Note: Descriptions are shown in the official language in which they were submitted.
CA 02845263 2014-02-13
CONSTRUCTION PANEL
DESCRIPTION
The invention relates to a construction panel having at
least one honeycomb core, which is laminated on both flat
sides.
Such construction panels are known and established in a
variety of embodiments. Different coatings, for example
consisting of woven glass fibres, cement, paper, plastic
film or the like, depending on the purpose, are usually
applied to a core consisting of a foamed plastic, generally
an extrudate.
As well as the limited dimensions of such construction
panels, the recycling thereof is problematic owing to the
different materials, and the weight is burdensome for the
tradesperson. In particular, the high dead weight can
result in deformation of the construction panel, which
makes processing more difficult.
Against this technical background, the object of the
invention is to provide a construction panel, in particular
for wet rooms, which has a high compressive strength and a
low weight and in principle allows a multiplicity of
possibilities for use. This construction panel should in
addition ensure an even substrate for example for tiles
adhesively bonded thereto.
This technical problem is solved in a construction panel
having at least one honeycomb core, which is laminated on
both flat sides, according to Claim 1 by the measures that
the honeycomb core consists of a thermoplastic and that the
construction panel is itself stress-free owing to stresses
running in opposite directions in the laminations.
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Thermoplastics have a number of advantages over
conventional foamed plastics, for example in terms of shape
cutting. Furthermore, they are dimensionally stable over
wide temperature ranges, it being possible nevertheless to
keep the weight of the core low owing to the honeycomb
structure.
This is the case in particular if the honeycomb core is
formed by a deformed film and/or by tubes connected to each
other.
The weight of the honeycomb core can then preferably be set
to between 60 kg/m3 and 120 kg/m3 and the properties of the
honeycomb core can therefore be influenced within wide
ranges.
This can also be done by the measure that honeycombs are
filled. The functionality of the construction panel
according to the invention can thus be varied within wide
ranges. In particular, filling with a mineral foam or
granulate is conceivable, preferably a thermally insulating
glass foam or glass foam granulate.
Alternatively, fire-retardant or fire-extinguishing powder
fillings of the honeycomb can increase fire protection by
the construction panel according to the invention. In
additional to many other fillings and functionalities
resulting therefrom, moisture-regulating and odour-
absorbing materials should also be mentioned as the powder
or granulate filling.
Such honeycomb cores can be produced comparatively simply
and therefore cost-effectively with a material thickness
between 3 mm and 30 mm. Greater material thicknesses can be
achieved by means of several layers of honeycomb cores of
thinner material.
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In a design of the construction panel according to the
invention, it is provided for at least one flat side to
have a lamination consisting of an outer nonwoven and a
film lying underneath.
Nonwovens are suitable as the adherent surface for
adhesives or mortars for example for tiling to be applied.
The nonwoven should then consist of a material that is
resistant to alkaline adhesives and mortars and to
surfactants in detergents. Polypropylene nonwovens are
ideally suited to this.
The film largely determines the physical properties of the
construction panel according to the invention in terms of
the diffusion of water vapour and the flow of indoor air.
If a metal foil is used, for example consisting of an
aluminium, the construction panel blocks vapour. However,
the use of a polypropylene film is in particular
conceivable, which can be both permeable to vapour, for
example filled with chalk and then drawn out and/or
stretched, or in other configurations can inhibit or block
vapour.
Alternatively, a covering layer consisting of a duroplast
is also conceivable, by means of which the honeycomb core
is likewise provided with a skin. Such a construction panel
then also blocks vapour and wind.
It can optionally be provided for an intermediate layer
such as a further nonwoven or a looped or knitted fabric to
be arranged between the honeycomb core of the lamination.
This can be advantageous for the stability of the
construction panel. Expediently, an intermediate layer
consisting of a polypropylene is again provided here in
order to construct the construction panel solely from
polypropylene, which makes recycling much easier.
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Alternatively, other materials are also suitable for this
layer, in particular plastics, but also organic or mineral
fibres such as carbon, paper or glass, since this
intermediate layer cannot come into contact with alkaline
media or surfactants.
The low weight of the construction panel according to the
invention, suitable depending on the embodiment as a
carrier panel for tiling in wet rooms, as an extension
panel for such rooms or else as an extension panel for
interiors with an integrated vapour retarder and wind
barrier, furthermore with sealing of the cut edges as
thermal and/or sound insulation, allows dimensions of more
than 60 cm x 200 cm, in particular a standard width
dimension of 1.20 m and lengths of more than 6 m compared
to conventional panels having a width of 60 cm.
The structure of the construction panel according to the
invention is explained in more detail using the drawing,
the single Figure 1 of which shows a section through a
construction panel according to the invention,
schematically and not to scale.
The construction panel 1 shown in Figure 1 is basically
constructed symmetrically to a centre plane 2. At least one
inner honeycomb core 3 is provided with a two-layered
lamination 4. Optionally, a further nonwoven or woven or
knitted fabric can be provided as an intermediate layer 5
between the lamination 4 and the core 3.
The honeycomb core 3 preferably consists of a deformed,
folded PP film or of PP tubes having a weight of 60 kg/m3
to 120 kg/m3. Assuming a typical material thickness of 3 mm
to 30 mm, constructional panels of comparatively greater
material thickness can also be created by means of several
layers of such honeycomb cores 3.
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Depending on the intended use, the honeycombs can also be
filled, in particular with foams, powders or granules that
fulfil the intended use.
Where necessary adhesively bonded to the honeycomb core 3,
the lamination 4 consists of a nonwoven 6 on the outside
with a film 7 underneath. In the case of a use as a carrier
panel for tiles, the nonwoven 6 will be a polypropylene
nonwoven, since this material is resistant to alkaline
adhesives or mortars and furthermore also to surfactants in
detergents.
The film 7 largely determines the functionality of the
construction panel 1. The construction panel 1 is made to
block vapour and wind by a metal foil, for example
consisting of an aluminium. A vapour-retarding or vapour-
permeable configuration is likewise possible if suitably
formed PP films are used.
In an alternative configuration of the lamination 4, an
application of a duroplast is provided under the nonwoven 6
instead of the film, with which the construction panel 1
likewise forms a vapour barrier and wind barrier.
Optionally, another intermediate layer 5 such as a nonwoven
or a looped or knitted fabric can be arranged between the
lamination 4 and the honeycomb core 3. Since this
intermediate layer 5 generally hardly comes into contact
with alkaline materials or surfactants of detergents at
all, organic and/or mineral fibres can be used in addition
to plastics such as preferably polypropylene as the
intermediate layer 5.
Construction panels 1 according to the invention can have
dimensions of preferably 1.20 m in width to over 6 m in
length. If the construction panels are in particular
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fabricated entirely of polypropylene, segregated recycling
is furthermore possible.
The structure is basically symmetrical to the centre plane
2, from the outside inwards nonwoven, film or duroplast and
optionally intermediate layer, it being possible however
for the functionality and materials to differ on each side
of the centre plane 2.
