Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
  • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
  • E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
  • E04C2/32—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material
  • E04C2/322—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material with parallel corrugations
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
  • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
  • E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
  • E04C2002/3444—Corrugated sheets
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
  • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
  • E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
  • E04C2002/3472—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets with multiple layers of profiled spacer sheets

Definitions

• the present invention relates to a composite construction panel, a kit for making such a panel, panel elements for making the composite construction panel, as well as method for producing the panel elements and composing the construction panel.
• the panel can be applied in a corner of a building or building element such as a wall, ceiling, floor, door frame or window frame.
• the supporting frame or structural elements can be built from a combination of concrete, reinforced concrete, bricks, steel profiles, etc., and other building elements such as floors or floor coverings, non-supporting or non-load- bearing walls, ceilings, false ceilings, frames, etc.
• the supporting frame or structural elements can be built from a combination of concrete, reinforced concrete, bricks, steel profiles, etc., and other building elements such as floors or floor coverings, non-supporting or non-load- bearing walls, ceilings, false ceilings, frames, etc.
• a wall can be constructed from self- supporting materials such as medium density fibreboard (MDF), plasterboard, wood, (thin) steel panels, bricks, etc. or a combination thereof such as a wooden framework combined with MDF boards.
• MDF medium density fibreboard
• plasterboard plasterboard
• wood wood
• (thin) steel panels bricks, etc.
• a combination thereof such as a wooden framework combined with MDF boards.
• the building elements needs to be fitted within the existing structure, i.e. the dimensions of the building element are essentially defined or at least limited by the existing structural elements or already existing building elements. Due to small deviations from e.g. architectural plans, the exact dimensions of the building element are not known up front.
• the construction worker typically needs to adapt the dimensions of the building element either on the spot, or needs to make accurate measurements in order to allow custom-made fabrication of the building element. Either case will lead to an increased amount of time required by the construction worker. In the former case, one also has the problem of dirt (e.g. wood chips, gypsum dust, metal flakes) being distributed in the space where the building element is installed, due to e.g. sawing or cutting of the material at the corners or edges of the building element.
• One way of providing easy-to-install materials is disclosed in document DE 3224883 Al, which discloses a stable housing frame with rounded corners, preferably made of wooden materials, which can be manufactured from the unrolled, stretched-out slab.
• the frame of DE 3224883 Al seems only useful when applied in a corner and basically cannot be used to make a different type of constructional element due to the incisions, e.g. if the frame is used to construct a wall, the incisions are lead to apparent gaps in the wall. Furthermore, the frame of DE 3224883 Al is particularly designed to allow formation of a rounded corner.
• the present invention aims to resolve at least some of the problems and disadvantages mentioned above.
• the invention thereto aims to provide an improved construction panel which may still allow easy construction of corners, but can be used more generally, and which is less sensitive to small variations in the construction.
• temporary constructions such as exposition spaces, buildings which need to be erected quickly such as outdoor shelters, or buildings of non-residential nature such as stables, sheds, outdoor sauna's, garageboxes, etc., also require building elements which are easy to place and fixate.
• the present invention also aims to provide a building element which allows easy, fast and reliable erection of the above mentioned constructions.
• structural elements of a building such as load-bearing walls and beams of (reinforced) concrete, also tend to take time for the construction worker to construct or place.
• the present invention also aims to provide means for reducing the time needed to construct certain structural elements of buildings, in particular for structural elements comprising concrete.
• the present invention and embodiments thereof serve to provide a solution to one or more of above-mentioned disadvantages.
• the present invention relates to kits, panel elements and methods as described in the claims and further below.
• the present invention concerns in a first aspect a kit for a composite construction panel comprising at least a first panel element and a second panel element, at least said first panel element comprising a substantially flat side and an opposing profile side, and said second panel element comprising at least a profile side, the first panel element comprising a substantially flat bendable layer at the flat side of the first panel element and a structural layer at the profile side of the first panel element, whereby the bendable layer is laminated to the structural layer and whereby the bendable layer is manually cuttable, the second panel element comprising a structural layer at the profile side of the second panel element, wherein the structural layer of said first and second panel elements is at least partially periodically provided with a set of protrusions and recesses at the profile side, the protrusions and recesses being elongated along an x-direction substantially parallel with the flat side and the protrusions and recesses forming a periodic pattern in a y-direction perpendicular to the x-direction, wherein the protru
• the set of protrusions and recesses preferably allow bending of the panel element with respect to the y-direction over an angle alpha (a), which is at most a maximal single- recess bending angle alpha_max (a max ).
• This maximal single-recess bending angle is preferably determined by the shape of the recesses and protrusions in the sense that when a reaches a max for a specific recess, the protrusions directly adjacent this recess touch each other.
• a max is at least about 45°.
• a max is at least 85°, even more preferably at least 88°, such as 89° or 90°.
• a max is at most about 135°.
• a max is at most 95°, even more preferably at most 92°, such as 91° or 90°. Most preferably, a max is about 90°. Nevertheless, other values for a max can be appropriate to construct certain types of building elements. By allowing bending of one or both panel elements, corners can be constructed. These corners can be corners of a room, e.g. corners between side walls or corners between walls and ceiling or floor, or the corners can be part of a door frame or window frame.
• the present invention also concerns a kit for a composite construction element, the kit comprising a set of substantially planar, interconnectable panel elements, each interconnectable panel element comprising a structural layer at least partially, and preferably completely, periodically provided with a set of protrusions and recesses at a first profile side, the protrusions and recesses being elongated along an x-direction within the plane of the panel element and the protrusions and recesses forming a periodic pattern in a y-direction within the plane of the panel element and perpendicular to the x-direction, preferably whereby the set of protrusions and recesses of two planar panel elements are configured to fit into one another.
• the kit for a composite construction element comprises a subset of second panel elements in accordance with the rest of this document.
• This subset hereby may include second panel elements comprising an essentially flat side opposite the first profile side.
• the subset may comprise second panel elements comprising a second profile side opposite the first profile side.
• the second profile side is provided with a second set of protrusions and recesses.
• One particularly preferred use of this embodiment is its application in a formwork for concrete building elements.
• the second panel element can be used, either by itself or in combination with other second panel elements comprising two opposing profile sides, to construct a formwork with the second set of protrusions on an inner surface of the formwork.
• the formwork can subsequently be filled with concrete, which is then allowed to harden.
• a concrete structural element of a building can be constructed, whereby the concrete is clad with the second panel element and is attached thereto, preferably by the shape of the second set of protrusions and recesses.
• the shape of the protrusions of this second set is such that the width of the protrusions essentially increases and the width of the recesses essentially decrease at least partially in an outwards direction.
• the kit for a composite construction element may comprise a first panel element in accordance with the present document, and/or a second panel element comprising a flat side opposite the first profile side.
• a first panel element in accordance with the present document and/or a second panel element comprising a flat side opposite the first profile side.
• the second panel element used for the formwork does not have to be removed (as is the case generally for formwork) and that the structural element can be easily finished by attaching a first panel element to the first set of protrusions and recesses of the second panel element, or that another second panel element can be connected to second panel element used for the formwork.
• the concrete used may be cellular concrete or foamed concrete.
• the composite construction panel can be installed easily and reliably.
• the present invention relates to a method for constructing a composite construction panel, comprising the steps of: providing a kit for a composite construction panel in accordance with the present invention, comprising the first panel element and the second panel element, wherein the recesses in the structural layer of at least the first panel element have a minimal distance to the bendable layer, said minimal distance being configured to allow manually cutting the first panel element along the x-direction; installing the second panel element; installing the first panel element by inserting the protrusions of the first panel element in the recesses of the second panel element, and by inserting the protrusions of the second panel element in the recesses of the first panel element, thereby attaching the first panel element to the second element, and cutting away excess material from the first panel element by manually cutting the first panel element along the x-direction, preferably at a position corresponding to an edge or corner of the second panel element.
• the present invention relates to a method for constructing a composite construction element, comprising the steps of: providing a kit for a composite construction element in accordance with the present invention, comprising a set of substantially planar, interconnectable panel elements, each interconnectable panel element comprising a structural layer at least partially, and preferably completely, periodically provided with a set of protrusions and recesses at a first profile side, the protrusions and recesses being elongated along an x-direction within the plane of the panel element and the protrusions and recesses forming a periodic pattern in a y-direction within the plane of the panel element and perpendicular to the x-direction, preferably whereby the set of protrusions and recesses of two planar panel elements are configured to fit into one another connect the planar panel elements of the set to each another to construct a composite construction element.
• the construction element is formwork
• the set of panel elements comprise a subset of at least 4, and preferably at least 6, second panel elements comprising a second profile side opposite the first profile side, wherein the second profile side is provided with a second set of protrusions and recesses.
• the construction element is a wall, floor, ceiling or a combination thereof
• the set of panel elements comprise a subset of second panel elements comprising a flat side opposite the first profile side
• the invention provides multiple advantages over existing techniques.
• the main idea behind the invention is that building elements such as walls, floor panels or floors, ceilings, door frames, window frames, etc. can be installed in basically two installation steps rather than one, each of the installation steps however being easy, fast and clean such that the total installation time is less and with less dirt.
• one of the panel elements can be installed at the position of the building element.
• the building element is a separation wall extending over the full width of a room
• a panel can be installed across the full width with the x-direction of the panel corresponding with the height direction of the room, such that each protrusion or recess of the panel element runs essentially vertically.
• the panel element Due to the structural layer of the panel element, the panel element is at least self-supporting. Attachment of this panel element to existing building elements, e.g. structural walls, floor and/or ceiling, can be done using a number of available techniques, e.g. by bolts, glue, screws, nails or any other type of fastening means.
• the height of this panel element can be a standard height to correspond with the standard height of the room, or the panel can be pre-cut to the required height.
• the width of the panel element can be made to fit by either bending the panel at the edges to form an angle, or by manually cutting the panel vertically along a recess at the line where the structural layer has the minimal thickness, i.e. at the position of the minimal distance between recess and the bendable layer, in order to substantially correspond to the width of the wall.
• the other panel can subsequently be attached to the installed panel by inserting corresponding protrusions into the recesses and vice versa. Any excess width of this other panel, i.e.
• the protrusions and recesses are therefore provided periodically with a period which is at most 15 cm, more preferably at most 10 cm, still more preferably at most 8 cm, yet more preferably at most 7 cm, and still more preferably at most 6 cm, such as 5 cm, 4 cm, 3 cm, 2 cm, 1 cm or any value there between.
• the minimal period preferably is selected taking into account the thickness of the structural layer and/or the type of material, in particular the strength of said material.
• the invention further relates to the panel element as described above and further in this document and in the claims, and to a method for manufacturing such a panel element.
• a specific preferred embodiment relates to an invention wherein the recesses in the structural layer of both of the first or second panel elements have a minimal distance to the bendable layer, said minimal distance being configured to allow manually cutting the panel element along the x-direction and/or said recesses and protrusions comprising a shape which is configured to allow bending of the panel element with respect to the y-direction at the position of each of the recesses.
• first and second panel element are essentially similar and preferably interchangeable. This makes production and installation even more easy and reliable as one does not require different types of panel elements, but can use a single type of panel element for both first and second panel element in the present invention.
• the second panel element is essentially different from the first panel element.
• the second panel element may comprise a second profile side opposite the first profile side.
• the second profile side may be provided with a second set of protrusions and recesses.
• One particularly preferred use of this embodiment is its application in a formwork for concrete building elements.
• the second panel element can be used, either by itself or in combination with other panel elements comprising two opposing profile sides, to construct a formwork with the second set of protrusions on an inner surface of the formwork.
• the formwork can subsequently be filled with concrete, which is then allowed to harden.
• a concrete structural element of a building can be constructed, whereby the concrete is clad with the second panel element and is attached thereto, preferably by the shape of the second set of protrusions and recesses.
• the shape of the protrusions of this second set is such that the width of the protrusions essentially increases and the width of the recesses essentially decrease at least partially in an outwards direction.
• One very large advantage of this embodiment is that the second panel element does not have to be removed (as is the case generally for formwork) and that the structural element can be easily finished by attaching the first panel element to the first set of protrusions and recesses of the second panel element.
• kit of the present invention may comprise more than two panel elements, such as 3, 4, 5, 6, 7, 8, 9, 10 or more panel elements.
• Figs. 1A and IB show perspective views of first and second panel elements and how they fit together.
• Figure 2A shows an enlarged perspective view of a panel element.
• Figs. 2B-2D show enlarged views of the cross section of the panel elements taken perpendicular to the x-direction, i.e. perpendicular to the direction of elongation of the recesses and protrusions.
• Fig ures 3A and 3B show another embodiment of the invention, wherein a clear difference between the first panel element in fig. 3B and the second panel element in fig. 3A is illustrated.
• Fig. 4 A plinth in accordance with this invention is shown in fig. 4.
• Figures 5A and 5B illustrate a number of different embodiments of the panel elements of the present invention.
• Fig ures 6A-6B illustrate clamping devices for connecting two panel elements or for stabilizing a panel element in a corner in accordance with the present invention.
• Figures 7A-7C show an embodiment of a corner and how such a corner can be constructed from the panel elements of the kits according to the present invention.
• Figure 8 also shows an embodiment of a corner, similar to the embodiment shown in figs. 7A-7C.
• Figure 9 illustrates a corner clamping device in use, in accordance with the present invention.
• Figs. 10A and 10B illustrate how formwork can be constructed using the present invention, for a concrete wall portion.
• a window frame is illustrated in figs. 13A-13B for a first embodiment and figs. 14A-14B for a second embodiment in accordance with the present invention.
• Figures 16, 17A and 17B illustrate how a floor with and without floor heating can be constructed from the kits of the present invention.
• Figure 18 shows a straight dovetail profile for the set of recesses and protrusions.
• the embodiment which is shown has an asymmetric straight dovetail profile, in that each protrusion has an upstanding side which is essentially perpendicular to the x-y plane of the panel element, and another upstanding side which is slanted with respect to the direction perpendicular to the x-y plane, such that the protrusion's width in the y-direction increases in the direction of the protrusion.
• Such an asymmetric straight dovetail profile is particularly preferred for wall panels, as the panel element can be easily suspended to, and if necessary, taken away from the vertical wall by a slight lifting movement.
• Figure 19 shows a rounded dovetail profile for the set of recesses and protrusions.
• Figure 20 shows a teethed profile for the set of recesses and protrusions.
• Figures 21A-21B illustrate a corner element and a frame comprising corner elements constructed in accordance to the present invention.
• Figures 22A-22B illustrate how a window can be constructed in a structural element using a kit in accordance with the present invention.
• Figs. 23A-23C illustrate how the present invention can be used to construct a house.
• Fig ures 24A-24E illustrate how adjacent panel elements according to the present invention can be connected to each other in the same plane.
• the present invention concerns a kit for a composite construction panel or element, the kit comprising panel elements.
• the present invention also concerns the panel elements for said kits and methods for constructing a composite construction panel or element.
• the value to which the modifier "about” refers is itself also specifically disclosed.
• the terms "one or more” or “at least one”, such as one or more or at least one member(s) of a group of members, is clear per se, by means of further exemplification, the term encompasses inter alia a reference to any one of said members, or to any two or more of said members, such as, e.g., any >3, >4, >5, >6 or >7 etc. of said members, and up to all said members.
• first panel element and second panel element refer to two types of panel elements, which may nevertheless be of the same type.
• first panel element is used to refer to the panel element which can be placed onto an already installed second panel element.
• first panel element is also used to denote the panel element whose flat side is visible after the composite panel is installed.
• the flat side of the first panel element may therefore be provided with a finishing, such as a coating or a pattern or any other type of ornaments.
• second panel element is used to refer to a panel element which is installed as a basis for constructing the composite panel, and onto whose structural side a first panel can typically be fitted.
• a composite construction panel can be constructed from more than one "first" panel elements, possibly in combination with more than one "second” panel elements.
• the multitude of “second” panel elements are positioned adjacent to each other at their edges, and likewise for the multitude of "first” panel elements.
• the term “adjacent” herein refers to a positioning whereby edges in the x-direction or in the y-direction of adjacent panels are placed next to each other without the panels overlapping. Adjacent panels can be connected to each other by connecting portions (123a, 123b) at x-direction edges of the panel elements, as illustrated in figs. 24A-24E.
• the kit for a composite construction panel of the present invention comprises at least a first panel element and a second panel element, each of said first and second panel elements comprising a substantially flat side and an opposing profile side, each panel element comprising a substantially flat bendable layer at the flat side of the panel element and a structural layer at the profile side of the panel element, whereby the bendable layer is laminated to the structural layer and whereby the bendable layer is manually cuttable,
• the structural layer is at least partially periodically provided with a set of protrusions and recesses at the profile side, the protrusions and recesses being elongated along an x-direction substantially parallel with the flat side and the protrusions and recesses forming a periodic pattern in a y-direction perpendicular to the x-direction,
• the protrusions of the first panel element are adapted to fit in the recesses of the second panel element and wherein the protrusions of the second panel element are adapted to fit in the recesses of the first panel element, wherein the recesses in the structural layer of at least one, and preferably both, of the first or second panel elements have a minimal distance to the bendable layer, said minimal distance being configured to allow manually cutting the panel element along the x-direction, preferably said recesses and protrusions comprising a shape which is configured to allow bending of the panel element with respect to the y-direction at the position of each of the recesses.
• kit for a composite panel element may also comprise a first panel element as described above.
• said minimal distance is 5 mm or less, preferably 4 mm or less, even more preferably 3 mm or less, yet more preferably 2 mm or less, still more preferably 1 mm or less, and, most preferably, said recesses substantially extend to the bendable layer.
• the set of protrusions and recesses of the first panel element is substantially the same as the set of protrusions and recesses of the second panel element, preferably the first panel element is substantially the same as the second panel element.
• the set of protrusions and recesses of the panel elements show a sawtooth profile, more preferably a symmetric sawtooth profile, most preferably a symmetric sawtooth profile with essentially right angles.
• the set of protrusions and recesses of the panel elements show an essentially rectangular profile. Embodiments using sawtooth profiles are illustrated in the figures, in particular figures 1A-6B, 91 14A-15B.
• the set of protrusions and recesses of the first panel element form a snap-fit connection with the set of protrusions and recesses of the second panel element for easy attachment of the first panel element to the second panel element by snap-fitting the protrusions of the first panel element into the recesses of the second panel element and the protrusions of the second element into the recesses of the first panel element.
• Snap-fit connections are illustrated in the figures, in particular figures 7A-8, 10A-11C, 12A-13B (combined with other type of connection), 16-19, 21B (combined with other type of connection), 22A-24E.
• the set of protrusions and recesses show a dovetail-like profile.
• a "dovetail-like profile” herein relates to a profile wherein the protrusions have a width in the y-direction which becomes slightly larger in the direction of the protrusion, i.e. in the direction away from the bendable layer, and the recess have a width in the y-direction which becomes slightly wider in the direction of the recess, i.e. in the direction towards the bendable layer.
• the dovetail-like profile may be a straight dovetail profile, a rounded dovetail profile or a dovetail profile having a combination of straight and rounded sides and/or edges.
• Dovetail-like profiles are illustrated in the figures, in particular in figs. 7A-8, 10A-11C, 12A-13B (combined with other type of connection), 16-17, 18 (straight dovetail), 19 (rounded dovetail), 21B (combined with other type of connection), 22A-24E.
• the protrusions provided on the panel elements of the present invention may also be teethed, as illustrated in fig. 20, wherein the profile formed by the set of protrusions and recesses is a combination of triangular and rectangular shapes.
• Such a profile can also be used to construct a corner element as illustrated in fig. 21A, which on its turn can be used to construct a frame for a door or window as in fig. 21B.
• the set of protrusions and recesses show an asymmetric profile, preferably in such a way that longitudinally open channels remain when the first panel element is placed on the second panel element.
• Such open channels may serve as space for e.g. electrical cabling, sanitary ducts or heating ducts.
• the set of protrusions and recesses of the first panel element and/or the second panel element are provided with glue for attachment of the first panel element to the second panel element by inserting the protrusions of the first panel element into the recesses of the second panel element and the protrusions of the second element into the recesses of the first panel element.
• the first and second panel are attached by gluing, preferably by applying a layer of glue to the profile side of the first and/or second panel element.
• a gluing layer can be pre-applied to the panel elements, or it can be applied on-site.
• the gluing attachment is preferably permanent, but may also be temporarily.
• the structural layer comprises a medium density fibreboard (MDF) or a high density fibreboard (HDF), and/or the bendable layer comprises a PVC-based sheet, preferably wherein the bendable layer is a PVC- based sheet.
• MDF medium density fibreboard
• HDF high density fibreboard
• Other materials which can be used for the structural layer include wood and rigid plastic such as rigid polymer.
• the structural layer comprises fiberboard, preferably medium density fiberboard (MDF), which typically comprises wood fibers and resin glue which are pressed in a dry state.
• MDF medium density fiberboard
• the MDF can have a smooth surface, be moisture resistant, water repellent, fire retardant, without formaldehyde, colored, coated, of deep-milling quality.
• the bendable layer may comprise, and preferably consists of a polymer layer, preferably a polyvinyl-based layer such as a polyvinylchloride (PVC) based layer or a polyvinylideenfluoride (PVDF) layer, for example as produced under the name of Renolit Exofol MX, Renolit Exofol PX or Renolit Exofol MT.
• PVC polyvinylchloride
• PVDF polyvinylideenfluoride
• the bendable layer is weakener-free to prevent migration of weakeners from the bendable layer to other components of the panel element.
• the bendable layer comprises two foils.
• the bendable layer may be colored and may comprise colored pigments, e.g. in a base foil of the bendable layer.
• the base foil may comprise a uniform color or may be printed upon.
• a second foil of the bendable layer may be a transparent foil, preferably an acryl foil, more preferably a PMMA foil, to protect colors and designs against fading due to e.g. UV radiation.
• the bendable layer may be provided with a primer to increase adhesive properties.
• the bendable layer is preferably 100 micron to 300 micron thick, more preferably between 150 and 250 micron, still more preferably between 170 and 180 micron.
• the bendable layer comprises a PVDF foil, a transparent polymethylmethacrylate (PMMA) foil and a PMMA base layer which can be colored.
• PMMA transparent polymethylmethacrylate
• the bendable layer is UV-resistant and/or comprises a low surface energy to repel dirt.
• the bendable layer is attached to the structural layer by glue.
• glue examples of glue that can be used are Jowat 609.30 PU Hotmelt, in particular for gluing a Renolit Exofol layer to MDF, or Jowat 270.90 Haft Hotmelt.
• the glue comprises a density between 0.9 and 1.3 g/cm 3 , preferably about 1.0 or 1.1 g/cm 3 or any value therebetween.
• the glue comprises a viscosity between about 9.000 and 23.000 m.Pa.s at temperatures between 110 and 130 °C.
• the set of periodic protrusions and recesses is provided over the whole width in the y-direction of the panel element.
• the set of periodic protrusions and recesses is provided partially over the width in the y-direction of the panel element, hereby defining a first profiled portion of the panel element.
• the panel element preferably comprises a second portion. This second portion may comprise:
• a non-profiled portion i.e. a portion which has an essentially flat surface at the profile side
• a mirror-imaged portion i.e. a portion comprising a set of periodic protrusions and recesses which essentially is a mirror image of the set of periodic protrusions and recesses of the first profiled portion;
• a solid edge portion i.e. a non-profiled portion at an edge along the y-direction of the panel element
• a solid edge portion comprising a lateral recess, i.e. a recess provided in the edge along the y-direction of the panel element, the recess thus extending in the y-direction;
• a solid portion comprising a lateral recess, i.e. a non-profiled portion which is not at an edge, and which is provided with a lateral recess;
• the panel element comprises a multitude of at least two perpendicularly positioned panel portions, at least one of the portions being provided with a set of periodic protrusions and recesses. At least one of the portions is preferably provided with a lateral recess.
• FIGS. 5A and 5B show panel elements comprising :
• first profiled portion having the profile on a first side
• second profiled portion having the profile on a second side opposite the first side and a solid edge portion (28);
• a solid edge comprising a lateral recess, a profile portion, a second solid edge connected to a perpendicularly positioned panel portion comprising a lateral recess attached (39);
• the panel element is provided at least partially with a coating, preferably at least at the profile side.
• the kit for a composite construction panel or for a composite construction element according to the present invention comprises one or more clamping devices. These clamping device may comprise a limited set of protrusions and recesses, such as at least two protrusions bordering one recess, which are configured to connected two adjacent panel elements such as two panel elements placed adjacent to each other to form a single wall.
• the clamping devices can be used to connect adjacent panel elements temporarily or permanently. They can also be applied to connect panel elements at a corner, e.g. they can be used to connect panel elements forming a side wall to panel elements forming a ceiling.
• FIG. 6A-6B Clamping devices for connecting two panel elements or for stabilizing a panel element in a corner are illustrated in Fig. 6A-6B, for a panel element comprising a sawtooth profile.
• the corner clamping device (44) comprises compartments (45, 46, 47) which are configured to receive the edges at the x-direction of 1 or 2 first panel elements (e.g. 45) and 1 or 2 second panel elements (e.g. 46, 47).
• the corner clamping device (44) is shown in use in fig. 9.
• the panel element can be provided with a number of clamping grooves, preferably said panel element being a second panel element as described in this document.
• the kit comprises one or more plinths which are connectable to an edge of a panel element, preferably the edge of a first panel element, and preferably an edge along the x-direction.
• a plinth in accordance with this invention is shown in fig. 4.
• the plinth (22) is connected to the edge of a panel element (23) by a set of clamping elements (24).
• the clamping elements (24) may be an integral part of the plinth, or may be separate elements which can be connected to the plinth, preferably in a slideable manner through a set of regularly provided openings through the side (25) of the plinth. Note that when the first panel element is installed onto a second panel element, a part of the first panel element near the edge can be left unconnected such that the plinth can be easily installed.
• Example 1 Sawtooth profile
• FIGS 1A to 2D show embodiments of the present invention wherein the protrusions and recesses show a sawtooth profile.
• Figs. 1A and IB show perspective views of first and second panel elements and how they fit together.
• Figure 2A shows an enlarged perspective view of a panel element and figs. 2B-2D show enlarged views of the cross section of the panel elements taken perpendicular to the x-direction, i.e. perpendicular to the direction of elongation of the recesses and protrusions.
• a perspective view is shown of a first panel element (3) and a second panel element (2).
• the panel elements have a sawtooth profile, i.e. the set of protrusions (4a, 4b, 4c; 6a, 6b) and recesses (5a, 5b; 7a, 7b) of each panel element, show a triangular shape in a cross section taken in the y-z plane, i.e. perpendicular to the x- direction.
• the protrusions and recesses stretch along the x-direction.
• the first panel element (3) of fig. 1A has been positioned on the second panel element (3) such that the protrusions of the first panel element fit into the recesses of the second panel element and vice versa, thereby obtaining a composite construction panel (1) according to the present invention.
• the second panel element (2) is provided with a set of through-holes (8) in the z-direction, for attaching the second panel element to other construction elements.
• Fig. 2A shows a perspective detail view of a recess (9a) between two protrusions (10a, 10b) in a sawtooth profile.
• the recess and protrusions belong to a first panel element as the one shown in figs. 1A-1B, but can equally apply to the second panel element in this embodiment.
• Fig. 2B shows the same detail in cross section.
• the panel element comprises a structural layer (11) at a profile site (13) and a bendable layer (12) at a flat side (14) of the panel element.
• angles at the top of the protrusion (Oi) and the bottom of the recess (a 2 , a 3 , a' 3 ) can be designed according to predefined conditions, in particular, the angles can be determined such that the panel element can be bend over an angle a max at the position of the recess (9a).
• the angles Oi and a 2 are essentially 90°
• angles a 3 and a' 3 are essentially 45°, leading to a very symmetrical sawtooth profile which can be bent over about 90° in the direction where the protrusions 10a and 10b are rotated towards each other.
• a rotation in the other direction is also possible for the shown embodiment, the angle of rotation essentially being unconstrained, but limited to 180°.
• the recess 9a also shows a rounded shape (15), rather than a sharp edge. This has the advantage that it provides more strength to the structural layer and the panel element, and it is easier to produce by milling.
• the structural layer (11) in the shown example is about 3 cm thick, leading to a period (P) of 6 cm.
• the recesses in the structural layer (5a, 5b, 7a, 7b, 9a) of the panel element (2, 3) have a minimal distance to the bendable layer which in figs. 1A-2B is essentially zero, i.e. the recesses essentially extend up to the bendable layer (14).
• the minimal distance can also be nonzero, yet small as illustrated in fig. 2C.
• a detailed cross-sectional view of a panel element (16) is shown, similar to fig. 2B. Different from the embodiment of fig. 2B, the embodiment in fig. 2C clearly shows a nonzero minimal distance (D) between the recess (17) and bendable layer (14).
• the minimal distance (D) must be such that it allows manual cutting.
• this minimal distance (D) is about 5 mm or less, such as 4 mm, 3 mm, 2 mm, 1 mm or any value therebetween or below.
• the minimal distance (D) may be larger than required for manual cuttability, e.g. larger than about 5 mm, and may preferably be even much larger to provide additional strength or stability to the second panel element, in particular extra stability against bending.
• the panel element (16) may be provided with a cut (18) through the structural layer, between the recess (17) and the bendable layer (14), preferably a cut over essentially the minimal distance (D) as illustrated in fig. 2D.
• Figures 3A and 3B show another embodiment of the invention, wherein a clear difference between the first panel element (19) in fig. 3B and the second panel element (20) in fig. 3A is illustrated.
• the second panel element (20) comprises a structural layer which is thick and provides more strength and stability to the panel element than in the first panel element (19).
• the thickness of the structural layer (21) of the second panel element at the position of the recesses can be large, such as 2 cm or more, preferably 3 cm or more, more preferably 4 cm or more, such as 5 cm, 6 cm, 7 cm, 7 cm, 8 cm, 9 cm, 10 cm or any value therebetween or larger.
• the second panel element is not manually cuttable, but is strong and stable. Further, it also cannot be bent.
• the second panel element does not have to be provided with a bendable layer which is manually cuttable.
• the panel element (19) of fig. 3B can also be used as a second panel element if desired.
• the panel elements (19, 20) in figs. 3A-3B are provided with through holes (8) for e.g/. allowing easy connection to other building elements, e.g. by screws or bolting means.
• Example 2 floor with floor heating
• a particularly preferred use of the present invention is in the construction of a floor with (105) or without (106) floor heating, as illustrated in figs. 16, 17A and 17B.
• one of the second panel elements (104) of a kit is preferably placed on top of a levelled surface, with the set of protrusions and recesses upwards.
• Another of the second panel elements having a flat side on the opposite side of the profile side, or a first panel element (109) is also provide to be placed on top of the second panel element (104).
• a protrusion may be removed, e.g. by milling or cutting. This removal may be done prior to installation, or may be performed on-site e.g. by cutting and/or breaking off the protrusion at the desired position. This removal of a protrusion essentially allows a heating duct (108) to be placed at this position.
• the heating duct may run in the x-direction along the length of the panel element, or the panel element may be provided with transverse (along the y-direction) connecting openings (109) through a set of adjacent protrusions which allow the duct to turn within the floor. Note that such transverse connecting openings may also be provided by cutting portions of protrusions or by breaking off such portions along pre-cut lines (110).
• transverse connecting openings may also be provided by cutting portions of protrusions or by breaking off such portions along pre-cut lines (110).
• another second panel element having a flat side on the opposite side of the profile side or a first panel element (109) can be placed on top of the second panel element (104).
• the heating duct may take the place of a protrusion in the panel elements, it can fit within a recess of the corresponding panel element. If the heating duct turns within the floor and thus runs partially in the y- direction, transverse connecting openings can also be provided in the upper panel element (109), e.g. by
• the upper panel element (109) which preferably is a first panel element, may be provided with a floor finishing after or before installation, for instance a set of tiles or a tile-like finishing may be provided on the flat side of the first panel element.
• the floor constructed according to the above procedure, with or without floor heating, can be perfectly lined up. It can also be connected to the side walls which can also be provided with a wall covering using the panel elements and composite panel according to the present invention.
• the protrusions and recesses of the panel elements form a snap-fit connection, allowing easy installation. Note that when the inhabitant desires to change the appearance of the floor, the present invention allows easy replacement by simply replacing the upper panel element (109).
• Wall heating can be used in addition to or alternatively to floor heating to heat up a room, for instance if inhabitants do not like floors to be heated or to be heated too much.
• the present invention can be used to construct walls or to clad existing walls. Furthermore, the present invention allows an easy customization of a wall.
• the width of walls or the width available for a walls in a building is not always known in advance, typically due to small variations characteristic of the building processes.
• the typical size of these variations can lie between a few millimeters up to a few centimeters.
• structural elements may not always be exactly vertical or horizontal.
• the present invention provides a solution to such problems as the composite panel can be positioned easily and the width can be adapted easily up to half the period of the periodic pattern of protrusions and recesses of the panel elements.
• the composite panel of the present invention lends itself to easy installation of illumination, mirrors, ornaments, other walls, cupboards, (electrical) furnaces, etc.
• first panel elements may comprise a finishing such as wall paper, magnetic fleece, veneer, etc. which may be attached to the flat side of the first panel element prior to installation whereby the cuttability of the first panel element is maintained.
• a pallet is a flat transport structure that supports goods in a stable fashion while being lifted by a forklift, pallet jack, front loader, work saver, or other jacking device, or a crane.
• a pallet is the structural foundation of a unit load which allows handling and storage efficiencies. Goods or shipping containers are often placed on a pallet secured with strapping, stretch wrap or shrink wrap and shipped.
• a pallet (67) has a transportation surface onto which goods can be placed. This transportation surface (68) needs to be smooth and certainly without sharp edge to prevent damage to goods placed onto the transportation surface.
• the present invention can thus be used to construct a pallet by using a first panel element to construct the transportation surface.
• the first panel element is installed with its flat side upwards, onto a structure comprising one or more second panel elements.
• the construction is illustrated in figures 11A-11C.
• a set of five panel elements (65) which can be first panel elements or which can be second panel elements comprising a flat side opposite the profile side, can be attached to the first set of protrusions and recesses of an upper set of three second panel elements (66), which have a second set of recesses and protrusions on the opposite side.
• the upper set of second panel elements can be attached, preferably by a snap-fit connection to a set of blocks (69) (nine blocks in the illustrated panel), each block comprising an upper side with a set of protrusions and recesses, and a lower side with a set of protrusions and recesses.
• the protrusions and recesses on the lower side of the blocks (69) can be attached to a lower set of second panel elements (70), which comprise an essentially flat side opposite the profile side.
• the profile side of the first panel elements is provided only partially with a set of periodic protrusions and recesses in the present case, in order to ensure a strong transportation surface.
• the formwork can be constructed using a set of 4 side panel elements (53, 54, 55, 56).
• Each of the side panel elements comprises a first profile side (e.g. side (57) for panel element (53)) oriented outwards and provided with a first set of protrusions and recesses which, in the shown embodiment, form a dovetail-like profile.
• the 4 rectangular panel elements are connected to each other at y-direction edges, thereby forming an open cuboid, which can be closed off by an additional bottom panel element (58) and top panel element (59), which are also provided with a set of protrusions and recesses on an outer side thereof, and which may also be part of the kits of the present invention.
• the bottom panel element (58) and top panel element (59) comprise protrusions and recesses which are oriented in an x-direction and other protrusions and recesses oriented in the y-direction.
• the panel elements (53, 54, 55, 56), and also the bottom (58) and top (59) panel elements can be attached to each other permanently, e.g. by gluing, screwing, nailing, bolting, etc., or temporarily. Once the bottom panel element and the side panel elements are attached to each other, concrete can be poured into the constructed open cuboid formwork.
• the side panel elements (53, 54, 55, 56), and also the bottom (58) and top (59) panel elements comprise a second set of periodic protrusions and recesses on a second profile side opposite the first profile side, and thus oriented inwards of the constructed cuboid.
• the top panel element (59) is placed onto the open cuboid after it has been filled completely.
• the width of the protrusions on the second profile side of the panel elements increases in the direction of the protrusions, i.e. in an inward direction with respect to the cuboid.
• the concrete once solidified, is firmly attached to all panel elements. If the panel elements were attached to each other temporarily, e.g. by clamps, this temporary attachment can be removed if the concrete has solidified as the panel elements stay in place because of the attachment to the concrete block.
• the top and bottom panel elements comprise holes (60) through which the concrete can penetrate and form support surfaces for concrete blocks above and below, thereby ensuring that concrete is supported by concrete in the full wall, i.e. that the weight of the wall is fully supported by concrete and not by panel elements.
• the panel elements are intended to remain in place, thereby showing a profile side in an outward direction which allows to connect adjacent concrete blocks and to attach finishing first panel elements thereto.
• Fig. 10B shows a block which can be constructed similarly as described here above, with the different parts separated from each other for illustration purposes.
• the side panel elements (53, 54, 55, 56) are separated from the concrete block (64), as well as the bottom panel element (58) and the top panel element (59) comprising through holes (60).
• the concrete block (64) shows periodic protrusions and recesses all around, which grip into the corresponding protrusions and recesses of the panel elements.
• the concrete block also has support surfaces (61) at the top and bottom (not visible on the figure) to provide structural support for concrete blocks on top and below the shown block.
• additional isolation (63) is present which can also be poured or injected into the open cuboid formed by the side panel elements and bottom panel element.
• a separation panel (62) can be present, which can for instance be fixed in recesses of the side panel elements (54, 55), whereby the isolation material is inserted on one side, and concrete is inserted on the other side.
• Example 6 building a house
• a complete house may be constructed quicker and cheaper, as illustrated in figs. 23A-23C.
• Structural elements such as foundation (117), supporting walls (118), floor (119) or ceiling beams (120) can be constructed from concrete using the present invention to construct the formwork with second panel elements as described above. These second panel elements remain in place and can be cladded with first panel elements both on the outside of the house as on the inside of the house.
• First panel elements on the outside of the house may already comprise a finishing at the flat side, the appearance of which can be selected before installation.
• Additional insulation e.g. cavity wall which may be filled with PUR, can be provided by constructing a second wall parallel to the structural wall, this second wall being constructed from a composite panel according to the present invention.
• Space for electrical wiring and also for water supply and heating ducts can be provided by removing a protrusion at well-chosen positions in the panel elements, which can preferably already be selected in the factory, i.e. a number of panel elements can be customized in the factory.
• the removed protrusions allow to create a network of tube-like openings in which electrical wiring, heating ducts, water supply ducts, etc. can be installed.
• domotica wiring UTP cables, optical fibres, coax cables, etc.
• protrusions can be removed on-site, it is possible to make customized panel elements in the factory, which can then be joined onsite in a pre-specified order and position, thereby allowing a house to be built from a limited number of building blocks.
• FIGS. 7A-7C show an embodiment of a comer and how such a corner can be constructed from the panel elements of the kits according to the present invention.
• the corner can be a constructed from 2 second panel elements (48a, 48b) which are connected to each other at x-direction edges using a connector element (49) comprising a set of protrusions and recesses with a dovetail-like profile, which correspond to the protrusions and recesses of the 2 second panel elements in a snap- fit connection, thereby forming a corner.
• the corner can be finished by snapping 2 more panel elements (50a, 50b) onto the 2 installed second panel elements.
• These 2 more panel elements (50a, 50b) may be first panel element, which are manually cuttable along their x-direction following a recess, or they can be second panel elements comprising a flat side opposite the profile side, or a combination thereof.
• Figure 8 also shows an embodiment of a corner, similar to the embodiment shown in figs. 7A-7C, but with a different type of connector element (51), which comprises a slanted flat side (52) which allows to produce a smooth type of corner.
• a different type of connector element (51) which comprises a slanted flat side (52) which allows to produce a smooth type of corner.
• a door frame (71) using kits of the present invention is illustrated in figs. 12A-12C.
• the door frame is constructed from a set of second panel elements (72a, 72b, 72c, 72d, 72e) which can be attached first to the edges of a wall, onto which first panel elements or second panel elements comprising a flat side opposite the profile side (73a, 73b) can be attached around the corners (74a, 74b).
• the door frame can be finished with plinths (75a, 75b) attached to the second panel elements (72a, 72e) and the flat side of the first panel elements (73a, 73b).
• the door (76) can be installed into the frame using a door connector element (77) and hinges (78a, 78b, 78c), the door connector element being attached to the central second panel element (72c) by 2 protrusions (79a, 79b) which fit into 2 recesses of the central second panel element by a snap-fit connection.
• the panel elements (73a) and (73b) can be separate panel elements, or can be, in a preferred embodiment, portions of a single panel element whereby they can be connected via portion (72c), e.g. as better illustrated in fig. 21B.
• a window frame (81) can be done similarly as the construction of a door frame, and is illustrated in figs. 13A-13B for a first embodiment and figs. 14A- 14B for a second embodiment.
• a wall (80) comprises an edge (82) into which a window frame (81) with a double-glazed window (83) needs to be placed.
• the frame can be constructed from one or more second panel elements (84, 85) which are attached to the edge (82) of the wall.
• a first panel element or a second panel element comprising a flat side opposite the profile side (86, 87), which is bent (88) around a corner of the edge or which comprises a perpendicularly positioned portion (89), can be attached to the second panel element (84, 85) by e.g. glue or by a snap-fit connection, and with a clamping device (90, 91).
• the window can then be placed into the frame using window connector elements (92, 93).
• the frame can be finished by a plinth (94, 95).
• a wall side frame (96) over an edge (97) of a wall (98) is illustrated in figs. 15A-15B.
• a second panel element (99) can be attached to the edge (97) and first panel elements or second panel elements comprising a flat side opposite the profile side (100a, 100b, 100c), can be attached to the wall (100a, 100c) or to the second panel element ((100b) fixed to (99)).
• the attachments can be done by screws (101).
• Other elements, such as a rail (102) can also be attached easily.
• the frame is finished off with plinths (103a, 103b).
• a frame be it a door frame, a window frame, a wall side frame or other, is also illustrated in fig. 21B.
• Example 11 structural element with a window opening
• Figures 22A-22B illustrate how a window can be constructed in a structural element using a kit in accordance with the present invention. Similar to the construction of formwork, 2 side panel elements (111, 112) are combined with a top panel element (113) and a bottom element (114) to create an window, which can be positioned in between wall portions (115) which are also constructed using kits of the present invention.
• the side panel elements (111, 112), the top panel element (113) and the bottom panel element (114) comprise a partially flat side opposite the profile side, said partially flat side comprising an edge (116) which can be used to attach the glazing, e.g. in correspondence with example 9.
• the present invention can be used in a number of dedicated applications, such as: finishing of corners for built-in apparatuses such as ovens, bathtubs, Jacuzzi; construction of outdoor cabins;
• kit may also comprise plastic finishing or tiles which are connected or connectable to the bendable layer of the first panel element at the flat side of the first panel element;
• outer walls e.g. rainproof outer wall cladding whereby the flat side of the first panel element comprises a waterproof layer or coating
• furniture whereby the furniture such as cupboards, sofa's, seats, drawers can be integrated with the walls or floors;

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• 2017
  • 2017-12-04 WO PCT/EP2017/081411 patent/WO2019110085A1/en not_active Ceased
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