
12. The building board or building element or the like according to
claim 1, characterized in that, in the preferred case, their two
covering layers (3, 4) are formed with essentially the same
orientation or parallel to one another (fd3, fd4) of the fibres
(30, 40) or grains of the material forming them, preferably the
wood forming them--the reinforced or stiffening strips (7) in the
vertical fibre layer (5) are arranged in their direction of
longitudinal extension (II) such that the fibres (7) or the grains
of the material forming them, preferably wood, extend or extends
essentially at a right angle to the orientation (fd3, fd4) of the
fibres (30, 40) or grains of the two covering layers (3, 4).
13. The building board or building element or the like according to
claim 1, characterized in that the two covering layers (3, 4) are
formed with essentially the same or parallel orientation (fd3, fd4)
of the fibres (30, 40) or grains of the material forming them,
preferably wood.
14. The building board or building element or the like according to
claim 1, characterized in that the vertical fibre layer (5) or the
vertical fibre bodies (51) or vertical body strips (510) forming it
is/are formed from or with a conventional wood, e.g. oak, of or
with a wood of this type with lower quality or of or with a light
wood, e.g. balsa and okume wood, with a density in the range of 0.1
to 0.8 g/cm.sup.3.
15. The building board or building element or the like according to
claim 1, characterized in that the vertical fibre bodies (51)
forming the vertical fibre layer (5) are formed with the same size
and/or form and/or from or with the same materials, in particular
from or with the same type of wood or wood of uniform quality.
16. The building board or building element or the like according to
claim 1, characterized in that the vertical fibre layer (5) is
formed with vertical fibre bodies (51) arranged over their vertical
sides (55) adjoining one another, in particular bonded to one
another, each with an essentially ridge-like cross-sectional form
with a ridge beam (53) and tooth extensions (52) projecting away
from it, preferably at a right angle, whereby the tooth spaces (54)
between them form the vertical cavities (6) of the vertical fibre
layer (5).
17. The building board or building element or the like according to
claim 16, characterized in that the tooth spaces (54) of the
vertical fibre bodies (51) are configured as grooves, channels or
the like which are parallel to one another, preferably formed by
milling, preferably having essentially the same depth, size or
width or cross-sectional area and/or form.
18. The building board or building element or the like according to
claim 16, characterized in that the tooth spaces (54) of the
vertical fibre bodies (51) or the vertical cavities (6) of the
vertical fibre layer (5) essentially have an elongated rectangular
cross-sectional shape, optionally with a rounded base, whereby the
rectangular length is in a ratio to the width (5:1) to (1:1),
preferably (5:2) to (4.3).
19. The building board or building element or the like according to
claim 16, characterized in that, in the case of the ridge-like form
of the cross section of the vertical fibre bodies (51), the width
(br) of the tooth spaces (54) is half to double the width (bz, bb)
of the tooth extensions (52) and/or the ridge beam (53), however,
that the just noted widths (br, bb, bz) are preferably essentially
the same.
20. The building board or building element or the like according to
claim 1, characterized in that it is sealed on at least two
opposite narrow side flanks, preferably on all, with cover moldings
(2), preferably made of wood.
21. The building board or building element or the like according to
claim 1, characterized in that it is curved or arched, whereby the
vertical fibre bodies (51), optionally arranged in more than one
layer on top of one another, or the vertical fibre body strips (51)
formed with them are bonded with their upper and lower sides to the
first or lower curved covering layer (4) and to the second or upper
covering layer (3) and vertical fibre bodies (51) or vertical fibre
body strips (510) which are adjacent to one another--with a convex
curvature or arching of the first covering layer (4) thereto--are
arranged directly adjoining or adjacent with their lower
longitudinal edges lying on this covering layer (4) and spread
apart to the second or upper covering layer (3) at an acute angle,
whereby elongated vacuums or gusset-like spaces expanding in a
wedge-like manner to the second upper covering layer (3) are formed
between them.
22. The building element, in particular a light-construction
support, beam, girder or the like according to claim 1,
characterized in that the building element, in particular the
support (1.sup.X) has essentially the same basic structure with
covering layers (3, 4) and, between them, vertical fibre layer (5),
optionally arranged in several layers, with vertical cavities (6)
as the building boards (1), whereby it is preferable that each of
the covering layers (3, 4) is formed with at least two covering
layers made of wood and bonded together so as to be flat, the at
least one layer of which is formed with an orientation of the
fibres of the wood forming it in direction of the longitudinal
extension of the support (1.sup.X) or the like and the other layer
of which is formed with an orientation of the fibres of the wood
forming it in direction diagonally or at a right angle to the
longitudinal extension of the support (1.sup.X) or the like,
wherein it is preferably further provided that the vertical fibre
layer (5) is formed with vertical fibre body strips (50) extending
essentially at a right angle to the longitudinal extension of the
support (1.sup.X), and wherein a stiffening or reinforcing strip
(7) which extends from covering surface (3) to covering surface
(4), and with grains in vertical direction to the longitudinal
extension of the support (1.sup.X) arranged between each of these
strips (50) or between at least two layers of two or multiple
strips formed from strips (50) of this type which are arranged
adjacent to one another and on top of one another.
23. The building board or building element or the like according to
claim 1, characterized in that it is formed as a sound-absorbing or
acoustic board, preferably made of wood, and either does not
essentially have a covering plate toward the sound source or that
its covering layer (4) facing the sound source is made with
sound-transmitting openings (41) which passes through it,
preferably arranged and formed corresponding to the respectively
desired design and the vertical fibre layer (5) and its vertical
cavities (6) are directly sound-accessible through these openings
(41), whereby, for safety reasons, it is preferred if the inner
walls of the vertical cavities is coated with a fireproof polymer
substance that expands under the effect of heat in case of fire or
is intumescent, or that the building board (1) is configured as a
vibration and resonance board, e.g. for floors and ceilings of
sound-generating or sound-projecting equipment, as in particular
speaker boxes, musical instruments or the like, whereby one of its
covering surfaces (3, 4) can be optionally provided with
sound-projecting openings and the vertical fibre layer (5) and its
vertical cavities (6) are sound-radiating effective through these
openings.
24. The building board or building element or the like according to
claim 1, characterized in that it is configured as a safety
building board, e.g. as a door plate, with two covering layers (3,
4), made for example of wood or in particular of a wood material,
and that the reinforcing or stiffening strips (7), preferably in
hand, in the vertical fibre layer (5), preferably formed with wood,
consist of metal, preferably steel, arranged at a distance from one
another parallel to one another, and/or that a metal plate, sheet
or the like is glued to at least one of the wood covering layers
(3, 4) on the outside, or that, in place of the wood covering
layers, a metal plate, sheet or the like is directly bonded to the
vertical fibre layer (5) in each case, whereby it is preferable
that the metal plate, sheet or the like is bonded by means of an
adhesive which is intumescent or expands under the influence of
heat in the case of fire.
25. The building board or building element or the like according to
claim 1, characterized in that it is made as a heat-insulated
heating building element (9.sup.VI) on the back, having heating
pipes (76), tubes, conductors or the like on one side through which
a heating medium can flow and which are installed in heating
grooves (75) that are worked into the vertical fibre layer (5)
formed with wood, preferably primarily in its reinforcing and
stiffening strips (7), and extending along it, whereby the said
grooves (75) and the heating pipes (76) or the like placed in them
are covered toward the outside with the covering layers (3, 4).
26. The building board or building element or the like according to
claim 1 comprising one of a wall, a partition, a covering element
and a board with high heat, sound and footfall sound-absorbing
action for new constructions, expansions and rehabilitation of
buildings, rooms or the like, characterized in that it is formed
with at least two building boards (1, 1') which are essentially
identical to one another in their basic construction, are spaced
from one another by means of spacers (91), preferably made of wood,
and arranged parallel to one another, preferably formed with
building boards (1, 1') of the type whose two covering layers (3,
4) are made of wood, laminated wood, layerwood, wood chip material
or the like and whose vertical fibre layer (5) also consists of
wood, or that it is formed with at least two building boards (1,
1') which are essentially identical in their basic construction and
directly joined together via their respective main surfaces,
preferably by flat glueing, preferably with building boards (1, 1')
of the type whose two covering layers (3, 4) consist of wood,
laminated wood, layerwood, wood chip material or the like and whose
vertical fibre layer (5) also consists of wood.
27. The building board or building element or the like according to
claim 1, characterized in that it is made with a preferably
load-bearing building board (1) or with more than one building
board (1) of this type bonded together so as to be flat, to which a
fire-retarding board (1) with two covering layers (3, 4) built in a
similar manner on at least one side to obtain the highest fire
safety is bonded and with a vertical fibre layer (5) with vertical
cavities (6) is formed between them, preferably with a not easily
inflammable and burnable wood, e.g. oak, however, of low strength
or thickness, in particular with 2 to 5 cm thickness, whereby the
inner walls and possibly also the base of the vertical cavities (6)
of the vertical fibre layer (5) are coated with a fireproof polymer
substance which expands under the effect of heat in case of fire or
is intumescent.
28. The building board or building element or the like, in
particular a wall, partition or cover element or board according to
claim 27, characterized in that it is designed with three building
boards (1, 1', 1''), each of which is spaced from one another by
means of spacers (91), essentially as designed according to this
claim, and at least basically arranged as noted there.
29. The building board or building element or the like, in
particular a wall, partition or cover element or board according to
claim 28, characterized in that the spacers (91) in the vacuums or
spaces (90) between the building boards (1, 1') are each formed
with one or more bonded vertical fibre bodies (51) having the
vertical cavities (6) and vertical fibres (50) or grains,
preferably made of wood, and that they are arranged such that its
grains also run essentially at a right angle to the main extension
of the building boards (1, 1').
30. The building board or building element or the like according to
claim 1 comprising one of a wall, a partition, a cover element and
a board with high heat, sound and footfall sound-absorbing action
for new constructions, expansions and rehabilitation of buildings,
rooms or the like, characterized in that it is formed with at least
two building boards (1, 1') which are essentially identical to one
another in their basic construction, are spaced from one another by
means of spacers (91), preferably made of wood, and arranged
parallel to one another, preferably formed with building boards (1,
1') of the type whose two covering layers (3, 4) are made of wood,
laminated wood, layerwood, wood chip material or the like and whose
vertical fibre layer (5) also consists of wood, whereby the spacers
(91) are formed by bodies having an open pore structure or free
cavities, in particular by mineral or plastic-based foam or pore
bodies or preferably by pipe pieces preferably oriented diagonally
to the main extension (ed) of the covering layers (3, 4), and that
the space (90), which is optionally provided with a steel
reinforcement (92), is filled with a mineral-based, hardening or
hardened bonding agent, in particular concrete, light-weight or
cellular concrete (95) or the like between the building boards (1,
1').
31. The building board or building element or the like, in
particular wall, partition or cover element or board according to
claim 30, characterized in that the surfaces of the covering layers
(3, 4) thereof which face the space (90) between the building
boards (1, 1') are provided with an adhesion-promoting layer (19),
sanding, foil, net or the like for the adhesive connection of the
binding agent, concrete, light-weight concrete or the like with the
building boards (1, 1') introduced into the space (90).
32. The building board or building element or the like, in
particular wall, partition or covering element or board (9)
according to claim 26, characterized in that at least one of the
covering layers (3, 4) of the building boards (1, 1') is provided
with a plaster-based layer, sheet, net (181) or the like on the
outside which at least repels moisture, but preferably permits
steam diffusion, in particular based on a plastic, e.g. an epoxy
adhesive, with adhesion-increasing sanding or the like.
33. The building board or building element or the like, in
particular wall, partition or covering element or board according
to claim 26, characterized in that it is built directly at the
building or installation site on site as a wall, partition or
ceiling, the two building boards (1, 1') being positioned as,
connected to one another via the spacers (91) and planking boards
of a "lost boarding" with a steel reinforcement inserted in the
space (90) between them and the said space (90) is filled with
concrete, light-weight concrete (95) or the like and at least one
of the building boards (1, 1') can be or is provided with a plaster
and facing plaster layer (18).
34. The building board or building element or the like, in
particular wall, partition or cover element or board (9''')
characterized in that it is formed with a building board (1)
according to claim 1, that an (inner) lining layer (190),
preferably formed with at least one light-construction board, in
particular with a gypsum board or a water or fire-resistant mineral
board, optionally having fire-retarding and/or moisture and
water-repelling properties, is joined to its at least one covering
layer, preferably to its two covering layers (3, 4) on the
outside.
35. The building board or building element or the like, in
particular wall, partition or covering element or board,
characterized in that it is formed with a building board (1)
according to claim 1, whose (inner) finishing layer (190) is
provided with a plaster base (181) or with a finished plaster layer
(18) comprising one.
36. A method for producing a building board or a building element
or the like according to claim 1, characterized in that, in a first
step, parallel longitudinal grooves (60), extending in direction of
the grain, are worked in longitudinally extending beams (58),
steps, boards or the like made of wood or light wood, preferably
corresponding to the ridge-like cross-sectional form of the
vertical fibre bodies (51) with the vertical cavities (6)
traversing them and provided for their formation, and the grooved
beams (58) or the like thus obtained are each arranged in the
arrangement or sequence: tooth extension (52)--ridge beam (53) or
side-by-side longitudinal flank--longitudinal flank adjacent to one
another, joined together so as to seal the material to form
vertical fibre body boards (580), that, in a second step, the
vertical fibre body boards (580) thus obtained are divided into a
number of vertical fibre body strips (510) with the vertical
cavities (6) or tooth spaces (54) that are open to one side by cuts
(S) that lead diagonally to the extension of the longitudinal
grooves (60), each corresponding to the desired thickness of the
vertical fibre layer (5) uniformly spaced from one another, that,
in a third step--optionally or if desired after arranging the
reinforcing or stiffening strips (7) between them--the vertical
fibre body strips (510) are turned by 90.degree. and either
laterally adjoining one another with their longitudinal sides (511)
or adjoining the tooth extension (52)--ridge beam or, after
application of an adhesive, bonded to one another and placed on a
first layer (4) of the covering layers (3, 4) and bonded to it in
such a way that the vertical cavities (6) and the vertical fibres
(50) are oriented essentially at a right angle to the extension
(ed) of this covering board (4), and that, in a fourth step, the
covering layer (3) still missing after an adhesive has been applied
and bonded to the vertical fibre layer (5) is placed on the e.g.
vertical fibre layer (5) which is still open to the top on one side
with the cavities (6) there which are also still open.
37. A method for producing a building board or a building element
or the like according to claim 1, characterized in that, in a first
step, parallel longitudinal grooves (60'), extending in direction
of the grain, are worked into longitudinally extending boards
(58'), beams, steps, or the like made of wood or light wood,
preferably corresponding to the ridge-like cross-sectional form of
the vertical fibre bodies (51) with the vertical cavities (6)
traversing them and provided for their formation, that, in a second
step, the boards (58') or the like provided with the longitudinal
grooves (60') adjoin one another along their longitudinal side
flanks (55') while forming a layer or first partial layer (TL1)
with their non-grooved or grooved main surfaces are deposited on a
reinforcing strip layer (700) provided for the forming of the
reinforcing strips (7), preferably made of wood, while bonding so
as to seal the material to it laterally joined to one another,
that, at least in an intermediate optional step, at least one
second partial layer (TL2) of grooved boards (58') or the like
which also adjoin one another along their longitudinal side flanks
(55'), is deposited on the first partial layer (TL1) of grooved
boards (58'), mutually offset with respect to their longitudinal
side flanks (55'), and joined to the first partial layer TL1, that,
in a third step, a further strip layer (700') which is preferably
similar to the strip layer (700') already mentioned above, is
attached to a third partial layer (TL3), respectively bonded as the
last one and to the previous partial layer (TL2), also laterally
offset again, and bonded to the last partial layer (TL3), that, in
a fourth step, the plate-like initial body (580') thus formed is
divided into a number of vertical fibre body strips (510'),
optionally each flanked on both sides by a stiffening strip (7'),
by cuts (S) made essentially at a right angle to the longitudinal
grooves (60') and the grain of the partial layers (TL1, TL2, TL3)
or the grooved boards (58') or the like forming them, each spaced
(as) equidistantly from one another, and that, in a fifth step,
these vertical fibre body strips (510') adjoin one another
laterally or in the arrangement or series after an adhesive has
been applied: tooth extension (54)--ridge beam (53) placed on a
layer (4) of the covering layers (3, 4) and in this way bonded to
it, that the vertical cavities (6) are oriented essentially at a
right angle to the extension (ed) of these covering plates (4), and
that, in a sixth step, after an adhesive has been applied, the
still missing covering layer (3) is placed on the vertical fibre
layer (5) which is still open to the top and bonded to the vertical
fibre layer (5).
38. The method according to claim 37, characterized in that the
strip layers (700) are used with grains that conform to one another
or are parallel, extending essentially at a right angle to the
grain of the boards (58') provided with the grooves (60').
39. Use of building boards or building elements or the like
according to claim 1, either directly as light-weight, dividing and
optionally supporting elements, such as in particular walls,
partitions (intermediate) ceilings, (intermediate) floors and the
like, for new constructions, reconstructions and expansions of,
optionally mobile, buildings, in particular finished part
buildings, or as facing boards or the like that are optionally used
in the manner of a "lost boarding", in particular as heating and
sound-absorbing and insulating boards for buildings and building
structures.
40. Use of building boards or building elements or the like
according to claim 1 for furnishing buildings, building parts and
rooms, attics, cellars and the like of buildings with heat and
sound-insulating facings and linings.
41. Use of building boards or building elements or the like
according to claim 1 with the proviso that it is formed with a
vertical fibre layer (5), whose vertical cavities (6) are coated
with a fireproof or fire-retarding substance which expands under
the effect of heat in case of a fire or is intumescent, and/or that
they are provided on at least one side with a fireproof mineral
board bonded to it or similar fire-resistant coating or that at
least one of its covering layers is formed directly with a
fireproof mineral board of this type or the like, for furnishing
buildings, building parts and rooms, attics, cellars and the like
of buildings with fireproof and also heat and sound-insulating
facings.
42. Use of building boards or building elements or the like
according to claim 1 for interior furnishing of buildings and
rooms, in particular for hinged and sliding doors, safety doors and
the like.
43. Use of building boards or building elements or the like
according to claim 1 for shipbuilding, boat and mobile home
construction, trailer and camper building, in particular as
"sandwich board" for light-weight furnishing of vehicles, ships,
boats, mobile homes and the like, such as floors, facings, built-in
elements, built-in furniture and the like.
44. Use of building boards or building elements or the like
according to claim 1 for erecting halls, bunks, stands,
superstructures and extensions of the fair, exhibition,
presentation and market sector.
45. Use of building boards or building elements or the like
according to claim 1 for furniture building as well as for interior
architecture and building furnishing purposes.
46. Use of building boards or building elements or the like
according to claim 1 for instrument making, preferably for
resonance and vibration boards of sound-emitting equipment, such as
loudspeaker boxes, in particular for ceilings and floors, of
(string) instruments and the like.
Description
[0001] The present invention relates to a new building board or a
new building element, in particular a support element, structural
element, wall element, facing element or the like, having a
multilayer structure, preferably wood-based or consisting of wood
materials, which consists of at least three bonded layers, plies,
boards, sheets or the like, in particular having two covering
layers which are spaced from one another and parallel to one
another and having a core layer arranged between them and connected
with them.
[0002] A great number of essentially lamellar and/or beam-like
building, structural, support, wall and/or facing elements,
constructed according to various principles, for various purposes,
as have become known for building elements for installation in
already existing building structures or the like with a multilayer
structure for new buildings, extensions, redevelopment, furnishings
or the like of buildings, structures, and the like as well as for
mobile structures, partition elements or the like, as used e.g. for
exhibitions, fairs, presentations, markets or the like, and
furthermore, in particular, for boards for outfitting buildings and
for partitions in buildings, with heat insulating and sound
insulating panelling or the like, for the furniture and exhibition
construction sector and for panelling and lining elements in
vehicle and boat or ship building, for outfitting trailers, mobile
homes or the like or also for auxiliary devices used in the
building and construction industry, such as boarding in highrises
and the like, and used widely nowadays to an ever increasing
extent.
[0003] Based on concrete experiences obtained in practice and
expanded series of experiments within the scope of corresponding
development work, it has now been found successful to create new
building boards or building elements or the like of the
aforementioned type with substantially improved strength, sound and
heat insulating values as well as other advantageous physical,
constructional, physical and biological properties which are
furthermore distinguished by high quality of use and environmental
friendliness and, furthermore, by biological degradability and thus
high waste disposal quality, in particular when they--as preferably
provided--are produced or predominantly produced with biogenic
materials, i.e. in particular with natural, i.e. gown, wood or
based on such wood materials.
[0004] The object of the invention now is the aforementioned
building boards or building elements, such as in particular support
elements, structural elements, wall elements, boarding elements or
the like according to the preamble of claim 1 which have the
features or combination of features disclosed in the characterizing
part of this claim.
[0005] By orienting the fibres or grains of the core layer
diagonally, which is imperatively provided according to the
invention, i.e. at least essentially at a right angle to the main
extension of the new building boards, a structurally physically and
biologically valuable, compensating diagonal diffusion of moisture
and the like is made possible while fully maintaining the high
mechanical strength and resistance, vibration absorbing and heat
insulating properties and, at the same time, a high mechanical load
capacity and load-carrying capacity of the new building elements
or, in particular, also surface load capacity in the new building
boards, is ensured.
[0006] The tendency of wood to shrink or expand in fibre direction
is, e.g. when the ambient moisture changes, very low and is at most
about 1%, with which an almost constant thickness of the vertical
fibre core layer is ensured, preferably having a substantially
higher thickness than the covering layers, and consequently
essentially of the entire building element or the entire new
building board.
[0007] To a large extent, the new building board or the new
building element or the like enables the use of even inferior
quality wood, waste wood and, in particular, also light-weight wood
in a conventional and in as cost-efficient manner possible in
accordance with market conditions for the core layer, i.e. vertical
fibre layer, occupying relatively thick and thus a relatively high
portion of the overall volume thereof in comparison to its covering
layer, as a result of which substantial costs can be saved in each
case without having to accept losses with respect to stability and
strength of the new building elements.
[0008] An essential further advantage is that, as a result of the
"vertical orientation" of the fibres or grains in the vertical
fibre layer, even woods having a slight thickness and/or lateral
strength can be used which are, however, nevertheless definitely
sufficiently stable in direction of the wood grain against the
effect of pressure in direction of grain, with which mechanically
stable building boards having thusfar unattainable volumetric
density can be obtained, whereby the material thickness of the new
boards, supports and the like can also be kept low, if required. At
this point, it should be noted that the term "building boards"
which is used often here in no way relates only to structural,
boarding and facing boards for buildings, but that this also
generally includes boards for various other purposes, such as e.g.
for outfitting buildings, for the furniture and installation
industry as well as for various support and dividing elements and
the like for building and other purposes.
[0009] According to the embodiment especially preferred within the
scope of claim 1, in particular in the sense of a substantial
reduction of the weight or mass of the new building boards or
building elements or the like increasingly demanded nowadays and a
consequently substantially improved handling ease and mobility
thereof with definitely high stability and mechanical strength, it
is provided that the vertical fibre layer, which is preferably
formed with wood, with a plurality of vertical cavities, recesses,
millings, bores or the like which traverse said vertical layer,
with the essentially vertical orientation of the vertical fibres or
grains of the material forming this layer, preferably wood, having
at least essentially corresponding orientation, in particular
parallel thereto.
[0010] The advantage of this embodiment, which is especially
preferred within the scope of the invention, is based on the fact
that it was found that a substantial reduction of the weight of the
new building board can be obtained by the vertical cavities in the
vertical fibre layer, oriented in conformity with the direction of
the fibres, which does not, however, in any way dramatically lower
the strength as could perhaps be expected, however, wherein
transverse (moisture) diffusibility and moisture compensation are
substantially increased.
[0011] Further particulars regarding the embodiments preferred for
the properties of the new building boards or building elements
within the scope of the invention, the advantageous design and
distribution of the vertical cavities and the dimensional ratios
between vacuum volumes and wood mass in the vertical fibre layer
can be found in claims 2, 3 and 4.
[0012] When using wood in the building industry, it is quite
essential that great attention be given to fire prevention.
[0013] With the coating of the inner walls of the vertical cavities
with an intumescent polymer substance described in claim 5, which
can be easily applied in a thin layer thickness, preferably by
spraying from nozzles temporarily installed in these cavities
during the production process, a highly secure fire-retardation is
obtained by filling the cavities with the polymer which foams in
the heat in the case of a fire, in particular, by preventing any
air suplayer.
[0014] Furthermore, an embodiment of the new building boards or the
like according to claim 6, which comprises at least essentially
corresponding covering layers with respect to their materials
and/or material properties, is preferred.
[0015] An advantageous embodiment of the vertical fibre layer of
the building board according to the invention, in particular along
the lines of high production savings, can be found in claim 7.
[0016] To further increase the mechanical strength and resistance
to distortion, claims 8 to 11 disclose advantageous embodiments of
the new building board or the like in which stiffening or
reinforcing strips are arranged that increase the strength and
preferably consist of wood and which are "upright" within the
vertical fibre layer, i.e. also "vertical", and increase the
strength, however, for which other materials can also be used, e.g.
plastics or metals.
[0017] In addition to the two embodiments of the building boards
according to claim 8, it should also be noted that boards according
to the first variant noted there are primarily provided for the
furniture and interior furnishings industry, and that boards
according to the second variant are primarily suitable for
supporting components, i.e. for example for ceilings.
[0018] An especially preferred embodiment according to the
invention for the new building boards with stiffening strips can be
found in claim 12, said embodiment being distinguished by
especially high mechanical stability, strength and constancy of
shape.
[0019] Claims 13 and 14 disclose advantageous embodiments of the
covering layers and, having regard to as high a reduction in weight
as possible, advantageous materials for the vertical fibre layer of
the new building board, of the new building element or the
like.
[0020] Claim 15 relates to a special embodiment of the vertical
fibre layer which is preferably formed from or with individual
vertical fibre bodies laterally bonded to one another over their
vertical lateral side.
[0021] In particular with respect to a cost-effective production,
the use of embodiments of the vertical fibre body, as described in
detail in claims 16, 17, 18 and 19, is especially preferred for
forming the vertical fibre layer of the new building boards,
building elements or the like.
[0022] Claim 20 provides detailed information about the lateral
covering, i.e. the covering of the narrow sides of the new building
boards or building elements or the like.
[0023] A special building board or the like which is either curved
or perhaps even arched according to a further embodiment of the
invention can be found in claim 21, which is suitable e.g. for
facing components with correspondingly curved or arched
"topography".
[0024] Furthermore, the invention is in no way restricted to boards
or the like for the most varied purposes, it is also directed to
supporting elements, girders or the like in the building industry,
i.e. to predominantly longitudinally extending building elements
having a support function, which inherently combine the advantages
of high mechanical strength with the other advantageous
characteristic properties of wood. An especially preferred
construction and embodiment of such a supporting element, girder
support or the like according to the invention is disclosed in
claim 22. It should be emphasized that every type of design of such
supporting elements are possible here when only the basic principle
of the construction according to the invention is retained.
[0025] In total, claims 23 and 24 disclose four forms of the new
building boards or building elements or the like which are
specifically directed to the object and which fulfil the object and
which can be used, on the one hand, as sound-absorbing elements or
boards and, on the other hand, as sound-generating, amplifying or
resonance elements in the sound equipment and instrument building
industry and, furthermore, for a completely different purpose,
namely for highly stable door plates of burglar-proof doors or the
like.
[0026] Since sound-absorbing boards according to claim 23 are
installed in residential and work rooms, e.g. studio rooms, and
since the preferred material for this is wood, the greatest
attention should be paid to fireproofing: It was now found that a
thin coating on the inner walls of the vertical cavities of the
vertical fibre layer with a fire-protection polymer is quite
adequate, even when the thickness of the board consisting
completely of wood is only 2 cm and, accordingly, its vertical
cavities ultimately only have a depth of about 1.5 cm, in order to
obtain a problem-free fire-retarding effect, which corresponds in
any case to the fireproof class F90 (at least 90 min fire-retarding
effect, however, whereby this value of F90 is exceeded by far in
most cases.
[0027] Therefore, if, for example, the ceilings in a building are
made with building boards made exclusively of wood according to the
invention, e.g. multilayer in sandwich form, then it is sufficient
(as tests have shown) to place a thin board having the basic
construction of the invention and coated with the fire-retarding
polymer in the vertical cavities, as just described, on the side in
question or endangered by a possible fire, i.e. for example in
ceilings, mostly on the face or underside, and, in this simple way,
it is made fully fireproof, although the wood building boards which
form the ceiling in several layers, e.g. laminated to one another,
do not themselves have any fireproof coating or the like. Of
course, fireproof boards provided with the fire-retarding polymer
can also be placed on both sides of a ceiling, as just
described.
[0028] With respect to the special embodiment of the new building
boards noted in the second part of claim 24, it is especially
suitable for supporting floors, ceilings, wall elements and the
like, in which increased fire protection is required. Boards of
this type can be used e.g. in railroad construction, vehicle
construction, ship and aircraft construction, furthermore for
installation in traffic construction, e.g. tunnels, for safety door
plates and the like.
[0029] Claim 25 relates to a completely new embodiment of the new
building board which can be used as an actively heating module
heating wall, as a ceiling heating element or directly as a heating
module or structural heating element, even though it consists
predominantly of wood or of a wood material.
[0030] Claim 26 relates to an especially preferred embodiment of
the invention for wall, partition, ceiling elements or the like
having a high heat insulating and sound insulating effect using the
building boards of the invention, in particular in its basic
form.
[0031] Within the sense of the above comments regarding obtaining
the highest fire-protection safety, an embodiment of the building
boards, building elements or the like according to claim 27 is
especially preferred, wherein the fireproof values required
according to "F90" are in any event always attained, however,
exceeded by far most of the time, so that any concerns against the
basic material wood, on which the new building boards or building
elements are based, are dispelled. With respect to the wood which
is not easily flammable and combustible and can be advantageously
used according to this claim, the advantage is here given that it
is quite sufficient to use fireproof wood, e.g. oak, for the
vertical fibre layer, which can definitely be of a lower quality
and which could thusfar practically find no use otherwise and which
can therefore be obtained at a very low cost.
[0032] Claims 28 and 29 relate to further advantageous embodiments
which are each directed to special types of uses in construction,
for wall elements, ceiling elements or the like according to the
invention using the new building boards.
[0033] A mechanically especially stable, structure-forming building
element furnished with the building boards according to the
invention comprises the high sound and heat insulating properties
can be found in claim 30.
[0034] The subject of claims 31 and 32 are wall or ceiling elements
or boards or the like, as described above, in which a stable
connection to the supporting concrete or the like is ensured and
which, furthermore, can be provided with a plaster layer in a
conventional manner or already provided with a finished plaster
coating.
[0035] Claim 33 relates to wall elements or the like furnished with
building boards having a heat and sound insulating effect which can
be used and set up in situ, i.e. directly, at the installation
site, or already produced as finished elements.
[0036] Claims 34 and 35 relate to easy-to-handle wall elements,
wall boards or the like which are distinguished by low weight and
are especially suitable for light construction, installations in
buildings, for exhibition purposes, for fair construction and the
like, and whose face or top surface structure is formed with
conventional means or in a known manner.
[0037] Furthermore, within the scope of the invention, claims 36 to
38 relate to especially advantageous methods distinguished by an
economic manufacturing mode for the production of two advantageous
main embodiments of the new building boards, namely for the
especially preferred cases of the invention that they are formed
completely or at least predominantly with wood. It should now be
briefly mentioned here that the method according to claims 36 and
37 is nevertheless distinguished by especially high manufacturing
economy in spite of the apparently expensive, multi-step processes,
since all procedural steps can be fully automated without
difficulty and thus minimize the staff expenditure.
[0038] Claims 39 to 46 relate to the most important fields provided
according to the invention for aplayering or using the new building
boards, building elements or the like for which they are especially
suitable. However, this does not in any way exclude other or
further application sectors.
[0039] On the whole, it should be noted that the new building
boards, building elements or the like are distinguished by low
weight with simultaneously high mechanical bending strength,
torsional strength and compressive strength, in particular due to
the "cross connection" provided according to the invention of
covering layers and core layer which have relatively different, in
particular vertical orientation of the fibres or grains and due to
possible reinforcing strips, and by high heat and sound insulating
properties, furthermore, by high economy especially with respect to
the (wood) material used for producing them which includes
essentially cost-effective economically useable wood, as well as
especially with respect to the type of production itself which can
be automated without difficulty. With respect to the economic
efficiency, it should furthermore be pointed out that e.g. wood
scraps resulting during milling of the grooves for the vertical
fibre bodies can be used for producing the covering layer boards of
the new building boards made from this waste wood or generally for
chipboards, furthermore, for the direct energy recovery by burning
for recovery of wood distillate products, melamine raw materials
and the like.
[0040] By no means last, reference is made to the aspect of the
high environmental friendliness of the new building boards made
preferably of natural wood without treating with chemicals or the
like within the scope of the invention, which are ultimately
biodegradable without difficulty and can be returned into the
natural cycle or are energy recyclable without generating fossil
CO.sub.2.
[0041] The invention will be described in greater detail with
reference to the drawings:
[0042] FIG. 1 shows a partially cut open building board according
to the invention in an diagonal view;
[0043] FIG. 2 shows an especially preferred embodiment of the
vertical fibre body provided for the formation of the vertical
fibre layer in an diagonal view;
[0044] FIG. 3 shows a vertical fibre body strip formed with the
vertical fibre bodies with reinforcing strips bonded to their
lateral sides interconnected with further vertical fibre
bodies;
[0045] FIG. 4 shows a schematic diagonal view of a beam provided
with grooves which forms the initial component for producing the
vertical fibre bodies, also interconnected with further beams of
this type;
[0046] FIGS. 5 to 7 show a similar variant for the production of
the new building boards with another design of their vertical fibre
layer;
[0047] FIG. 8 shows a wall element furnished with the new building
boards on both sides in a diagonal view;
[0048] FIG. 9 shows a sectional view through a wall piece produced
on site using the new building board in the production phase;
[0049] FIG. 10 schematically shows the on-site production of a
concrete cover furnished from the start with the new sound and heat
insulating building boards according to the invention, in
accordance with the principle of the lost facing;
[0050] FIGS. 11 and 12 show two partition elements based on the new
building board;
[0051] FIG. 13 shows a three-layer wall element produced with the
new building boards in section; in a diagonal view,
[0052] FIG. 14 shows a building board formed as a sound-absorbing
board according to the invention;
[0053] FIG. 15 schematically shows a building board formed as a
heating element;
[0054] FIGS. 16 and 17 show quasi photographic views of two
building boards partially robbed of their face-sided covering layer
which is made completely of wood;
[0055] FIGS. 18 to 20 illustrate an especially preferred type
according to the invention for producing the new building
board;
[0056] FIG. 21 shows one of the possible embodiments of a support
built according to the same basic principle as the building board;
and
[0057] FIG. 22 shows a building board according to the invention
having a curved shape.
[0058] The building board 1 shown in a diagonal view in FIG. 1
comprises as main components a first covering layer 3, joined
together by heat sealing or the like and having a thickness dd3,
and a covering layer 4, arranged at a distance therefrom and
parallel thereto, having a thickness dd4, and a vertical fibre
layer 5, arranged between these two covering layers 3 and 4 as a
core layer and having fibres 50 or grains in direction fv at a
right angle to the two-dimensional extension ed of the covering
boards 3 and 4. This layer 5 is formed with vertical fibre bodies
51 which is here parallelepiped in shape, with a width bv, and
arranged in a row behind one another to the linear straight
vertical fibre body lines or strips 510, bonded together via their
opposite lateral sides 55.
[0059] In the embodiment shown here, upright reinforcing or
stiffening strips 7, each adjoining their vertical longitudinal
lateral sides 511, with narrow rectangular cross section having an
upper and lower narrow side 72 and vertical side surfaces 71 on
both sides, between vertical fibre body strips 510 adjacent to one
another and directed toward the observer. The reinforcing or
stiffening strips 7 are here also formed with wood, whereby the
direction fl of their fibres 70 corresponds to the longitudinal
direction of extension II of these reinforcing strips 7.
[0060] It is especially preferred within the scope of the invention
and for the structural strength of the new building board 1 if the
wood grain 70 of the reinforcing strips 7 extends in a direction fl
which runs at a right angle to the fibres 30, 40 of the wood
forming the two covering surfaces 3 and 4 which have flow
directions fd3, fd4 that correspond to one another or are parallel
to one another, i.e. when a "crossed" run of the fibres 30, 40 of
the covering surfaces 3, 4 is provided relative to the fibres 70 of
the reinforcing strips 7.
[0061] It should be clearly pointed out at this point that not
every vertical fibre body strip 50 must be accompanied by a
reinforcing strip 7 adjoining it, but, depending on the required
strength and (torsion) rigidity of the new building boards in the
vertical fibre layer 5, two or more vertical fibre strips 510 can
be arranged horizontally without reinforcing strips 7 arranged
between them, i.e. directly along one another, so that e.g. a
reinforcing strip 7 only follows after two or more directly
adjacent vertical fibre body strips 510 and then again two or more
directly adjoining vertical fibre body strips 7 without interposed
reinforcing strips 7, etc.
[0062] Furthermore, it should be clearly noted that, in particular
when new building boards 1 are subjected to relatively slight or
almost no loads, i.e. when they are provided e.g. for heat or sound
insulating facings without a substantial support function, of
course, no reinforcing strips at all can be provided between the
vertical fibre body strips 510, i.e. that these strips 510 all
directly adjoining one another longitudinally form an ultimately
uniform vertical fibre body layer 5 without interruption by
reinforcing strips. In this case, it is especially advantageous if
the covering layers 3 and 4 are not formed of grown wood but as
homogeneous chipboards which do not have a distinct grain direction
and which are direct and compact and have a quite thin material
thickness, e.g. between 3 and 55 mm.
[0063] It is provided within the scope of the invention in an
especially preferred manner, in particular for reasons of a
substantial reduction of the weight of the building boards 1, that
the vertical fibre layer 5 or the vertical fibre bodies 51 forming
it is or are traversed by a plurality of advantageously similar
shaped cross sections Qh, e.g. having a rectangular,
parallelepiped, U-shaped or circular cross section (as shown in
FIG. 1) which run parallel to one another and are preferably
distributed in a uniform manner, extending in direction fv of the
fibres 50 of the vertical fibre bodies 51, passing through the
vertical fibre layer 5 completely from covering board 3 to cover
board 4, in vertical cavities 6 oriented in vertical direction hv,
i.e. by channels, bores, through holes or the like.
[0064] Furthermore, it should be clearly noted at this point that
the covering layers 3 and 4 do not have to be made of wood or wood
materials, e.g. homogeneous boards, but may be made of the most
varied materials, e.g. of plastics reinforced with fibres having a
uniform orientation and/or longitudinally extended, of metals,
paper and cardboard, of textile fleeces, woven fabrics, foils or
the like, however, it is preferred if these materials have an
essentially intrinsically inherent parallel fibre structure, as is
the case especially preferred in wood or e.g. also in greatly
elongated plastics. Furthermore, plastics reinforced with silicate
or carbon fibres having an essentially uniform orientation can be
used as material for the covering layers 3 and 4.
[0065] With respect to the aforementioned stiffening strips 7 in
the vertical fibre layer 5, the same applies more or less for the
materials forming them, as just described for the covering surfaces
3 and 4, they also advantageously have longitudinal fibres of
longitudinal fibre reinforcement, as is especially the case in
wood.
[0066] It is especially preferred if the vertical fibre layer 5 is
formed with conventional wood or light wood within the scope of the
present invention, whereby it is almost of no consequence for the
stability and strength of the new building boards if this wood only
has average quality or in many cases even below average quality,
which contributes substantially to lowering the costs of the new
building boards 1 without disadvantageously affecting their
quality.
[0067] On its lateral sides, the vertical fibre layer 5 of the new
building board 1 is advantageously covered toward the outside with
side strips 2 or the like.
[0068] With otherwise the same reference numbers, FIG. 2 shows one
of the vertical fibre bodies 51, bonded together, and a plurality
of which form the vertical fibre layer 5 shown in FIG. 1: In the
form shown here, it has an essentially basic parallelepiped form
with a width bv. The height hk of the body 51 is variable,
depending on the overall thickness of the building board 1 desired.
The vertical fibre body 51 has an approximately ridge-like
cross-sectional form with a basic or ridge beam 53 and tooth
extensions 52 protruding at a right angle away from them and ending
freely, formed the same here with end faces 521. In this case also,
uniformly shaped notches or tooth spaces 54 are placed between the
tooth extensions 52, which ultimately form the vertical cavities 6
in the vertical fibre layer 5 according to FIG. 1. The ridge beam
52 has a width bb, the tooth extensions 52 have the width bz and
the tooth spaces 54 between them the width br. Optionally, the just
noted widths bb, bz and br can be the same. The overall
cross-sectional area of the wood mass of the vertical fibre body 51
is designated with Qm. The width of the vertical fibre body strips
510 is here designated with bl and equal to the width bv of the
vertical fibre body 51 shown in FIG. 1.
[0069] FIG. 3 shows (with otherwise the same reference characters)
shows a vertical fibre body strip 510 with its vertical lateral
sides 511, present in association with additional similar vertical
fibre body strips 510, formed with several ridge-like vertical
fibre bodies 51 which are each joined together over their tooth end
faces 521 and their basic beam 53. The vertical fibre strip 510 is
joined on both sides with similar vertical fibre strips 510,
optionally with the insertion of a stiffening or reinforcing strip
7 each, said vertical fibre strips as a whole forming the vertical
fibre layer 5 of the new building board 1.
[0070] By joining the vertical fibre bodies 51 to form the vertical
fibre body 510, the tooth spaces 54 of the vertical fibre bodies 51
(as shown in FIG. 2) form the vertical cavities 6 here having an
elongated rectangular cross section. The ratio of its longitudinal
side to its broadside is, for example, in the extreme (1:10) to
(1:1) and advantageously about (2:3) to (3:4).
[0071] With respect to an especially preferred method for producing
the vertical fibre layer 5 of the new building boards 1 or the
vertical fibre body 51 provided for forming it within the scope of
the present invention, which is distinguished by its high economic
efficiency, FIG. 4 provides further details in association with
FIGS. 2 and 3 (with the same reference characters):
[0072] FIG. 4 shows several longitudinally extending wood beams 58
which are arranged above one another, each connected on the top and
bottom adjoining one another to form a strip body 580, into each of
which a number of parallel longitudinal grooves 60 have been milled
corresponding to the cross sectional form of the individual
vertical fibre body 51 shown in FIG. 2, in a prior first procedural
step I not shown separately here.
[0073] By means of cuts S extending at a right angle to the
longitudinal direction of extension 1b of the grooved beams 58,
each corresponding to the desired thickness of the vertical fibre
layer 5 in the building board 1, at the same distance as from one
another, the beams 58, which are first provided with the grooves 60
are divided into the individual vertical fibre body strips 510 in a
second step II, as shown in FIG. 3, even if still temporarily in
another position.
[0074] In the transition from the second step II to the third step
III of the manufacturing process, these vertical fibre body strips
510 are turned by 90.degree. into the position of FIG. 3 and a
number of them arranged in a row beside one another. Together with
the reinforcing strips 7 each arranged laterally between them, the
vertical fibre body strips 510 are glued together laterally on both
sides so as to adjoin one another and ultimately form the vertical
fibre layer 5. After gluing its lower side, the vertical fibre body
strips 510 thus joined to form the layer 5 are placed on the lower
covering layer 4 made of wood and bonded to it.
[0075] It is especially effective for the case that reinforcing
strips are to be provided in the vertical fibre layer 5 to proceed
in such a manner that, before the strip body 580 in the vertical
fibre body strips 510 thereon is opened, a board whose thickness
corresponds to the thickness of the desired reinforcing strip 7,
and with grains extending at a right angle here, is glued to the
strip body 580. Vertical fibre body strips 510 are obtained by the
cuts S, also in vertical direction, which are also connected with
the reinforcing strip, resulting together with it from the cut S,
at least on one side.
[0076] Finally, in step IV, the upper covering layer 3 is attached
from the other, here upper side, after the upper side of the
vertical fibre body layer 5 has been glued, after which all the
aforementioned components are joined under the application of
pressure and perhaps heated to form the complete building board
1.
[0077] FIGS. 5 to 7 show another type of production of the new
vertical fibre body layer 5 with the otherwise same reference
characters:
[0078] In a first step, in the same manner as in FIGS. 3 and 4,
parallel grooves 60 are worked into longitudinally extending
strips, boards, beams 58 or the like in longitudinal direction and
grain direction, the grooved beams 58 thus obtained are then glued
together, side by side, i.e. not on top of one another, but beside
one another, as will be shown directly in the following FIG. 6, so
that the grooves 60 of said beams are open toward one side, toward
the top in FIG. 6. A wood board which covers the open grooves 60 of
the adjacent grooved beams 58, can then perhaps be glued onto the
freely upwardly protruding tooth extensions 52 or onto their ends
521, the grain of said wood board being at a right angle to the run
of the grooves 60, from which ultimately the reinforcing strips 7,
as previously described, would be produced, as indicated in FIG. 7
by broken lines.
[0079] According to FIG. 6, this does not occur, however, cuts S
which extend at a right angle to the run of the grooves 60 are made
in the grooved beams 58 which are bonded side-by-side and on the
whole form an essentially board-like strip body 580, as symbolized
by a saw blade in FIG. 6, and the strip body 580 is opened in this
way into the individual vertical fibre body strips 510.
[0080] Subsequent thereto, as indicated by an arrow between FIGS. 6
and 7, the vertical fibre body strips 7 are tilted by 90.degree.
and are then deposited adjacent to one another on the first
covering layer 4, namely such that they each adjoin one another in
the arrangement tooth extension 52 of a strip 510/ridge beam 53 of
the adjacent strip 510, whereby the vertical fibre layer 5 is
simultaneously bonded to the lower covering layer 4. Finally, the
vertical fibre layer 50 is glued on the upper side and the second,
i.e. here upper covering layer 3 attached to it and bonded to it,
usually by means of (hot) press under pressure.
[0081] With otherwise the same reference characters, FIG. 8 shows,
in a diagonal view, the formation of a wall element 9 with two
building boards 1 and 1' which adjoin said wall element and
function as facing, in particular as heat-insulating boards, as
described above.
[0082] The two building boards 1, 1' are stabilized in position at
a distance from one another, whereby the space 90 between them is
traversed by spacer elements 91 which are uniformly distributed,
bridge them and essentially adjoin the building boards 1, 1' here
functioning for the first time as planking boards on the inside,
said spacer elements 91 here being formed with tubular pieces, made
e.g. of plastic. Reinforcing bars 92 are installed in the spaces
90.
[0083] On the inside, the building boards 1, 1' can be provided
with a moisture-repelling, yet preferably steam-permeable
adhesion-promoting layer 19, e.g. based on epoxy resin with a
sanding.
[0084] Light-weight concrete 95, for example, is then poured into
the spaces 90 between the two building boards 1 and 1', whereby the
spacer tubular pieces 91 remaining free on the inside are recast
and the concrete 95 binds to the building boards 1, 1' forming the
so-called one "lost boarding".
[0085] After the concrete 95 has hardened, a wall piece provided
with finished heat and sound insulating facing boards 1, 1' on both
sides or a finished wall element 9 of this type is obtained. On the
outside, the boards 1, 1' can also be provided with a coating
carrier 181, e.g. with a coating net, or directly with a finished
coating 18.
[0086] The design of the spacer elements 91 as tubular pieces that
are empty on the inside has the advantage that steam diffusion can
occur there diagonally through the wall 9. Of course, any other
type of spacer element 9 can also be used.
[0087] With otherwise the same reference characters, FIG. 9
schematically shows the actual procedure in on-site construction of
a wall or wall piece 9' corresponding the wall element shown in
FIG. 6. It is shown there that the two building boards 1, 1', which
first serve as sheathing boards and finally form the facing of the
wall piece are held in position on the outside against deformation,
in particular bulging, by means of supporting beams 901 and 902 or
the like and continuous screw shafts 903 with butterfly nuts 904,
before the space 90 between the boards 1 and 1' housing the
reinforced irons 92 is filled with concrete 95.
[0088] With otherwise the same reference characters, FIG. 10
schematically shows the production of a cover 9'' by pouring the
cover 9'' with concrete 95 on an again "lost boarding" formed
according to the invention, supported by means of screw bolts 905
and supporting beams 901 after the reinforced irons 92 have been
laid. After solidification thereof, the support construction 901,
905 is removed and a finished concrete cover 9'', provided e.g.
with a sound insulation or acoustic lining on the ceiling.
[0089] With otherwise the same reference characters, FIG. 11 shows
a further wall element 9''' which is formed with a building board 1
and conventional gypsum boards 190 bonded to it on both sides.
Instead of the gypsum boards 190, highly fireproof fire-retarding
mineral fibre boards can be attached and a wall with F90
fire-retarding effect can be produced in this way.
[0090] The two covering layers 3, 4 are themselves immediately
formed with the gypsum board 190 or the like in the building board
1 which is constructed even more similar and can be used directly
as such e.g. as a partition element 9.sup.IV (shown in FIG. 12 with
otherwise the same reference characters).
[0091] With otherwise the same reference characters, FIG. 13 shows
a wall element 9.sup.V formed with three building boards 1, 1' 1''
which are arranged parallel to one another at a distance from one
another, in which spacer elements 91 are arranged in the two spaces
90 between two boards 1, 1', 1'' each, said spacers 91 bonded
together e.g. from several vertical fibre bodies 51 which are shown
in principle in FIGS. 1 and 2, and designed appropriately
simpler.
[0092] With otherwise the same reference characters, FIG. 14 shows
a building board 1 made as an acoustic of sound-absorbing facing
board for acoustically neutral areas, said building board differing
above all from the building board 1 shown e.g. in FIG. 1 in that
the same continuous, here oval sound-absorbing openings 41 are made
in the covering layer 4 facing the sound generator, which releases
the access of the sound to the vertical fibre layer 5 visible due
to the openings 41 with the vertical cavities 6 which are here
functioning as sound-absorbing cavities that nullify sound energy
by the multiple reflection.
[0093] With otherwise the same reference characters, FIG. 15
schematically shows an embodiment of the new building board 1
designed and usable as a modular board heating element 9.sup.VI or
directly as a heating unit or the like:
[0094] Copper heating pipes 76 or plastic heating tubes, through
which a heating medium, e.g. hot water, can flow, are here placed
in grooves 75 having an appropriately sized cross section on the
upper side of correspondingly wide reinforcing strips 7 of the
vertical fibre layer 5. The heating medium is, for example, brought
to the desired preliminary temperature by means of electrical
heating elements and circulated through the heating pipes 76 by
means of an electrically operated pump.
[0095] The building board designed in this way for heating purposes
can be developed alone or together with further heating building
plates 9.sup.VI of this type to form a type of furnace body having
any shape desired and with, for example, a tile covering on the
outside, which is either designed "self-sufficient" and mobile and
requires only one branch connection, plug cable or the like, or is
attached via pipes or tubes to a heating thermal spring and
supplied by it with heating medium.
[0096] These can also be heating plates for hot pressing which are
highly heat-insulated toward the back and supplied with heat by
means of a medium which is heated higher or by electrical heat
conductors that are essentially built in the same way as the
heating building boards 9.sup.VI just described; these heating
plates are used e.g. for veneer pressing in the wood-processing and
furniture industry.
[0097] Furthermore, with otherwise the same reference characters,
FIGS. 16 and 17 show photo-like 1:1 pictures of building boards 1
which are partially stripped of their upper covering layer 3 and
free the view onto the vertical fibre layer 5.
[0098] In the embodiment of FIG. 16, the vertical fibre bodies 51
are formed from elongated individual elements bonded together,
having vertical cavities 6 that are made therein and a U-shaped
cross sectional design Qh, whereby two rows each of these
individual elements are joined and an intermediate strip 70 is
fastened between two individual elements joined in this way and
here "symmetrically" arranged to one another.
[0099] In the variant according to FIG. 17, vertical fibre bodies
51, which each have protruding "teeth" on both sides and vertical
cavities 6 each with a rectangular cross section Qh formed between
them, thus having a more or less "double ridge" cross sectional
design, form the vertical fibre layer 5. In this case also,
"vertically grained intermediate strips" 7.degree. are also
fastened between these vertical fibre bodies 51 diagonally to the
reinforcing strips 7.
[0100] With otherwise the same reference characters, FIGS. 18 to 20
schematically show an especially preferred type of production of an
advantageous embodiment of the new building board 1, inter alia,
for economical production reasons:
[0101] The fundamental module for the vertical fibre layer 5 of the
new building board 1 shown here are advantageously elongated boards
58', as shown in FIG. 18, into which parallel grooves 60' which
each have the same cross sectional form, in this case
parallelepiped, which are milled in direction of extension of the
wood grain 55'.
[0102] Several of these boards 58' are placed "side by side", with
their longitudinal sides 55' adjoining one another, on a
thin-layered strip plate 700', provided ultimately for forming the
reinforcing strips 7 of the building board 1, in a first partial
layer TL1, see FIG. 19, whereby a lateral bonding of the boards 58'
to one another on the longitudinal side and their flat bonding to
the strip plate 700 is ensured by corresponding application of an
adhesive.
[0103] A second, similar partial layer TL2 of grooved boards 58' is
bonded to the first partial layer TL1 of grooved boards 58',
whereby however the lateral sides 55' of the boards 58' of the
partial layer TL2 are laterally offset vis-a-vis those of the
boards 58' of the partial layer TL1.
[0104] A third partial layer TL3 of boards 58' are bonded to the
second partial layer TL2 and finally, to the same, a strip plate
700 similar to the aforementioned lower strip plate 700 having the
same grain direction.
[0105] A sandwich board 580' is then obtained, which is divided by
parallel cuts S (symbolized by a saw blade), to form vertical fibre
body strips 510' which are laterally flanked by reinforcing
half-strips led at a right angle to the run of the grooves 60' and
for the longitudinal extension and the grain of the boards 58' in
the partial layers TL1, TL2 and TL3 and in direction of the grain
of the strip plates 700', spaced equidistantly as from one
another.
[0106] After a corresponding 90 degree swing of the "three-layer"
vertical fibre body strips 510 thus formed, they are attached to
the lower covering layer 4 adjacent to one another with their
reinforcing (half) strips 7', whereby the vertical fibre body
strips 510 are glued thereto and via which reinforcing half-strips
7' flanking them are formed while forming reinforcing strips 7.
[0107] Finally, the core or vertical fibre layer 5 forming the flat
bond of the second covering layer 3 to the core or vertical fibre
layer 5, which is formed with all of the vertical fibre body strips
510, forms the building board 1.
[0108] With otherwise the same reference characters, FIG. 21 shows
an advantageous embodiment of a supporting or girder element
1.sup.X built according to the same principles as the building
board just described. A vertical fibre layer 5 formed with vertical
fibre body strips 510 is formed in the same way as in the building
board 1 according to the invention between two lateral covering
layers 3 and 4 which are here each formed with at least two layers
of wood, with the grain oriented at a right angle to one another,
whereby a stiffening strip 7 is here not arranged between each
vertical fibre board strip 510, but only after each second one. The
direction of its grain is both vertical to the direction of the
grain in the vertical fibre layer 5 and also to the direction of
the grain in one of the two layers of the two covering layers 3 and
4.
[0109] The new support element 1.sup.X differs from the previously
described "conventional" building board 1 in that it has a
predominantly longitudinal extension in one direction and that the
load, tension or the like thereof does not occur in direction of
the grain in the vertical fibre layer 5, but at a right angle
thereto.
[0110] FIG. 22 schematically shows a curved embodiment of the new
building board 1. In this case, the vertical fibre body strips 510
are arranged adjacent to one another along the generator of the
lower covering layer 4 curved convexly upward in the manner of a
cylinder jacket surface in such a way that they contact one another
along their lower longitudinal edges.
[0111] Due to the convex curvature of the contact surface which
this covering layer 4 offers, wedge-like or gusset-like
longitudinal spaces 560 form between the vertical fibre body strips
510 that extend along them, expanding upward, which do not however,
as was unexpectedly shown, exert any negative influence on the
mechanical and other properties of the curved new building board 1,
as described here, as long as its wedge angle is in the range of up
to about 5.degree.. The vertical fibre body layer 5 is covered
toward the top with a second covering layer 3 which is curved
accordingly and bonded to it.
[0112] The spectrum of the use of the new building board 1 is
substantially expanded, in that it can be especially well adapted
to architectural detail solutions with this curved embodiment.
* * * * *