[go: up one dir, main page]

WO2008131005A1 - Panneaux structurels - Google Patents

Panneaux structurels Download PDF

Info

Publication number
WO2008131005A1
WO2008131005A1 PCT/US2008/060478 US2008060478W WO2008131005A1 WO 2008131005 A1 WO2008131005 A1 WO 2008131005A1 US 2008060478 W US2008060478 W US 2008060478W WO 2008131005 A1 WO2008131005 A1 WO 2008131005A1
Authority
WO
WIPO (PCT)
Prior art keywords
concrete
forming
structural panel
rib structures
core
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2008/060478
Other languages
English (en)
Inventor
Steven R. Maimon
Victor H. Klein
William N. Calland
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Maxam Industries Inc
Original Assignee
Maxam Industries Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Maxam Industries Inc filed Critical Maxam Industries Inc
Publication of WO2008131005A1 publication Critical patent/WO2008131005A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G9/00—Forming or shuttering elements for general use
    • E04G9/02—Forming boards or similar elements
    • E04G9/06—Forming boards or similar elements the form surface being of metal
    • 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
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/292—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and sheet metal
    • 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
    • E04C2/34—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
    • E04C2/36—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 transversely-placed strip material, e.g. honeycomb panels
    • E04C2/365—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 transversely-placed strip material, e.g. honeycomb panels by honeycomb structures
    • 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 generally to structural panels, methods of making structural panels, methods of using structural panels for building and construction applications, and methods of using structural panels for concrete pouring applications.
  • the face of the concrete form that will be in contact with the poured concrete needs to be coated with a release agent, for example, diesel or other oil, so that the concrete does not stick to the form during curing, thus permitting the form to be removed from the concrete after it is cured without damage to the surface of the concrete or the concrete form itself, and thus permitting the form to be used again for additional pours.
  • a release agent for example, diesel or other oil
  • Plain plywood and metal sheets employed for concrete forming require the use of a release agent for each pour. Construction industry experience indicates that treated concrete forming products typically require a release agent after a limited number of pours, typically less than five, due to adherence of the concrete to the surface and damage to the overlay.
  • the protective covering laminated on to the substrate is very thin and of a material that is susceptible to physical damage by the alkalinity of the concrete mix and by the presence of sand, gravel, and other aggregates in the concrete mix and normal handling of the concrete form at the construction site.
  • the disadvantages of using these types of products for concrete pouring, versus a durable form that does not require a release agent include primarily: 1) the additional time and labor required to apply the release agent to form and then to clean the release agent from the form after it is removed from the cured concrete; 2) the additional time and labor required to clean any residual release agent, or staining caused by the release agent, from the surface of the cured concrete after the form is removed; 3) the potential additional time, labor and materials required to repair damage, if any, to the surface of the cured concrete after the form is removed, which damage is caused by failure of the release agent, if any, to provide effective release from the surface of the cured concrete; 4) the potential eventual damage to the form caused by the alkalinity of the concrete mix and the presence of sand, gravel and other aggregates in the concrete mix and the chemicals in the release agent, limiting the useful life of the form and thus increasing the number of forms that need to be purchased and then disposed of; and 5) the potential environmental and related impacts resulting from the use
  • a structural panel for use as a building or construction structure may comprise: a core comprising a corrugated composite structure; and first and second plates disposed on opposing sides of the core.
  • the core may comprise a plurality of first rib structures running along a first direction that is disposed on the first plate and a plurality of second rib structures running along a second direction that is disposed on the plurality of first rib structures.
  • a structural panel for use as a building or construction structure may comprise: a core comprising a foamed polymer structure; a first sheet and a second sheet; and first and second plates disposed on opposing sides of the core.
  • the first and second sheets may be polyethylene terephthalate polyester sheets or polyester sheets. The first sheet may be inserted between the core and the first plate and the second sheet may be inserted between the core and the second plate.
  • a method of forming a concrete structure may comprise the steps of: forming a concrete forming structure into which uncured concrete is to be poured; pouring concrete into the concrete forming structure; and removing the concrete forming structure after the concrete has cured.
  • the concrete forming structure may comprise at least one panel having a core and first and second plates disposed on opposing sides of the core.
  • the core may comprise a plurality of first rib structures running along a first direction that is disposed on the first plate and a plurality of second rib structures running along a second direction that is disposed on the plurality of first rib structures.
  • a method of forming a concrete structure may comprise the steps of: forming a concrete forming structure into which uncured concrete is to be poured; pouring concrete into the concrete forming structure; and removing the concrete forming structure after the concrete has cured.
  • the concrete forming structure may comprise at least one panel having a core, first and second plates disposed on opposing sides of the core, and a laminated layer disposed on one of the first and second plates that contact the uncured concrete.
  • the at least one laminated layer may be a flexible membrane comprising a thermoplastic material as a base, alumina, and carbon.
  • FIG. 1 is a schematic view of an embodiment of a structural panel according to the present invention.
  • FIGS. 2A-2B are front and side views, respectively, of an embodiment of a structural panel with a corrugated composite structure according to the present invention.
  • FIGS. 3A-3B are views of an embodiment of a structural panel with a honeycomb structure according to the present invention.
  • FIG. 3A is a perspective view of the structural panel.
  • FIG. 3B is a view of only the honeycomb structure.
  • FIGS. 4A and 4B are perspectives view of an embodiment of a structural panel with a flame retardant foamed polymer structure according to the present invention.
  • FIG. 4A shows the structural panel with a polymer foam structure and metal plates.
  • FIG. 4B shows the structural panel of FIG. 4A with Mylar or polyester sheets between the polymer structure and the metal plates.
  • FIGS. 5A-5C are cross-sectional views of embodiments of construction panels according to the present invention, which use structural panels.
  • FIG. 6 is a perspective view of an embodiment of a concrete forming panel according to the present invention.
  • FIGS. 7A-7C are perspective views of embodiments of the concrete forming panel according to the present invention.
  • FIG. 8 is a perspective view of an embodiment of a concrete form comprising a plurality of concrete forming panels according to the present invention.
  • a structural panel may comprise a light-weight yet strong structure.
  • the structural panel may comprise any one of a corrugated composite structure, a honeycomb structure, or a flame retardant foamed polymer structure.
  • the structural panel may also comprise one or more plates mounted or laminated on each side of the corrugated composite structure, the honeycomb structure, or the flame retardant foamed polymer structure.
  • the structural panel may be used as part of a building and construction structure.
  • such applications include the structural panel being part of the following structures: interior/exterior walls or panels, floors, roofs, sub-roof structures, decks/platforms, pallets, tilt-up walls, bulkheads and marine sheet piling, highway sound barriers; and mobile structures (such as trailers, homes, and shipping containers).
  • the additional laminated layers may be attached to the structural panels for forming more aesthetically pleasing construction panels for use in building and construction structures.
  • the additional laminated layers may include one or more of the following: real or faux brick, stone, wood, stucco, or the like, as well as polymer and other materials employed as laminations for functional and/or decorative purposes (such as acoustical tiles, wood panels, paint, plaster moldings, and the like).
  • One or more flexible membranes may be mounted on the structural panels to form concrete forming panels which may be used in making concrete forms for concrete pouring applications.
  • FIG. 1 presents a perspective view of a general embodiment of a structural panel 100 according to the present invention.
  • the structural panel may take may different forms.
  • the structural panel 100 preferably includes a core 116 and plates 114 on opposing sides of the core 116
  • FIGS. 2A and 2B Another embodiment of the structural panel 200 is shown in FIGS. 2A and 2B.
  • This embodiment includes a core 216 comprising a corrugated composite structure.
  • the corrugated composite structure of the core 216 comprises a layer 210 formed by a first series of first rib structures or legs 211 that run along a first direction of the structural panel 200 and a layer 212 formed by a second series of second rib structures or legs 213 that run along a second direction of the structural panel 200.
  • the second direction is substantially perpendicular to the first direction.
  • the rib structures 211, 213 are elongated and can be any suitable cross-sectional shape including, for example, rectangular, square, triangular, trapezoidal, I-shaped or the like.
  • the presently preferred cross-sectional shape is rectangular.
  • the presently preferred height of the rib structures 211, 213 is in the range of 3 mm to 9 mm, and the presently preferred width of the rib structures 211, 213 is in the range of 3 mm to 9 mm.
  • the length of the rib structures 211, 213 can be modified to suit the particular application.
  • the rib structures 211, 213 can be formed from a variety of materials. It is presently preferred that the rib structures 210, 212 be formed from polypropylene. [0029] The spacing between the rib structures 211, 213 can be varied according to the application and design requirements, such as strength. Preferably the rib structures 211 in the first layer 210 are spaced about 2 to 6 mm apart from one another, more preferably 4 mm apart. Though a different spacing could be used for the rib structures 213 in the second layer 212, it is presently preferred that the same spacing be used as in the first layer 210.
  • the first layer 210 and the second layer 212 are preferably connected together to form the core 216.
  • An adhesive layer (not shown) disposed between the first layer 210 and the second layer 212 may be used to attach the rib structures 211, 213 to each other. Also, nails or screws might be utilized.
  • the adhesive layer may be a substance that is not affected or substantially affected by water, alkali, and petrochemicals. The adhesive layer is such to be sufficient to bond the rib structures 211, 213 in such a manner as to be suitable for the performance requirements of the intended application, for example, one or more of the class of moisture-cured urethane, and isocyanate, adhesive systems, or equivalent.
  • the adhesive includes one-part acrylics, two-part acrylics, epoxies, polyurethanes, phenolics, hot-melt adhesives, polyvinyl acetates, ethylene vinyl acetates, pressure-sensitive adhesives, and/or mixtures thereof.
  • Plates 214 are placed on either side of the core 216.
  • the plates 214 may be, for example, formed from aluminum, anodized aluminum, or other suitable material such as steel. It is presently preferred that the plates have a thickness in the range of 0.1 mm to 0.4 mm.
  • An adhesive layer may be used to attach the plates 214 to the core 216. Also, nails or screws might be utilized. In some embodiments of the present invention, the adhesive layer may be a substance that is not affected or substantially affected by water, alkali, and petrochemicals.
  • the adhesive layer is such to be sufficient to bond the different materials of the plates 214 and the core 216 in such a manner as to be suitable for the performance requirements of the intended application, for example, one or more of the class of moisture- cured urethane, and isocyanate, adhesive systems, or equivalent.
  • the adhesive includes one -part acrylics, two-part acrylics, epoxies, polyurethanes, phenolics, hot-melt adhesives, polyvinyl acetates, ethylene vinyl acetates, pressure-sensitive adhesives, and/or mixtures thereof.
  • rib structures 211 extend in a direction substantially perpendicular to the direction of the rib structures 213, as opposed to running parallel to each other. This improvement allows embodiments of the structural panel 200 to maintain essentially equal strength in both directions across the plane of the panel, thereby minimizing deflection under an equal load, as may be encountered when used in concrete forms.
  • the overall thickness of the structural panel 200 can be about 1/2 inch, although the thickness can vary depending on the application. For example, thicknesses such as 3/8, 1/2, 5/8, 3/4, 7/8, and 1 inch can be used.
  • the structural panel can have a variety of widths, such as 48 or 60 inches, and a variety of lengths, such as 72, 96, 120 and 144 inches.
  • FIGS. 3A-3B show another embodiment of the structural panel 300 according to the present invention.
  • This embodiment includes a core 316 that is substantially a honeycomb structure similar in at least some respects to that used in the manufacture of aircraft.
  • the honeycomb structure of the core 316 includes a collection of slender members connected together by conventional means to form walls 311.
  • These walls 311 preferably are rectangular in shape and have a density of about 1.5 - 2.0 lb/ft 3 , a width of about 2-8 mm and a length of 6-24 mm, preferably a density of 1.8 Ib/ lb/ft 3 , a width of 4 mm and a length of 13 mm.
  • the skins are preferably galvanized, or stainless steel or aluminum.
  • the honeycomb material, cell structure and wall thickness is such that the combination provides the required strength and weight, and is cost-competitive, for the intended application.
  • the dimensions of the walls 311 and the spacing between them can be modified to suit the particular application.
  • the honeycomb structure can be made from various types of materials. It is presently preferred that it be formed from metal (such as galvanized or stainless steel or aluminum). Other materials, however, such as polymer or paper, may also be used.
  • Plates 314 are placed on either side of the core 316.
  • the plates 314 may be, for example, formed from galvanized steel or aluminum. It is presently preferred that the plates have a thickness in the range of 0.1 mm to 0.4 mm.
  • An adhesive layer (not shown) may be disposed between the plates 314 and the core 316 to attach the plates 314 to the core 316. Because the contact area between the edge of the honeycomb structure of the core 316 and the plates 314 is small, an extremely strong adhesive preferably is used to attach the plates to the honeycomb structure. A notable improvement over the prior art is the use of an adhesive layer that is sufficient to bond the different materials of the core 316 and the plates 314 in such a manner as to be suitable for the performance requirements of, and cost-competitive for, the intended application, for example, one or more of the class of 2-part epoxy adhesive systems, or equivalent.
  • the overall thickness of the structural panel 300 can be about 1/2 inch, although the thickness can vary depending on the application. For example, thicknesses such as 3/8, 1/2, 5/8, 3/4, 7/8, and 1 inch can be used.
  • the structural panel can have a variety of widths, such as 48 or 60 inches, and a variety of lengths, such as 72, 96, 120 and 144 inches.
  • FIGS. 4A-4B shows other embodiments of the present invention in which the structural panel 400 comprises core 416 formed of a flame retardant foamed polymer structure.
  • the foamed polymer structure could be, for example, polyvinyl chloride (PVC), such as 30% volume PVC foam.
  • PVC polyvinyl chloride
  • Other foamed polymers can be used, if flame retardancy is not required and they provide the performance and other performance properties required for the intended application.
  • the presently preferred height of the core 416 is 3/4 inch but other heights can be used, such as about 3/8, 1/2, 5/8, 3/4, 7/8, or 1 inch.
  • Plates 414 may be provided on either side of the core 416.
  • the plates 414 may be formed from polyester and/or metal. If polyester is used, for example, the plates 414 may be a concrete release overlay such as Maxam's MCOTM, or a decorative surface. If metal is used, for example, the plates 414 may be aluminum. It is presently preferred that each of the plates 414 have a thickness in the range of 0.01 mm to 0.25 mm. In FIG. 4A, the plates 414 are attached to either side of the core 416 and an overlay surface on one or both sides at 414; however an embodiment of the present invention may have only one metal or polyester layer plate 414 attached to the core 416.
  • FIG. 4B shows a modification of the structural panel of FIG. 4A in which a polyethylene terephthalate polyester (Mylar) sheet or polyester sheet 413 is inserted between the metal plates 414 and the polymer structure 416.
  • Mylar polyethylene terephthalate polyester
  • An adhesive layer (not shown) may be disposed between the plates 414 and the core 416 to attach the plates 414 to the core 416.
  • An adhesive system used to connect the plates 414 to the core 416 in the structural panel 400 of FIG. 4A.
  • the adhesive system may use the polyester layer at 413 as a carrier and be coated on one or both sides depending on whether plate 414 is attached.
  • the adhesive layer preferably is sufficient to bond the different materials of the core 416 and plates 414 in such a manner as to be suitable for the performance requirements of, and cost-competitive for, the intended application, for example, one or more of the class of moisture-cured urethane, and isocyanate, adhesive systems, or equivalent.
  • the adhesive system may include compounds that include those inherent in the materials being bonded together.
  • the overall thickness of the structural panel 400 can be about 1/2 to 1 inch thick, although the thickness can vary depending on the application. For example, thicknesses such as 3/8, 1/2, 5/8, 3/4, 7/8, or 1 inch can be used.
  • the structural panel can have a variety of widths, such as 48 or 60 inches, and a variety of lengths, such as 72, 96, 120 and 144 inches.
  • the various embodiments of the structural panels 200, 300, and 400 as seen in FIGS. 2-4 can be used in a variety of applications, such as building and/or construction applications.
  • the embodiments of the structural panels may be used as part of the following structures: interior/exterior walls or panels, floors, roofs, sub-roof structures, decks/platforms, pallets, tilt-up walls, bulkheads and marine sheet piling, highway sound barriers; and mobile structures (such as trailers, homes, and shipping containers).
  • the building and construction industry often require panels of high strength.
  • the structural panels according to the present invention can be advantageously used as light weight alternatives to various conventional heavier solid forms of panel, while providing the necessary strength.
  • the concrete wall may weigh many tons and costly crane equipment is typically used to erect the wall (i.e., tilt- up the wall upward) so that it is planted into the trench and secured to the final structure. If warehouse wall is instead made from the structural panel, like those disclosed in FIGS. 2A- 4B, less costly equipment will be necessary to lift and fix the walls into place due to its lighter weight.
  • the structural panels 200, 300 and 400 may include layers laminated onto the structural panels to form construction panels 501, as shown in FIGS. 5 A through 5C.
  • some laminated layers can be attached to one or more sides of the structural panel, such as one with a corrugated structure as shown in FIGS. 2A-2B, a honeycomb structure as shown in FIG. 3 A, or a polymer structure as shown in FIG. 4A or 4B.
  • Some laminated layers may include one or more of the following: real or faux brick, stone, wood, stucco, or the like, as well as polymer and other materials employed as laminations for functional and/or decorative purposes (such as acoustical tiles, wood panels, paint, plaster moldings, and the like).
  • FIG. 5A shows a laminated layer 503 of acoustical tiles mounted on one side of a structural panel 200, 300, or 400, in which the layer 503 is mounted using an adhesive.
  • FIG. 5B shows a laminated layer 504 of wood on both sides of a structural panel.
  • FIG. 5C shows one laminated layer 505 of a plaster molding on one side of the structural panel 200, 300, or 400, and another laminated layer 506 of paint on the other side.
  • additional layers can be used to provide a more aesthetically structure for either indoor or outdoor use.
  • such applications for the construction panel in which the construction panel is a permanent part of the finished structure include: interior/exterior walls or panels, floors, roofs, sub-roof structures, decks/platforms, and the like.
  • the structural panels can include anti-pest and/or anti-fungal/mold/mildew capabilities in building and/or constructions applications.
  • a long lasting natural anti-pest additive is used, for example, the additives disclosed in U.S. provisional application 60/721972, filed on September 30, 2005, and U.S. Patent application 11/529740, filed September 29, 2006, both herein incorporated by reference in their entireties. These additives will typically be incorporated in the outer layer of the panel.
  • FIG. 6 shows another embodiment of the present invention in which a structural panel 600 (which can be the structural panel 200 in FIG. 2A-2B; 300 in FIG.
  • Such concrete forming panels can be used in the formation of concrete forms used to create concrete structures such as concrete walls, garage floors, pillars/columns, and pre-casted items (such as Jersey barriers or walls).
  • pre-casted items such as Jersey barriers or walls.
  • Using structural panels according to the present invention provides concrete forming panels that are light weight, which can greatly ease the time and effort necessary during the construction process.
  • the use of light weight concrete forming panels should include material, such as one or more flexible membranes 602, that facilitates the separation of the concrete forming panel from the finished concrete product.
  • the flexible membrane 602 may include the flexible membrane as disclosed in U.S. Provisional Application 60/810,156, entitled “Flexible Release Agent-Free, Multiple-Use Materials Employed for Concrete Pouring Forms and Methods of Making and Using the Same," filed June 2, 2004, (herein incorporated by reference in its entirety).
  • Such a flexible membrane may be used to form concrete products that exhibit excellent release properties, and that could be reused repeatedly without the use of a release agent.
  • the flexible membrane 602 may include ethylene propylene and a diene monomer and/or a terpolymer of ethylene, propylene and a diene monomer.
  • the flexible membrane 602 includes a polymer comprising butylene monomers and/or a polymer comprising chlorosulfonated polyethylene, such as, by way of example only and not by way of limitation, Hypalon®.
  • the flexible membrane comprises an elastomer, a vulcanizable elastomer, a vulcanized elastomer, a poly- rubber blend.
  • the flexible membrane 602 includes a combination/mixture of at least some of these compositions. In some embodiments of the present invention, the flexible membrane 602 is in accordance with ASTM-D-1418-64. In some embodiments of the present invention, the flexible membrane is a rubber product.
  • the flexible membrane may comprise a thermoplastic material (such as polyvinyl chloride (PVC), polypropylene, high density polyethylene (HDPE) or other type of polyethylene) as a base; alumina (Al 2 O 3 ); and/or carbon.
  • a thermoplastic material such as polyvinyl chloride (PVC), polypropylene, high density polyethylene (HDPE) or other type of polyethylene
  • the flexible membrane may comprise an amount by weight of about 50-95% of thermoplastic material (preferably 63.75% of HDPE), about 25% to 45% of alumina (preferably 35% of alumina), and preferably about 1.25% by weight of carbon (such as carbon black).
  • the carbon may be selected from the group consisting of activated carbon, non-activated carbon, carbon fibers, and/or carbon black.
  • the flexible membrane 602 provides easy, quick, and clean release from cured concrete without the use of a release agent, such as form oil or diesel oil or chemicals, of either a barrier or reactive type.
  • the concrete forming panel 603 can be used to construct concrete forms.
  • the concrete pouring form may be usable for, in some embodiments, at least 20 pours, at least 25 pours, at least 30 pours, and in some embodiments even more than 30 pours, without the use of one or more release agents.
  • the quick, easy, and clean release properties of the flexible membrane 602 are such that the surfaces of both the cured concrete and the flexible membrane 602 may be smooth and undamaged after the concrete form made from the concrete forming panel 603 is removed from the cured concrete and/or visa-versa.
  • the concrete forming panel 603 may be used to construct and disassemble concrete pouring forms using commercially available building and constructions industry tools, equipment, and standard practices.
  • the quick, easy, and clean release capability of the flexible membrane 602 without release agents of some embodiments of the present invention is provided at least in part by the low surface energy of the flexible membrane.
  • the low surface energy may result from the combination of the types and amounts of material employed in the flexible membrane 602 and the method by which the flexible membrane is manufactured. Surface energy may be determined, for example, by measuring the contact angle formed by a droplet of distilled water upon the membrane 602. The more that the water droplet "beads up," the greater the contact angle is, and the lower the corresponding surface energy is.
  • the flexible membrane can have a surface energy of less than or approximately equal to about 25 or 30 dynes/cm.
  • Some embodiments of the present invention may incorporate, in the flexible membrane 602, functional or decorative surface textures, patterns, or designs, which surface treatments also do not require the use of release agents for quick, easy, and clean release or any change in the method of cleaning as set forth above.
  • the flexible membrane 602 has a thickness of at least approximately 40 mils. In other embodiments of the present invention, thicker or thinner flexible membranes may be used.
  • the concrete forming panel 703 may take a variety of forms.
  • FIG. 7 A show an embodiment of the present invention in which concrete forming panel 603 comprises a structural panel 700 with a corrugated composite structure of the type shown in FIGS. 2A and 2B.
  • the flexible membranes is attached to the structural panel 700 using an adhesive layer.
  • the adhesive layer may comprise any suitable adhesive.
  • an adhesive according to U.S. Patent No. 4,657,958 to Feldhouse, et al., issued April 14, 1987, the contents of which are incorporated herein in their entirety may be utilized to bond a flexible membrane 602 to the metal plates of the structural panel 700.
  • Other adhesives may be utilized as well.
  • Some embodiments of the present invention maybe practiced utilizing adhesive number 92256 obtainable from Portals Plus Inc. of Chicago, Illinois, U.S.A. Any adhesive or other substance that may be utilized to sufficiently connect the flexible membrane 602 to the metal plates of the structural panel 700 may be used. Also, nails or screws might be utilized, at least when the portions of the nails or screws would not leave an impression in the concrete product (e.g., nails may be utilized to secure portions of the flexible membrane 602 that do not come into contact with the concrete, nail heads may be "covered over" with a patch, etc).
  • the adhesive layer may be a substance that is not affected or substantially affected by water, alkali, and petrochemicals.
  • the bond resulting from the use of the adhesive layer(s) may remain intact and effective for the useful commercial life of the structural panel 200 (e.g., for at least 20, 30, or 30+ pours, etc.).
  • the adhesive includes one-part acrylics, two-part acrylics, epoxies, polyurethanes, phenolics, hot-melt adhesives, polyvinyl acetates, ethylene vinyl acetates, pressure-sensitive adhesives, and/or mixtures thereof.
  • the concrete forming panel 703 may be, by way of example only, attached and secured to a concrete forming frame or otherwise positioned and secured in the desired orientation or alignment in a free-standing configuration using, for example, screws or clamps. Holes in the concrete forming panel 703 remaining after the screws are removed can be resealed, in the field, with material to restore the concrete forming panel 703 to its original condition.
  • two flexible membranes may be bonded or otherwise connected to opposite sides of the structural panel, thus creating a dual-faced concrete forming panel with a useful commercial life of, by way of example, at least 40, 50, or 60+ concrete pours (i.e., at least 20, 25, 30+ pours respectively for each face of the dual- faced concrete forming panel used as a concrete form).
  • a composite material with desirable release characteristics vis-a-vis cured concrete such as one according to Provisional Application No.
  • 60/559,005 entitled “Release Agent-Free, Multiple-Use, Polymer-Based Composite Materials Employed for Concrete Pouring Forms and Methods of Making and Using Same,” filed April 5, 2004, is connected to one opposite side of the substrate, thus creating a dual-faced concrete forming panel with a useful commercial life as just recited.
  • the flexible member may be subjected to a surface treatment to improve adhesion between the flexible member and the metal plates of the structural panel.
  • the surface treatment may be selected, by way of example only and not by way of limitation, from the group of a corona discharge, a flame treatment, a plasma treatment, and/or combinations thereof.
  • the concrete forming panel 703 of FIG. 7A as disclosed may have the following advantages: (1) a 1/2" thick section is equivalent to plywood; (2) the weight of a 1/2" thick section is half the weight of 3/4" thick plywood; (3) there is no organic components to support rot, mold, or mildew; and (4) there is low maintenance and life-cycle costs.
  • FIG. 7B shows another embodiment of the present invention in which the concrete forming panel 703' may comprise structural panel 700' with a honeycomb structure such as the one shown in FIG. 3A.
  • An adhesive layer similar to the adhesive layer discussed in relation to the embodiment of FIG. 7A may be used to attach the flexible membrane(s) 602 to the metal plates of the structural panel.
  • the concrete forming panel may be, by way of example only, attached and secured to a concrete forming frame or otherwise positioned and secured in the desired orientation or alignment in a free-standing configuration using, for example, screws or clamps. Holes in the concrete forming panel remaining after the screws are removed can be resealed, in the field, with material to restore the form to its original condition.
  • two flexible membranes may be bonded or otherwise connected to opposite sides of the structural panel, thus creating a dual- faced concrete forming panel with a useful commercial life of, by way of example, at least 40, 50, or 60+ concrete pours (i.e., at least 20, 25, 30+ pours respectively for each face of the dual-faced structural panel used as a concrete form).
  • the flexible member may be subjected to a surface treatment to improve adhesion between the flexible member and the metal plates of the structural panel.
  • the surface treatment may be selected, by way of example only and not by way of limitation, from the group of a corona discharge, a flame treatment, a plasma treatment, and/or combinations thereof.
  • the concrete forming panel 703' of FIG. 7B may have the following advantages: (1) the strength of the a 1/2" thick section is several times that of 3/4" thick plywood; (2) the weight of a 1/2" thick section is similar or less then the weight of 3/4" thick plywood; (3) there is no organic components to support rot, mold, or mildew; and (4) there is low maintenance and life-cycle costs.
  • FIG. 7C shows another embodiment of the present invention in which concrete forming panel 703" comprises a structural member 700" comprising a flame retardant foamed polymer structure, such as the one shown in FIG. 4 A or 4B.
  • An adhesive layer similar to adhesive layer discussed in relation to the embodiment of FIGS. 7A-7B or other adhesive may be used to attach the flexible membrane 602 to the metal plates of the structural panel 700".
  • the concrete forming panel 703" may be, by way of example only, attached and secured to a concrete forming frame or otherwise positioned and secured in the desired orientation or alignment in a free-standing configuration using, for example, nails, screws or clamps.
  • the concrete forming panel may be cut or sawed, nailed or screwed into, framed and clamped and otherwise used, handled and stored in the same manner as, and employing the same commercially available tools and equipment and standard industry practices currently employed with, non-metal concrete forming products employed in normal building and constructions applications and conditions.
  • two flexible membranes may be bonded or otherwise connected to opposite sides of the structural panel, thus creating a dual-faced concrete forming panel with a useful commercial life of, by way of example, at least 40, 50, or 60+ concrete pours (i.e., at least 20, 25, 30+ pours respectively) for each face of the dual-faced concrete forming panel used as a concrete form).
  • the flexible member may be subjected to a surface treatment to improve adhesion between the flexible membrane and the metal plates of the structural panel.
  • the surface treatment may be selected, by way of example only and not by way of limitation, from the group of a corona discharge, a flame treatment, a plasma treatment, and/or combinations thereof.
  • the concrete forming panel 703" of FIG. 7C may have the following advantages: (1) the strength and weight of the structural panel is equivalent or better than plywood of similar thickness; (2) the structural panel can be cut with normal wood tools; (3) the edges of the structural panel do not require sealing; (4) there is no organic components to support rot, mold, or mildew; and (4) there is low maintenance and life-cycle costs.
  • the concrete forming panel of FIGS. 7A-7C can all be used in concrete pouring applications.
  • concrete forming panels may be arranged using wooden braces and tie rods or big metal frames.
  • a method of pouring concrete using one or more structural panels of the present invention may include the actions of providing a flexible membrane, providing a structural panel, bonding the flexible membrane to the structural panel to provide a concrete form that may be released from cured concrete without using a release agent such that at least one surface of the concrete form and at least one surface of the cured concrete are left smooth and undamaged.
  • the flexible membrane may be bonded to the structural panel using an adhesive.
  • the method may also include the steps of pouring concrete into the concrete form such that the flexible membrane comes into contact with the poured concrete, allowing the poured concrete to cure, and separating the cured concrete from the concrete form, in the absence of a release agent, to provide one or more corresponding flat or curved surfaces on the cured concrete, which surfaces require little to no finishing work.
  • concrete forming panels can be used to create a concrete form having a rectangular cavity or other suitable form with the flexible membrane 602 forming the interior surfaces of the concrete form.
  • the resulting concrete pour form is filled with a concrete composition comprising a very high alkalinity cement mix with various aggregates of various sizes and shapes, including sand and gravel with sharp edges.
  • No form oil or other oils or release agents is applied to the surfaces of the flexible membrane prior to pouring the concrete composition into the concrete form.
  • the concrete in the concrete form is vibrated and tamped to remove trapped air and to condense the composition in accordance with standard building and construction industry practice.
  • the concrete composition is then cured in place in the container.
  • the container is then disassembled and the cured concrete block is removed.
  • the flexible membrane forming the interior faces of the walls of the container would be released easily from the cured concrete block when the concrete forming panel samples are disassembled and removed from the cured concrete block.
  • the surfaces of the flexible membrane would be smooth, and no damage to any of the surfaces of the flexible membrane would be observed. Further, any residual concrete mineral dust remaining on the surface of the flexible membrane is washed off easily with water.
  • the panel (hereinafter referred to as Panel A) comprises a corrugated composite structure and first and second plates disposed on opposing sides of the core.
  • the core comprises a plurality of first rib structures running along a first direction that is disposed on the first plate and a plurality of second rib structures running along a second direction that is disposed on the plurality of first rib structures.
  • Both Panel A and the plywood panel had Maxam's MCOTM facing on one face, and the plywood panel also had MDO on the back face.
  • the samples were placed in 2' x 8' steel frames for the pour and a concrete section approximately 2.5" thick and 8' high was poured.
  • the purpose was to compare the deformation of the concrete wall due to deflection of the face material under load in a real-world field test. A straight edge was placed at the exact center where the arc of deflection was the greatest and used as a reference to measure the deflection at the edges. The following deflections were measures:
  • Panel B which is a profile-core, all-composite forming panel comprising a corrugated composite structure and first and second plates disposed on opposing sides of the core.
  • the core comprises a plurality of first rib structures running along a first direction that is disposed on the first plate and a plurality of second rib structures running along a second direction that is disposed on the plurality of first rib structures.
  • Panel B had Maxam's MCOTM facing on one face and was the standard nominal 0.500" thick. The sample was placed in a 2' x 8' steel frame which had an airbag above it to apply a measured uniform loading across the face.
  • the deflection under load in the center of each section was compared to and reduced by the average deflection of the steel framing on either side to get a measure of the actual deflection of Panel B.
  • the average deflection of Panel B was 0.1004 inches at 7.0 PSI and 0.1686 inches at 10.4 PSI. The deflection of Panel B was consistent across the test bed.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un panneau (100, 200, 300, 400) qui comprend un noyau (116, 216, 316, 416) et des première et seconde plaques (114, 214, 314, 414) disposées sur les côtés opposés du noyau (116, 216, 316, 416). Le noyau peut comprendre des pluralités de premières et secondes structures de nervure, une structure de polymère expansé ou une structure en nid d'abeilles. Le panneau (100, 200, 300, 400) peut être utilisé comme structure de bâtiment ou de construction ou dans une application de coulage de béton.
PCT/US2008/060478 2007-04-17 2008-04-16 Panneaux structurels Ceased WO2008131005A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US91232807P 2007-04-17 2007-04-17
US60/912,328 2007-04-17

Publications (1)

Publication Number Publication Date
WO2008131005A1 true WO2008131005A1 (fr) 2008-10-30

Family

ID=39608159

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2008/060478 Ceased WO2008131005A1 (fr) 2007-04-17 2008-04-16 Panneaux structurels

Country Status (2)

Country Link
US (1) US20080307729A1 (fr)
WO (1) WO2008131005A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2941254A1 (fr) * 2009-01-21 2010-07-23 Sateco Sa Banche de coffrage d'un mur en beton.
WO2011106901A1 (fr) * 2010-03-05 2011-09-09 Innovative Composites Inc. Système de construction modulaire utilisant des panneaux composites à noyau de mousse
CN105256994A (zh) * 2015-11-03 2016-01-20 广西平果北融林木业发展有限公司 一种光膜板
CN105781006A (zh) * 2016-04-22 2016-07-20 广东省建筑科学研究院集团股份有限公司 一种梯度复合发泡混凝土轻质隔断及其制备方法
CN105986639A (zh) * 2014-08-19 2016-10-05 中晔科技有限公司 用于环保建筑的复合板

Families Citing this family (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100233503A1 (en) * 2009-03-13 2010-09-16 Zachman Joseph M Panel for a storage container
US8307604B2 (en) * 2009-08-27 2012-11-13 Voltek International, Inc. Underground utility vault replacement system
DE102010062061A1 (de) * 2010-11-26 2012-05-31 Wacker Chemie Ag Bauelemente in Plattenform
US20140260045A1 (en) * 2013-03-15 2014-09-18 Compatico, Inc. Tackable acoustic wall panel system
CN103397738A (zh) * 2013-08-14 2013-11-20 南通华恒机械制造有限公司 新型建筑用金属隔热复合板
US10059077B2 (en) * 2014-12-31 2018-08-28 Joe Ru He Zhao High resistance panels (HRP)
US9469567B2 (en) * 2015-03-20 2016-10-18 Harold S Friedman Decorative panel
CN111648490A (zh) * 2020-06-16 2020-09-11 黄宜侦 一种可一体式安装的绿色保温墙板
FR3137698A1 (fr) * 2022-07-08 2024-01-12 Roger de KALBERMATTEN Elément de construction en structure sandwich
EP4303379A1 (fr) * 2022-07-08 2024-01-10 Roger De Kalbermatten Panneau de coffrage composite et banche, comprenant une âme non métallique et une feuille métallique magnétique

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH254025A (de) * 1943-09-03 1948-04-15 Jonkopings Och Vulcans Tandsti Sperrplatte.
FR1024889A (fr) * 1950-09-25 1953-04-08 Perfectionnements aux panneaux composites creux
FR2105000A7 (fr) * 1970-09-15 1972-04-28 Malafaye Robert
DE8525341U1 (de) * 1985-09-05 1987-01-08 Alkor GmbH Kunststoffe, 8000 München Betonschalungsplatte
EP0487945A2 (fr) * 1990-11-28 1992-06-03 Kanegafuchi Kagaku Kogyo Kabushiki Kaisha Matériau d'âme pour un stratifié et procédure pour sa fabrication
DE9415570U1 (de) * 1994-09-14 1995-01-26 Starke, Lothar, Dr., 06128 Halle Schalungstafel aus Kunststoff
WO2000030845A1 (fr) * 1998-11-19 2000-06-02 G.O.R. Applicazioni Special S.P.A. Panneau multicouche et son utilisation en tant que coffrage
FR2803315A1 (fr) * 1999-12-31 2001-07-06 Maurice Villibord Panneaux isolants indeformables
US20030091856A1 (en) * 2000-05-19 2003-05-15 Wittebrood Adrianus Jacobus Composite metal panel
EP1504889A2 (fr) * 2003-07-28 2005-02-09 Hexcel Corporation Panneau sandwich avec barrière intérieur
WO2005045158A1 (fr) * 2003-10-07 2005-05-19 M.A.S. Systeme Gesellschaft für Kunststoffprodukte mbH Panneau de coffrage a noyau alveolaire

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4657958A (en) * 1985-03-05 1987-04-14 The Firestone Tire & Rubber Company Contact adhesive and adhesive system for EPDM elastomers

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH254025A (de) * 1943-09-03 1948-04-15 Jonkopings Och Vulcans Tandsti Sperrplatte.
FR1024889A (fr) * 1950-09-25 1953-04-08 Perfectionnements aux panneaux composites creux
FR2105000A7 (fr) * 1970-09-15 1972-04-28 Malafaye Robert
DE8525341U1 (de) * 1985-09-05 1987-01-08 Alkor GmbH Kunststoffe, 8000 München Betonschalungsplatte
EP0487945A2 (fr) * 1990-11-28 1992-06-03 Kanegafuchi Kagaku Kogyo Kabushiki Kaisha Matériau d'âme pour un stratifié et procédure pour sa fabrication
DE9415570U1 (de) * 1994-09-14 1995-01-26 Starke, Lothar, Dr., 06128 Halle Schalungstafel aus Kunststoff
WO2000030845A1 (fr) * 1998-11-19 2000-06-02 G.O.R. Applicazioni Special S.P.A. Panneau multicouche et son utilisation en tant que coffrage
FR2803315A1 (fr) * 1999-12-31 2001-07-06 Maurice Villibord Panneaux isolants indeformables
US20030091856A1 (en) * 2000-05-19 2003-05-15 Wittebrood Adrianus Jacobus Composite metal panel
EP1504889A2 (fr) * 2003-07-28 2005-02-09 Hexcel Corporation Panneau sandwich avec barrière intérieur
WO2005045158A1 (fr) * 2003-10-07 2005-05-19 M.A.S. Systeme Gesellschaft für Kunststoffprodukte mbH Panneau de coffrage a noyau alveolaire

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2941254A1 (fr) * 2009-01-21 2010-07-23 Sateco Sa Banche de coffrage d'un mur en beton.
FR2991359A1 (fr) * 2009-01-21 2013-12-06 Sateco Sa Banche de coffrage d'un mur en beton
WO2011106901A1 (fr) * 2010-03-05 2011-09-09 Innovative Composites Inc. Système de construction modulaire utilisant des panneaux composites à noyau de mousse
CN105986639A (zh) * 2014-08-19 2016-10-05 中晔科技有限公司 用于环保建筑的复合板
CN105256994A (zh) * 2015-11-03 2016-01-20 广西平果北融林木业发展有限公司 一种光膜板
CN105781006A (zh) * 2016-04-22 2016-07-20 广东省建筑科学研究院集团股份有限公司 一种梯度复合发泡混凝土轻质隔断及其制备方法

Also Published As

Publication number Publication date
US20080307729A1 (en) 2008-12-18

Similar Documents

Publication Publication Date Title
US20080307729A1 (en) Structural panels
US20080088056A1 (en) Flexible release agent-free, multiple-use materials employed for concrete pouring forms and methods of making and using the same
EP0730699B1 (fr) Systeme de coffres modulaires pour constructions en beton et procede de construction de murs en beton
GB2456659A (en) High structural strength sandwich panel
KR101942986B1 (ko) 콘크리트 일체형 유무기 하이브리드 방수재와 단열 및 보강재료를 이용한 외단열, 방수 및 보강 복합 구조 및 그 시공공법
JP4975464B2 (ja) 鋼床版舗装構造およびその構築方法
US4894270A (en) Fold and bond for constructing cement laminate structural shapes
JP2004011226A (ja) 改修パネル
US20030200711A1 (en) Prefabricated, prefinished reinforced panels for building exterior and interior surfaces and method of manufacture
US20080199682A1 (en) Structural Elements Made From Syntactic Foam Sandwich Panels
JP3884142B2 (ja) コンクリート型枠用板材
EP1739253A2 (fr) Panneau de plancher calorifuge avec renforcement et structure de plancher supportée
JP4097028B2 (ja) 多角柱構造物の改修方法
AU708837B2 (en) Modular concrete form system and method for constructing concrete walls
CN2828214Y (zh) 塑料模板
US20250059784A1 (en) Brace bracket for form wall
KR20130085277A (ko) 건축용 고강도 시트 및 이에 의해 제조된 거푸집판재
WO2023056488A1 (fr) Paroi préfabriquée et procédé associé de construction de paroi
AU782290B2 (en) Transparent concrete formwork
US20180178501A1 (en) Surface Coated Structural Members Suitable for Marine Environments and Method of Production
KR200300596Y1 (ko) 콘크리트 거푸집용 패널
US20140242402A1 (en) Flexible composite material
JPH0571172A (ja) 永久型枠用フレーム
AU2006274503A1 (en) Structural elements made from syntactic foam sandwich panels
JPH07150651A (ja) 型枠兼用断熱パネルおよびその施工方法

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 08745976

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 08745976

Country of ref document: EP

Kind code of ref document: A1