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WO2014080089A1 - A construction element and a method for manufacturing said element - Google Patents

A construction element and a method for manufacturing said element Download PDF

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Publication number
WO2014080089A1
WO2014080089A1 PCT/FI2013/051106 FI2013051106W WO2014080089A1 WO 2014080089 A1 WO2014080089 A1 WO 2014080089A1 FI 2013051106 W FI2013051106 W FI 2013051106W WO 2014080089 A1 WO2014080089 A1 WO 2014080089A1
Authority
WO
WIPO (PCT)
Prior art keywords
construction element
load bearing
bearing sheet
insulating material
previous
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/FI2013/051106
Other languages
French (fr)
Inventor
Timo Kelloniemi
Timo Friman
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.)
TERMO PANELS Oy
Original Assignee
TERMO PANELS Oy
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 TERMO PANELS Oy filed Critical TERMO PANELS Oy
Publication of WO2014080089A1 publication Critical patent/WO2014080089A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/48—Special adaptations of floors for incorporating ducts, e.g. for heating or ventilating
    • 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
    • E04C2/02—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
    • E04C2/296—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 non-metallic or unspecified sheet-material
    • 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
    • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
    • E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
    • E04C2/521—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits serving for locating conduits; for ventilating, heating or cooling
    • E04C2/525—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits serving for locating conduits; for ventilating, heating or cooling for heating or cooling
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
    • E04D3/351—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material
    • E04D3/352—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material at least one insulating layer being located between non-insulating layers, e.g. double skin slabs or sheets
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
    • E04D3/357—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation comprising hollow cavities
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
    • F28F3/12—Elements constructed in the shape of a hollow panel, e.g. with channels
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2270/00—Thermal insulation; Thermal decoupling

Definitions

  • the invention relates to a construction element and a manufacturing method of the element.
  • the invention relates to a construction element for example for buildings, roofs, walls, floors or the like, where the element can be used for insulation as well as structural element or a supporting structure purposes.
  • construction elements are nowadays broadly used for building constructions.
  • the elements may have been devised for a certain purpose, such as functioning as a structural element or a supporting structure, as well as a protecting and insulating element.
  • different kinds of integrated elements are known, where the construction element has for example both the supporting structure and the insulation feature, where the feature of the supporting structure is achieved by the covering sheets and the insulation feature by insulating material in the space formed between the covering sheets forming said construction element.
  • the inner supporting structure is in a very essential role for example for conducting thermal energy from the first covering element through the insulating material to the second covering elements, so thought the construction element.
  • An object of the invention is to alleviate and eliminate the problems relating to the known prior art. Especially the object of the invention is to provide a construction element, which is rigid, durable and resistant e.g. to changing and demanding weather conditions and loads. Additionally, an object of the invention is to provide a thermally effective construction element where the heat conductivity through the element is minimized, and which is easy, fast and inexpensive to manufacture and also easy and fast to install.
  • the invention relates to a construction element according to claim 1.
  • the invention relates to a manufacturing method of the element according to claim 15.
  • a construction element comprises two covering sheets, which are arranged to form a space between them.
  • the construction element comprises a load bearing sheet arranged into the space between the covering sheets.
  • the space between the covering sheets and around the load bearing sheet is filled at least partially with insulating material.
  • the construction element is advantageously configured to receive or it comprises at least one support member, which is arranged through said insulating material to extend to the surface of the load bearing sheet in order to transfer at least portion, and advantageously the main portion, of the load introduced by the load bearing sheet outside the construction element.
  • the load bearing sheet has a corrugated form with plurality of sequential ridges and grooves, which in turn makes the supporting structure of the load bearing sheet very durable and strong.
  • the support members may be introduced at the location of the ridge portions pointing to the side from where the support members are introduced, which effectively divides the load to the load bearing sheet and at the same time maximizes the rigidity of the load bearing sheet.
  • the support members may be arranged essentially at the end portions, or according to an embodiment only to the end portions, of the construction element and not for the whole length or width of the element.
  • the end portions of the construction element are advantageously the portions via which said construction element is supported to external structures when mounted in the construction, such as a roof, ceiling or wall or the like.
  • the total surface area of the support members of the construction element is kept minimal, and is according to an exemplary (but not limiting) embodiment less than 5% of the total surface area of the construction element comprising said support members.
  • the total surface area of the support members of the construction element is less than 3%, according to another embodiment less than 1 % of the total surface area of the construction element comprising said support members.
  • the thermal conductivity cross-section of the supporting structure inside and through the element can be kept minimal and thereby minimizing the heat diffusion through the construction elements (the thermal conductivity is proportional to the cross-section area of the conducting material extending through the construction elements).
  • the insulating material inside the space is advantageously configured to extend essentially through the whole length and/or width of the construction element.
  • the support member advantageously comprises metal, plastic, wood or other essentially incompressible material.
  • the construction element may comprise support member only in the other side of the load bearing sheet (such as only between the first covering sheet and the load bearing sheet), or also in the both sides of the load bearing sheet (both between the first covering sheet and the load bearing sheet, as well as between the second covering sheet and the load bearing sheet).
  • the covering sheets, as well also the load bearing sheet may advantageously comprise steel sheet, aluminium board, aluminium film, gypsum board, magnesium oxide board, wood fibre board, or cross laminated timber, for example.
  • the load bearing sheet comprises steel having thickness advantageously in the range of 0.15 - 4 millimetres, and most advantageously in the range of 0.3 - 2.5 millimetres, and which has the total height advantageously in the range of 0.1 - 300 millimetres.
  • the insulating material advantageously comprises polyurethane (PUR), polyisocyanurate (PIR), expanded or extruded polystyrene (EPS), polyisocyanurate or mineral wool, such as stone wool or glass wool, but also other advantageously extrudable insulating material can be used, such as XPS (extruded polystyrene).
  • PUR polyurethane
  • PIR polyisocyanurate
  • EPS expanded or extruded polystyrene
  • XPS extruded polystyrene
  • the insulating material may be used both for thermal insulation as well as for attaching, such as bonding or gluing, the covering elements to each other and thereby forming the construction element.
  • the insulating material (such as EPS and wool) should either be glued to the covering elements, or they (such as PIR and PUR) may have the ability to bond the covering elements when they are applied (such as injected or injection moulded) between the elements.
  • the space between the first covering sheet and load bearing sheet comprises first insulating material and the space between the second covering sheet and load bearing sheet comprises second insulating material with different properties than the first insulating material.
  • the compressibility factor of the first insulating, such as polyurethane, material might be much more than the compressibility factor of the second insulating material, such as mineral wool (depending e.g. positioning and orientation of the materials, namely the materials may be much more rigid in one direction than another direction).
  • the properties of the first and second materials differ, they also improve soundproofing, because sounds will disperse at the interface of two different materials.
  • the very strong but light construction element can be provided.
  • the second material (to be placed at the bottom side of the construction element) is for example mineral wool or the like it will not be collapsed due to rigid first material at the first (upper) side of the element.
  • at least one of the insulation material may also be soundproofing material.
  • a method for manufacturing the construction element is provided, where two covering sheets are arranged to form the construction element and a space between them.
  • a load bearing sheet is arranged in the space between the covering sheets.
  • the space between the covering sheets and around the load bearing sheet is then filled at least partially with insulating material.
  • the method further comprises providing the construction element with at least one support member, which is arranged through said insulating material to extend to the surface of the load bearing sheet in order to transfer at least portion of the load introduced with the support member to the load bearing sheet.
  • the construction element as described in this document can advantageously be used as a conventional construction element in different arrangements, such as e.g. in buildings, roofs, walls, and floors or the like, but also in base structures of streets, paths and courtyards etc. areas, where the area should be thermally insulated.
  • the present invention offers clear advantages using the support members, because at first the support members divide the pressure or loads induced into the covering sheet for larger areas via the load bearing sheet. Secondly the support members are advantageously located at the portion of the ridge portions of the load bearing sheets to effectively divide the load to/from the load bearing sheet. Also the support members introduces minimal cross- section are in order to minimize the thermal conductivity through the construction element. In addition, according to advantageous embodiment the support members locating essentially at the end portions of the construction element transfer the load of load bearing sheet outside the construction element and again to exterior framework of the construction.
  • Figures 1 -2 illustrate a principle of an exemplary construction element according to an advantageous embodiment of the invention
  • Figure 3 illustrates another exemplary construction element according to an advantageous embodiment of the invention.
  • FIGS 1 -2 illustrate a principle of an exemplary construction element 100 according to an advantageous embodiment of the invention, where the construction element 100 comprises two covering sheets 101 , 102 forming a space between them.
  • the element 100 comprises also a load bearing sheet 103 arranged in the space between the covering sheets 101 , 102.
  • the space between the covering sheets 101 , 102 and around the load bearing sheet 103 is filled at least partially with insulating material 104.
  • the construction element 100 is adapted to receive or comprises at least one support member 105, which is arranged through the insulating material 104 to extend to the surface of the load bearing sheet 103 in order to transfer at least portion or main portion of the load introduced by the covering sheet 101 , 102 and especially the load bearing sheet 103 outside the construction element.
  • the construction element may either comprise the support members or according to an embodiment area(s) for receiving the support member(s) afterwards so that the support member(s) can be introduced through the first covering sheet and through the insulating material to the surface of said load bearing sheet.
  • the load bearing sheet 103 has a corrugated form with plurality of sequential ridges 103a and grooves 103b, which increases the supportive rigidity of the load bearing sheet structure.
  • the support members 105 may be introduced at the location of the ridge portions 103a pointing to the side from where the support members 105 are introduced again to maximize the structural strength of the whole load bearing sheet 103 and the constructional element, as well as minimize the thermal conductivity of the inner structure through the constructional element 100.
  • the support members may also be arranged essentially at the end portions of the construction element 100 again additionally minimizing the entire cross-section area of the all support members.
  • these end portions of the construction element 100 correspond to outer structures, such as footing beams, headers or the like, against which the construction element 100 is to be faced and which also induce spot type loads (loads to very small surface areas of the construction element).
  • the insulating material inside 104 the space is advantageously configured to extend essentially through the whole length and/or width of the construction element 100.
  • the space between the first covering sheet 101 and load bearing sheet 103 may comprise first insulating material 104a and the space between the second covering sheet 102 and load bearing sheet 103 may comprise second insulating material 104b with different properties than the first insulating material 104a.
  • a construction element may also be adapted to receive a follow-through 107 e.g. in the connection with grooves 103b of the load bearing sheet of corrugated form for instrument or electric cables or water or wastewater pipes.
  • Figure 3 illustrates another exemplary construction element 100 according to an advantageous embodiment of the invention, where at least one of the covering sheet 101 , 102 is coupled with an additional sheet to form a heat transfer element 106, where said two sheets are connected to each other by multiple connecting seams so that said heat transfer element thereby formed comprises at least one conduit 108 for a heat transfer medium.
  • the conduit is advantageously defined by said multiple connecting seams between said connecting seams and said sheets.
  • the conduit may be formed by multiple connecting seams for example when high pressure is applied into the space between two seams

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Electromagnetism (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Building Environments (AREA)
  • Floor Finish (AREA)
  • Laminated Bodies (AREA)

Abstract

A construction element (100) comprises two covering sheets (101, 102) forming a space between them, and a load bearing sheet (103) in said space between said covering sheets. The space between the covering sheets and around said load bearing sheet is filled at least partially with insulating material (104). The construction element is adapted to receive or comprises at least one support member (105), which is arranged through said insulating material (104) to extend to the surface of the load bearing sheet (103) in order to transfer at least portion of the load introduced by the load bearing sheet outside the construction element.

Description

A CONSTRUCTION ELEMENT AND A METHOD FOR MANUFACTURING SAID ELEMENT
TECHNICAL FIELD OF THE INVENTION The invention relates to a construction element and a manufacturing method of the element. In particular the invention relates to a construction element for example for buildings, roofs, walls, floors or the like, where the element can be used for insulation as well as structural element or a supporting structure purposes.
BACKGROUND OF THE INVENTION
Different kinds of construction elements are nowadays broadly used for building constructions. The elements may have been devised for a certain purpose, such as functioning as a structural element or a supporting structure, as well as a protecting and insulating element. Also, different kinds of integrated elements are known, where the construction element has for example both the supporting structure and the insulation feature, where the feature of the supporting structure is achieved by the covering sheets and the insulation feature by insulating material in the space formed between the covering sheets forming said construction element.
There are, however, some disadvantages relating to the known prior art solutions. In order to make the construction element strong enough the covering sheets should be sufficiently thick and made of durable material, like steel, so that they can resist induced loads, pertain their form and do not bend. However some problems are related to the elements with thick sheets, namely they typically are quite heavy and also expensive. It is known from the prior art to arrange supporting structures between the covering sheets to support the structure of the element so that the covering sheets do not bend e.g. against each other. However, since on the other hand the construction element should have suitable insulating properties in order to minimize heat dissipation and thermal conductivity, the inner supporting structure is in a very essential role for example for conducting thermal energy from the first covering element through the insulating material to the second covering elements, so thought the construction element.
SUMMARY OF THE INVENTION An object of the invention is to alleviate and eliminate the problems relating to the known prior art. Especially the object of the invention is to provide a construction element, which is rigid, durable and resistant e.g. to changing and demanding weather conditions and loads. Additionally, an object of the invention is to provide a thermally effective construction element where the heat conductivity through the element is minimized, and which is easy, fast and inexpensive to manufacture and also easy and fast to install.
The objects of the invention can be achieved by the features of the attached independent claims.
The invention relates to a construction element according to claim 1. In addition, the invention relates to a manufacturing method of the element according to claim 15.
According to an embodiment a construction element comprises two covering sheets, which are arranged to form a space between them. In addition the construction element comprises a load bearing sheet arranged into the space between the covering sheets. Advantageously the space between the covering sheets and around the load bearing sheet is filled at least partially with insulating material. The construction element is advantageously configured to receive or it comprises at least one support member, which is arranged through said insulating material to extend to the surface of the load bearing sheet in order to transfer at least portion, and advantageously the main portion, of the load introduced by the load bearing sheet outside the construction element..
According to an embodiment the load bearing sheet has a corrugated form with plurality of sequential ridges and grooves, which in turn makes the supporting structure of the load bearing sheet very durable and strong. In addition, according to an example the support members may be introduced at the location of the ridge portions pointing to the side from where the support members are introduced, which effectively divides the load to the load bearing sheet and at the same time maximizes the rigidity of the load bearing sheet.
In addition, according to an embodiment the support members may be arranged essentially at the end portions, or according to an embodiment only to the end portions, of the construction element and not for the whole length or width of the element. The end portions of the construction element are advantageously the portions via which said construction element is supported to external structures when mounted in the construction, such as a roof, ceiling or wall or the like. In addition, the total surface area of the support members of the construction element is kept minimal, and is according to an exemplary (but not limiting) embodiment less than 5% of the total surface area of the construction element comprising said support members. According to another embodiment the total surface area of the support members of the construction element is less than 3%, according to another embodiment less than 1 % of the total surface area of the construction element comprising said support members.
By the arrangements above the thermal conductivity cross-section of the supporting structure inside and through the element can be kept minimal and thereby minimizing the heat diffusion through the construction elements (the thermal conductivity is proportional to the cross-section area of the conducting material extending through the construction elements). However, the insulating material inside the space is advantageously configured to extend essentially through the whole length and/or width of the construction element. The support member advantageously comprises metal, plastic, wood or other essentially incompressible material. It is to be noted that the construction element may comprise support member only in the other side of the load bearing sheet (such as only between the first covering sheet and the load bearing sheet), or also in the both sides of the load bearing sheet (both between the first covering sheet and the load bearing sheet, as well as between the second covering sheet and the load bearing sheet).
As an example the covering sheets, as well also the load bearing sheet may advantageously comprise steel sheet, aluminium board, aluminium film, gypsum board, magnesium oxide board, wood fibre board, or cross laminated timber, for example. According to an exemplary embodiment the load bearing sheet comprises steel having thickness advantageously in the range of 0.15 - 4 millimetres, and most advantageously in the range of 0.3 - 2.5 millimetres, and which has the total height advantageously in the range of 0.1 - 300 millimetres. The insulating material advantageously comprises polyurethane (PUR), polyisocyanurate (PIR), expanded or extruded polystyrene (EPS), polyisocyanurate or mineral wool, such as stone wool or glass wool, but also other advantageously extrudable insulating material can be used, such as XPS (extruded polystyrene). In an advantageous embodiment the insulating material may be used both for thermal insulation as well as for attaching, such as bonding or gluing, the covering elements to each other and thereby forming the construction element. The insulating material (such as EPS and wool) should either be glued to the covering elements, or they (such as PIR and PUR) may have the ability to bond the covering elements when they are applied (such as injected or injection moulded) between the elements.
According to an embodiment the space between the first covering sheet and load bearing sheet comprises first insulating material and the space between the second covering sheet and load bearing sheet comprises second insulating material with different properties than the first insulating material. For example, the compressibility factor of the first insulating, such as polyurethane, material might be much more than the compressibility factor of the second insulating material, such as mineral wool (depending e.g. positioning and orientation of the materials, namely the materials may be much more rigid in one direction than another direction). This offers advantages namely the construction element can still be kept very light, but very strong and stable with very good insulating properties at the same time. In addition, when the properties of the first and second materials differ, they also improve soundproofing, because sounds will disperse at the interface of two different materials. For example when the first material is e.g. polyurethane or the like hard and essentially non-compressible material, the very strong but light construction element can be provided. In addition when the second material (to be placed at the bottom side of the construction element) is for example mineral wool or the like it will not be collapsed due to rigid first material at the first (upper) side of the element. In addition at least one of the insulation material may also be soundproofing material. In addition, according to an embodiment a method for manufacturing the construction element is provided, where two covering sheets are arranged to form the construction element and a space between them. In addition a load bearing sheet is arranged in the space between the covering sheets. The space between the covering sheets and around the load bearing sheet is then filled at least partially with insulating material. The method further comprises providing the construction element with at least one support member, which is arranged through said insulating material to extend to the surface of the load bearing sheet in order to transfer at least portion of the load introduced with the support member to the load bearing sheet.
The construction element as described in this document can advantageously be used as a conventional construction element in different arrangements, such as e.g. in buildings, roofs, walls, and floors or the like, but also in base structures of streets, paths and courtyards etc. areas, where the area should be thermally insulated.
The present invention offers clear advantages using the support members, because at first the support members divide the pressure or loads induced into the covering sheet for larger areas via the load bearing sheet. Secondly the support members are advantageously located at the portion of the ridge portions of the load bearing sheets to effectively divide the load to/from the load bearing sheet. Also the support members introduces minimal cross- section are in order to minimize the thermal conductivity through the construction element. In addition, according to advantageous embodiment the support members locating essentially at the end portions of the construction element transfer the load of load bearing sheet outside the construction element and again to exterior framework of the construction.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following the invention will be described in greater detail with reference to exemplary embodiments in accordance with the accompanying drawings, in which:
Figures 1 -2 illustrate a principle of an exemplary construction element according to an advantageous embodiment of the invention, and Figure 3 illustrates another exemplary construction element according to an advantageous embodiment of the invention.
DETAILED DESCRIPTION Figures 1 -2 illustrate a principle of an exemplary construction element 100 according to an advantageous embodiment of the invention, where the construction element 100 comprises two covering sheets 101 , 102 forming a space between them. In addition the element 100 comprises also a load bearing sheet 103 arranged in the space between the covering sheets 101 , 102. The space between the covering sheets 101 , 102 and around the load bearing sheet 103 is filled at least partially with insulating material 104.
The construction element 100 is adapted to receive or comprises at least one support member 105, which is arranged through the insulating material 104 to extend to the surface of the load bearing sheet 103 in order to transfer at least portion or main portion of the load introduced by the covering sheet 101 , 102 and especially the load bearing sheet 103 outside the construction element.
It is to be noted that the construction element may either comprise the support members or according to an embodiment area(s) for receiving the support member(s) afterwards so that the support member(s) can be introduced through the first covering sheet and through the insulating material to the surface of said load bearing sheet.
According to an embodiment the load bearing sheet 103 has a corrugated form with plurality of sequential ridges 103a and grooves 103b, which increases the supportive rigidity of the load bearing sheet structure. In addition in this embodiment the support members 105 may be introduced at the location of the ridge portions 103a pointing to the side from where the support members 105 are introduced again to maximize the structural strength of the whole load bearing sheet 103 and the constructional element, as well as minimize the thermal conductivity of the inner structure through the constructional element 100.
The support members may also be arranged essentially at the end portions of the construction element 100 again additionally minimizing the entire cross-section area of the all support members. Typically these end portions of the construction element 100 correspond to outer structures, such as footing beams, headers or the like, against which the construction element 100 is to be faced and which also induce spot type loads (loads to very small surface areas of the construction element).
Anyhow, the insulating material inside 104 the space is advantageously configured to extend essentially through the whole length and/or width of the construction element 100.
According to an embodiment the space between the first covering sheet 101 and load bearing sheet 103 may comprise first insulating material 104a and the space between the second covering sheet 102 and load bearing sheet 103 may comprise second insulating material 104b with different properties than the first insulating material 104a.
A construction element may also be adapted to receive a follow-through 107 e.g. in the connection with grooves 103b of the load bearing sheet of corrugated form for instrument or electric cables or water or wastewater pipes.
Figure 3 illustrates another exemplary construction element 100 according to an advantageous embodiment of the invention, where at least one of the covering sheet 101 , 102 is coupled with an additional sheet to form a heat transfer element 106, where said two sheets are connected to each other by multiple connecting seams so that said heat transfer element thereby formed comprises at least one conduit 108 for a heat transfer medium. The conduit is advantageously defined by said multiple connecting seams between said connecting seams and said sheets. The conduit may be formed by multiple connecting seams for example when high pressure is applied into the space between two seams
The invention has been explained above with reference to the aforementioned embodiments, and several advantages of the invention have been demonstrated. It is clear that the invention is not only restricted to these embodiments, but comprises all possible embodiments within the scope of the inventive thought and the following patent claims.

Claims

1. A construction element (100) comprising two covering sheets (101 , 102) forming a space between them, and a load bearing sheet (103) in said space between said covering sheets, wherein said space between said covering sheets and around said load bearing sheet is filled at least partially with insulating material (104), characterized in that said construction element is adapted to receive a support member (105) to be arranged through said insulating material and to be in connect with said load bearing sheet (103), where said support members are configured for transferring at least (main) portion of the load introduced by the load bearing sheet outside the construction element.
2. A construction element according to claim 1 , wherein the load bearing sheet (103) has a corrugated form with plurality of sequential ridges (103a) and grooves (103b), whereupon the support members are introduced with the ridge portions pointing to the side where the support members are introduced.
3. A construction element according to any of previous claims, wherein the support members is arranged essentially at the end portions of said construction element.
4. A construction element according to any of previous claims, wherein the insulating material inside the space is configured to extend essentially through the whole length and/or width of the construction element.
5. A construction element according to any of previous claims, wherein at least one of the covering sheets comprises steel sheet, aluminium board, aluminium film, gypsum board, magnesium oxide board, wood fibre board, cross laminated timber.
6. A construction element according to any of previous claims, wherein at least one of the covering sheet is coupled with an additional sheet to form a heat transfer element (106), where said two sheets are connected to each other by multiple connecting seams so that said heat transfer element thereby formed comprises at least one conduit (108) for a heat transfer medium, and where said conduit is defined by said multiple connecting seams between said connecting seams and said sheets.
7. A construction element according to any of previous claims, wherein said insulating material comprises polyurethane, expanded or extruded polystyrene, polyisocyanurate or mineral wool, such as stone wool or glass wool.
8. A construction element according to any of previous claims, wherein the load bearing sheet comprises steel having thickness advantageously in the range of 0.15 - 4 millimetres, and most advantageously in the range of 0.3 - 2.5 millimetres, and which has the total height advantageously in the range of 0.1 - 300 millimetres.
9. A construction element according to any of previous claims, wherein the space between the first covering sheet and load bearing sheet comprises first insulating material (104a) and the space between the second covering sheet and load bearing sheet comprises second insulating material (104b) with different properties than the first insulating material.
10. A construction element according to claim 9, wherein the compressibility factor of said first insulating, such as polyurethane, material is higher than the compressibility factor of said second insulating material, such as mineral wool.
1 1. A construction element according to any of previous claims, wherein the element is adapted to receive a follow-through in the connection with grooves of the load bearing sheet of corrugated form for instrument or electric cables or water or wastewater pipes.
12. A construction element according to any of previous claims, wherein the support member comprises metal, plastic, wood or other essentially incompressible material.
13. A construction element according to any of previous claims, wherein the total surface area of the support members of the construction element is less than 5%, more advantageously less than 3% or still more advantageously less than 1 % of the total surface area of the construction element comprising said support members.
14. A construction element according to any of previous claims, wherein said construction element comprises said support member or wherein said construction element comprises an area for receiving said support member and to be introduced through the first covering sheet and through the insulating material unto the surface of said load bearing sheet.
15. A method for manufacturing the construction element (100) according to any of previous claims, wherein the construction element comprises two covering sheets (101 , 102) forming a space between them, and a load bearing sheet (103) in said space between said covering sheets, wherein said space between said covering sheets and around said load bearing sheet is filled at least partially with insulating material (104), characterized in that the method comprises adapting said construction element to receive a support member (105) through said insulating material to the surface of said load bearing sheet for transferring at least portion of the load introduced by the load bearing sheet outside the construction element.
PCT/FI2013/051106 2012-11-26 2013-11-26 A construction element and a method for manufacturing said element Ceased WO2014080089A1 (en)

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FI20126242A FI20126242A7 (en) 2012-11-26 2012-11-26 Building element and method for manufacturing the element
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Cited By (1)

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Publication number Priority date Publication date Assignee Title
CN112144720A (en) * 2020-10-12 2020-12-29 天元建设集团有限公司 A staggered interlocking prefabricated concrete floor system and its construction method

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Publication number Priority date Publication date Assignee Title
GB593756A (en) * 1945-02-02 1947-10-24 Jack Antonio Coia Improvements in corrugated sheet members for use in building construction
GB625462A (en) * 1948-01-02 1949-06-28 John Storrar Improvements in building elements
US5685124A (en) * 1994-04-21 1997-11-11 Jandl, Jr.; Adolf Wall, ceiling or roof elements with heat insulation properties on one side and sound insulation properties on the other
EP1074670A2 (en) * 1999-07-30 2001-02-07 Günther Jelonnek Building construction
EP1379379B1 (en) * 2001-04-02 2007-02-28 Intelligent Engineering (Bahamas) Limited Improved structural sandwich members
WO2008103099A1 (en) * 2007-02-19 2008-08-28 Benny Fransson Structural components
GB2457879A (en) * 2008-02-26 2009-09-02 Samuel Bailey Controllable insulation panels

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB593756A (en) * 1945-02-02 1947-10-24 Jack Antonio Coia Improvements in corrugated sheet members for use in building construction
GB625462A (en) * 1948-01-02 1949-06-28 John Storrar Improvements in building elements
US5685124A (en) * 1994-04-21 1997-11-11 Jandl, Jr.; Adolf Wall, ceiling or roof elements with heat insulation properties on one side and sound insulation properties on the other
EP1074670A2 (en) * 1999-07-30 2001-02-07 Günther Jelonnek Building construction
EP1379379B1 (en) * 2001-04-02 2007-02-28 Intelligent Engineering (Bahamas) Limited Improved structural sandwich members
WO2008103099A1 (en) * 2007-02-19 2008-08-28 Benny Fransson Structural components
GB2457879A (en) * 2008-02-26 2009-09-02 Samuel Bailey Controllable insulation panels

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112144720A (en) * 2020-10-12 2020-12-29 天元建设集团有限公司 A staggered interlocking prefabricated concrete floor system and its construction method
CN112144720B (en) * 2020-10-12 2021-08-13 天元建设集团有限公司 A staggered interlocking prefabricated concrete floor system and its construction method

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