U.S. patent application number 13/019091 was filed with the patent office on 2011-09-01 for reinforced composite panel for building floors, walls, beams and pillars.
Invention is credited to Sebastiano BERTERO.
Application Number | 20110209437 13/019091 |
Document ID | / |
Family ID | 42985082 |
Filed Date | 2011-09-01 |
United States Patent
Application |
20110209437 |
Kind Code |
A1 |
BERTERO; Sebastiano |
September 1, 2011 |
REINFORCED COMPOSITE PANEL FOR BUILDING FLOORS, WALLS, BEAMS AND
PILLARS
Abstract
A composite panel for the construction of floors, walls, beams
and pillars, comprising a prismatic or parallelepiped-shaped
laminated structure body consisting of a plurality of corrugated
sheets that are arranged in parallel planes. The corrugations of
each sheet are extended in directions parallel to each other and
crossed relative to those of the adjacent corrugated sheets. The
valleys of the corrugations of a sheet are linked to the peaks of
the corrugations of the adjacent sheet. The panel comprises
perforated reinforcing tubular members that are fixed on outer
surfaces of the laminated structure body.
Inventors: |
BERTERO; Sebastiano; (Cuneo,
IT) |
Family ID: |
42985082 |
Appl. No.: |
13/019091 |
Filed: |
February 1, 2011 |
Current U.S.
Class: |
52/783.11 |
Current CPC
Class: |
B32B 13/00 20130101;
B32B 2264/101 20130101; B32B 2419/04 20130101; E04C 2/365 20130101;
B32B 27/06 20130101; B32B 2262/08 20130101; B32B 3/28 20130101;
B32B 21/04 20130101; B32B 13/08 20130101; B32B 2307/558 20130101;
B32B 3/20 20130101; B32B 2419/00 20130101; B32B 7/03 20190101; B32B
29/08 20130101; B32B 2260/028 20130101; B32B 2262/062 20130101;
E04C 2/388 20130101; B32B 7/08 20130101; B32B 3/08 20130101; B32B
2307/50 20130101; B32B 5/16 20130101; B32B 2260/046 20130101; B32B
15/04 20130101; B32B 5/02 20130101 |
Class at
Publication: |
52/783.11 |
International
Class: |
E04C 2/32 20060101
E04C002/32 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 2, 2010 |
IT |
TO2010A000072 |
Claims
1. A composite panel for building floors, walls, beams and pillars,
comprising a laminated structure body of substantially prismatic or
parallelepiped shape comprising a plurality of corrugated sheets
arranged in parallel planes, wherein the corrugations of each sheet
extend parallel in directions crossing the directions of the
adjacent corrugated sheets, and wherein the valleys of the
corrugations of one sheet are secured to the peaks of the
corrugations of the adjacent sheet, wherein the panel comprises a
plurality of perforated tubular reinforcing members fixed on outer
surfaces of the laminated structure body.
2. The composite panel of claim 1, wherein at least some of the
tubular reinforcing members are fixed along at least two parallel
edges of the laminated structure body.
3. The composite panel of claim 2, wherein the tubular reinforcing
members are connected to one another so as to form a cage-like
frame around the edges of the laminated structure body.
4. The composite panel of claim 1, wherein the tubular reinforcing
members are connected to one another by mechanical fastening
means.
5. The composite panel of claim 3, wherein the tubular reinforcing
members are connected to one another at the vertices of the prism
or parallelepiped of the laminated structure body.
6. The composite panel of claim 2, wherein the tubular reinforcing
members are partially accommodated in seats shaped as elongate
recesses obtained along the edges of the laminated structure
body.
7. The composite panel of claim 6, wherein the seats have
transversal cross-sections partially matching those of the tubular
reinforcing members accommodated therein.
8. The composite panel of claim 1, wherein the tubular reinforcing
members have transversal cross-sections of rectangular or square
shape.
9. The composite panel of claim 6, wherein the tubular reinforcing
members have transversal cross-sections of rectangular or square
shape and that the seats of the laminated structure body each
provide a pair of consecutive walls at a right angle resting
against two consecutive faces of the reinforcing members
accommodated therein.
10. The composite panel of claim 1, wherein the tubular reinforcing
members are embedded in a hardened covering, such as mortar or
plaster, which fills their inner cavities.
11. The composite panel of claim 1, wherein the outer surfaces of
the tubular reinforcing members are recessed with respect to the
outer faces of the laminated structure body.
12. The composite panel of claim 10, wherein the hardened covering
covers at least partially at least one outer face of the laminated
structure body.
13. The composite panel of claim 1, wherein the tubular reinforcing
members have a closed ring transversal cross section.
14. The composite panel of claim 1, wherein the tubular reinforcing
members have an open ring transversal cross section with a
longitudinally extending slit.
15. The composite panel of claim 1, wherein the tubular reinforcing
members are made of a rigid material, preferably selected from the
following: steel, fibreglass-reinforced resin, polycarbonate, wood,
bamboo.
16. The composite panel of claim 1, wherein the tubular reinforcing
members are obtained by bending and welding a perforated metal
sheet of reticular structure.
17. The composite panel of claim 1, wherein the tubular reinforcing
members provide a substantially uniformly distributed
perforations.
18. The composite panel of claim 1, wherein the corrugated layers
of the laminated structure body are made of paper-like material
impregnated with artificial resin.
Description
[0001] This application claims benefit of Serial No. TO2010A000072,
filed 2 Feb. 2010 in Italy and which application is incorporated
herein by reference. To the extent appropriate, a claim of priority
is made to each of the above disclosed applications.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a reinforced composite
panel for the construction of floors, walls, beams and pillars, of
the type stated in the preamble of claim 1.
[0003] A panel having a composite structure of the above-mentioned
type is known from EP-A-1 840 290. Generally, the panel consists of
corrugated sheets made of resin-impregnated paper, which are
overlapped and bonded to each other and alternately inclined, where
the valleys of the corrugations of a sheet are linked to the
corrugation peaks of the adjacent sheet. These panels have been
mainly used for the construction of non-load bearing curtain walls,
due to the fact that they are capable of receiving and holding,
without undergoing any shape variation, many varying construction
materials in their receptacles. These materials are applied by
buttering, bonding, spraying or other fastening systems. Typically,
normal or fiber-reinforced mortars, lime, pre-mixed plasters,
cements, tiles and ceramics, fiberglass, glass- and carbon fibers,
plastics and composite materials, paper and decorative laminates,
wallpaper, wood, plywoods and derivatives, polystyrene and
polyurethane are used. These panels are also used as lightweight
members in the construction of ribbed slab floors made of
reinforced concrete.
[0004] Said panels offer high performance in terms of lightness,
cost-effectiveness, easiness of assembly and sound-deadening
capacity, and withstand both dynamic and sysmic stress as well.
However, they do not have such characteristics of static stiffness
as to make them suitable for the construction of load-bearing walls
and/or floors, unless other traditional structural members, such as
beams and joists, H-beams and the like, are provided.
SUMMARY OF THE INVENTION
[0005] The general object of the invention is, accordingly, to
provide a reinforced composite panel that combines the
characteristics of lightness and cost-effectiveness of the panels
as discussed above, in addition to having such an inherent
load-bearing capacity as to be suitable for withstanding structural
loads, which allows to build floors, walls, beams and pillars.
[0006] Another object of the invention is to provide a panel that
is particularly easy to assemble and mount with similar panels,
according to a substantially modular pattern, in order to build the
load-bearing structure of a building.
[0007] These and other objects and advantages, which will be better
understood below, are achieved according to the invention by a
reinforced composite panel having the features stated in the
annexed claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Several preferred though non-limiting embodiments will be
now described, which are provided by way of examples, of a
reinforced panel according to the invention; reference will be made
to the annexed drawings, in which:
[0009] FIGS. 1 and 2 are perspective, partially cut-away views of a
panel according to an embodiment of the invention;
[0010] FIG. 3 is another perspective view of the panel in FIGS. 1
and 2; and
[0011] FIG. 4 is a partial cross-sectional view of an edge area of
a panel according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] Referring first to FIG. 1, a composite panel is generally
designated at 10 which comprises a laminated structure body 11,
which consists of a plurality of corrugated sheets 12, 13 that are
arranged according to parallel planes. The corrugations of each
sheet 12 (or 13) are extended in parallel directions to each other
and are crossed relative to those of the two adjacent sheets 13 (or
12), and the valleys of the corrugations of a sheet are secured to
the peaks of the corrugations of the adjacent sheet.
[0013] The laminated structure body 11 is not much different from
the one illustrated and described in EP-A-1 840 290. The corrugated
layers 12, 13 preferably consist of a paper-like material
impregnated with artificial resins. By paper-like material is meant
herein a material of vegetal origin in the form of a thin foil,
such as paper, card and cardboard. In a particularly preferred
embodiment, the layers 12, 13 are made with "Kraft" paper having
particular characteristics of resistance and toughness. The paper
providing the layers 12, 13 preferably has a maximum paper density
of 1000 g/m.sup.2, preferably a paper density ranging between 20
and 200 g/m.sup.2, and still more preferably between 80 and 140
g/m.sup.2. Alternatively, other types of paper can be used, such as
for example newsprint or paper obtained by means of recycled waste
materials.
[0014] The artificial resins that impregnate the paper for
providing the corrugated layers 12, 13 are preferably polymeric
materials that can be obtained by means of the well-known
polycondensation method, such that the paper material can be
impregnated with the not-yet condensed polymers and then wait for
the polymers to solidify. For example, melamine resins, or phenolic
resins can be used. These artificial resins provide the paper
material with high resistance to water, humidity and chemical
agents, as well as higher mechanical strength. Alternatively, the
corrugated layers can consist of polymer, metal, composite
materials, such as fiberglass, or others (for example, wood,
textiles, felt, wool, and cotton).
[0015] The linear corrugations of the corrugated layers are
preferably of regular shapes and sizes. For example, the length of
each wave is about twice the height, thereof, suitably the length
ranges between about 5 and 30 mm, preferably between 16 and 20 mm,
and a maximum height preferably of 30 mm, more preferably ranging
between 3 and 15 mm, and still more preferably 8 and 10 mm. By
increasing or decreasing the amplitude of these waves the
structural strength of the laminated body 11 can be decreased or
increased, respectively.
[0016] The successive layers are preferably bonded to each other by
means of the same artificial resins with which the paper is
impregnated, for example by means of vynilic resins. As known per
se, the mutual bond of the layers results to be easy because the
corrugations of the adjacent layers are extended in different
directions, where an upper layer is laid on the ridges of the
corrugations of the lower layer, without requiring any intermediate
laying plane.
[0017] In the particular embodiment illustrated in the drawings,
reference is made to a panel shaped as a rectangular
parallelepiped. It is understood that the choice of a
parallelepiped shape is preferred for several applications though
it is not compulsory in view of implementing the invention.
Particularly, the invention is suitable to be implemented with a
prismaticshaped panel, for example with two opposite faces having a
curved profile, or with a geometrical structure different from a
symmetrical structure.
[0018] With 14, 15 are designated perforated reinforcing tubular
members, which are suitable to be integrated in the finished panel.
The tubular members are fixed to the outer surfaces of the
laminated body 11. In the preferred embodiment illustrated herein,
the tubular members 14 are partially accommodated within seats 16
that are shaped as elongated recesses provided along the edges of
the laminated body. This location facilitates the proper
positioning of the tubular reinforcements relative to the laminated
body 11 and allows an improved integration of these reinforcements
in the finished panel.
[0019] The arrangement of the tubular reinforcements along the
edges of the laminated body results in a cage-like framework that
serves to optimize the strength of the panel against both
compression and flexural or shear stresses acting according to any
direction, particularly acting on planes perpendicular to the most
extended face 17 of the panel in case the latter is used for
obtaining a deck, and according to directions parallel to the face
17 when the panel is intended to act as a modular member for
obtaining a load-bearing wall. Alternatively, according to a less
preferred variant embodiment, not illustrated herein, the housing
seats for the reinforcing members may be provided along the outer
surfaces of the laminated body but not along the edges of the
latter.
[0020] On the reinforced panels, a covering 18 of mortar or other
hardening blend is applied, which in addition to covering at least
one part of the outer surfaces of the laminated body 11, it also
embeds the tubular reinforcing members, makes the latter integral
with the laminated body and fills the inner cavities thereof
thereby providing a monolith mixed structure along with the
reinforcing members, which in the preferred embodiment has the
appearance of a peripheral cage made of reinforced concrete and
integral with the laminated body.
[0021] Still in accordance with the preferred embodiment, the
tubular members have a cross-section of a rectangular or square
shape with a diffuse perforation which has the double task of
allowing the mortar to fill the space within the tubular member and
facilitating the mechanical connection to other similar reinforcing
members. The mechanical connection is mainly carried out with other
reinforcing members of a same panel, in this example by means of
fastening members such as bolts 19, advantageously connected at the
vertices of the body 11. In the same manner, the mechanical
connection can be carried out between consecutive or adjacent
panels, according to the specific part of building to be built. The
diffuse perforation is a particularly advantageous way to uniformly
introduce and spread the mortar (or other blend) being applied.
Furthermore, the even spread of the perforation is preferred over a
small number of passageways for the mortar because it does not
create any stress concentrations or peaks in certain areas relative
to others, and thus it does not create particular structural
weakening points. The permeation of the mortar in a plurality of
holes creates a particularly effective and well settled anchoring
of the reinforcing members to the rest of the panel. It will be
further appreciated that a tubular, and accordingly hollow,
reinforcement has a higher moment of inertia than a solid member,
with the cross-sectional area being equal. The hollow shape of the
reinforcing members further offers a particularly comfortable seat
for housing further reinforcing members, such as steel bars and/or
wires that can be arranged within the tubular member to be then
embedded in the same hardening mixture.
[0022] The square or rectangular shape of the cross-section of the
reinforcing members facilitates the right-edge connection of these
members around a prismatic or parallelepiped-shaped body. The
coupling and the subsequent anchoring of the reinforcing members
relative to the laminated body result to be more effective when, as
in the embodiment illustrated herein, the seats provided along the
edges of the laminated body have a cross-section that is partially
corresponding to that of the tubular body. In this example, with
square- or rectangular-section tubular members, the seats in the
laminated body are provided by a pair of consecutive right-angled
walls, against which two consecutive faces of the reinforcement
tube 14 are rested (FIG. 4). According to other embodiments of the
invention (not illustrated), the reinforcing members have an
open-ring section (for example according to a C-shaped section), of
a polygonal or rounded shape. For several applications, in fact, a
longitudinal slit can be preferred, which facilitates the mortar to
pass therethrough in order to fill the inner cavity of the
reinforcing tubular member.
[0023] Suitable materials for making the reinforcing members can be
selected from steel, fiberglass, wood or bamboo and more generally
any rigid material capable of withstanding tensile stress. For
example, the reinforcing members can be made of polycarbonate,
advantageously obtained by means of pultrusion. In the preferred
embodiment illustrated in the drawings, the reinforcing members are
obtained by folding and welding a perforated metal sheet plate
having a reticular structure, with drillings of any shape, square
in this example.
[0024] The mortar can be applied by spraying, for example by means
of plaster machines. According to a particularly preferred
embodiment (FIG. 4), in the assembled condition, the outer surfaces
of the reinforcing members are not flush with the outer surfaces of
the laminated body, but are slightly recessed, in order to have a
greater assurance that the metal member has been completely coated
by the mortar that is spread on the outer faces of the panel and in
which the reinforcing members are embedded.
[0025] The reinforcing members 15 act as brackets that
transversally connect two of the longer reinforcing members that
develop along parallel edges, and are mainly subjected to shear and
torsion stresses when the panel is used for making a floor, whereas
they counteract the peak load instability when the panel is used
for the construction of a load-bearing wall.
[0026] As known, the outer surface of the laminated structure body
is very uneven and offers an ideal grip for the concrete material,
which is thereby easily held on all the outer faces of the laminate
body 11. After the mortar has hardened, which coats the outer faces
of the panel and provides reinforced concrete beams along the panel
edges, the panel has such characteristics of flexural, compression
and tensile strength as to make it suitable for acting as a modular
member for obtaining a load-bearing wall or a floor, without
requiring further reinforcing members.
[0027] While several embodiments have been illustrated and
described herein, a number of variant embodiments can be obviously
carried out, and the panel can be subjected to modifications
relating to shape, size, arrangement of parts, construction details
and materials used. For example, other connection means can be
selected to fasten the reinforcing members to each other, without
however departing from scope of the invention as defined by the
annexed claims.
* * * * *