Self-and load-supporting component
The invention relates to a self-supporting and load-transferring construction element (1) with at least one, preferably two cover layers (7), on which preferably several strip-shaped spacing elements (18) are placed, distributed on an inner facing surface (15a) of the cover layer (7), which are joined to the cover layer (7) in a non-positive and/or a positive join by means of a curable joining and/or fixing means (70). The cover layer (7) and/or the spacing elements (18) are made from randomly oriented wood or wood material elements (73) joined by a binder with cavities (75) and pores (74) disposed in between them. Disposed in a joining region (71) between the cover layer (7) and the spacing elements (18) is a joining and/or fixing zone (80) comprising cured joining and/or fixing means (70) and wood or wood material elements (73) and/or pores (74) and/or cavities (75), which has a higher mechanical strength than regions of the cover layer (7) and/or spacing elements (18) adjoining the joining and/or fixing zone (80).
[0001] The invention relates to a self-supporting and load-transferring construction element and a method of making the construction element as outlined in the generic parts of claims 1, 2, 3, 4, 5, 44, 45, 76, 84 and 32, 33, as well as the use of the construction element as defined in claims 30, 31 and 83.
[0002] Patent specification DE 925 858 C2 discloses a support-type construction element with one or more wave-shaped spacing elements disposed offset from one another by a half wavelength or in phase alignment and extending parallel with the longitudinal direction of the construction element and at a distance apart in a transverse direction relative thereto, in which the spacing elements made from a non-bonded plywood, in particular webs, locate in recesses set back from strip-shaped, in particular board-shaped or beam-shaped cover layers, to which the spacing elements are joined in a non-positive and positive fit. Spacing elements of this type made from plywood are disposed at distance apart from one another and preferably joined to the cover layers in a non-positive and positive fit but construction elements of this type made from wood exhibit only a low capacity to transmit transverse forces acting in a transverse direction. Furthermore, because the cover layers made from a wood veneer section have a slim width, which is limited due to the build-up limits, the applications in which such construction elements can be used as a cladding element are very much restricted and such construction elements may only be permitted to take an average load in order to avoid the risk of lateral tipping which would otherwise occur. They have a further disadvantage insofar as the amplitude and lateral opening width of the spacing elements are of very small dimensions and intrinsically high return forces in the spacing element cause high shearing forces in the bonded seams between the cover layer and spacing element transversely to the longitudinal extension of the construction element, making it necessary to bond the facing layers to the spacing element to retain the shape, which is expensive as well as being technically complex in terms of manufacturing.
[0003] Patent specification EP 0 568 270 B1 discloses a construction element with cover layers which are held at a distance apart from one another by means of spacing elements, the spacing elements forming several mutually separate cellular chambers or cavities in the longitudinal extension of the construction element. The spacing elements, in particular webs, which are in mutual contact in at least certain regions, are joined to the cover layers at the part-regions in mutual contact and by their narrow ends. The cellular chambers formed by the webs are packed with a filler and form a core, which is disposed between and joined to the first and second cover layer. The disadvantage of construction elements of this type made from wood is that the cover layers are supported by the spacing elements over a part of their width only, which as a result imparts only a low bearing capacity to them, especially in the peripheral regions of the narrow end faces and in particular in a plane perpendicular to their longitudinal extension. Moreover, they can only be used in structures designed to support very low loads and not for high load-bearing primary structures, which again severely limits the range of applications for which they may be used.
[0004] Another construction element is known from document DE 195 21 027 A1, in particular a double T-shaped bar, consisting of two cover layers mutually spaced apart by spacing elements, in particular webs, in which only one non-flat or corrugated web is provided between the cover layers in the longitudinal extension of the construction element. Several of these construction elements, in particular corrugated webs, can also be assembled to make up a flat element. The disadvantage of construction elements of this design made from wood is that the support elements joined to a flat element in the longitudinal extension are subjected to high shearing stress in the region of the seam faces when load is applied, which can cause mutual shifting between two cover layers joined to one another. Consequently, in order to make up a component with a large surface area, it is necessary to use a large number of joining seams, incurring a correspondingly high amount of production work. Again the range of potential applications is severely limited because several double-T-bars have to be aligned in a row to make up a flat construction element, which means that the construction element has only a low bending stiffness in the transverse direction due to the absence of fibre elements in the widthways direction of the component.
[0005] Another construction element is known from published patent specification EP 0 314 625 A1, in which two cover layers mutually spaced apart by a spacing element have a further layer on their surfaces remote from one another, one of which is a base for a decorative plate and the other of which is a base for a rear-face protective plate. The spacing element, in particular the cells of the core layer, which is provided in the form of a honeycomb arrangement for example, is joined to the cover layers, and in particular is adhered to them by means of a non-combustible adhesive. The disadvantage of this arrangement primarily resides in the fact that these structural elements are not designed to be load-bearing, which precludes their use in primary structures. Furthermore, compared with the construction element proposed by the invention, this structural element requires a much higher volume of material in terms of the core layer for more or less the same load-bearing capacity, and does so by approximately 50% by reference to the volume of material in the construction element, and the spacing elements of the core layer are extremely expensive to make.
[0006] The disadvantage which all these systems have in common is the large amount of material required for a relatively low load-bearing capacity of the construction element and the fact that the design is very limited in terms of production when it comes to making up a wall, floor or ceiling element with a large surface area, or is extremely complex to produce. However, these construction elements are also not suitable for use with rapid assembly systems used in the construction of buildings nowadays and are barely in keeping with the cost-conscious approach to building, where preference is given to ready-made, prefabricated components based on a length of up to 20 m and a width of up to 4 m, for example, which merely have to be attached to ready-fitted anchoring posts or joined directly to one another by fixing elements such as screws, nails, etc. As disclosed in patent specification DE 925 858 C2, for example, the spacing elements are inserted and bonded in recesses counter-sunk in the cover layers in order to make the joining surfaces between the spacing elements and the cover layers bigger, for which purpose the thickness of the cover layers is designed to be at least bigger than the depth of the recess in order to avoid reducing the load-bearing capacity, which necessarily increases the amount of material needed for the cover layers as a result. Consequently, these construction elements made from wood can not be made for span widths of up to 20 m and a width of 4 m and those which are available on the market do not meet current economic requirements in any event.
[0007] Another significant disadvantage of these construction elements made from wood which are bonded into shape is the fact that they are only of limited use in regions which are susceptible to earthquakes because they can only be designed as a construction element with a large surface area serving as mutually spaced supports, which are then spanned by flat panels of a large surface area but do not automatically transmit force to the panel when the panel is subjected to dynamically acting forces. In the other situation, where several longitudinally aligned construction elements are joined to one another by their longitudinal end faces, the cover layers or belts in the region of the bonded seam tend to fail, causing the assembled flat construction element to tip over or break.
[0008] The underlying objective of the present invention is to propose a self-supporting, load-transferring, dimensionally stable construction element from a wood material that is easy to manufacture, and whereby the amount of material needed to make it is kept as low as possible. In particular, the construction element should be of a thin-walled construction which can also be used in regions susceptible to earthquakes. Furthermore, the construction element should also have different properties enabling it to be used in different applications, for example as heat and/or noise insulation.
[0009] This objective is achieved by the invention as a result of the features defined in the characterising part of claim 1. The surprising advantage of this approach is that the open-pored or diffusion-promoting joining surfaces of the cover layers and spacing elements, in conjunction with wood or wood material elements with a large surface area relative to the thickness of the spacing elements, impart a high tearing resistance to every individual wood or wood material element joined to the spacing element and the load-bearing capacity, in particular the ability to withstand tensile, compression and thrust load, can be significantly enhanced in the region of the joining surfaces. Another advantage is the fact that the joining and/or fixing means diffuses into the interior of the material of the cover layers and spacing elements, thereby enabling a high load rating to be obtained, even if the spacing elements have small thicknesses and a butt joint is used.
[0010] The objective set by the invention is also achieved by means of the characterising features set out in claim 2. The surprising advantage of this approach is that in the initial state, free-flowing joining and/or fixing means is able to penetrate the open-pored or diffusion-promoting joining surfaces of the cover layers and spacing elements and adheres or is at least partially absorbed by the wood or wood material elements offset from the joining surfaces and may even fill out the cavities between the wood or wood material elements, and, after a pre-definable setting time, the cured joining and/or fixing means is joined to a plurality of wood or wood material elements on and underneath the joining surfaces.
[0011] The objective set by the invention is also achieved by means of the features set out in the characterising part of claim 3. The advantage resides in the fact that the free-flowing joining and/or fixing means penetrates joining regions through the joining surfaces of the spacing elements and the cover layers and the cured joining and/or fixing means forms a joining and/or fixing zone between the cover layers and the spacing element which extends beyond into the interior of the material of the spacing element and the cover layers, thereby providing simple ways and means of increasing the size of the load-transmitting joint cross section. Producing this joining and/or fixing zone enables high loads, in particular tensile, pressure, thrust and torsional loads, to be transmitted, even if the spacing elements and cover layers have slim cross sections.
[0012] The objective of the invention is also achieved by the characterising features set out in the characterising part of claim 4. The surprising advantage achieved as a result is that by using spacing elements and cover layers made from wood material and because of the design of the spatially deformed, in particular wave-shaped, spacing elements, the amount of wood needed is significantly reduced compared with wood used in other construction elements offering the same load capacity and the inherent weight and overall material requirement can be kept low, even across large span widths. Furthermore, the wave-shaped, curved spacing elements also prevent warping, even if using cover layers of a low thickness, and a significant amount of load can be transmitted in the direction of both the length and breadth of the construction element.
[0013] The objective set by the invention is also achieved by the features defined in the characterising part of claim 5. The advantage resides in the fact that because the spacing elements are oriented perpendicular to the inner facing surface of the cover layers, the moment of resistance is increased, and with it the bending resistance of the construction element to forces acting perpendicular to the plane of the construction element, whilst requiring a low volume of material for the core element.
[0014] In the embodiments defined in claims 6 and 7, it is possible to use known, tried and tested chipboard panels or fibreboard panels, in particular FPY, MDF, etc., which can be produced in large numbers at low manufacturing costs, which helps keep the cost of the structure used for the construction element down.
[0015] As a result of the further improvement defined in claims 8 to 11, it is possible to use known, tried and tested coarse chipboard panels, in particular OSB, LSL, which helps to keep the cost of making the construction element down. It also offers the possibility of adapting to different types of load and adapting to different applications.
[0016] The embodiments defined in claims 12 and 13 are of advantage because the thin-walled, load-transmitting structure primarily enables the wave-shaped, curved spacing elements to be produced using standard manufacturing processes known from the prior art, such as compression moulding under the action of temperature, etc.
[0017] The embodiment defined in claim 14 has an advantage because, as mentioned in connection with claim 4, the moment of resistance is increased on the one hand and on the other, because the spacing elements are disposed perpendicular to the inner facing surface and as a result of the butt joint between the spacing elements and the cover layers, fully automated production machinery can be used to make the construction element.
[0018] Advantages are also to be had from the embodiments of the cover layers and spacing elements made from wood or wood material elements obtained by the manufacturing process defined in claims 15 and 16, whereby the joining and/or fixing means, in particular the adhesive, is diffused through the open-pored pattern structure due to capillary action through the cover layers and spacing elements, which increases the size of the active join cross section.
[0019] Other advantageous embodiments are defined in claims 17 to 19, the advantage of these being that, as it diffuses through the join surfaces, the free-flowing adhesive is able to fill out even larger pores and/or cavities and is at least partially absorbed by the wood or wood material elements to form a fixing zone within the spacing element and the cover layers and produce a joining zone or joining element between the spacing element and the cover layers, which is specifically suited to transmitting higher thrust forces via the joining and fixing zone. This is possible because the free-flowing adhesive is sucked into the structure of the spacing elements and cover layers made from wood so as to be distributed over a part-region thereof by capillary action and because of the structure, a meshing or hooking effect is produced between the cover layers and the spacing element, so that breaking values can be significantly increased to levels of up to 7 N/mm2 as a result of the butt adhesion.
[0020] The advantage of the embodiments defined in claims 20 and 21 is that an adjustment can be made for different static or dynamic load situations, particularly in respect of forces acting in a direction parallel with the construction elements, and the elastic behaviour and vibration behaviour of the construction element can be acted on, specifically with a view to use in regions susceptible to earthquakes. An expedient choice of the joining regions offers a simple means of making a part-region disposed between two successive joint regions reversibly and elastically flexible, thereby optimising its vibration behaviour when subjected to a dynamic load.
[0021] The embodiments defined in claims 22 and 23 enable a cover layer made from wood or wood material to be used in combination with a cover layer made from a material other than wood and wood material, to impart a three-dimensional structure with this construction element.
[0022] Also of advantage is the embodiment defined in claim 24, as a result of which a single layer can be rendered suitable for various functions, such as heat insulation, protecting against fire, noise insulation, etc.
[0023] Also of advantage are the embodiments defined in claims 25 to 28, which offer a simple way of adapting to the different requirements which might be demanded of the construction element.
[0024] In accordance with the features defined in claim 29, the material requirement or material volume of the core layer constituting spacing elements of the construction element can be optimised and warping of the cover layers due to sudden impacts can be prevented by means of the wave-shaped spacing elements. The cover layers with their large surface area spanning the core layer also enable a force to be transmitted into the cover layers and force to be transmitted through the core layer.
[0025] The construction element proposed by the invention and defined in claim 30 is primarily used as a wall and/or ceiling element, etc., for a framework of a building in regions susceptible to earthquakes and/or on ground where the foundations are soft, because it has a low mass and high stiffness and hence a high natural vibration frequency, particularly when subjected to forces acting in a direction parallel with the construction element. Furthermore, the design whereby the construction elements are of a large format relative to a pre-determined surface, e.g. ceiling surface, wall surface, etc., enables the number of statically problematic joining points between construction elements to be drastically reduced. As a result of the variously aligned wood or wood material elements in the cover layer and/or in the spacing element, the stress peaks which occur, in particular during an earthquake, are reduced, especially in corner regions such as in door and window openings of a building, thereby making optimum use of the construction element in earthquake regions.
[0026] It is also of advantage to use the construction element defined in claim 31 as a formwork shuttering, because it is capable of withstanding a high load, in particular up to 10 tonnes, even if formats of a large surface area, such as a length of 10 m and a width of 3 m, without being inadmissibly deformed as a result.
[0027] The objective of the invention is also achieved as a result of the features defined in claim 32. The advantage of this approach is that the construction element can be made on a largely fully automated basis in an endless production process in a simple manner and at a low manufacturing cost.
[0028] The objective of the invention is also achieved as a result of the features set out in claim 33. The advantage gained here is that it provides the possibility of reacting to different loads with different formats, quickly and without the need for major modifications, whilst also offering a high degree of flexibility with regard to manufacturing.
[0029] Other advantageous features for producing the construction element with two cover layers are described in claims 34 to 36.
[0030] The feature defined in claim 37, whereby the production cycle of the construction element is significantly reduced, is also of advantage.
[0031] The features defined in claims 38 to 40 highlight different variants in terms of producing the construction element, whereby a different sequence of manufacturing process can be run and the core layer incorporating the spacing elements, which forms a lattice arrangement in the extended state, can be placed on the bottom cover layer and adhered to it continuously or in cycles. Of particular advantage in this respect is the feature defined in claim 39, whereby the joining and/or fixing means can be applied to the thin end faces of the spacing elements in a simple manner. As a result of the advantage obtained by claim 40, ready pre-formed spacing elements, in the form of compression moulded or extruded strips of board made from wood material, can be placed on the cover layer and joined to it in a tension-free state. The core layer is therefore formed as a substantially force-free system, which avoids the occurrence of stress, in particular thrust forces, within the adhered seam due to rebound forces in the spacing elements.
[0032] As a result of the feature defined in claim 41, the filler material can be metered, which provides a simple means of adapting to different application conditions, such as reducing the heat transmission value or the level of noise damping, etc. The airtight design of the interior of the construction element imparts a high resistance to fire because air is prevented from flowing between the individual chambers, which prevents fire from spreading.
[0033] Also of advantage is the feature defined in claim 42, whereby, on the one hand, the pattern formed by the pores and cavities and wood material elements in the region of the joining surfaces of the cover layer and spacing elements can be rendered accessible and enlarged, thereby improving the flow and diffusion of the joining and/or fixing means to interior of the material used for the cover layer and spacing elements, and, on the other hand, a flat, full surface contact can be obtained between the spacing elements and the inner facing surface of the cover layer.
[0034] The feature defined in claim 43 is made possible because, during the process of manufacturing the construction element, the construction element can be made into a specific end product, such as a roof element with support elements, e.g. roof battens and/or weather protection, immediately in a subsequent process.
[0035] The objective of the invention is also achieved by the features defined in claim 44. The surprising advantage gained as a result of the features set out in the characterising part is that, in spite of the slim material thicknesses of the cover layers and the spacing elements, a self-supporting and load-transferring, dimensionally stable, lightweight and torsionally resistant flat construction element can be produced, requiring little in the way of material, but which is capable of withstanding a high degree of stress and moments in the longitudinal direction and in a direction disposed transversely thereto.
[0036] The objective of the present invention is also achieved by the features defined in claim 45. The surprising advantage gained as a result of these features is the forces and/or moments acting on the spacing elements, which constitute a major part of the volume of the construction element, can be transmitted, especially transversely to the construction element, whilst simultaneously distributing the loads, by the thin-walled board-shaped cover layers and by the thin-walled spacing elements. Another advantage primarily resides in the fact that forces in the longitudinal and/or transverse direction of the construction element can now be absorbed and transferred uniformly across the entire cross section.
[0037] The advantage of claim 46 is that even in the event of high loads and large span widths, only slight bending will occur because the entire width of the construction element is used to transmit load when subjected to tensile and/or compression stress.
[0038] Also of advantage is an embodiment of the type defined in claim 47, whereby construction elements disposed one above the other are able to absorb different loads. Furthermore, the construction elements may have different properties, in which case providing different materials in the core layer of the construction elements will help to increase their load-bearing capacity and ability to withstand thrust.
[0039] The advantage of the embodiment defined in claim 48 is that the construction elements, which overlap in certain regions, project beyond a longitudinal end face and/or width end face, forming a construction element with a large surface area in conjunction with other construction elements, the construction elements of which, one facing the standing surface and the other opposite it, adjoin one another in a butting arrangement, providing a fluid-tight joint.
[0040] Also of advantage is an embodiment is defined in claim 49, whereby the diffusion capacity of the cover layers can be improved by providing continuous orifices.
[0041] Claim 50 avoids incurring additional production costs for extra processing because standard materials are used.
[0042] Also of advantage is another embodiment defined in claim 51, since the film used provides weather protection and/or optionally a vapour barrier.
[0043] The embodiment defined in claim 52 enables the construction element to be provided with a zone of specifically defined melt-down with pre-definable properties, as a result of which another construction element joined to it will take the load of the other construction element for a pre-defined period of fire resistance.
[0044] The embodiment defined in claim 53 is of advantage because the fact of providing an additional layer with a different intrinsic property enables the construction element to be adapted to different requirements, such as fire resistance or resistance to damp, for example.
[0045] The embodiments defined in claims 54 and 55 have been found to be of advantage because the cover layers, generally of a large surface area, have a low component weight whilst nevertheless offering a high load-bearing capacity and torsion resistance, which means that a construction element with a low intrinsic weight can be made at low cost. Furthermore, the cover layer may incorporate one or more layers of differing properties, enabling the construction elements to cater for different requirements. Another advantage resides in the fact that higher loads can be accommodated and bigger span widths covered.
[0046] Claim 56 makes the use of inexpensive, standard wood or wood materials possible.
[0047] Also of advantage is the embodiment defined in claim 57, which prevents penetration by vapour, thereby helping to maintain the functional capacity of the construction elements.
[0048] Also of advantage are the embodiments defined in claims 58 and 59, whereby a continuous force- and/or moment-transmitting connecting region is produced between several construction elements joined to one another in the longitudinal and/or transverse direction to make up a roof panel or an end-to-end support, for example.
[0049] As a result of the embodiment defined in claim 60, the construction elements are provided with a wear-resistant surface capable of withstanding high loads.
[0050] The embodiments defined in claims 61 to 63 also offer advantages because they afford a simple means of manufacturing a unit of any volume which can be used in a whole range of applications.
[0051] As a result of the embodiment defined in claim 64, supply lines can be run in the free spaces left between the spacing elements, in particular water pipes, power lines, etc. Furthermore, these free spaces or ducts can be used for venting and/or air conditioning functions.
[0052] The embodiment defined in claim 65 enables a support-type construction element to be produced with a low material requirement.
[0053] Claims 66 to 68 increase the load-bearing capacity of the webs and hence the construction element.
[0054] Also of advantage is the embodiment defined in claim 69, because the fact that a plurality of closed, air-tight cavities or chambers are distributed across the facing surface of the construction elements means that when mounted, especially in an inclined mounting position, the material with which they are packed will not sag and impair the intended property as a result. Another advantage of this is that the materials are contained in the air-tight, closed cavities or chambers and therefore remain unaffected by external environmental influences, which makes the construction elements more durable and resistant and further enhances the resistance of the construction element to fire as a result.
[0055] As a result of claim 70, vapour valves, etc., are provided so that any pressure which builds up in the cavities, particularly under the effect of sunshine or in the event of high temperature differentials, can be adjusted to atmospheric pressure, since the cavities are air-tight relative to one another in their longitudinal extension but are permeable to vapour.
[0056] Also of advantage is the embodiment defined in claim 71, since an endless, dimensionally stable construction element with a large surface area can be assembled from a plurality of construction elements, and the construction elements to be joined to one another are also capable of absorbing high tensile and/or compression forces in a joint region without causing inadmissible shifting between the construction elements in a vertical and/or horizontal direction.
[0057] Also of advantage is an embodiment of the type defined in claim 72, because a recess and/or projections are provided in the construction elements, particularly in the cover layer, so that construction elements to be joined to one another can be held in position relative to one another and mutually joined in a positive and non-positive connection.
[0058] Also of advantage are the embodiments defined in claims 73 and 74, as a result of which any slight shifting which might have occurred between two mutually positioned construction elements when subjected to high loads, in particular thrust forces, can be absorbed by the mutually inclined supporting and/or joining surfaces without giving rise to stress or breaking inside the construction element due to thrust forces in the transverse direction.
[0059] As a result of the embodiment defined in claim 75, the load acting on the flat construction element is transmitted to several other construction elements joined to it and, because of the load distribution, the construction elements can be designed with a lower height and wall thickness, thereby obtaining a lower component weight.
[0060] The objective of the invention is also achieved by the features defined in claim 76. The features set out in the characterising part have a surprising advantage because the fibres of the individual layers are oriented to optimise the flow of forces, which means that the loads to be absorbed can be distributed in the best possible way across the entire construction element in the longitudinal and/or transverse direction, significantly increasing load capacity. The continuous flow of forces in the cover layers and/or spacing elements enables the construction elements to be made with thin wall thicknesses for larger span widths or lengths.
[0061] The embodiment defined in claim 77 provides a lightweight construction element capable of withstanding high loads.
[0062] Also of advantage is the embodiment defined in claim 78, since it enables a load-transmitting construction element to be made in a simple structure with a small number of layers incorporating fibres individually oriented in different or crossing directions, which is capable of withstanding longitudinal and/or transverse bending and/or twisting, in which at least one bundled layer absorbs the transverse distribution of loads acting from outside, whilst the other bundled layer is able to absorb a high proportion of tensile and compression forces in the board plane.
[0063] The embodiment defined in claim 79 is of advantage, enabling a simple production method to be used and requiring little in way of complex machinery. Another advantage is the fact that there is no need for the sections of veneer to provided with laps and any irregularities in the layers are avoided.
[0064] In claim 80, the full-surface overlap of the joint region enables several plies or layers to be joined within a cover layer and/or a spacing element, rendering it capable of withstanding high tension or compression. Offsetting and overlapping the individual layers and plies reduces the cross-sectional region to the maximum.
[0065] Also of advantage is an embodiment of the type defined in claim 81, which, on the one hand keeps production complexity to a minimum, and, on the other hand enables full use to be made of the entire nett cross section, due to the overlap of the preferably adjoining veneer sections, as a means of transmitting tensile forces in the longitudinal direction of the construction element.
[0066] As a result of the embodiment defined in claim 82, the construction elements can be adapted to cater for different physical requirements and applications.
[0067] Use of the self-supporting and load-transferring construction element as a roof element, as described in claim 83, means that it can be supported or seated directly on the gable walls and/or dividing walls, thereby avoiding extra work and costs for building the roof truss.
[0068] Finally, the objective is also achieved by the present invention as a result of the features defined in claim 84. The surprising advantage of the features defined in the characterising part is that the construction element has a high load-bearing capacity in several spatial directions in spite of having a relatively thin-walled structure because the load can be distributed uniformly. An additional advantage is the fact that the transmission of transverse forces in the width direction of the construction element is also enhanced, thereby preventing the webs from tilting if the construction elements are mounted in an inclined position.
[0069] The invention will be explained in more detail with reference to examples of embodiments illustrated in the appended drawings. Of these:
[0070] FIG. 1 is a highly simplified, schematic diagram showing a perspective view of a construction element proposed by the invention;
[0071] FIG. 2 is a highly simplified, schematic diagram showing a plan view of part-regions of two construction elements joined to one another;
[0072] FIG. 3 is a highly simplified diagram showing a perspective view of a part-region of the construction element proposed by the invention;
[0073] FIG. 4 is a highly simplified, schematic diagram showing a plan view of a part-region of the construction element;
[0074] FIG. 5 is a highly simplified, schematic diagram showing a perspective view of another embodiment of the construction element proposed by the invention;
[0075] FIG. 6 is a highly simplified, schematic diagram showing an end-on view of another embodiment of the construction element proposed by the invention;
[0076] FIG. 7 is a highly simplified, schematic diagram showing another embodiment of the construction element proposed by the invention with a plan view of the core layer;
[0077] FIG. 8 is a highly simplified, schematic diagram showing a perspective view of several mutually joined construction elements;
[0078] FIG. 9 is a highly simplified, schematic diagram showing an end-on view of another embodiment of the construction element proposed by the invention;
[0079] FIG. 10 is a highly simplified, schematic diagram showing an end-on view of another embodiment of a construction element proposed by the invention;
[0080] FIG. 11 is a highly simplified, schematic diagram showing an end-on view of the construction element proposed by the invention;
[0081] FIG. 12 is a highly simplified, schematic diagram showing an end-on view of another embodiment of the construction element proposed by the invention;
[0082] FIG. 13 is a highly simplified, schematic diagram showing an end-on view, in section, of another embodiment of the construction element proposed by the invention;
[0083] FIG. 14 is a highly simplified, schematic diagram showing a front view, in section, of a part-region of the construction element in which the cover layer or spacing element has the structure proposed by the invention;
[0084] FIG. 15 is a highly simplified, schematic diagram showing a front view, in section, of another embodiment of the structure of the cover layer or spacing element;
[0085] FIG. 16 is a highly simplified, schematic diagram showing a perspective view of the construction element proposed by the invention;
[0086] FIG. 17 is a highly simplified, schematic diagram showing a side view of the construction element in section along line XVII-XVII indicated in FIG. 16;
[0087] FIG. 18 is a highly simplified, schematic diagram, in section, showing a joining region for the spacing element and a part-region of the cover layer and the spacing element;
[0088] FIG. 19 is a highly simplified, schematic diagram showing an end-on view of a spacing element torn out from the cover layer intended to illustrate the clawing effect between the spacing element and the cover layer;
[0089] FIG. 20 is a highly simplified, schematic diagram showing a side view, illustrating an example in which the construction element is used as a wall and ceiling element;
[0090] FIG. 21 is a highly simplified, schematic diagram showing a perspective view of an example of a production line for producing the construction element proposed by the invention;
[0091] FIG. 22 is a highly simplified, schematic diagram showing a side view of an example of a production line for producing the construction element proposed by the invention.
[0092] Firstly, it should be pointed out that the same parts described in the different embodiments are denoted by the same reference numbers and the same component names and the disclosures made throughout the description can be transposed in terms of meaning to same parts bearing the same reference numbers or same component names. Furthermore, the positions chosen for the purposes of the description, such as top, bottom, side, etc relate to the drawing specifically being described and can be transposed in terms of meaning to a new position when another position is being described. Individual features or combinations of features from the different embodiments illustrated and described may be construed as independent inventive solutions or solutions proposed by the invention in their own right.
[0093] FIGS. 1 to 4 are highly simplified, schematic diagrams showing various views of a flat, self-supporting, dimensionally stable construction element 1, as proposed by the invention. The flat, self-supporting and/or load transferring and torsion-resistant construction element 1, which is made at least partially from wood or wood material, specifically forms a multi-layered panel board, which may be used as a roof element and/or a wall element and/or a floor element and/or a ceiling element, etc. The fact that the construction element has a high torsional strength means that fragile materials and substances may be placed on it. In the embodiment illustrated as an example here, a width 2 constitutes the distance between two mutually parallel longitudinal end faces 3, extending perpendicular to width end faces 5 spaced apart from one another by a length 4.
[0094] A height 6 measured perpendicular to the width 2 represents the distance, in this particular example of an embodiment, between two mutually parallel single-or multi-ply cover layers 7, between which another layer, in particular a core layer 11, is disposed across a height 9. A height 12 of the construction element 1 is made up of the sum of the height 6 of side walls 13 and thicknesses 14 of the cover layers 7. The board-shaped cover layers 7, which for practical purposes may be flat, grooved and/or polished and optionally made from several layers as applicable, form, together with facing surfaces 15a directed towards one another, a joining surface 16a for the core layer 11 disposed between them. Mutually facing width end faces 17 of the side walls 13 disposed perpendicular to the facing surface 15a adjoin the width of the core layer 11, in which case the core layer 11 in the embodiment described in this particular example adjoins at least certain regions of the width end face 17.
[0095] Strip-shaped spacing elements of a single-ply or multi-ply structure, preferably made from wood, space the cover layers 7 apart from one another by a height 6 and provide mutual support for them. In the direction of the length 4, the spacing elements 18, which are preferably disposed perpendicular to the cover layers 7, form one or more wave-shaped or meandering webs 19 spaced at a distance apart from one another in the direction of the length 4 and/or width 2, extending on the basis of a periodically recurring constant function or curve, the amplitude of which as measured in the direction of the width 2 may be of the same or different values or variables in the direction of the length 4. Naturally, the spacing elements 18, the length of which is greater than the length 4 of the construction element 1, may also extend substantially parallel with the cover layers 7, so that peaks 20 are supported on the facing surfaces 15a of the cover layers 7 directed towards one another. In a preferred embodiment—as illustrated in FIG. 1—at least two mutually parallel spacing elements 18, in particular webs 19, are offset from one another by a half wavelength, which may optionally be mutually supported in the unloaded state or may not be so until load is applied, so that they overlap or are in contact with one another, in particular in a linear arrangement, at a tangent in the region of peaks 20, at least at certain points. Since the webs 19 are mutually supported, high transverse forces can be absorbed. Between two successive peaks 20, the mutually parallel webs 19 offset from one another by a half wavelength enclose, optionally on all sides, an airtight but vapour-permeable cavity 21 or chamber. The flat construction element 1, in particular the composite board, therefore has a plurality of cavities 21 or chambers separated by contact regions 22. For practical purposes, the part-regions of two mutually facing width end faces 23, 24 of the webs 19 are in tangential contact and may be roughened if necessary. The cavities 21 or chambers may naturally also be lozenge-shaped. Optionally, the spacing elements 18 may be arranged spaced apart from one another so that they do not mutually support one another until placed in the loaded state or they are biassed towards one another in the longitudinal direction and/or transverse direction of the construction element 1.
[0096] By preference, an opening width 25 between two mutually facing webs 19 in the direction of the width 2 is between 200 mm and 700 mm, preferably between 300 mm and 500 mm, and hence smaller than a longitudinally oriented opening width 26 in the longitudinal direction between two consecutive contact regions 22, which are between 800 mm and 3000 mm, preferably between 1000 mm and 1400 mm. A thickness 27 of the webs 19 is between 4 and 20 mm, preferably between 8 and 12 mm, and is preferably the same size as or bigger than the thickness 14 of the cover layer 7, which is between 2 and 20 mm, preferably between 5 and 10 mm. Opposing narrow end faces 28 of the webs 19 directed towards the facing surfaces 15a of the cover layers 7 and preferably having a width the same size as or bigger than the thickness 27 of the spacing elements 18 are joined to the facing surface 15a or joining surface 16a of the cover layers 7, at least in certain regions, in a positive and/or non-positive fit, in particular are adhered in a form fit or adhered to one another in a butting arrangement. A thickness 29 of the straight webs 30 or side walls 13, which is between 5 and 40 mm, preferably between 20 and 35 mm, is smaller than or the same size as or bigger than, preferably bigger than, the thickness 27 of the webs 19.
[0097] The self-supporting construction element 1 comprising two or more spatially deformed and/or multi-ply cover layers 7 is joined together by several spacing elements 18 distributed across the facing surfaces 15a of the cover layers 7, in a positive and/or non-positive connection, at least in certain regions. The fixing points between the spatially deformed spacing elements 18 and the cover layers 7 are arranged at points spaced at a distance apart from one another in the longitudinal direction of the spacing elements 18 and spaced at a distance apart from one another in the direction running transversely to the longitudinal direction, the distance being greater than the thickness 27 of the spacing elements 18 and the spacing elements 18 being supported and displaceably joined in a load-transmitting arrangement, at least in part-regions, to transmit force to adjacent spacing elements 18.
[0098] The spacing elements 18 may optionally not be placed in the mutually supported and load-transmitting state until load is applied, in which case they will remain at a slight distance from one another in the unloaded state.
[0099] In order to enlarge the joining surface 16b of the spacing elements 18, they may have a strip in the direction of their height 9 at both their mutually opposite peripheral regions, at least over a part of the length of the spacing elements 18, which is joined to the width end face 23; 24 of the spacing elements 18.
[0100] The ratio of the opening widths 25 disposed transversely to the longitudinal direction to the opening widths 26 disposed in the longitudinal direction is between 1:2 and 1:4, preferably between 1:3.33 and 1:3.5.
[0101] The major advantage of the self-supporting and load-transferring, lightweight construction element 1 primarily resides in the fact that the amount of wood needed to make the cover layers 7 and spacing elements 18, which are preferably made from wood and/or wood materials, in the case of the cover layers 7 with a minimum span width or length 4 of 6 m, is less than 0.04 m3/m2 facing surface 15a; 15b, preferably between 0.01 and 0.035 m3/m2 facing surface 15a; 15b, and the amount of wood used for the strip-shaped spacing elements 18, in particular for the webs 19; 30 and/or side walls 13, is between 0.0015 and 0.01 m3/m2 of the total construction element 1.
[0102] Taking an example, if the thickness 27; 29 of the spacing elements 18, in particular the spatially deformed or corrugated or non-flat webs 19, is 12 mm and the straight webs 30 or side walls 13 are 30 mm for a height 6; 9 of the side walls 13 or web 19 of 140 mm, the amount of material needed will be approximately 0.00826 m3/m2. Consequently, the amount of material needed for the non-flat webs 19 with an opening width 25 of 400 mm and a height 9 of 140 mm, will be approximately 0.005 m3/m2 and the amount of material needed for the straight webs 30 will be approximately 0.0033 m3/m2. Naturally, the thickness of the side wall 13 may be of dimensions other than the thickness 27 of the webs 19; 30.
[0103] The total material requirements in terms of wood and/or wood materials for a thickness 14 of the cover layers 7 of 6 mm is approximately 0.0203 m3/m2. This is based on two straight side walls 13 or webs 30 and seven spatially deformed or non-flat or corrugated webs 19, where the construction element 1, which is positioned by the two oppositely lying end regions and in the centre and thus forms several part-regions between contact points, has a length 4 of 12 m and a width 2 of 2500 mm.
[0104] The following functional relationships form the basis for the calculation:
[0105] m2 non-flat web/m2 construction element=(height of the spacing elements*1 metre length*number of non-flat webs*1.06):(width of the construction element*1 metre length)
[0106] m2 straight web/m2 construction element=(height of the spacing elements*1 metre length*number of straight webs):(width of the construction element*1 metre length)
[0107] m3 non-flat web/m2 construction element=(height of the spacing elements*1 metre length*number of non-flat webs*thickness of the webs*1.06):(width of the construction element*1 metre length)
[0108] m3 straight web/m2 construction element=(height of the spacing elements*1 metre length*number of straight webs*thickness of the webs):(width of the construction element*1 metre length).
[0109] In this example, the straight webs 30 are used as side walls 13.
[0110] The amount of material in terms of wood and/or wood material needed for this example is broken down as follows.
[0111] The total volume or spatial volume for the part-length of a part-region of 6 m is approximately 0.152 m3/m2.
[0112] The non-flat webs 19 require 3.2%, the straight webs 30 approximately 2.1%, the cover layers 7 approximately 7.8% of the total volume or spatial volume, which means that the volume of the core layer 11 accounts for approximately 92%.
[0113] Naturally, it would be possible to opt for any structural design, depending on static requirements.
[0114] The self-supporting, dimensionally stable construction element 1 with one or more cover layers 7 has several spatially deformed spacing elements 18 distributed across the facing surfaces 15a of the cover layers 7 which are joined to at least certain regions of the cover layers 7 in a positive and/or non-positive arrangement and form the core layer 11, which is made up of strip-shaped and non-flat spacing elements 18, the core layer 11 accounting for between 50% and 98% of the volume of the construction element 1. The spacing elements 18 distributed across the facing surface 15a of the cover layer 7 require between 10% and 50% of the material volume of the construction element 1, and the narrow end faces 28 of the spacing elements 18 directed towards the facing surfaces 15a are aligned substantially parallel with the facing surface 15a of the cover layers 7.
[0115] It should be pointed out that the construction element 1, in particular the cover layers 7 and/or the webs 19; 30 may also be made from a metal or non-metal material and/or a plastics reinforced with glass fibre.
[0116] Naturally, another option would be to space the preferably curved or arcuate webs 19, which are arranged offset or in identical phase extending mutually parallel, at a distance from one another in the direction of the width 2 and hence in the longitudinal direction of the construction element 1, thereby forming several cavities 21 or chambers bounded by wave-shaped webs 19 and/or straight webs 30 or side walls 13 extending adjacent to one another.
[0117] The webs 19; 30 and/or the webs 19 and the side walls 13 may also be joined to one another in the region of the peaks 20 or the contact regions 22, optionally in a positive and/or non-positive join.
[0118] FIG. 2 is a highly simplified, schematic diagram showing a plan view of several construction elements 1. The webs 19 having a thickness 29, which are spaced at a distance apart from one another in a mutually offset arrangement, adjoin, in a linear arrangement in at least certain regions, the width end face 17 of the side walls 13 and/or width end face 23; 24 of the straight web 30, which is designed to have a thickness 29 matching the distance.
[0119] If a distance is kept free between two adjacent spacing elements 18, a resulting cavity or duct formed by the distance between them may be used for circulating media, such as used in air-conditioning or venting functions.
[0120] The web 30 or side wall 13 and the wave-shaped curved web 19 bound the cavity 21 or chamber. Naturally, it would also be possible for the mutually adjoining wave-shaped webs 19 to be extend parallel with one another in an identical phase or shifted in phase and at a distance apart from one another. One or more webs 30 may be provided between the webs 19. Naturally, the webs 19 on one or more cover layers 7 and/or the web 30 may be joined to one another in an overlapping or lapping region 22. It would naturally also be possible to provide several non-flat webs 19 between the straight web 30 and/or the side walls 13.
[0121] Several construction elements 1, which may be placed one against the other in a butting arrangement and joined or mounted with one another in a positive and/or non-positive connection in a joining region 32, may be joined by means of one or more joining elements 31 to form a construction element 1 with a large surface area. By preference, these mutually joined construction elements 1, in particular the cover layers 7, have at least one supporting and/or joining surface 34 extending obliquely across the thickness 14 on at least one of the mutually facing terminal end faces arranged on the end-face end regions 33 and/or on the narrow end faces of the cover layers 7. The supporting and/or joining surface 34 preferably extends across the entire width 2 and/or length 4 or may extend across only a part of the width 2 and/or length 4 of the cover layers 7. For practical purposes, one of the cover layers 7 has at least one groove-type recess 35 with at least two inclined converging supporting and/or joining surfaces 34, in which a matching projection on the other construction element projects or locates. A filler and/or adhesive layer is expediently provided between the mutually facing supporting and/or joining surfaces 34 of the two mutually facing construction elements 1 connected to one another. Incorporating joining elements 31 in this manner enables an integral load-transferring construction element 1 to be produced which is capable of withstanding a tensile load and/or has a high bending strength. Naturally, the side walls 13 may also be provided with a joining element 31 to enable overlapping side walls 13 to be joined to one another.
[0122] The webs 19 and/or 30 of the construction elements 1 to be connected to one another may adjoin one another in a butting arrangement in the joining region 32 or overlap or lap to a certain degree, and may be joined in a positive and/or non-positive connection where necessary.
[0123] As may be seen more clearly from FIG. 3, the construction element 1 has an end region 33 with the recess 35 designed to be connected to another construction element 1, into which the projection of the other construction element 1 extends. The spacing elements 18 and/or cover layers 7 of the construction elements 1 adjoining one another in a butting arrangement and/or overlapping or lapping in the joining region 32 form a flat transition between the construction elements 1 to be connected to one another and the positive and/or non-positive connection will enable a force- and/or moment-transmitting joining element 31 to be formed. Naturally, the mutually facing spacing elements 18 and/or cover layers 7 may have laps in the joining region 32. The webs 19 and/or the webs 30 keep the cover layers 7, which are preferably of a multi-ply structure, apart from one another by the height 9, less a depth of receiving grooves accommodating one of the webs 19;30, as will be explained in more detail below. Naturally, it would also be possible for several construction elements 1 to be joined to one another in a positive and/or non-positive join by means of at least one connecting element on the facing surfaces 15b of the cover layers 7 directed towards one another.
[0124] As also illustrated in FIG. 3, the cover layer 7 may be of a multi-ply structure. The cover layer 7 may be made up of intermediate layers 36 arranged between mutually spaced facing layers 37, which are joined to one another with a filler and/or adhesive layer or bonding layer or synthetic resin, for example. The intermediate layer 36 may be made up strips 38 adhered and compressed with one another, made from wood and/or wood materials, or by a sandwich-type component, for example consisting of various types of plastic foams or a corresponding aluminium construction and wood or wood materials and such like.
[0125] Naturally, another possibility would be for the intermediate layer 36 to be made from a prepreg of a type known from the prior art, in particular a fibre-based prepreg or veneer plies overlapping or crossing with one another in the longitudinal direction or in the direction disposed transversely thereto and bonded to one another, disposed in a manner intended to optimise the flow of forces.
[0126] To this end, at least one veneer layer of the cover layers 7 and/or the webs 19; 30 and/or the side walls 13 has at least one lap S in the plane perpendicular to its longitudinal extension and/or in a longitudinal extension of the veneer layer disposed transversely thereto, which matches another lap S to be joined to it. An overlapping or connecting region is formed between the individual layers of veneer as a result. Preferably, the laps extend at a distance apart in the longitudinal direction of the oppositely lying cover layers 7, and therefore butt in an offset arrangement. To provide a clearer view, this is schematically indicated in FIG. 2.
[0127] In another embodiment, not illustrated, several spacing elements 18, in particular webs 19; 30 are provided one after the other in the longitudinal direction of the construction element 1 and adjoin in a butting arrangement or are joined in an at least partially overlapping or lapping layer. For practical purposes, the resultant joining regions are arranged so that they butt offset from one another in the longitudinal direction of the construction element 1, so that there is essentially no breaking point which could occur in joining regions of a same plane. Naturally, the cover layers 7 may also be designed in the same manner.
[0128] Vapour barriers or fibre reinforcements or flame-retardant means, etc., may naturally also be provided between the individual veneer layers. Extending between the facing layers 37, which are expediently of the width 2 and/or the length 4, are strips 38 with a rectangular cross section, the larger cross-sectional dimension of which is preferably aligned in the direction of the thickness 14 of the cover layer 7. The strips 38 extending in the longitudinal direction and/or in the transverse direction of the cover layer 7 are joined to the facing layers 37, in particular are adhered thereto. The facing layers 37 overlapping with or lapping the narrow ends of the strips 38 impart a high bending and tensile strength to the cover layer 7, and providing one or more strips 38 of metal and/or plastics will further enhance the bending strength in the longitudinal and/or transverse direction.
[0129] As schematically indicated, the spacing elements 18, in particular the webs 19 and/or 30 may comprise several layers, in which case one or more intermediate layers 40 may be provided between facing layers 39, and may be provided as wood and/or wood materials or plastic resins and/or filler or adhesive layers or bonding layers of plastic foams or aluminium constructions or similar. Naturally, it would also be possible for the cover layers 7 and/or the webs 19 and/or 30 to be made from laminated boards or compression-moulded plywood or compression moulded chipboard with or without reinforcing or made from metal, for example.
[0130] The mounting groove 41 counter-sunk into at least one of the mutually facing width end faces 17 of the cover layers 7 positions and retains the webs 19 and/or webs 30 projecting into the mounting grooves 41 in the longitudinal extension and/or in a direction extending transversely thereto. Accordingly, the cross-sectional contour of the webs 19 and/or webs 30 matches the cross-sectional contour of the mounting grooves 41 and a width of the receiving grooves 41 is purposely of slightly larger dimensions than a thickness 27 or 29 of the webs 19 or 30 and sealing compound etc., is packed into the hollow pockets left as a result of the difference in the width and thickness dimensions 27; 29 or a plastics compound can be introduced to retain the positioning of the webs 19; 30. Naturally, the mounting groove 41 may also be designed as a snap-fit groove.
[0131] FIG. 4 provides a highly simplified, schematic diagram showing a plan view of another embodiment of the construction element 1. Extending in the longitudinal direction between the two oppositely lying side walls 13 are several webs 19 and webs 30, a straight web 30 being arranged between at least two webs 19 mutually offset from one another by a half wavelength. The subsequent or adjacent wave-shaped web 19 directly adjoins the preceding wave-shaped web 19 so that wave-shaped webs 19 or wave-shaped and linear webs 30 border with one another. At least one of the cover layers 7 has another layer 43 which is joined by a filler or adhesive layer 42 to the facing surface 15b of the cover layer 7 remote from the core layer 11, in particular in the form of a protective plate 44, which is made from an inflammable or flame-retardant material, in particular a mineral. Naturally, the protective plate 44 may also be provided with a flame-retardant coating. The inflammable or flame-retardant protective plate 44, optionally with an inflammable or flame-retardant coating, is joined to the cover layer 7 by means of a flame-retardant adhesive. Another possibility would be for the layer 43 to be provided in the form of a mineral wool, for the purposes of heat insulation for example, or from a plastics, such as an expanded polystyrene foam, or veneer layers or metal materials or radiation-deflecting materials, such as lead, for example.
[0132] The protective plate 44 may also be made from an inflammable material but which expands and provides insulation in the event of a fire, for example potassium silicate or sodium silicate. Naturally, the layer 43 could also be provided in the form of a cladding, such as a decorative board, for example, or as a film made from plastics or a film of composite of plastics or aluminium or tin or a layer of veneer or water-repellent material, in particular impregnated material.
[0133] Another option would be to integrate elements for making use of solar energy, in particular accumulators or photovoltaic cells.
[0134] FIGS. 2 and 4 illustrate examples of embodiments with regard to various arrangements of the webs 19; 30 between the two oppositely lying, preferably mutually parallel side walls 13. Naturally, the webs 19, as illustrated, may also extend in a mutually parallel arrangement in identical phase and/or several webs 19 may be mutually offset by the half wavelength and combined with other webs 19 extending in the same phase alignment, between which linear webs 30 may be provided, at least in certain regions. The webs 19; 30 and/or the side walls 13 and/or the cover layers 7 may be joined to one another in a positive and/or non-positive connection, in particular adhered, bonded, stapled, etc.
[0135] FIGS. 5 and 6, which will be described together, provide highly simplified, schematic diagrams showing end-on views of other embodiments. The construction element 1 illustrated in FIG. 5 essentially has the cover layers 7 with the width 2 and the length 4, the side walls 13 bounding the width 2 and the spacing elements 18, in particular the webs 19 and/or 30 forming the height 9. The webs 19; 30 extending between the cover layers 7 extend in the direction of the length 4 and/or the width 2 of the construction element 1, in the same way as the other embodiments and may be made up of different layers. One of the two single-ply or multi-ply spatially deformed cover layers 7 has a curved, in particular a concave cover layer 7 directed towards the other board-shaped cover layer 7. Naturally, the cover layer 7 lying opposite the flat cover layer 7 may form a convexly curved cover layer 7 in the direction facing away from it or both oppositely lying, mutually parallel cover layers 7 may have a convex or concave curvature of the same dimensions so as to form a substantially arcuate segment. This enables three-dimensional bodies or construction elements 1 to be made in a whole range of embodiments. By preference, the spacing elements 18 are adhered to the cover layers 7 by compression, which will increase their load capacity. The requisite individual construction elements parts can expediently be made by CNC-controlled machinery keeping production costs low.
[0136] If one of the two oppositely lying heights 9 of the core layer 11 or the height 12 of the construction element formed by the height 9 and the thicknesses 14 of the cover layers 7 is substantially greater than a height 9 lying opposite it, a construction element 1 of this type can be made by applying a wear-resistant plastics lining on the facing surface 15b of the cover layer 7 remote from the core layer 11, for example a skateboard track, which, once the cavities 21 or chambers have been filled with material, in particular recycled material, plastics material or similar, will firstly impart a damping action and secondly help to minimise noise by damping sound waves.
[0137] In another embodiment illustrated in FIG. 6, at least one of the cover layers 7 or side walls 13 extends at an angle to the oppositely lying cover layer 7 or side wall 13 in the longitudinal direction and/or in a direction of the construction element 1 disposed transversely thereto and forms a support element for a support structure, for example.
[0138] Accordingly, at least one cover layer 7 extending between the side walls 13 runs at an angle to the cover layer 7 lying opposite it. Naturally, however, it would also be possible for both cover layers 7 to taper towards one another or to extend parallel with one another. Extending between the cover layers 7 parallel with the side walls 13 are the webs 19; 30, the height 9 of which will depend on the angular contour constantly decreasing in the direction towards the shorter height 6 of the side wall 13.
[0139] Naturally, it would be possible for the cover layers 7 and/or the side walls 13 and webs 19 and/or 30 to be of any geometrical or structural design in terms of their layout. For example, the construction element 1 may have a substantially trapezoid-shaped cross section or square or rectangular cross section in a plane perpendicular to its longitudinal extension, the cross-sectional dimensions of which may increase or decrease in the longitudinal extension.
[0140] FIG. 7 is a highly simplified, schematic diagram showing a plan view of another embodiment. The spacing elements 18 are formed by a plurality of cells 45, the walls 46 of which may be made from wood or wood materials or metal, etc., preferably aluminium, extending at a right angle to the facing surface 15a of the cover layer 7 in the direction of the cover layer 7 lying opposite. The cells 45 have a four-cornered and/or hexagonal honeycomb structure, the walls 46 of which have partially single as well as double-walled dividing walls 47, which are joined to one another, in particular are adhered or welded to one another. The side walls 13 and/or dividing walls 47 bound closed, airtight cavities or chambers 21, which may optionally be filled with inflammable or flame-retardant material and/or heat insulating material.
[0141] FIGS. 8 to 13, which will be described together, show different views of a construction element 48 as proposed by the invention. The construction element 48 is formed by one or more construction elements 1 which overlap in at least certain regions. The construction element 1 essentially has the cover layers 7 with the width 2 and the length 4, the side walls 13 bounding the width 2 and the spacing elements 18 of a height 9, in particular the webs 19 and/or 30 and/or the cells 45. As with the other embodiments, the cavities 21 or chambers of each of these embodiments may be provided with noise insulating, heat insulating, inflammable or flame-retardant material, as schematically indicated. The width end faces 5 bound the height 12, and the height 12 in the longitudinal direction of the construction elements 1 may vary in dimensions.
[0142] Although not illustrated in detail, one or more construction elements 1 may be joined to another with a bonding adhesive or a support structure etc., in the form of a primary structure.
[0143] As may be seen more clearly from FIG. 8, the construction element 48 is of a multi-layered design and is made up of at least two construction elements 1 placed one on top of the other joined in a positive and/or non-positive connection and offset from one another in the direction of the width 2 and/or length 4. The multi-layered construction elements 48 placed one behind the other and/or adjacent to one another overlap in a joining region 49, where the construction elements 48 can be joined to one another in a positive and/or non-positive connection by their mutually facing longitudinal end faces 3 and/or width end faces 4 and/or the outer mutually facing, overlapping facing surfaces 15b of the cover layers 7. Naturally, the joining region 32 may be provided in the region of the longitudinal end face 3 for connecting several construction elements 48. By preference, the oppositely lying construction elements 1 on either side of the construction element 48 directed towards the standing surface 50 sit against one another in a butting arrangement. A filler or adhesive layer is provided between the mutually facing longitudinal end faces 3 and/or width end faces 4 and/or on the facing surfaces 15b of the cover layers 7 directed towards one another, which joins the two construction elements 48 to one another in a positive fit. The mutually facing construction elements 1 of the construction elements 48 lying opposite the standing surface 50 are preferably arranged at a slight distance apart from one another so that when the two construction elements 48 are placed against one another and joined, a distance or an elastic expansion joint is formed and any manufacturing tolerances, such as angular errors, etc., will not affect a liquid-tight connection of the construction elements 48 to be jointed to one another on the standing surface 50. The construction elements 1 may optionally also be joined to one another by the mutually facing, overlapping width end faces 5 or facing surfaces 15b in the joining region 49. Any stress which occurs as a result of temperature differences can also be compensated. A flat element with a large surface area, in particular a floor element or wall element or roof element, can be made up by aligning several construction elements 48 in a row.
[0144] The construction elements 1 could naturally also be disposed offset from one another in the direction of their length 4 and/or width 2. Another option would be for the construction element 1 directed towards the standing surface 50 to project beyond the construction element 1 lying opposite the standing surface 50 at the two oppositely lying longitudinal end faces 3 and/or the terminal-side end region 33.
[0145] As schematically illustrated, it would also be possible to use substantially I-shaped spacing elements 18, made from wood or more preferably extruded sections made from plastics, etc., comprising essentially symmetrical U-shaped web sections remote from one another with a common upstanding web and transverse webs. Between the upstanding web and the transverse webs, an arcuate transition region of a large dimension extends across the height 9 of the spacing elements 18. A chamber disposed between the oppositely lying transverse webs is used to accommodate adhesive, in particular a water-resistant adhesive, thereby increasing the size of the joining surface 16b.
[0146] As may be seen in particular from FIGS. 9 and 10, the cavities 21 or chambers are at least partially filled with heat-insulating and/or noise-insulating and/or flame retardant and/or inflammable fillers 51, which may have a whole range of properties or characteristics. The cavities 21 or chambers between the spacing elements 18 are bonded to the cover layers 7 so as to be closed on all sides, rendering them airtight but permeable to vapour. Providing a plurality of cavities 21 or chambers firstly ensures that a planar distribution of load imparts to the construction element 1 a high resistance to thrust and secondly splits the filler 51 up into segments. The filler 51 may be a free-flowing material, organic or inorganic substances, in particular chips, cellulose, etc., or inflammable rock wool or plastics or recycled materials, etc. Splitting it up into segments primarily prevents settlement, such as would otherwise occur if the construction elements 1 or 48 were mounted in an inclined or vertical mounting position. An optimum heat transfer can be obtained by providing a plurality of layers of fillers 51 with a different heat conduction coefficient. Naturally, the filler 51 may also be reinforced with fibre.
[0147] As illustrated in FIG. 10, the cavity 21 or chamber may also be only partially packed with fillers 51, in which case a static layer of air will form in the space left free between the surface of the filler 51 and the facing surface 15a. As a result, the filler 51 is not directly and constantly exposed to changing environmental conditions and the effectiveness or properties of the filler 51 will not be adversely affected.
[0148] As may be seen more clearly from FIG. 11, several construction elements 1 may also be arranged one on top of the other, in which case at least one additional construction element 1 may be disposed between two outer construction elements 1, for example, with at least one longitudinal end face 3 and/or width end face 4 projecting beyond at least one of the outer construction elements 1. This will enable several construction elements 1 to be joined by slotting them into one another. Naturally, at least one construction element 1 in this embodiment could also have cavities 21 or chambers which may be entirely or partially packed with the filler 51.
[0149] FIGS. 12 and 13 illustrate two other embodiments, in which the cavities 21 or chambers are completely or partially packed with fillers 51.
[0150] As illustrated in FIG. 12, webs 19; 30 spaced at a distance apart from one another in at least one construction element 1 are used for circulating a medium, in which case it may not be necessary to provide an additional vapour barrier in the filled construction element 1. The other construction element 1 arranged on top will further enhance the load-bearing capacity. By providing a cover layer 7 that will promote diffusion, for example by providing continuous orifices through the cover layer 7 or using materials designed to promote diffusion, a medium may be circulated through one of the two construction elements 1. Extra work during manufacturing can be avoided by additionally providing or applying a coating or adhered vapour barrier to the construction element 1. Another option would be to circulate a medium through the orifices or diffusion-promoting materials between several filled or non-filled construction elements 1.
[0151] As also illustrated in this drawing, the spacing elements 18 may have at least one facing layer 39 and at least one intermediate layer 40. The intermediate layer 40 is made up of several longitudinal strips extending in the longitudinal direction between the oppositely lying facing layers 39 of the spacing elements 18 arranged at a distance apart from one another. These are expediently spaced apart from one another in the direction of the height 9 and joined to the facing layers 39, a longitudinal strip being provided in the end regions directed towards the cover layers 7. The advantage of this is that it increases the size of the joining surface 16b on the one hand and ensures an improved thermal effect on the other.
[0152] FIG. 13 illustrates another embodiment, in which at least one construction element 1, in particular the cover layers 7, form a defined melt-down zone 52, the material composition of which is defined by the required period of resistance to fire. This flame retardant defined melt-down zone 52 may be made from a metal or organic or inorganic material, for example. This naturally includes all materials which give off water at higher temperatures, for example such as aluminium hydroxide, alkali metal salts of silicates, hydrated phosphates, hydrated borosilicates, etc. For practical purposes, the strength-enhancing core layers 11 are also made from flame retardant or inflammable materials and fillers 51, and may incorporate various different components or substances. The particular advantage of this embodiment is that once the defined melt-down zone 52 of the construction element 1 has burned, the tensile and/or compression forces can be still be transmitted by the construction element 1 because it still has a residual load-transmitting capacity. As may be seen from the individual drawings, the spacing elements 18 in the same cross-sectional plane of construction elements 1 arranged one above the other may overlap with one another in the direction of the width 2 or be arranged offset from one another, which primarily leads to improvements in thermal properties.
[0153] Naturally, the construction element 1 may simultaneously have at least some of the cavities 21 or chambers that are packed with fillers 51 to provide a noise-insulating and/or heat-insulating core layer 11, which will assume air conditioning and/or venting functions, and/or the defined melt-down zone 52.
[0154] By preference, the webs 19 and/or 30 forming the spacing elements 18 in the longitudinal direction and/or in a direction disposed transversely thereto may be provided in the form of mutually overlapping veneer layers or board laminations adhered to one another, etc. Naturally, vapour barriers of aluminium or plastics films or fibre reinforcements or flame retardants or heat-insulating materials and/or metal substances, etc., may also be disposed between the individual veneer layers. The spacing elements 18 are adhered to the cover layers 7, in particular the joining surface 16a thereof, in a butting arrangement and/or adhered in a form-fitting arrangement by means of the receiving groove 41. The cover layers 7 may naturally be provided in the form of boards known from the prior art, such as fibre boards, for example, in particular medium-density fibre boards of MDF, or OSB or plyboard or compact boards or coated chipboards or sandwich boards, etc. Spacing elements 18 of several construction elements 1 that are to be joined to one another may naturally be provided with a lap and/or a dovetail arrangement, enabling an endless construction element to be produced.
[0155] Finally, it should be pointed out that the cavities 21 or chambers, which are air-tight but permeable to vapour, are provided with an orifice having an air-impermeable membrane or vapour valve, so that any pressure building up in the chambers, particularly when exposed to the sun's rays or high temperature differences, can be kept at atmospheric pressure. For practical purposes, the oppositely lying end regions 33 of a construction element 1 or, in the case of several construction elements 1 joined to one another, the end region 33 of the first construction element 1 and the end region 33 of the last construction element 1, is provided with at least one closing strip, in which at least one air-impermeable membrane or vapour valve is disposed so that the vapour pressure can escape through the membrane or vapour valves in the longitudinal direction of the construction element 1. Vapour permeability can be achieved by means of mutually spaced spacing elements 18 and/or by vapour permeable spacing elements 18 or cover layers 7.
[0156] FIGS. 14 and 15, which will be described together, are highly simplified, schematic diagrams seen in section from a side view, showing a part-region of the construction element 1. The cover layers 7 consisting of several layers 53; 54 are mutually spaced apart by the height 9 of the spacing elements 18, in particular the webs 19; 30, and constitute the height 12 of the construction element 1. The layers 53; 54, made from wood and/or from a material other than wood and/or wood materials, have two or more plies 55; 56, at least one of the plies 55; 56 incorporating several veneer sections 57; 58 or veneer layers one after the other within a cover layer 7 and/or a spacing element 18 of the construction element 1, and a joining region 59 of a ply 55; 56 formed between the successively arranged veneer sections 57; 58 or veneer layers is overlapped across its entire surface by another ply 55 of the same layer 53 and extending parallel therewith or the ply 56 of the other layer 54. Consequently, the joining regions 59 or butts of the individual plies 55; 56 in the cover layer 7 are arranged offset from one another in the longitudinal direction and/or offset from a butt of the spacing elements 18. The individual plies 55; 56 of the cover layers 7 are of a symmetrical or asymmetrical design relative to the mid-plane of the construction element 1 and joined to one another.
[0157] As may be seen from the drawings, a join 60 is provided extending between the mutually facing end faces, in particular the end side faces, of the veneer sections 57 of the ply 55 and between the mutually facing end faces, in particular the end side faces, of the veneer sections 58 of the play 56. As a result of the multi-layered structure of the cover layers 7 every join 60 of a ply 55; 56 is totally overlapped by another ply 55; 56, which means that there is no need to provide a lap for the individual plies 55; 56, although it would still be possible to provide one.
[0158] The layers 53 directed towards the spacing elements 18, in particular their veneer portions 57 of the individual plies 55 disposed one above the other and in succession, are aligned with a transversely extending fibre direction 61 in the longitudinal direction of the cover layer 7, as a result of which the veneer sections 58 of the other layer 54 overlapping the layer 53, preferably with its entire surface, is disposed with a fibre direction 62 extending substantially parallel in the long extension of the cover layer 7. The longitudinally aligned fibres of the outer layer 54 are able to absorb or transmit tensile forces in particular and the inner layer 53 with fibres extending transversely to the longitudinal direction is able to absorb or transmit compression forces. Consequently, the fibres of the individual layers 53; 54 cross with one another. The outer layer 54 is preferably provided with between two and seven, more preferably between three and five plies 56 of veneer sections 58 arranged one on top of the other, which are joined to one another by mutually facing width end faces 63 of the veneer sections 57 or 58, being adhered in particular. The inner layer 53 is preferably provided with between 1 and 3, more preferably 2 plies 55 of veneer section 57 disposed one on top of the other. As a result of the adhesion across a large surface area at the width end faces 63, it is no longer necessary to join the successively arranged or mutually butting veneer sections 57; 58 to one another at their join 60. Naturally, the layers 53; 54 could be arranged in the reverse order. The individual layers 53; 54 of the two oppositely lying cover layers 7 could, of course, be disposed in any arrangement. The layer 53 and/or layer 54 may be made from strips of wood aligned in the longitudinal direction and/or in the direction disposed transversely thereto, and be joined to one another in the joining region 59 by means of laps or may be arranged lapping or overlapping or by a dovetail arrangement.
[0159] As may be seen from FIG. 15, it is also possible for at least one of the layers 53; 54, in particular the outer layer 54, to be made from a material other than wood, in particular a thin-walled sheet metal 64 or a plastics, the thickness 65 of which is between 0.2 and 1.0 mm, in particular between 0.2 and 0.5 mm. This being the case, the sheet metal 64 may likewise assume the function of the vapour barrier or a roof lining. Naturally, it would also be possible to provide the sheet metal 64 between the layer 53 and the spacing elements 18 and/or between the two layers 53 and 54 and to join it to them, in particular by adhering it. The plies 55; 56 are joined to one another by means of a waterproof and fully cured, irreversible multi-component adhesive, in particular glue.
[0160] The same type of structure that is used for the cover layers 7 may naturally also be used for the spacing elements 18 and side walls 13, in which case the outer facing layers 39 may be formed by veneer sections with fibres extending transversely to the longitudinal direction of the spacing elements 18 and the intermediate layer 40 by several veneer sections with fibres extending parallel with the longitudinal direction of the spacing elements 18. A join 66 is formed between the veneer sections of the plies.
[0161] In another embodiment, not illustrated, the construction element 1 has several, in particular more than two cover layers 7, between which the spacing elements 18 are disposed and joined to the cover layers 7, in which case the two outer cover layers 7 may expediently comprise several layers 53; 54 and the cover layer 7 disposed in between may have one of the layers 53 or 54. The spacing elements 18 between the two cover layers 7 may be disposed in the longitudinal direction and/or in a direction of the construction element 1 disposed transversely thereto or crossing it. If the spacing elements 18 between the two cover layers 7 are disposed in the longitudinal direction, they may extend offset from one another in the widthways direction and/or longitudinal direction.
[0162] The self-supporting and load-transferring construction element 1 proposed by the invention may also be used as a roof element extending between two oppositely lying gable walls and is placed and supported on the gable walls and/or on or more partition walls. The facing surface 15b of the construction element 1 lying remote from the interior of the building may already be fitted with cross-battens for receiving the roof tiles prior to being assembled.
[0163] In another embodiment which might be used for the construction element 1, not illustrated, at least one of the cover layers 7 has at least one diffusion-proof layer 53; 54, in particular layers 55; 56, or at least one other layer 43 disposed on the cover layer 7 and the other cover layer 7 has at least one hygroscopic and/or other layer 53; 54 capable of acting as a liquid barrier, in particular layer 55; 56, which absorbs, stores and/or gives off into the ambient air of the building any condensation which occurs in the core layer 11 of the construction element 1. The diffusion-proof layer 53; 54 or layer 43 may be provided in the form of a film of plastics, aluminium, etc., or using metal materials. For practical purposes, the airtight and force transmitting cover layer 7 directed towards the building interior has openings, pores, etc, which can be sealed off.
[0164] FIGS. 16 to 18, which will be described together, are highly simplified, schematic diagrams showing different views of the self-supporting and load-transferring construction element 1. The construction element 1, which is at least partially made from a wood material, is a multi-ply composite board and may be used as a construction element 1 covering a large surface area, for example as wall, ceiling or floor panels. In this example of an embodiment, the width 2 constitutes the spacing of two longitudinal end faces 3 extending parallel with one another, which extend at a right angle to mutually spaced width end faces 5 extending through the length. The height 6 as measured perpendicular to the width 2 is the spacing between two mutually parallel single-ply or multi-ply cover layers 7, between which the core layer 11 constituting the height 9 is disposed. The height 12 of the construction element 1 is made up of the sum of the height 6 of the side walls 13 and thicknesses 14 of the cover layers 7.
[0165] In the most basic case, although this is not illustrated, the construction element 1 consists of a cover layer 7 and the core layer 11 bounded by the side walls 13. The core layer 11 is made up of strip-shaped spacing elements 18 distributed across the inner facing surface 15a of the cover layer 7. The core layer 11, in particular the spacing elements 18, is or are joined in a positive and/or non-positive join by at least one joining and/or fixing means 70, preferably extending across the entire length of the spacing element 18, by their joining faces 16b directed towards the facing surface 15a to at least part of the facing surface 15a of the cover layer 7. At least one joining region 71 extends across the length 4 of the spacing element 18 between the spacing element 18 and the cover layer 7. To allow for the possibility of adapting the construction element 1 to different applications, several joining regions 71 may be provided—as illustrated in FIG. 16—at points 72 between the spacing element 18 and the cover layer 7 spaced apart from one another in the longitudinal direction of the spacing element 18, in which the joining and/or fixing means 70 are disposed.
[0166] In this example of an embodiment, the cover layer 7, whose thickness 14 is bounded by the inner facing surface 15a and outer facing surface 15b extending parallel with it, is provided in the form of a board 76 consisting of wood or wood material elements 73 in a random spatial arrangement, in particular wood chips and/or wood-type fibre materials, with cavities 75 lying between the wood or wood material elements 73 in at least certain regions and/or having pores 74 at surfaces of the wood or wood material elements 73. Such a board 76 might be a chip board (FPY) or medium-density fibre board (MDF) or laminated-strand lumber board (LSL) or oriented-strand board (OSB), for example. For practical purposes, an OSB coarse chip board is used for the cover layer 7. OSB boards 76 are known from the prior art and are usually constructed as an integral multi-ply board in which the two outer facing layers 37 or facing layer regions are oriented lengthwise and the intermediate layer 36 or the intermediate region consists of transversely oriented coarse wood or wood material elements 73, in particular strands. The thickness of the two outer facing layers 37 of the OSB board may naturally be varied depending on the load to be supported.
[0167] Accordingly, the facing layers 37 or facing layer regions bounding the intermediate layer 36 or intermediate region usually form a part of the thickness 14 of the cover layer 7. Naturally, it would also be possible to provide several layers 36 and/or 37. The thickness of the two outer facing layers 37 or facing layer regions is between 0.3 mm and 8 mm, in particular between 0.5 mm and 2 mm, for example 0.8 mm. This enables the load-bearing capacity in the longitudinal direction or the length 4 of the construction element 1 to be increased or raised significantly. The wood or wood material elements 73 or strands, in particular of the facing layers 36 or the facing layer region of the cover layers 7 have a cross section of approximately 75 mm in length and 0.7 mm in thickness. In another embodiment of the multi-ply OSB board 76, the wood or wood material elements 73 or strands of the facing and middle layer 36, 37 or the facing layer region or intermediate layer region are provided in the form of adhered veneer strips of approximately 120 mm to 350 mm, for example 150 mm in length, which may optionally be waterproof. The distinctive feature of this embodiment is primarily that it prevents any undesirable deformation of the cover layer 7 which might otherwise occur due to moisture for example. Such cover layers 7, in particular of OSB boards, usually contain a high proportion of wood, in particular more than 96%, for example selectively cut wood, and are capable of absorbing high loads in the lengthways and widthways direction because the two outer facing layers 37 are adhered in a cross-wise arrangement to the intermediate layer 36. These boards 76 are also distinctive due to their high resistance to weathering. The thickness 14 of the cover layer 7 is between 8 mm and 14 mm, for example 10 mm.
[0168] As may be seen from FIG. 16, the spacing elements 18 extend in the direction of the length 4 of the construction element 1 and are aligned perpendicular to it on the inner facing surface 15a and the joining surfaces 16b of narrow end faces 28 of the spacing elements 18 extend parallel with the flat inner facing surface 15a of the cover layer 7 receiving the joining surfaces 16a and between them form the joining region 71. Consequently, the inner facing surface 15a receiving the joining surface 16a and the narrow end face 28 receiving the joining surface 16b extend in the same plane and the spacing element 18 and the cover layer 7 are disposed perpendicular to one another and are joined to one another in a butting arrangement. Consequently, there is no need to provide any groove-type recesses to accommodate and support the spacing elements 18 as a means of fixing the spacing elements 18 relative to the cover layer 7.
[0169] The spacing element 18, which is spatially deformed, in particular wave-shaped, in its longitudinal extension, is made from board strips 77 consisting of wood or wood material elements 73, in particular wood strands and/or wood-type fibres, in a random spatial arrangement, with cavities 75 lying between at least certain regions of the wood or wood material elements 73 and/or pores 74 at a surface of the wood or wood material elements 73, in particular a chip board (FPY), medium-density fibre board (MDF) or oriented-strand board (OSB) or laminated-strand lumber board (LSL). For practical purposes, the spacing element 18 is a board strip 77 of a flexural particle board (FPY). Such single-ply, three-ply or multi-ply pressed boards or flexural particle boards are known from the prior art.
[0170] As may be seen from this preferred embodiment, several mutually parallel spacing elements 18 are arranged offset from one another by a half wavelength across the inner facing surface 15a, and turning regions 78 of two mutually parallel spacing elements 18 butt with and mutually support one another. The opening width 26 between two consecutive turning regions 78 as measured in the longitudinal extension of the construction element 1 is between 800 and 3000 mm, in particular between 2000 mm and 2800 mm, for example 2500, mm and is preferably bigger than the opening 25 between two turning regions 78 of two adjacent spacing elements 18 as measured transversely to the longitudinal extension of the construction element 1, which is between 200 and 700 mm, in particular between 300 mm and 500 mm, for example 400 mm. Consequently a ratio of the lateral opening width 26 to the transverse opening width 25 is between 1:4 and 1:4.3.
[0171] For practical purposes, the spacing elements 18 are joined to one another in a positive and/or non-positive join in their mutually facing width end faces 23, 24 in the turning region 78 and in contact regions 22 formed by the latter and constitute an integrally formed core layer 11. The cavity 21 or the chamber is bounded by part sections of two adjacent spacing elements 18 and/or a part-region of the spacing element 18 and the side wall 13 between two consecutive turning regions 78 and the preferably two cover layers 7. The thickness 27 of the spacing element 18 is between 4 mm and 8 mm, for example 6 mm. As explained above with respect to the cove layer 7, the spacing element 18 may be of a multi-ply design—although this is not illustrated—and incorporate the two outer facing layers 39 or facing layer regions and the intermediate layer 40 or intermediate layer regions.
[0172] Accordingly, the facing layers 39 or facing layer regions and the intermediate layer 40 or intermediate layer regions of the cover layer 7 and/or the spacing elements 18 may be of differing density, for example, and/or the wood or wood material elements 73 may be aligned crossing over one another or may be made from a material other than wood or wood material elements 73, such as plastics and/or metal, etc. Consequently, the spacing element 18 may be made from the three-ply or multi-ply strips of stranded board or a strip of OSB chip board described above. Naturally, the cover layer 7 and/or spacing elements 18 may also have at least one reinforcing layer, provided in the form of a fibre prepreg and/or resin impregnated fibre matting, e.g. with carbon and/or glass and or netting and/or latticework of the same or different yearns or fibres to provide a fabric reinforcement.
[0173] As may be seen more clearly from the highly simplified diagram of FIG. 17, the construction element 1 has two cover layers 7 and spacing elements 18 extending in between them, and at least one respective joining region 71 is provided between the first bottom and other top cover layer 7 and the spacing elements 18. As explained above, the cover layers 7 are made from OSB board 76 and the spacing elements from strips of FPY board 77, the strip-shaped or strand-type wood or wood material elements 73 of the facing layer 37 of the cover layers 7 directed towards the spacing element 18 being aligned so as to extend substantially in the longitudinal direction of the construction element 1, whilst the intermediate layer 36 of the cover layers 7 extends transversely to the longitudinal direction of the construction element 1. Depending on which production process is used to make the cover layers 7, the cavities 75 between the wood or wood material elements 73 may be closed and pores 74 of an irregular arrangement are disposed across a surface of the wood or wood material elements 73. The cavities 75 in the region of the outer facing layer 37 or facing layer regions directed towards the spacing element 18 extend substantially parallel with and/or at least inclined towards the inner facing surface 15a and/or cross over one another. Wood or wood material elements 73 of the intermediate layer 36 of the cover layers 7 cross over and/or are inclined with respect to the wood or wood material elements 73 of the outer facing layer 37 and surround the cavities 75 between the wood or wood material elements 73, and the wood or wood material elements 73 extend transversely to the longitudinal extension and/or cross over one another.
[0174] The spacing elements 18, which are essentially made from the board strip 77 of wood material, preferably have wood or wood material elements 73 arranged in a crossed arrangement across their thickness 27, also having pores 74 irregularly distributed across their surface. The wood or wood material elements 73 of the spacing elements 18 are essentially inclined so that they run in several spatial directions relative to the joining surface 16b and the inner facing surface 15a of the cover layer 7. In a manner known from the prior art, the wood or wood material elements 73 made from board strips 77 of FYP or spacing elements 18 have a main dimension 79, in particular length or width, of approximately 1 mm to 10 mm, for example 6 mm.
[0175] At this stage, it should be pointed out that the cover layers 7 and spacing elements 18 of wood material may be used in any combination, such as FPY and FPY or OSB and FPY or FPY and OSB or OSB and OSB.
[0176] At least the longitudinally oriented wood or wood material element 73 of the cover layer 7 of OSB disposed substantially parallel with the inner facing surface 15a and in a facing surface 15a adjacent to the surface region, in particular the facing layer 37, is slightly bigger in its main dimension 79 in the joining region 71 for the spacing element 18 than the thickness 14 of the spacing element 18 or is a multiple of the thickness 14 of the spacing element 18. In order to join the spacing element 18 in a joining region 71 extending across the entire length of the joining surface 16b or at several points 72 spaced at a distance apart from one another at resultant mutually spaced joining regions 71 on the joining surface 16b, the joining and/or fixing means 70 is disposed in the joining region(s) 71 or mutually spaced joining regions 71 between the spacing element 18 and the cover layer 7. The free-flowing curable joining and/or fixing means 70 is provided in the form of adhesive which preferably fills the pores or cavities up to 2 mm deep, in particular urea formaldehyde condensation resins or melamine formaldehyde condensation resins or phenol formaldehyde condensation resins. Naturally, the cold or hot cured joining and/or fixing means 70 may also be a resorcinol adhesive or a preferably hot-cured plastics adhesive, e.g. PVAC or PUR. For joining the core layer 11 to at least one cover layer 7, any adhesives known from the prior art may be used which have a viscosity that will allow them to diffuse into the joining surfaces 16a, 16b of the facing surface 15a and the spacing element 18. The viscosity of adhesives with a syrupy viscosity may be modified at least whilst they are being applied to the joining surfaces 16a, 16b by microwave energy or the effect of temperature, etc., to ensure that they are effectively diffused into the joining surfaces 16a, 16b. Naturally, the joining and/or fixing means 70 may also be a single-component or two-component or multi-component adhesive, in particular glue, with or without extenders and fillers and/or hardeners. The curable, free-flowing adhesive applied to the narrow end face 28 and/or in the joining region 71 for the spacing element 18 on the cover layer 7 diffuses through the open-pored inner facing surface 15a and narrow end face 28 and the open-pored wood or wood material elements 73 thereof into the inside of the spacing elements 18 and cover layer 7. Due to the orientation of the wood or wood elements 73 of the cover layer 7, the adhesive, which is free-flowing in the initial state, is substantially absorbed in the longitudinal direction and/or partially in the direction of the width and through a part of the thickness 14 thereof and, due to the orientation of the wood or wood material elements 73 in the spacing element 18, is absorbed essentially in the direction of the height 9 thereof.
[0177] Consequently, a joining and/or fixing zone 80 is formed in a simple manner in the joining region 71 between the cover layer 7 and the spacing element 18 with the wood and/or wood elements 73 and/or pores 74 and/or cavities 75 between the cover layer 7 and the spacing element 18 and consists of cured joining and/or fixing means 70. This joining and/or fixing zone 80 has a higher mechanical strength than the regions of the cover layer 7 and spacing element 18 adjoining it, in particular a higher compression, tensile, bending, shear and torsional strength. The joining and/or fixing zone 80 extending between the cover layer 7 and the spacing element 18 across a part of the thickness 7 and height 9 has an approximately T-shaped join cross section in each of these joining regions 71, as a result of which a maximum join cross section 81 of a first region of the joining and/or fixing zone 80 projecting in the direction of the spacing element 18 is bounded by a minimum thickness 14 of the spacing element 18 and a minimum join cross section 82 of another region of the joining and/or fixing zone 80 projecting in the direction of the cover layer 7 is bigger than the maximum thickness 14 of the spacing element 18. Consequently, where two cover layers 7 are provided, a substantially I-shaped join cross section (not illustrated) is formed between the cover layers 7 and a spacing element 18. The joining and/or fixing zone 80 extending into the cover layer 7 and the spacing element 18 is bigger in its thickness d, by a multiple, than a maximum surface roughness of the cover layer 7 and the spacing element 18 in the joining region 71 of the abutting cover layer 7 and spacing element 18 and is approximately between 0.02 mm and 8 mm, in particular 4 mm, for example 4 mm. The joining and/or fixing zone 80 is flame-retardant and/or inflammable.
[0178] It should be pointed out that the joining and/or fixing zone 80 formed by the cured joining and/or fixing means 70 in the joining regions 71 is only schematically indicated in FIG. 17 and tests have shown that it assumes a shape somewhat rather like a hedgehog, whereby the individual spine-like arms of the joining and/or fixing zone 80 key into the wood or wood material elements in a claw-like arrangement. As a result of the joining and/or fixing zones 80 formed in the joining regions 71, the construction element is able to withstand higher tensile and compression loads.
[0179] As also illustrated in FIG. 17, it is also possible for at least one of the cover layers 7 on the external facing surface 15b remote from the core layer 11 and/or in the region of the core layer 11 between the spacing elements 18 to be provided with at least one other layer 43, as indicated by dotted-dashed lines, which will preferably be a fibre matting of subsequently expanding raw materials with a porous surface and with inorganically displaced insulating material, in particular ground silicate. For practical purposes, this fibre matting is non-detachably joined to the facing surface 15a, 15b by the filler and adhesive layer 42. Naturally, the layer 43 arranged on the inner and/or outer facing surface 15b may be made from a coating of plastics or film or paint or varnish or a melamine resin finish. This layer 43 may also optionally be coloured or may be an adhesive layer forced at least partially into the outer facing layer 37 of the cover layer 7, such as melamine resin-formaldehyde resin or phenol formaldehyde resin, or may be made from a plastic film. The outer facing surface 15b may also be smooth or of a structured design, at least in certain regions.
[0180] In order to provide a clearer understanding of and explain how little the amount or volume of material is, an example will now be described of a two-field system in which the total length of the construction element 1 is 12 m and where a length 4 measured between two support points spaced at a distance apart from one another in the longitudinal direction of the construction element 1 is 6 m and the width 2 is 2 m, whilst the transverse opening width 25 is 400 mm and a lateral opening width 26 is 2500 mm.
[0181] For a thickness 27 of the spacing elements 18, in particular with the spatially deformed or waved or non-flat webs 19 of 6 mm and with a height 9 of the webs 19 of 140 mm, the amount of material used is approximately 0.0043 m3 non-flat web/m2 construction element.
[0182] With a thickness 27;29 of the spacing elements 18, in particular with the straight webs 30 or side walls 13 of 12 mm and if the height 6; 9 of the side walls 13 or webs 19 is 140 mm, the amount of material is approximately 0.00168 m3 of non-flat web/m2 construction element. The total amount of material required for the flat and non-flat spacing elements 18 is then approximately 0.00598 m3/m2 construction element and for the cover layers 7 approximately 0.024 m3/m2 construction element. The basis for this is two straight side walls 13 or webs 30 and ten spatially deformed or non-flat or waved webs 19. A correction factor of 3% was determined for the non-flat webs 19 and allowance was made for this in calculating the amount of material m3 of non-flat web/m2 construction element.
[0183] The core layer 11 accounts for approximately between 50% and 98% of the volume of the construction element 1 and the flat and/or non-flat spacing elements 18 distributed across the inner facing surface 15a of the cover layers 7 accounts for between 10% and 50%, in particular between 18% and 25%, for example 20% of the material volume of the construction element 1. It should be pointed out that the height 9 of the core layer 11 may naturally vary and the volume of the construction element 1 and the amount of material used for the construction element 1 and the proportion of material used for the spacing elements 18 will vary accordingly. The height 9 may be between 80 mm and 350 mm, in particular between 120 mm and 300 mm, for example 140 mm.
[0184] A particular advantage as a result is that because of the structural design of the core layer 11 and the flat cover layers 7 spanning it, a span width or length 4 of 6 m, the height 9 of approximately 140 mm and the thickness 27 of approximately 6 mm of the spacing elements 18 as well as the thickness 14 of the cover layers 7 of approximately 12 mm is sufficient to withstand a nominal load of approximately 1 kN/m2.
[0185] FIG. 19 is a simplified, schematic diagram illustrating a part region of the cover layer 7 and a part-region of the spacing element 18 pulled away from the cover layer 7. From this, it is evident that when load was applied to the spacing element 18 and/or the cover layer 7 during tests in the form of an inadmissible force essentially perpendicular to the cover layer 7, the region of the joining and/or fixing zone 80 consisting of the wood or wood material elements 73 and the joining and/or fixing means 70 projecting into the cover layer 7 was torn out. Due to the fact that the lateral join cross section 82 in the region of the cover layer 7 is bigger than the maximum join cross section 81 of the spacing element 18, the resistance preventing the spacing element 18 from being torn out of the cover layer 7 is high, as is the likelihood of the cover layer 7 being lifted away from the spacing element 18.
[0186] Tests have shown that the shear strength of the spacing element 18, even with a butting adhesive join, and the cover layer 7 can exhibit breaking values of up to 7 N/mm2.
[0187] FIG. 20 is a simplified, schematic diagram illustrating an example of an application using a construction element 1 with a large surface area as a wall element 83 and/or ceiling element 84 for a building, seen from a side view. The construction element 1 has at least one cover layer 7 and spacing elements 18 distributed across the inner facing surface 15a, which is joined to the cover layer 7 in a positive and/or non-positive fit. As explained in detail above, the cover layer 7 and spacing elements 18 are made from wood materials. In the embodiment of the wall element 83 illustrated as an example here, the width 2 is the spacing between two longitudinal end faces 3 extending parallel with one another, running at a right angle to mutually spaced width end faces 5 through the length 4. By contrast with the embodiments described above, the spacing elements 18 made from wood material extend transversely to the longitudinal extension or length 4, extending mutually parallel offset from one another by a half wavelength. The wall element 83 and ceiling element 84 are attached by means of join connecting parts 85 to support elements 86 aligned perpendicular to a horizontal bedding plate 85. The horizontal, flat bedding plate 86 is supported on an earth foundation 88 and is made from concrete, which may or may not be pre-stressed. The support elements 87 spaced at a distance apart from one another by the length 4 of the wall element 83 are inserted in the bedding plate 86 and joined to it so as to be immobilised. The construction elements 1 are retained in an immobilised or floating arrangement by means of join connecting parts 85 disposed between the support elements 87 and the construction elements 1. The join connecting parts 85 might be section-type angle irons, for example, which extend along the wall element 83, at least across a part of the width 2 or height on the opposing width end faces 5 and/or longitudinal end faces 3.
[0188] By leaving a slight gap between the bottom longitudinal end face 3 and the bedding plate 86, the wall element 84 is essentially retained or supported exclusively by means of the support elements 87. The structure of the wall elements 84 corresponds to that described above with reference to FIGS. 1 to 19 and those details may be transposed to the embodiment illustrated in FIG. 20.
[0189] The construction element 1 proposed by the invention is extremely well suited for use in support structures, in particular buildings, in regions susceptible to earthquakes, where earth foundations 88 are soft, in particular sandy earth, because in the event of an earthquake, the dynamic forces transmitted to the support elements 87 acting substantially parallel with the construction element plane of the wall element 84 can be damped by its pre-determinable vibration behaviour. This is possible because the construction element 1 is of a large surface area and is low in weight, resulting in a high vibration amplitude. To this end, the construction element 1 has the wave-shaped spacing elements 18, which are joined to the inner facing surface 15a. Naturally the vibration behaviour of the construction element 1 may also be varied on the basis of the elasticity of the cured joining and/or fixing means 70, in particular the adhesive, and the layout of the joining regions 71 as well as the thickness 14, 27 of the cover layer 7 and spacing elements 18. When the construction element 1 is subjected to forces during an earthquake, it will be elastically deformed, essentially in the longitudinal direction. The skilled person will be familiar with this effect, which is similar to that of a windscreen.
[0190] The nature and manner of the join and the various structural features of the construction element are the same as those described above with reference to FIGS. 1 to 19.
[0191] As may also be seen from this drawing, one of the cover layers 7 is made from a plastics panel, in particular a transparent and optionally coloured plastics panel, for example a plexiglass.
[0192] FIG. 21 is a highly simplified, schematic diagram illustrating how the self-supporting, load-transferring construction element 1 is made. It should be pointed out that in this drawing, the construction element 1 comprises the bottom and top cover layer 7, between which the core layer 11 consisting of a plurality of spacing elements 18 is disposed. Naturally, this construction element 1 might also consist of only the bottom cover layer 7 and the core layer 11, in which case the method will be adapted accordingly.
[0193] The production line 89 for making the construction element 1 consists of at least one, preferably endlessly circulating conveyor system 90 for the bottom, cover layer 7 which is endlessly mounted on a first roller about a rotation axis 91, from which it is unreeled, and at least one applicator roll 92 for the joining and/or fixing means 70 arranged adjacent to the inner facing surface 15a of the bottom cover layer 7, which rotates about an axis 94 extending transversely to the feed direction—indicated by arrow 93—and a container 95 disposed downstream of the first applicator roll 92 in the feed direction—indicated by arrow 93—from which the filler 51 is metered, and at least one other applicator roll 92 downstream of the latter in the feed direction—indicated by arrow 93—which rotates about an axis 94 extending transversely to the feed direction—indicated by arrow 93—and at least one vibrator mechanism 96 disposed adjacent to the outer facing surface 15b remote from the core layer 11. The conveyor system 90, which can be driven in and is a belt conveyor in particular, has a length, which is preferably greater than the maximum format length by a multiple and at least slightly wider than a maximum format width of the construction element 1 to be manufactured.
[0194] The bottom cover layer 7, which is endlessly unreeled from the first roller, is fed along continuously in the feed direction—indicated by arrow 93—under its own weight at a pre-determinable speed above the circulating conveyor system 90. The applicator roll 92 cooperating with the bottom cover layer 7 and inner facing surface 15a is displaceable relative to the inner facing surface 15a by means of actuator elements, in particular pneumatic cylinders, hydraulic cylinders., not illustrated, as a result of which the process of applying joining and/or fixing means 70 to the inner facing surface 15a can be stopped and started.
[0195] Once the joining and/or fixing means 70 has been applied to at least certain regions, preferably the entire surface, of the inner facing surface 15a, the core layers 11, which are of a length 97, are placed on the inner facing surface 15a in series immediately one after the other. The successively disposed core layers 11 and their spacing elements 18 may be placed in a butting arrangement one against the other at their joining regions 32 or shifted into a partially overlapping position or lapped, as described with reference to FIG. 3. As a result, a substantially endless, web-type flat core 11 is formed, as may be seen in FIG. 21. The core layers 11 arranged immediately one after the other can be joined to one another in the joining region 32 in a positive and/or non-positive join.
[0196] Then, at least certain regions of the cavities 21 or chambers may be packed with filler 51 as illustrated in FIGS. 9, 10, 12, 13, or a layer or fibre matting 43 can be applied. In order to distribute the filler 51 more efficiently in the cavities 21 or chambers, the vibrator mechanism 96 vibrates the bottom cover layer 7 and the core layer 11, at least for a short period of time. Once the cavities 21 or chambers are filled, which may be the case if a top cover layer 7 is provided, joining and/or fixing means 70 is applied to the top narrow end faces 28 of the spacing elements 18 by means of the other applicator roll 92. The joining and/or fixing means 70 may be applied to the narrow end faces 28 along the entire length 97 of the core layer 11 or exclusively to joining regions 71 or points 72 spaced at a longitudinal distance apart from one another, as schematically indicated by crosses in FIG. 16 on the narrow end faces 28 of the spacing elements 18. To this end, the other applicator roll 92 can be displaced relative to the narrow end faces 28. Then, the top cover layer 7 with the inner facing surface 15a, which is endlessly unreeled from another roller, is applied to the narrow end faces 28 of the spacing elements 18 and the two are joined to one another in a butting joint in a non-positive join, in particular adhered. The top cover layer 7 is unreeled by means of a driven contact roller or due to adhesion between the top cover layer 7 and the core layer 11, the controllable speed of the top layer 7 to be unreeled being slightly lower than the adjustable speed of the bottom cover layer 7, causing a clamping force is exerted as the top cover layer 7 is unreeled from the other roller.
[0197] Once the top cover layer 7 has been applied, the endless construction element 1 is fed to a pressing device and/or optionally a curing device, not illustrated, in order to harden the joining and/or fixing means 70 more rapidly, arrange downstream in the feed direction indicated by arrow 93. The curing device might be a high-frequency radiator, a heating chamber, etc., so that the process of curing or setting the joining and/or fixing means 70 can be operated more quickly and shortened. Pressing and curing devices of this type are already known from the general background art. After pressing the construction element 1 and/or curing the joining and/or fixing means 70 if necessary, the overall length of the endless construction element 1 is cut into a pre-determined format length. The core layer 11 will have a shorter length 97 than the wound total length of the cover layer 7. Naturally, the joining and/or fixing means 70 may also be forced into or absorbed by the joining surfaces 16a; 16b by means of an applicator nozzle at a pressure other than atmospheric pressure, in particular a pressure above or below atmospheric pressure.
[0198] As also illustrated, the spacing elements 18 are positioned in the longitudinal extension of the unreeled bottom cover layer 7. They may of course, also be positioned on the internal facing surface 15a transversely to the longitudinal extension of the unreeled bottom cover layer 7 or feed direction—indicated by arrow 93—if they are to be used in an application for a wall element.
[0199] FIG. 22 is a highly simplified, schematic diagram showing another method of manufacturing the self-supporting, load-bearing construction element 1. It should be pointed out that the construction element 1 in this drawing has the bottom and top cover layer 7, between which the core layer 11 consisting of a plurality of spacing elements 18 is disposed. Naturally, this construction element 1 might also have the bottom cover layer 7 and core layer 11 only, in which case the process must be adapted accordingly. The conveyor system 89 is made up of several independently driven part-sections 98 to 103 arranged one after the other, fitted with driven rollers 104 rotating about axes disposed transversely to the feed direction—indicated by arrow 93—and forming a conveyor track, along which bottom layers 7 already cut to a predetermined length 4 and width are fed along on a timed basis and each of the individual bottom cover layers 7 is fed along individually driven part-sections 98 to 103 arranged one after the other in the feed direction—indicated by arrow 93. Preferably, several rollers 104 of a part-section 98 to 103 are driven by means of a drive element, e.g. chain, belt, in a common driving motion and one of the rollers 104 is driven by a motor flange-mounted thereon. Various work steps are performed in the individual part-sections 98 to 103. In the part-section 98, ready-cut bottom cover layers 7 are deposited by means of an appropriate handling system 105 onto the rollers 104 forming the conveyor track and fed in a timed motion on to the next part-section 99 in the feed direction—indicated by arrow 93. In this part-section 99, the joining and/or fixing means 70 is metered by means of an applicator nozzle 106 and applied to the bottom narrow end face 28 of the spacing elements 18 and/or inner facing surface 15a of the bottom cover layer 7 and in the next part-section 100 in the feed direction—indicated by arrow 93—the core layer 11 consisting of spacing elements 18 is positioned on it by a handling system 107, whilst in the subsequent part-section 101, the cavities or chambers may optionally be packed with filler, after which, in another part-section 102, the joining and/or fixing means 70 is applied by the applicator nozzle 106 to the top narrow end face 28 of the spacing elements 18 and/or the inner facing surface 15a of the cover layer 7, after which the top cover layer 7 is fed to the next part-section 103, where a handling system 108 places the top cover layer 7 on the core layer 11. The applicator nozzle 106 can be displaced, guided by a sensor, at least in the direction parallel with the construction element plane and hence in the longitudinal and widthways extension of the construction element 1, preferably along the longitudinal extension of the spacing elements 18. Before the core layer 11 is placed on top of the bottom cover layer 7, the latter is firstly positioned so that it is exactly aligned. The top cover layer 7 is likewise correctly aligned relative to the core layer 11 and the bottom cover layer 7 before being placed on top of the core layer 11. At the end of the production process, in the last part-section 109, the finished construction element 1 is delivered by means of a handling system 110 to another pressing process or finishing process.
[0200] Although not illustrated, the production line 89 illustrated in FIG. 21 or 22 may have another production line disposed immediately downstream in order to run other work processes, where, for example, finishing work might be done on the outer facing surface 15b, in particular a surface treatment, e.g. polishing, varnishing, coating, surface curing. Naturally, support elements, for example for roof tiles and/or a protective film, e.g. a plastics film, bitumen film, may also be applied to the construction element 1 or the construction element 1 may be subjected to a chemical treatment, e.g. sprayed with pesticide.
[0201] Although not illustrated, there are various possible ways of making the core layer 11. For example, it would be possible for several flat board strips 77 forming the spacing elements 18 to be positioned immediately one after the other in a row and, before or after positioning the core layer 11 on the inner facing surface 15a of the bottom cover face 7, adjacent flat board strips 77 specifically designed for the spacing elements 18 could be placed in pre-determinable joining regions 71 at adjoining width end faces 23, 24 and joined to one anther by means of the joining and/or fixing means 70 applied in an intermittent or linear pattern, in which case the joining regions 71 between two board strips 77 will be arranged offset in the longitudinal direction from the joining regions 71 of the other board strips 77 to be joined to one another and, before or after positioning the board strips parts located between the joining regions 71, force could be applied to a lattice forming the core layer 11 in order to pull it open or widen it.
[0202] Alternatively, another option is to align several flat board strips 77 directly adjacent to one another in a row and apply force to a lattice path forming the core layer 11 to pull it open or widen it, after which width end faces 23, 24 are joined at pre-determinable joining regions 71 by the joining and/or fixing means 70 applied in an intermittent or linear pattern and the core layer 11 with the spacing elements 18 is bonded to the inner facing surface 15a by means of the joining and/or fixing means 70 applied in an intermittent or linear pattern to predeterminable joining regions 71 first, before being joined to the top cover layer 7.
[0203] Once ready, the spacing elements 18 could, of course, be formed by appropriate devices, e.g. moulding presses, to impart their ultimate waved shape and the wave-shaped, pre-formed spacing elements 18 placed on the inner facing surface 15a in the joining region 71 for the spacing elements 18, after which directly adjoining width end faces 23, 24 of the spacing elements 18 in pre-determinable joining regions 71 are then joined to one another in an intermittent or linear pattern. Before positioning the spacing elements 18, the joining and/or fixing means 70 is applied to the joining regions 71 for the spacing elements 18, between the latter and the inner facing surface 15a of the bottom cover layer 7. A length of the joining regions 71 between the spacing elements 18 and the cover layers 7 corresponds to the longitudinal extension of the spacing elements 18. Naturally, the joining and/or fixing means 70 may also be applied directly to the inner facing surface 15a of the top cover layer 7.
[0204] It would also be possible for the spacing elements 18 and/or cover layer 7 made from wood material to be ground off slightly in predetermined joining regions 71, firstly to enlarge the pores 74 and/or cavities 75 and secondly to provide a flat seating, before applying the joining and/or fixing means 70 to the inner facing surfaces 15a and/or the narrow end faces 28 or width end faces 23, 24 remote from one another.
[0205] It should be pointed out that the spacing elements 18 and cover layers 7 are joined to one another by means of the joining and/or fixing means 70 in joining regions 71 and/or the spacing elements 18 are joined to the cover layers 7 at predetermined points 72 by means of joining elements, such as self-tapping screws or staples or nails, etc., if necessary. Another option is for the spacing elements 18 to be joined to one another at their abutting turning regions 78 in a positive and non-positive join, e.g. in the form of a dovetail or grooved and tongued joint in the height direction of the spacing element 18.
[0206] Finally, it should be reiterated that all the features and combinations of features disclosed in respect of FIGS. 1 to 15 also apply to the disclosures made in respect of the embodiments described with respect to FIGS. 16 to 22.
[0207] Finally, for the sake of good order, it should be pointed out that, in order to provide a clearer understanding of the construction element 1, it and its constituent parts are illustrated to a certain extent out of proportion and/or on an enlarged scale and/or on a reduced scale.
[0208] The independent inventive solutions underlying the various objectives may be taken from the description.
[0209] Above all, the individual embodiments and features illustrated in FIGS. 1, 2, 3, 4; 5, 6; 7; 8, 9, 10, 11, 12, 13; 14, 15; 16, 17, 18; 19; 20; 21; 22 may be construed as independent solutions proposed by the invention in their own right. The associated objectives and solutions may be found in the detailed descriptions of these drawings. 1 List of reference numbers 1 Construction element 2 Width 3 Longitudinal end face 4 Length 5 Width end face 6 Height 7 Cover layer 8 Layer 9 Height 10 Layer 11 Core layer 12 Height 13 Side wall 14 Thickness 15a Facing surface (inner) 15b Facing surface (outer) 16a Joining surface (facing surface) 16b Joining surface (spacing element) 17 Width end face 18 Spacing element 19 Web 20 Peak 21 Cavity 22 Contact region 23 Width end face 24 Width end face 25 Opening width 26 Opening width 27 Thickness 28 Narrow end face 29 Thickness 30 Web 31 Joining element 32 Joining region 33 End region 34 Supporting and/or joining surface 35 Recess 36 Intermediate layer (cover layer) 37 Facing layer (cover layer) 38 Strip 39 Facing layer 40 Intermediate layer 41 Mounting groove 42 Filler or adhesive layer 43 Layer 44 Protective plate 45 Cell 46 Wall 47 Dividing wall 48 Construction element 49 Joining region 50 Standing surface 51 Filler 52 Defined melt-down zone 53 Layer 54 Layer 55 Ply 56 Ply 57 Veneer section 58 Veneer section 59 Joining region 60 Join 61 Fibre direction 62 Fibre direction 63 Width end face 64 Sheet metal 65 Thickness 66 Join 67 68 69 70 Joining and/or fixing means 71 Joining region 72 Point 73 Wood or wood material element 74 Pore 75 Cavity 76 Board 77 Board strip 78 Turning region 79 Main dimension 80 Joining and/or fixing zone 81 Join cross section 82 Join cross section 83 Wall element 84 Ceiling element 85 Join connecting part 86 Bedding plate 87 Support element 88 Earth foundation 89 Production line 90 Conveyor system 91 Axis of rotation 92 Applicator roll 93 Arrow 94 Axis 95 Container 96 Vibrator mechanism 97 Length 98 Part-section 99 Part-section 100 Part-section 101 Part-section 102 Part-section 103 Part-section 104 Roller 105 Handling system 106 Applicator nozzle 107 Handling system 108 Handling system 109 Part-section 110 Handling system
Claims
1. Self-supporting and load-transferring construction element with at least one cover layer, on which preferably several strip-shaped spacing elements are positioned, distributed across an inner facing surface of the cover layer, and, in the longitudinal extension, the spacing elements are joined by their joining surfaces directed towards the facing surface, in at least certain regions, to the facing surface of the cover layer in a non-positive and/or a positive join by means of a curable joining and/or fixing means, characterised in that the cover layer (7) and/or the spacing elements (18) are made from randomly oriented wood or wood material elements (73) joined by a binder, in particular wood chips and/or wood-type fibre materials, with cavities (75) and pores (74) in at least certain regions between the wood or wood material elements (73), and at least a main dimension (79) of the wood or wood material elements (73) of the cover layer (7) is bigger, by a multiple, in the region of the joining surfaces (16a, 16b) than a thickness (27) of the spacing elements (18), and/or the joining surfaces (16b) of the spacing elements (18) and the inner facing surface (15a) of the cover layer (7) sit in a butting arrangement with one another and are joined to one another by nothing more than the joining and/or fixing means (70).
2. Self-supporting and load-transferring construction element with at least one cover layer, on which preferably several strip-shaped spacing elements are positioned, distributed across an inner facing surface of the cover layer, and, in the longitudinal extension, the spacing elements are joined by their joining surfaces directed towards the facing surface, in at least certain regions, to the cover layer in a non-positive and/or a positive join by means of a curable joining and/or fixing means, in particular as claimed in claim 1, characterised in that the cover layer (7) and/or the spacing elements (18) is/are made from randomly oriented wood or wood material elements (73) joined by a binder, in particular wood chops and/or wood-type fibre materials with cavities (75) and pores (74) in at least certain regions between the wood or wood material elements (73), and at least a main dimension (79), in particular a length, of the wood or wood material elements (73) is bigger in the joining region (71) for the spacing elements (18) than the thickness (27) of the spacing elements (18) and/or in the joining region (71) for the spacing elements (18), the free-flowing joining and/or fixing means (70) penetrates the joining surface (16b) of the spacing elements (18) and/or penetrates the inner facing surface (15a) of the cover layer (7) in the joining region (71), and the pores (74) of the wood or wood material elements (73) and/or cavities (75) are filled by the joining and/or fixing means (70) and/or the cured joining and/or fixing means (70) adheres to or is absorbed by the wood or wood material elements (73).
3. Self-supporting and load-transferring construction element with at least one cover layer, on which preferably several strip-shaped spacing elements are positioned, distributed across an inner facing surface of the cover layer, and, in the longitudinal extension, the spacing elements are joined by their joining surfaces directed towards the facing surface, in at least certain regions, to the cover layer in a non-positive and/or a positive join by means of a curable joining and/or fixing means, in particular as claimed in claim 1 or 2, characterised in that the cover layer (7) and/or the spacing elements (18) is/are made from randomly oriented wood or wood material elements (73) joined by a binder, in particular wood chips and/or wood-type fibre materials with cavities (75) and pores (74) in at least certain regions between the wood or wood material elements (73), and a joining and/or fixing zone (80) is formed in the joining region (71) between the cover layer (7) and the spacing elements (18), and joining and/or fixing zone (80) bonded to the wood or wood material elements (73) and/or pores (74) and/or cavities (75) is formed in the cover layer (7) and the spacing elements (18) by the cured joining and/or fixing means (70), and the joining and/or fixing zone (80) has a higher mechanical strength than the regions of the cover layer (7) and/or spacing elements (18) adjoining the joining and/or fixing zone (80).
4. Self-supporting and load-transferring construction element with at least two cover layers, spaced at a distance apart from one another by means of several strip-shaped spacing elements distributed across their mutually facing inner facing surfaces of the cover layers and the joining the surfaces of the spacing elements directed towards the facing surfaces are joined in at least certain regions in the longitudinal extension in a positive and/or non-positive to the cover layers by a joining and/or fixing means, in particular as claimed in one of claims 1 to 3, characterised in that the spacing elements (18) are spatially deformed transversely to their longitudinal extension, in particular are of a waved shape, and/or the spacing elements sit with their joining surfaces (16b) in a butting arrangement on the inner facing surface (15a) of the cover layer (7) and the cover layers (7) and the spacing elements (18) are made from wood material, and the amount of material in the cover layers (7) for a minimum span width or length (4) of 6 m is less than 0.03 m3/m2 facing surface (15a, 15b), preferably between 0.01 and 0.024 m3/m2 facing surface (15a, 15b), and the amount of material used for the strip-shaped non-flat spacing elements (18) is less than 0.005 m3/m2 construction element (1), preferably between 0.0035 and 0.0043 m3/m2 of the construction element (1).
5. Self-supporting and load-transferring construction element with at least two cover layers, spaced at a distance apart from one another by means of several strip-shaped spacing elements distributed across their mutually facing inner facing surfaces of the cover layers, and the joining surfaces of the spacing elements directed towards the facing surfaces are joined to the cover layers in the longitudinal extension in a positive and/or non-positive join in at least certain regions by a joining and/or fixing means, in particular as claimed in one of claims 1 to 4, characterised in that a core layer (11) is formed by strip-shaped, non-flat spacing elements (18) spatially deformed transversely to their longitudinal extension, in particular of a waved shape, and constitutes between 50% and 98% of the volume of the construction element (1) and the spacing elements (18) distributed across the facing surface (15a) of the cover layer (7) account for between 10% and 50%, in particular 20% of the volume of material in the construction element (1).
6. Self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 3, characterised in that the cover layer (7) is a board (76) made from wood or wood material elements (73) in a spatially random arrangement and joined to one another by a binder, in particular wood chips and/or wood-type fibres, with cavities (75) and pores (74) in at least certain regions between the wood material elements (73), in particular FPY board, MDF board (76), for example FPY board (76).
7. Self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 3, characterised in that the spacing element (18) is made from board strips (77) of wood or wood material elements (73) in a spatially random arrangement and joined to one another by a binder, in particular wood chips and/or wood-type fibres, with cavities (75) and pores (74) in between at least certain regions of the wood material elements (73), in particular FPY board strips, MDF board strips (77), for example FPY board strips (77).
8. Self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 7, characterised in that the cover layer (7) or the board (76) from which it is formed has at least two facing layers (37) or facing layer regions extending across their thickness (14) parallel with one another with respect to the orientation of the wood or wood material elements (73) and at least one intermediate layer (36) or intermediate layer region extending transversely thereto and the wood or wood material elements (73) of the facing layers (37) or of the facing layer region extend in planes in the longitudinal extension of the cover layer (7) substantially parallel with the inner facing surface (15a).
9. Self-supporting and load-transferring construction element as claimed in claim 8, characterised in that the cover layer (7) is preferably a multi-ply wood material board, in particular an OSB board (76).
10. Self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 7, characterised in that the spacing element (18) or the board strip (77) from which it is made has across its thickness (27) at least two facing layers (39) or facing layer regions extending mutually parallel with the orientation of the wood or wood material elements (73) and at least one intermediate layer (40) or intermediate layer region extending transversely thereto, and the wood or wood material elements (73) of the facing layers (39) or of the facing layer region extend in planes in the longitudinal extension of spacing element (18) substantially perpendicular to the narrow end face (28).
11. Self-supporting and load-transferring construction element as claimed in claim 10, characterised in that the spacing element (18) is preferably a multi-ply wood material board strip, in particular an OSB board strip (77).
12. Self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 11, characterised in that the thickness (27) of the spacing element (18) is between 4 mm and 8 mm, for example 5 mm.
13. Self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 12, characterised in that the thickness (14) of the cover layer (7) is between 6 mm and 14 mm, for example 8 mm.
14. Self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 13, characterised in that the joining surfaces (16b) of the spacing elements (18) directed towards the cover layer (7) extend parallel with the flat inner facing surface (15a) and the spacing elements (18) are aligned perpendicular to the inner facing surface (15a) of the cover layer (7) and sit against them in a butting arrangement.
15. Self-supporting and load-transferring construction element as claimed in one or more of claims 2 to 14, characterised in that the cavities (75) in the cover layer (7) bounded by the wood material elements (73), optionally crossing in a plane parallel with or perpendicular to the inner facing surface (15a), extend parallel with and/or at least slightly inclined with respect to the facing surface (15a) and the pores (74) are distributed irregularly across a surface of the wood or wood material elements (73).
16. Self-supporting and load-transferring construction element as claimed in one or more of claims 2 to 15, characterised in that the cavities (75) in the spacing element (18) bounded by the wood material elements (73), optionally crossing in a plane parallel with or perpendicular to the inner joining surface (16b), extend perpendicular to and/or at least slightly inclined with respect to the facing surface (15a) and the pores (74) are distributed irregularly across a surface of the wood or wood material elements (73).
17. Self-supporting and load-transferring construction element as claimed in claim 3, characterised in that joining and/or fixing zone (80) extending between the cover layer (7) and the spacing elements (18) across a part of the thickness (14) of the cover layer (7) and the height (9) of the spacing element (18) thereof has an approximately T-shaped join cross section in a joining region (71) and a maximum join cross section (82) of a first region of the joining and/or fixing zone (80) projecting in the direction of the spacing element (18) is bounded by the minimum thickness (27) of the spacing element (18) and a minimum join cross section (81) of another region of the joining and/or fixing zone (80) projecting in the direction of the cover layer (7) is bigger than the maximum thickness (14) of the spacing element (18).
18. Self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 5, characterised in that the joining and/or fixing means (70) is an adhesive, in particular a glue which fills the pores and cavities to a depth of at least 2 mm.
19. Self-supporting and load-transferring construction element as claimed in claim 18, characterised in that the adhesive is chosen from the group of synthetic adhesives and includes urea formaldehyde condensation resins or melamine formaldehyde condensation resins or melamine urea condensation resins or phenol formaldehyde condensation resins or resorcinol adhesive.
20. Self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 19, characterised in that the spacing elements (18) are shaped in at least one spatial direction and in particular are of a wave-shaped design and mutually spaced narrow end faces (28) and width end faces (23, 24) bound a substantially rectangular cross section, and at least one joining region (71) is formed by the joining and/or fixing zone (80) between a spacing element (18) and the cover layer (7) and/or between two spacing elements (18) extending adjacent to one another and/or the cover layer (7).
21. Self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 20, characterised in that the spacing elements (18) are shaped in at least one spatial direction and in particular are of a wave-shaped design and the joining regions (71) between the spatially shaped spacing elements (18) and the cover layer (7) are arranged at mutually spaced points (72) in the longitudinal direction of the spacing element (18) and at a distance from one another in the direction extending transversely to the longitudinal direction, the distance being bigger than the thickness (27) of the spacing elements (18), and the spacing elements (18) are mutually supported on adjacent spacing elements (18), at least in part-regions, or may be shifted relative thereto.
22. Self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 21, characterised in that the construction element (1) has cover layers (7) purposely spaced apart by the height (9) of the spacing elements (18) and extending parallel with one another by reference to the orientation of the wood or wood material elements (73), and/or at least one piece made from a material other than wood or wood material is arranged on an external facing surface (15b) of the cover layer (7) and/or in a recess set into the cover layer (7).
23. Self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 22, characterised in that the construction element (1) has cover layers (7) purposely spaced apart by the height (9) of the spacing elements (18) and one of the two cover layers (7) is a plastic panel, in particular a transparent and optionally coloured panel, for example plexiglass.
24. Self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 23, characterised in that at least one fibre matting of subsequently expanding raw materials forming a layer (43) is provided between the spacing elements (18) and the cover layer (7) and/or on an external facing surface (15b) remote from the spacing elements (18), which has a porous surface and is displaced with inorganic insulating material, in particular pulverised silicate.
25. Self-supporting and load-transferring construction element as claimed in claim 24, characterised in that a layer (43) is provided on the outer facing surface (15b) in the form of a plastics or film or paint or varnish coating or melamine resin finish.
26. Self-supporting and load-transferring construction element as claimed in claim 24 or 25, characterised in that the layer (43) is an optionally coloured adhesive layer at least partially pressed into the cover layer (7), e.g. melamine urea resin, formaldehyde resin or phenol formaldehyde resin.
27. Self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 26, characterised in that the external facing surface (15b) is smooth or has a structural pattern at least in part-regions.
28. Self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 27, characterised in that the cover layer (7) and the spacing elements (18) are made from a flame-retardant material.
29. Self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 28, characterised in that the wave-shaped spacing elements (18) are disposed parallel with and offset from one another by a half wavelength, preferably in the direction of the longitudinal extension of the construction element (1), and an opening width (26) measured between two consecutive turning points (78) in a longitudinal extension of the spacing elements (18) is between 800 and 3000 mm, in particular between 2000 and 2800 mm, for example 2500 mm, and an opening width (25) between two adjacent spacing elements (18) measured transversely to the longitudinal extension of the spacing elements (18) is between 200 and 700 mm, in particular between 300 and 500, for example 400 mm.
30. Use of the construction element as claimed in one of claims 1 to 29 in environments susceptible to earthquakes and/or on soft earth foundations as a wall and/or ceiling element for a support structure.
31. Use of the construction element as claimed in one of claims 1 to 29 as a shuttering board.
32. Method of producing a self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 29, in which at least one substantially endless bottom cover layer is unreeled from a roller and fed continuously along in a feed direction at a pre-definable speed, characterised in that a joining and/or fixing means (70) is firstly applied to a bottom cover layer (7) and/or spacing elements (18) at pre-defined joining regions (71) and the core layer (11) incorporating the spacing elements (18) and the bottom cover layer (7) are aligned with one another and the core layer (11) is then placed on the planar inner facing surface (15a) of the bottom cover layer (7) rolled out flat, after which the joining and/or fixing means (70) is cured until at least some of the spacing elements (18) are fixed in position relative to the bottom cover layer (7) and construction elements (1) are cut to a predetermined length (4) from the endless web.
33. Method of producing a self-supporting and load-transferring construction element as claimed in one or more of claims 1 to 29, in which at least a bottom cover layer cut to a given format is fed in timed cycles in the feed direction on part-sections disposed one after the other, characterised in that a core layer (11) consisting of spacing elements (18) is made in a format matching the bottom cover layer (7), after which, in one part section (99), a joining and/or fixing means (70) is applied to the inner facing surface (15a) and/or bottom joining surfaces (15b) of the bottom cover layer (7) and/or the spacing elements (18) at predetermined joining regions (71) for spacing elements (18), and the core layer (11) is aligned with the bottom cover layer (7), after which the narrow end face (26) and the flat inner facing surface (15a) of the spacing elements (18) and the bottom cover layer (7) are placed one on top of the other and the joining and/or fixing means (70) is cured until at least some of the spacing elements (18) are fixed in position relative to the bottom cover layer (7).
34. Method as claimed in claim 32, characterised in that, after applying a pre-determined volume of joining and/or fixing means (70) to the inner facing surface (15a) of the top cover layer and/or on top joining surfaces (16b) of the spacing elements (18) in pre-determined joining regions (71) for spacing elements (18), a top, essentially endless cover layer (7) is unreeled from a roller and pulled on top of the core layer (11) with a pre-determined clamping force.
35. Method as claimed in claim 32 or 34, characterised in that the core layer (11) is placed on the inner facing surface (15a) in the longitudinal or widthways direction of the bottom cover layer (7) in timed cycles depending on the speed and/or depending on the length (97) of the core layer (11).
36. Method as claimed in claim 33, characterised in that another top cover layer (7) is aligned with the bottom cover layer (7) and once joining and/or fixing means (70) has been applied in at least certain regions on the top narrow end faces (28) of the spacing elements (18) and/or the inner facing surface (15a) of the cover layer (7), they are placed one on top of the other, preferably in a butting arrangement and joined to one another in joining regions (71).
37. Method as claimed in one or more of claims 32 to 36, characterised in that when the spacing elements (18) and the cover layer(s) (7) have been placed one against the other, they are pressed together with a pre-definable pressing force and optionally under the action of temperature or the effect of microwave energy or in a high-frequency radiation field.
38. Method as claimed in one or more of claims 30 to 37, characterised in that several flat board strips (77) are aligned in a row immediately adjacent to one another and, before or after positioning the core layer (11) on the inner facing surface (15a) of the cover layer (7), specific adjacent, flat board strips (77) are firstly joined to one another in specific joining regions (71) for the spacing elements (18) between mutually adjoining width end faces (23, 24) by means of the joining and/or fixing means (70) applied in an intermittent or linear pattern, the joining regions (71) between two board strips (77) being offset in the longitudinal extension thereof from the joining regions (71) of the other board strips (77) to be mutually joined, and, before or after positioning, board strip parts located between the joining regions (71) are pulled apart and opened out under the action of force to form a lattice constituting the core layer (11).
39. Method as claimed in one or more of claims 32 to 38, characterised in that several flat board strips (77) are aligned immediately adjacent to one another in a row and are pulled apart and opened out under the action of force into a lattice forming the core layer (11) and predefined joining regions (71) between mutually adjacent width end surfaces (23, 24) are joined to one another by means of the joining and/or fixing means (70) applied in an intermittent or linear pattern, after which the core layer (11) is joined to the spacing elements (18) in predefined joining regions (71) by means of the joining and/or fixing means (70) applied in an intermittent or linear pattern to the inner facing surface (15a) firstly of the bottom and/or then the top cover layer (7).
40. Method as claimed in one or more of claims 32 to 39, characterised in that the spacing elements (18) are made in the form of wave-shaped, preformed, for example compression moulded or extruded, board strips (77) of wood material, after which, preferably after placing the wave-shaped formed spacing elements (18) on the inner facing surface (15a) of the bottom cover layer (7), the spacing elements (18) are joined to one another in predefined joining regions (71) between mutually adjacent width end faces (23, 24) by means of the joining and/or fixing means (70) applied in an intermittent or linear pattern.
41. Method as claimed in one or more of claims 32 to 40, characterised in that before positioning the top cover layer (7), a flame-retardant, heat-insulating, noise-insulating filler material (51) is metered and introduced into cavities (21) or chambers bounded by the wave-shaped spacing elements (18) and the cavities (21) or chambers are sealed off so as to be air-tight.
42. Method as claimed in one or more of claims 32 to 41, characterised in that spacing elements (18) and/or the cover layer (7) are ground in predefined joining regions (71) at the narrow end faces (28) and joining surfaces (16b) and/or the inner facing surface (15a) and/or the width end faces (23, 24).
43. Method as claimed in one or more of claims 32 to 41, characterised in that after assembling the construction element (1), a finishing process, in particular a surface treatment, e.g. grinding, varnishing, coating, surface hardening, is applied, preferably to an external facing surface (15b) of at least one cover layer (7), and/or fixing means for cladding elements or support elements, e.g. for roof tiles, and/or a protective film, e.g. plastic film, bitumen film, are applied in another work process.
44. Self-supporting and load-transferring construction element with two cover layers, joined to one another in a non-positive and/or positive join by means of several spacing elements distributed across the facing surfaces of the cover layers directed towards one another, characterised in that the cover layers (7) and the spacing elements (18) are preferably made from up to 50% wood and/or wood material and the proportion of wood in the cover layers (7) for a minimum span width or length (4) of 6 m is less than 0.04 m31 m2 facing surface (15a, 15b), preferably between 0.01 and 0.035 m3/m2 facing surface (15a, 15b), and the proportion of wood in the strip-shaped non-flat spacing elements (18) is between 0.0015 and 0.01 m3/m2 of the construction element (1).
45. Self-supporting and load-transferring construction element with two cover layers, joined to one another in a non-positive and/or positive join by means of several spacing elements distributed across the facing surfaces of the cover layers directed towards one another, characterised in that a core layer (11) consists of strip-shaped and non-flat spacing elements (18) and constitutes between 50% and 98% of the volume of the construction element (1) and the spacing elements (18) distributed over the facing surface (15) of the cover layer (7) accounts for between 10% and 50% of the material volume of the construction element (1), and narrow end faces (28) of the spacing elements (18) are aligned substantially parallel with the facing surface (15) of the cover layers (7).
46. Self-supporting and load-transferring construction element as claimed in claim 44 or 45, characterised in that the construction element (1) has a first cover layer (7), optionally reinforced with layers of materials other than wood or wood fibres at least in a part-region in order to absorb compression loads and, lying opposite, another cover layer (7) with at least one layer (36; 37; 53; 54) at least in a part-region for absorbing tensile load.
47. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 46, characterised in that several construction elements (1) overlap with one another in at least certain regions are arranged one on top of the other and joined to one another.
48. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 47, characterised in that the first construction element (1) has at least one other construction element (1) arranged above the first construction element (1) which projects beyond it along at least one longitudinal end face (3) and/or width end face (5) or terminal-side end region (33).
49. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 48, characterised in that at least one of several construction elements (1) arranged one on top of the other has cover layers (7) with diffusion-promoting orifices.
50. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 49, characterised in that at least one cover layer (7) of at least one construction element (1) is made from a diffusion-promoting material.
51. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 50, characterised in that the facing surface (15a, 15b) of the cover layer (7) directed towards and/or remote from the spacing elements (18) is provided with a metallic or non-metallic layer or a plastics, preferably water-repellent film, which is adhered and/or applied thereto as a veneer.
52. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 51, characterised in that at least one of the cover layers (7) constitutes a flat defined melt-down zone (52) of at least one construction element (1).
53. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 52, characterised in that the layer (43) is made from a material which releases water at increased temperatures.
54. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 53, characterised in that the cover layer (7) is made up of facing layers (37) joined to one another and at least one intermediate layer (36).
55. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 54, characterised in that the cover layer (7), and in particular the intermediate layer (36) is made from a fibre prepreg.
56. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 55, characterised in that the intermediate layer (36) extending perpendicular or transversely to the facing layer (37) is made from strips (38) of a rectangular cross section, preferably of wood and/or wood materials, adhered to one another and compressed.
57. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 56, characterised in that a vapour barrier is provided in the cover layer (7) between layers (36; 37; 53; 54) or plies (55; 56) or on at least one facing surface (15a; 15b) of the cover layer (7).
58. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 57, characterised in that the layers (36; 37; 53; 54) or plies (55; 56) of the cover layer (7) and/or spacing elements (18) of several construction elements (1) to be joined to one another are joined in an endless non-positive and/or positive join, in particular glued.
59. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 58, characterised in that the cover layers (7) and/or the spacing elements (18) are lapped or dovetailed so that several construction elements (1) can be endlessly joined.
60. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 59, characterised in that the facing surface of the cover layers (7) remote from the core layer (11) is coated or sealed with a wear-resistant material.
61. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 60, characterised in that the cover layers (7) and/or side walls (13), spaced at a distance apart from one another by the spacing elements (18) and joined to one another in a non-positive and/or positive join, extend at an angle to one another.
62. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 61, characterised in that the cover layers (7) and/or the side walls (13) extend at an angle towards one another in the direction of the length (4) and/or a height (12) of the construction element (1).
63. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 62, characterised in that the construction element (1) has at least one curved or arcuate cover layer (7).
64. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 63, characterised in that two mutually adjacent spacing elements (18) are positioned at a distance apart from one another and form a free space or passage.
65. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 64, characterised in that the spacing element (18) is provided in the form of at least one web (19) which is non-flat in its longitudinal direction and is wave-shaped in particular.
66. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 65, characterised in that at least one other spacing element (18) extending in a straight line or another web (30) extending in a straight line is disposed between adjacent and non-flat wave-shaped spacing elements (18) or webs (19).
67. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 66, characterised in that the webs (19; 30) have at least one facing layer (39) and at least one intermediate layer (40).
68. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 67, characterised in that several bar-shaped strips spaced at a distance apart from the in the direction of a height (9) of the webs (19; 30) are disposed transversely to the longitudinal direction of the webs (19; 30) between mutually spaced and parallel cover layers (39).
69. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 68, characterised in that a cavity (21) or chamber that is airtight and vapour-permeable on all sides is formed between the non-flat or wave-shaped web (19) and/or the straight web (30) and/or a strip-shaped side wall (13) in the assembled state.
70. Self-supporting and load-transferring construction element as claimed in one or more of claims 44 to 69, characterised in that at least one of the terminal side end regions (33) of the construction element (1) is provided with a closing strip, on which at least one air-permeable and vapour permeable membrane or a vapour valve is disposed.
71. Self-supporting and load-transferring construction element as claimed in claim 44, characterised in that joining elements (31) in the form of recesses (35) and/or projections are provided in the terminal side end region (33) of the construction element (1) or cover layers (7), in particular in a plane perpendicular to the longitudinal extension of the spacing elements (18), for receiving complementary joining elements of a joining region (31).
72. Self-supporting and load-transferring construction element as claimed in claim 71, characterised in that at least one of the cover layers (7) has at least one recess (35) and/or projections.
73. Self-supporting and load-transferring construction element as claimed in claim 71 or 72, characterised in that the recess (35) is provided in the form of support and/or joining surfaces (34) extending towards one another at an incline in a direction opposite the terminal side end region (33).
74. Self-supporting and load-transferring construction element as claimed in one or more of claims 71 to 73, characterised in that the cover layer (7) has at least one support and/or joining surface (34) extending at an incline to the longitudinal extension of the construction element (1) serving as the joining element (31).
75. Self-supporting and load-transferring construction element as claimed in one or more of claims 71 to 74, characterised in that the spacing elements (18) of immediately adjacent construction elements (1) abutting with one another by their end faces locate in one another and/or overlap with one another and are joined to one another in a non-positive and/or positive join in the overlapping or joining region (32).
76. Self-supporting and load-transferring construction element with two cover layers, joined to one another in a positive and/or non-positive join by means of spacing elements distributed across the facing surfaces of the cover layers directed towards one another, characterised in that the cover layers (7) and/or spacing elements (18) have several layers (53; 54) with crossing plies (55; 56) made from wood and/or wood material crossing over the individual layers (53; 54) by reference to the fibre directions (61; 62) and the number of those plies (56) of which the fibre direction (62) of the veneer layers extends substantially parallel with the longitudinal direction of the cover layer (7) or spacing element (18) is greater than the number of those plies (55) in which the fibre direction (61) extends transversely to the longitudinal direction of the cover layer (7) or the spacing element (18).
77. Self-supporting and load-transferring construction element as claimed in claim 76, characterised in that the plies (55; 56) of the spacing elements (18) and/or the cover layers (7) overlap within one another in the longitudinal direction and the individual plies (55; 56) are joined to one another, in particular glued.
78. Self-supporting and load-transferring construction element as claimed in claim 76 or 77, characterised in that the layers (53) of the cover layers (7) directed towards the spacing elements (18) have several plies (55) with the fibre direction (61) extending transversely to the longitudinal extension of the cover layers (7), which are at least partially overlapped by at least one other layer (54) with several plies (56) with a fibre direction (62) extending in the longitudinal extension of the cover layers (7) and are joined to one another.
79. Self-supporting and load-transferring construction element as claimed in one or more of claims 76 to 78, characterised in that the individual plies (55; 56) of the cover layers (7) or spacing elements (18) are preferably symmetrical with one another by reference to a longitudinal mid-plane or transverse mid-plane of the construction element (1).
80. Self-supporting and load-transferring construction element as claimed in one or more of claims 76 to 79, characterised in that a joining region (59) between veneer sections (57; 58) disposed immediately one behind the other is overlapped by at least one ply (55; 56) of the cover layer (7), and/or the spacing element (18) of the construction element (1) of another ply (55; 56) of the same or the other layer (53; 54) is in full surface contact and the joining regions (59) are offset from one another in the longitudinal direction of the cover layer (7) and/or the spacing element (18) of the individual plies (55; 56).
81. Self-supporting and load-transferring construction element as claimed in one or more of claims 76 to 80, characterised in that the mutually facing side faces, in particular end side faces, of the veneer sections (57; 58) overlap with or sit against one another in a butting arrangement or are lapped in at least certain regions of the joining region (51) and joined to one another, in particular adhered.
82. Self-supporting and load-transferring construction element as claimed in one or more of claims 76 to 81, characterised in that at least one layer (53; 54) of the spacing elements (18) and/or cover layers (7) is made from materials other than wood or wood materials.
83. Use of the self-supporting and load-transferring construction element as a roof element.
84. Self-supporting and load-transferring construction element comprising two spatially deformed and/or multi-layered cover layers, which are joined to one another in a positive and/or non-positive join by means of several spacing elements distributed across the facing surfaces of the cover layers, in particular as claimed in one claims 44 to 82, characterised in that the spacing elements (18) and/or side walls (13) extending between the cover layers (7) are supported in a load-transferring arrangement at least in part-regions in order to transmit force to adjacent spacing elements (18) and/or side walls (13).
Type: Application
Filed: Aug 13, 2003
Publication Date: Apr 22, 2004
Inventor: Michael Stache (Kirchdorf am Inn)
Application Number: 10333174
International Classification: E04C002/32;
