EP0097194A1

EP0097194A1 - Panel construction

Info

Publication number: EP0097194A1
Application number: EP19830900036
Authority: EP
Inventors: Matti Home
Original assignee: Individual
Current assignee: Individual
Priority date: 1981-12-08
Filing date: 1982-12-08
Publication date: 1984-01-04
Also published as: WO1983002127A1; FI66454C; FI66454B; FI813925L

Abstract

Construction de panneaux utilisés dans des structures de parois des dalles de plancher, des dalles de plancher intermédiaire, des pans de toiture ou des plaques de plinthes. La construction du panneau consiste en une combinaison structurale d'une couche d'un matériau d'isolation (3) consistant en un matériau d'isolation moussant pouvant se coller sur la plaque de structure, et une plaque de structure (1;1a;1b;1c;1d;1e;1f) pourvue d'une perforation (1') et d'éléments saillants de préhension (1''). La couche de matériau d'isolation (3) est directement liée des deux côtés à la plaque de structure (1;1a;1b;1c;1d;1e;1f) par l'effet de collage ou adhésion du matériau d'isolation moussant, pénétrant au travers de la perforation (1'). La couche de matériau d'isolation (3) consiste en du polyurétane ou du polyisocyanurate ou autre matériau d'isolation moussant qui a été fixé, par exemple au stade du moulage, sur les deux surfaces de la plaque de structure de manière à remplir au moins les rainures de la plaque de structure.Construction of panels used in wall structures of floor slabs, intermediate floor slabs, roofing panels or plinth boards. The construction of the panel consists of a structural combination of a layer of insulation material (3) consisting of a foaming insulation material capable of sticking to the structure plate, and a structure plate (1; 1a; 1b; 1c; 1d; 1e; 1f) provided with a perforation (1 ') and projecting gripping elements (1' '). The layer of insulation material (3) is directly bonded on both sides to the structure plate (1; 1a; 1b; 1c; 1d; 1e; 1f) by the bonding or adhesion effect of the foaming insulation material , penetrating through the perforation (1 '). The layer of insulation material (3) consists of polyurethane or polyisocyanurate or other foaming insulation material which has been fixed, for example at the molding stage, on the two surfaces of the structure plate so as to fill with minus the grooves in the structure plate.

Description

Panel construction

The object of this invention is a panel construction to be used in buildings in wall structures or in floor slabs, intermediate floor slabs, roof slabs, plinth plates etc., comprising a perforated frame plate and an insulation material layer.

As is apparent from the above, the present invention relates to panel constructions used in bxiilding,such as walls, floor slabs, intermedi¬ ate floor slabs, roof slabs, plinths and generally to structures that have to bear loads imposed upon them.

As wall constructions in buildings, for example in detached houses and -cowhouses, the following are already generally known, among others (the wall materials are listed from outside to inside) :

Construction 1. - external facing

- battening + air cavity

- wind barrier panel

- frame + insulation

- air barrier / moisture barrier - internal facing panel

Construction 2.

- external facing

- air cavity

- wooden frame + polyurethane insulation

- internal facing

Construction 3.

- brick - air cavity

- frame + insulation

- internal facing

_OMPI_ ^r As is seen in the examples, there is an air cavity next to the exter¬ nal facing of conventional wall constructions. This is necessary for leading out the moisture that permeates the wall. In the construction of this invention the air cavity may be emitted, because the wall is airtight, bringing many advantages. For example, when the sun shines onto the external wall and the roof, it rapidly heats the surface of the panel construction, and hereby the temperature difference between the outer -and inner surfaces of the panel construction is decreased, directly affecting the need of heating. The better the thermal conduc- tivity of the material of the outer surface of the panel construction is, the sooner its temperature increases. The whole wall and roof surface functions as a "solar energy collector".

When there is an air cavity in the wall, the outdoors air moves in this cavity and no significant advantage is gained frcm solar energy. The sun does not directly heat air but solid surfaces.

It is characteristic of the panel walls of detached houses and row- houses that they need a separate frame. Wood is the traditional frame material in such wallsI The use of steel as the frame material has not gained wide popularity,- at least not in the external wal s, as the frame has been placed inside the insulation. In this case a so-called cold bridge is formed in the wall.

When polyurethane is used as previously known as the insulation of the external wall, the throughgoing wooden frame forms a cold bridge in the wall, because the thermal conductivity of wood is considerably higher than that of polyurethane. On the other hand, the sealing of the joints between the wooden frame and the stiff polyurethane panels is problematic at least under winter conditions, because the polyure¬ thane foam used as the seali g material needs a certain temperature to harden.

In the known brick walls, on the other hand, the large thickness of the wall is a cost-adding factor, especially in areas where the so- called space cost has to be taken into account.

-W- TΪ_J In the Austrian patent specification 259 196 there is disclosed an insulation element resembling the present panel construction, in which element the reinforcement of a foamed plastic coated and reinforced building panel consists of two parallel perforated plates and crossing 5 supports between them.

. Both of the transverse end surfaces of the elements have rabbets, while the longitudinal sides have dovetail-shaped recesses. The disadvantage of this known solution has been amended by the construction disclosed 10 in the Finnish examined patent application FI-49694 in that the rein¬ forcement of the element is formed by one,- s .such kncwn, trapezoid- or meander-shaped corrugated perforated sheet, the longer sides of which are situated at a distance frαn the edges of the insulation material core. In Fig. 1_.of the above-mentioned Finnish examined patent ^' 15 application there is shown an embodiment in which the holes have a dia¬ meter of 20 mm and the distance between the edges of adjacent holes is 8 mm. Further the holes are offset in relation to each other and the insulation material goes through them so that a form-fast bonding is formed between the insulation material layer and the perforated sheet. 20 The production process of this construction comprises the of an as such known perforated steel sheet, its corrugation in a rolling apparatus, and its passing as an endless corrugated band into a foamed plastic applying machine. The perforated sheet acting as the reinforce¬ ment may also be manufactured by previously cutting it into pieces, 25 then perforating, corrugating and passing the pieces successively in a continuous manner into the foamed plastic applying machine.

The present invention aims at creating a panel construction with a good bearing capacity, allowing the panel to be manufactured in a continuous 30 manner, among others so that an unperforated sheet is unrolled, corru¬ gated in a rolling apparatus and perforated in the same process only after corrugating, before passing the sheet into the machine that applies the foamable insulation component.

35 It is an objective of the invention to m-ϋimize the size of the holes and to place the holes in such a position that the corrugated steel sheet or corresponding sheet will function as efficiently as possible

OMPI both in structures under compression and in structures under tension. It is an objective to make of the sheet component the bearing frame of a building, not only a reinforcen^*ent of an element. For achieving this objective it is necessary to form a mechanical joint between the steel sheet or similar sheet and the plastic material or similar foamable insulation material. Based on tests performed by the Technical Re¬ search Centre of Finland (VTT) it is known that the allowable shearing strength value, for example in the case of polyurethane and polyiso-

2 cyanurate, is about 40 l?N/m . Thus it is a fact that in structures under bending, shearing force can only be transmitted by using a high perforation percentage in the sheet. In vertical and horizontal con¬ structions, for example the ovstεnt of the facing panel caused by moisture is so large that a high hole percentage is needed in order to master the formed shearing force in the solution of the Finnish exam- ined patent application 49639. The hole percentage of the e-r-bodiment presented in the specification of the above-mentioned Finnish examined patent application and in Fig. 1 of the same is 40 % of the total surface area of the sheet. In addition to the above, for example in roof constructions the weight of .an internal facing panel is "support- ed" by the insulation material having penetrated the holes of the sheet, and as the above-mentioned moisture movements also take place, the hole percentage must be really significant.

high hole percentage, on the other hand, directly means that the steel cross-sectional area of the steel sheet is reduced in a decisive manner, and the bearing capacity necessary in practice for a bearing building element in vertical and horizontal structures is not achieved. In the solution of the above-mentioned Finnish examined patent appli-- cation the large holes have further been offset in relation to each other, and thus in practical terms the whole cross-sectional area of the steel sheet is perforated. This can only be called a reinforcement of the element, not a bearing frame. Such a reinforced element does not fulfill -the requirements set to, for example, the wall structures for house building. This may be compared with the conventional 2" x ^' 4" c/c 600 mm wooden frame, generally the minimum frame of wooden^' houses. Only a nearly unperforated steel sheet cross-section corres- ponds to this frame.

When the elements are manufactured in the way described in the Finnish examined patent application 49639, comprising the unrolling of the as such known perforated steel sheet and its corrugation for the element, unnecessary extra costs will arise.

It is an objective of the present invention to create a panel construc¬ tion with a very versatile use -and with several different characteris- tics superior to those of corresponding.known panel constructions. An additional objective^' of this invention is to avoid the disadvantages described above and to create a panel construction in which several advantages of different character, being described later, are gained.

In order to achieve the objectives described above and becoming appar¬ ent later, the invention is mainly characterized in that for forming wall structures and/or floor structures or similar structures essen¬ tially entirely of the mentioned panel construction, the panel con¬ struction comprises as a structural exami ation at least the following layers:

a) an insulation layer of polyurethane, polyisocyanurate or correspon¬ ding material, a foamable insulation material with an ability to glue itself onto the frame plate, the layer being fixed onto both surfaces of the frame plate, filling at least the recesses of the frame plate, in an as such known moulding stage.

b) a perforated frame plate to which the said insulation layer, pene¬ trating the said perforation, is connected on both sides by the gluing effect of the foamed insulation material,

and in which panel construction the said frame plate is a corrugated metal sheet with a gripping element series similar to nails, consis¬ ting of the sheet material deflected from the perforated positions, this gripping element series creating a mechanical gripping between the frame panel and the insulation material layer, and the perforation being such that it does not essentially weaken the frame plate which

I ORS mainly bears the loads imposed on the panel construction.

In this invention, the term insulation material denotes a foamable in¬ sulation material which by its gluing effect fastens on both sides to the perora-ted plate used as the frame structure. In the panel construc¬ tion of this invention, the plate used as the frame structure is situ¬ ated inside the insulation material so that if for example corrugated metal sheets are used, at least the grooves have been filled with the fo-amable i_nsulation material.

A foamable insulation material such as polyurethane and polyisocyanu- rate or similar is airtight and does not absorb moisture, and thus the risk of the sheet being corroded or getting wet is e-ϋininated, whereby the rusting and the moisture movements of the sheet tare prevented. When a load is imposed upon the panel construction of this invention, the solid insulation material layer supports the sheet from all sides and decreases the risk of buckling or dinting of the sheet. The insu¬ lation capacity of the^"panel construction is increased, as for example in the case of using a corrugated sheet the shape of the corrugated sheet does not locally make the insulation layer thinner. This brings about the additional advantage that even if the thickness of the insu¬ lation layers is increased, the same production moulds and lines can be used as before. As the sheet is situated inside the insulation ma¬ terial, facings can be fixed to the panel mechanically, allowing this stage of work to be done, among others, on the worksite. A mechanical fastener, for example a long screw or similar, penetrates through the insulation material and is fixed to the sheet. This means that the type and form of the facing material can be selected freely; this ad¬ vantage is also achieved in the case that the facing material is glued by the insulation material to the panel construction already in the manufacturing stage. I a factory the selection of facing materials has to be however restricted, v ch is v^*hy the possibility of mechani¬ cal fastening is a significant additional advantage.

This kind of wall or floor structure or similar contains a frame, an insulation, and if necessary, facing on one side or on both sides. Also- shaped facing materials may of course be used on the external and internal surfaces of the panel construction.

The bearing capacity and the stiffness of the panel construction ele¬ ments may still be improved by placing pipes or corresponding cavities inside the elements. These pipes constitute a component that stiffens the element- and increases its bearing capacity. If the pipes in ques¬ tion are filled by concrete or corresponding material, the bearing ca¬ pacity and the stiffness are still improved.

When the production of the panel const-ruction of this invention is so arranged that intact sheet is unrolled and corrugated in a rolling ap¬ paratus, after which it is perforated in the same production process, for example in the way described in the Finnish patent 54006 of the applicant or by some other method placed within the process, no extra process stages or costs are needed for perforation, which^'means that the production costs of the panel construction become lower than those of conventional solutions.

When the perforation is placed in^*the centre of the flanges of the cor- rugated sheet, the highest possible bearing capacity is achieved both in structures under compression and in structures under tension, for which the panel construction of the invention is mainly intended. When gripping elements are placed in connection with these holes, for exam¬ ple in the way described in the Finnish patent 54006 or in some other way, the gripping between the steel sheet and the insulation becomes mechanical, and thus no special requirements are necessary for the shearing strength of the insulation material.

When the perforation is situated in the centre of the flanges, it is known that this area is, for example in corrugated steel sheets, the area where the stresses of the sheet are first exceeded. Further it is known that in structural design exactly these areas are, as so-called yielding areas, not taken into account, even if there -were no holes at all in the centre of the flanges of the cross-section (in conventional corrugated sheet profiles that are used as load-bearing roof and wall structures) . The gripping elements may also be situated in other places than in connection with the holes, provided that they do not decrease the bearing capacity of the steel sheet or corresponding sheet.

In compression tests performed with panel constructions it was noticed that when the holes are situated in the centre of the lower flange of the corrugated sheet and vfaen the hole percentage is about 2.2 % of the total spread-out surface area of the steel sheet, the penetration of polyurethane and polyisocyanurate was rapid enough to allow the in¬ sulation material to reach the facing panel on the other side of the corrugated sheet and to glue the said panel. Further it was noticed that adjacent to the oblique flanges of the corrugated steel sheet were formed cracks that loosened a trapezoid-shaped strip of insula¬ tion material from these flanges of the corrugated sheet. When the sheet had the gripping mechanism according to the Finnish patent 45006 of the applicant, no cracks could be noticed at the flanges having these gripping mechanisms.

If the steel sheet would not have a gripping mechanism, the said -tra¬ pezoid-shaped insulation material strip would easily get loosened from the corrugated sheet, and thereby also the facing panel would be loos- Θied. For example^*in the case of a one-story house with the wall height of about 2.7 m, the moisture movement of fibreboards, particle- boards and asbestos cement boards may be 5-10 ππt, which creates a shearing force in the joint between the steel sheet and the insulation. This shearing force has to be taken by a sufficient shearing strength between the sheet ccrπponent and the insulation component. Only the mechanical joint applied in this invention can be reliable enough. With reference to thorough studies and calculations performed by the Laboratory of StructuralEngineering of the Technical Research Centre of Finland (VTT) it can be further shown that the span lengths re- quired in practical building c-an only be achieved in horizontal struc¬ tures if the corrugated steel sheet functions with its full calcula¬ ted cross-section.

In the following description of the invention the main emphasis is on such a description of the invention in v^*hich the frame structure of the panel construction is a perforated corrugated steel sheet with a gripping mechanism, and the insulation material is polyurethane or polyisocyanurate. In spite of this, it has to be emphasized that the invention is in no way limited to steel sheet and the said insulation materials, but the sheet constituting the frame structure may also be sane other metal sheet that can be provided with a gripping mechanism and perforation. Similarly, the insulation material may also be some ^• other foamable insulation material that by its gluing effect fastens to the frame material, such as aerated concrete "Siporex" (trademark) or a corresponding material.

When the steel sheet is sittiated in the panel construction of the in¬ vention in the form of a corrugated sheet, the sheet is enough to bear the loads imposed upon the structure, tut the sheet does not extend across the wall, and thus no cold bridges may arise. The joints be¬ tween the panel construction elements can also be sealed by other ma- terials than foamed polyurethane, and thus building in wintertime can also be managed by means of these solutions. The joints between the panel constructions may for example be fixed by mechanical fasteners, and thus they can be loosened and the panel construction can be moved to another place to be assembled again. This is a significant advan- tage as compared with the present wall and floor constructp.ons. The bearing capacity of the panel construction may be adjusted by means of changing the thickness and profile of the sheet. Similarly the thick¬ ness of the insulation may be selected so as to meet the requirements of the time and place of building.

The perforated steel sheet replaces the frame columns, and thus a steel frame, an insulation, and if required, facings of the wall or other structure, are produced in the same time in the production stage of the panel construction.

The production can be carried out simply in as such known moulds and in continuous production lines. Because the sheet is perforated, the foamed insulation material gets through to the other side of the sheet as well, which would not be possible without the perforation. Thus the sheet may be situated either above or under the injection point of the insulation material. Both of these ways are used in the production of the present known sandwich panels. When a self-gluing

OMPI insulation material is used, the insulation material fastens onto both surfaces of the sheet.

The steel sheet or other sheet is perforated so that projecting parts remain on one edge or on both edges of the hole, either on one side or on both sides of the sheet, for example in the way described in the Finnish patent 54006. The projecting -parts may also be handle-like strips which in both ends remain fixed to the sheet at the edges of the holes in the sheet, or other projecting parts bent out of the ma- terial of the sheet. In addition to its own gluing effect, the insula¬ tion material fastens to these projecting parts both mechanically and by its gluing effect, and thus the gripping between the sheet and the insulation is .still improved.

Ey means of these projecting gripping elements, so-called^'nails, a facing material can be fixed to the panel construction, for example by casting a layer of concrete or other material on the panel element.

The projecting parts may also function as distance-keeping spacers, when a cavity is required between the facing material and the panel. Due to this cavity the insulation glues the facing through its entire surface, and thus the gluing effect is improved and in the same time^' the protection of the sheet against corrosion and moisture are still improved. This cavity may also be formed by spacers or the like that are fixed to the sheet before the foaming of the insulation.

Advantageous are for example such αnbodiments of the invention in v^*hich the insulation material is a plastic-based insulation material

1 such as for example polyurethane or polyisocyanurate or other similar insulation material that can be fastened to the sheet by its own gluing effect. Besides such self-gluing insulation layer, the material on both sides of the sheet or other plate may be mineral wool, foamed polystyrene (styrαx) , excelsior plate, concrete, clinker plate, brick, aerated concrete (siporex) or wood-based fibreboard, metal sheet, panel or the like.

Advantageous are also such embodiments in vAiich thecαπponents are as

CMPI far prefabricated as possible.

It may be emphasized, that although the above description has taken steel sheet as the frame structure, the scope of protection of the invention also includes such solutions in which the frame plate is of some other material than steel, for example a corresponding perfora¬ ted metal sheet.

In the following, various advantages gained by the invention as cσn- pared with known solutions are listed shortly. For the sake of clari¬ ty, the term "element" is used in the following description.

The_, "element" according to the invention is

- a ready for assembly, self-bearing and ready-insulated building element;

- the insulation of the "element" is water vapour tight, uπwetting, strong, permanent and chemically resistant polyurethane or polyiso- cyanurate or the like;

- the core plate of the "element" is for example hot zinc-coated steel sheet, and the insulation protects the sheet, and thus no risk of corrosion exists under any circumstances;

- the "element" is a building material that even the do-it-yourself builder is able to use.

The superior heat insulation capacity of polyurethane and polyiso- cyanurate guarantees that the heat insulation capacity of the elements is maximized in the same time as the space cost is minimized. Moisture does not become condensed to the elements and tight joints are ob¬ tained.

By using the elements it is fast and siπple to build irrespective of the wsather conditions.

The standardization of the elements makes planning easier and building faster.

The building can be disassembled and moved to be assembled again. The elements do not need any special maintenance.

2

The weight of the elements as supplied to the worksite is 12-21 kg/πi .

The maximum length of the elements is 12.5 m.

A structure is obtained that can bear even high loads.

The elements are safe against fire. The inflai-mability class of poly- isocyanurate is 1 and the fire-propagation class of the surface of the steel sheet coated element is I.

Variations in shape of facades may be realized by varying the placing and the size of windows. Facing materials may also be varied in the same building project. The elements allow an almost ^*jnlimited freedom of alteration in facing materials. By using the same basic product it is possible to build a house with any required external facing.

The realization of all of the above-mentioned advantages, significant in practice, in the same panel construction of this invention is a proof of the inventive combined effect and synergy of the various parts of the construction.

In the following the invention is described in detail by referring to some embodiirεnts of the invention, presented in the figures of the attached drawing sheets, -to the details of v^*hich the invention is hσ ^ ever in no way limited.

Figures 1, 2, 3, 4, 5, 6 and 7-present cross-sections of some prefer¬ red embodiments of the panel construction of this invention.

Fig. 8 is a schematic view of the principle of the batch mould used advantageously in the production of the panel constructions of this invention.

Figures 9 and 10 present perspective views of some preferred joint methods and the projecting gripping elements of the panel construction of this invention.

OMPI In the embodiments of the invention shown in figures 1-7 the panel construction comprises a frame plate 1;1a;1l->;1c;1d;1e;1f provided with perforation 1' and a gripping mechanism 1". By remaining inside the cast insulation layer 3, this frame plate gives the panel construction a sufficient stiffness against loads with different directions. As shown in the figures, the frame plate 1;1a;1b;1c;1d;1e;1f is entirely inside the insulation layer 3. The insulation layer 3 is cast of foam¬ able insulation material and it can penetrate through the perforation 1' of the frame plate. The frame plate 1;1a;1b;1c;1d;1e;1f is directly connected to the .insulation material layer 3 by its gluing effect. By the gluing effect of the insulation material 3, also the facings 4a, 4a^,;4b,4b^,;4c,4c^,;4d,4d^,;4f,4f^,;4g,4g^,;4h,4h^,;4i,4i^« and 4j,4j' are connected to the construction. The mentioned separate facings are not needed in all cases, but the surfaces of the panel construction may be formed by the surfaces of the insulation material layer 3, in which, as is as such known, is formed a uniform plastic material surface layer with a density higher than"that of the rest of the foamed struc¬ ture, for example in the moulding stage due to the effect of the walls of the mould.

In Fig. 1 there is a corrugated sheet 1 provided with perforation 1 ' and a gripping mechanism 1", an insulation 3 and, depending on the production technology, a paper, an aluminium paper or similar coating 4a and 4a'. If batch moulds are used in the production, the surface of the insulation 3 must be coated by a coating 4a,4a' with at least the strength class of kraft paper, preferably an aluminium-coated paper. The same applies to continuous production lines. If the production is carried out in a process where the insulation 3 is allowed to expand freely, the paper 4a,4a* or the like may be left out.

According to Fig. 2, the upper surface coating 4a of Fig.1 has been replaced by a shaped plate 4b, in which case the production is carried out in batch moulds having an upper or a lower component of the corres¬ ponding shape, depending on whether the product is manufactured with the shaped plate upwards or downwards. Also a continuous production line may be in question here, in which case the shaped plate is for example a corrugated sheet. Both of the coatings 4b,4b' may be shaped. In other respects the construction is as shown in Fig. 1.

In Fig. 3 there is a clinker or brick plate 4c or the like on the upper surface of the panel construction and an even panel facing 4c' , for example a hard fibreboard, on the lower surface. In this solu¬ tion the clinker plates or the like are, before injecting the insula¬ tion material, placed on for example a rubber mat having formed re¬ cesses for the plates and projecting ridges between the recesses for seams between the plates, respectively. The panel construction shown in Fig. 3 can be manufactured primarily in batch moulding lines. The afterseaming of the seams between the wall plates is carried out by using known materials either in the factory or on the worksite. In continuous production lines this kind of solution is possible, if the rubber mat or the like is functioning like the wire of a paper machine and the speed of the line is so adjusted that there is time enough to place the plates on the mat either by machine or manually.

According to Fig. 4 there are two corrugated sheets .1a and 1b oppo¬ site to each other. Into the tube formed by the sheets 1a and 1b has been cast concrete 8' or the like, and thus the bearing capacity and the stiffness of the panel construction element are still increased.

In Fig. 5 the coatings 4e and 4e' of the upper and lcwer surface have been fixed by mechanical fasteners 6, vjhich go through the insulation 3 are fasten to the corrugated sheet 1, in which case a separate battening or other basis for fastening is not needed.

According to Fig. 6, spacers 7 have been fixed to the corrugated sheet 1c. When for example a wooden spacer is used, it functions as a nailing ground if for exaπple a wooden panel or board facing is used. By means of this spacer it is also possible to adjust the posi¬ tion of- the plate 4f as required. Also different spacers made of sane insulation material or"the like may be used as spacers 7.

According to Fig. 7, not only the frame plate 1d and the coatings 4g, 4g' have been placed in the mould but also tubes 8 made of steel, me¬ tal sheet, paperboard or the like, which tubes are glued in their position by means of the insulation material 3. The said tubes serve as moulds, when it is required to improve the bearing capacity and the stiffness of the panel construction element, by casting concrete 8' or the like into the said moulds. If the tubes 8 have been made of steel or the like, they increase already as such the bearing capacity and the stiffness of the element.

Fig. 8 shows the principle of the batch mould. In the mould 2 that can be closed tightly (holes for letting air out are needed) there are a corrugated sheet -1 and coatings 4h and 4h'. The foamable insulation material 3 is injected through the nozzle 5 into the mould 2, where it expands due to heat (or.other reason) , penetrates through the holes 1 ' of the corrugated sheet 1 also to the other side-of the sheet 1 and fills,the interior of the mould 2 reserved for the insulation in the same time as the insulation 3 glues all of the cαπponents to one tight and stiff.entity. The principle of continuous production lines is si¬ milar, but the closed mould is replaced by a curing tunnel. The char¬ acteristics of the insulation material 3 may be different depending on the production process. -

To the insulation material layer 3, pipelike channels may be formed either in the the moulding stage or later, if necessary, for electric, telephone, telecoπraunication and/or similar wires. Preferably these channels are made so that in connection with the moulding stage, pipes of metal, paperboard or other corresponding material are placed in the mould,for example fixed to the frame plate 1 or supported by it, with the interior of the pipes being left free from the insulation material 3. Such pipes may also serve as structural parts affecting the strength of the panel construction and at least partly they may replace the frame plate 1, or they are filled by casting into them concrete or other similar material, in which case the bearing capacity and the stiffness of the panel construction are still iitproved.

The edges of the mould 2 shown in Fig. 8 may be so formed that tongues and grooves or corresponding shapes are formed on the edges of the _.in¬ sulation material layer 3 so that a sufficient tightness is obtained . in joints between adjacent panel construction elements. The mentioned tongues and grooves may also be so formed that their edges are lined by the frame plate 1. In this case the edges of the frame plates 1 of adjacent panel construction elements can be fixed to each other by screws or the like, and thus a very reliable fastening and a stiff construction is obtained.

Fig. 9 shows in a partly cut perspective view a panel construction element and a joint solution between two elements. In the figure there is seen a perforation 1 ' and a gripping mechanism 1", a kind of nail system, in the frame plate 1. Further, facing plates 4i,4i' and the insulation material 3 are seen in the figure. The edges 9,9' of the frame plates 1 form a kind of tongue-and-groove joint and over¬ lap each other. In this case the frame plates of two adjacent pa- nel construction elements can be fixed to each other by screws 10 or the like through the plate 4i or the like, and thus a.reliable fasten¬ ing and a stiff construction is obtained. The joint may also be dis¬ assembled, in which case the elements can be assembled again. In the joint between two panel construction elements there has been made a grooving 11, which at the assembly stage of the elements is filled by polyurethane insulation material 12 or the like,

Fig. 10 shows a frame plate 1f, perforation 1' , a gripping mechanism 1", facing plates 4j and 4j* and and insulation 3. In this alternative solution of the elements the frame plate 9 extending beyond the edge of one of the elements is pressed between the plate 4j and the edge 9' of the frame plate. The elements are fixed to.each other by means of screws or the like. The joints between the elements are sealed by po¬ lyurethane insulation material 12 or the like,or mineral wool or plas¬ tic sealing strip is used.

In the following are presented the claims, defining the- inventive con¬ cept within which the various details of the invention may vary.

OMPI

Claims

1. A panel construction to be used in buildings in wall structures or in floor slabs, intermediate floor slabs, roof slabs, plinth plates or similar, comprising a perforated frame plate (1;1a;1b;1c;1d;1e;1f) and an insulation material layer, c h a r a c t e r i z e d in that for forming wall structures and or floor structures^"or similar struc¬ tures essentially entirely of the mentioned panel construction, the panel construction comprises as a structural combination at least the following layers: .

a) an insulation layer of polyurethane, polyisocyanurate or correspon¬ ding material (3) , being of foamable insulation material with an abili¬ ty to glue itself onto the frame plate, the layer being fixed in an as such known moulding stage onto both surfaces of the frame plate (1;1a; 1b;1c;1d;1e;1f) , filling at least the recesses of the frame plate,

b) a perforated (1*) frame plate (1;1a;1b;1c;1d;1e;1f) to vzhich the said insulation, layer (3) , penetrating through the said perforation (1') , is directly connected by the gluing effect of the foamsd insula¬ tion material (3) , and in v ich panel construction the said frame plate is a corrugated metal sheet with a projecting gripping element series (1") similar to nails, consisting of the sheet material deflected from the perforated positions (1 ') , this gripping element series creating a . mechanical gripping between the frame plate and the insulation material layer, and the perforation being such that it does not essentially weaken ths the frame plate which mainly bears the loads imposed upon the panel construction. ^• -. -

2. A panel construction according to claim 1, c h a r a c t e r ¬ i z ed in that the area of the holes (1') in the frame plate, from the edges of^'which are projecting the said gripping elements (1") , in the plane of the. sheet folds,is about 1-15 %,. preferably about 2-5 % of the corresponding area of the plate.

3. A panel construction according to claim 1 or 2, c h a r a c t e r ¬ i z e d in that pipelike channels have been made in the insulation material layer (3) in the moulding stage or otherwise for electric, telephone, telecαrrπunication and/or corresponding wires, or for cast- ' ing moulds for concrete or other similar material, or for increasing the bearing capacity and the stiffness of the panel construction as such.

4. A panel construction according to claim 1, 2 or 3, c h a r a c ¬ t e r i z ed in that a special plate, membrane (4a,4a';4b,4b' ;4d,4d' ; 4e,4e';4f,4f*;4g,4g*;4h,4h";4i,4i';4j,4j") or similar is used as the facing of the insulation material layer (3) , this facing for its part deciding the shape and material of the surfaces of the panel construc¬ tion.

5. A panel construction according to claim 1, 2, 3 or 4, c h a r - a ct e r i z e d in that on the edges of the panel construction in its insulation material layer (3) there are tongue-and-groove joints or similar (9,9*) so that a. sufficient tightness is obtained betwaen adjacent panel construction elements.

6. A panel construction according to some of the claims 1-5, c h a r ¬ ac t er i z e d in that the projecting gripping elements (1") are formed by handle-like strips *^*hi h by their both ends are connected with the frame plate on the edges of its holes.

7. A panel construction according to some of the claims 1-6, c h a r ¬ ac t e r i z e d in that one or both of the surface plates (4e,4e') of the panel construction -are fixed to the frame plate (1) of the panel construction by means of mechanical fasteners (6) through the insulation material layer (3) .

8. A panel construction according to some of the claims 1-7, c h a r ¬ ac t e r i z e d in that the panel construction comprises spacers (7) glued to the insulation material layer (3) , which spacers function as fixing grounds for surface plates (4f;4g) or for a separately made coating or facing.

9. A panel construction according to claim 8, c h ar a ct e r i z e d in that the said spacers (7) have been fixed to the frame plate (1c;1d) before the production of the insulation material layer (3) .

10. A panel construction according to some of the claims 1-9, c h a r - a c t e r i z e d in that the panel construction has as a coating (4c) a coating consisting of ceramic plates or corresponding plates, which coating has been fixed to the panel construction by means of the gluing effect of the insulation material layer (3) , and that the spaces be¬ tween the ceramic or corresponding plates have been kept free frαn the material of the insulation layer (3) by means of a special rubber mat or by a corresponding method, and that the spaces between the ceramic or corresponding plates have been seamed after the moulding stage or other corresponding production stage has been carried out.