Flat wall panel at least substantially made of cellulose material

Abstract

A flat wall panel at least substantially made of cellulose material, a special feature being the fact that the wall panel is at least substantially made of layers of paper/cardboard, each layer at least substantially being made up of a corrugated sublayer and a flat sublayer provided on one side thereof, which layers of paper/cardboard are interconnected via an adhesive applied to the corrugations of the corrugated sublayers, wherein the wall panel is impregnated, in particular with a resinous material, and wherein at least one strengthening layer which is stiffer (i.e. less deformable) than the layers of paper/cardboard is provided, which strengthening layer is connected to a layer of paper/cardboard on one side of the wall panel via an adhesive.

Description

CLAIM OF PRIORITY

This application claims priority to the Netherlands Patent Application No. NL 1024506 entitled FLAT WALL PANEL AT LEAST SUBSTANTIALLY MADE OF CELLULOSE MATERIAL, by Snel, filed 10 Oct., 2003, incorporated herein by reference.

TECHICAL FIELD

The present invention relates to a flat wall panel at least substantially made of cellulose material. The invention also relates to a method for manufacturing said wall panel.

BACKGROUND

Such a wall panel is known from German patent No. 2 026 768. Said patent describes a building that is built up of a great many different construction elements, such as a concrete floor, roof and side wall panels made of an intermediate layer of corrugated cardboard sandwiched between two flat outer layers, as well as cramps and corner elements. In practice, the constructional strength of the roof and side wall panels appears to be insufficient to give the building sufficient strength.

The object of the invention is to improve the wall panel that is known from the aforesaid German patent publication, in the sense that a wall panel having an optimum constructional stiffness is provided for use as a construction element of a building, as a wall panel in, for example, a separation wall, etc. It is noted that the term wall panel is understood to include an element for use in a wall, a floor, a ceiling, a roof, etc.

According to the invention, a wall panel of the kind referred to in the introduction is characterized in that the wall panel is at least substantially made of layers of paper/cardboard, each layer at least substantially being made up of a corrugated sublayer and a flat sublayer provided on one side thereof, which layers of paper/cardboard are interconnected via an adhesive applied to the corrugations of the corrugated sublayers, wherein the wall panel is impregnated, in particular with a resinous material, and wherein at least one strengthening layer which is stiffer (i.e. less deformable) than the layers of paper/cardboard is provided, which strengthening layer is connected to a layer of paper/cardboard on one side of the wall panel via an adhesive.

In other words, the sum of a number of adhered-together layers of paper/cardboard are connected on at least one flat (outer) side thereof to the stiffer (i.e. less deformable) strengthening layer. Experiments have shown that the present construction leads to an unexpectedly great constructional stiffness of the wall panel, so that it is possible to subject the wall panel to large forces without the dimensional stability being affected.

In a preferred embodiment of a wall panel according to the invention, the wall panel comprises two strengthening layers, which are connected to a layer of paper/cardboard on either side of the wall panel via an adhesive. Thus a sandwich construction is obtained, in which the whole of various adhered-together layers of paper/cardboard are connected to a stiffer (i.e. less deformable) strengthening layer on both flat outer sides. The result is an even greater constructional stiffness having a corresponding dimensional stability.

It is noted that impregnating the wall panel with, for example, a resinous material not only has the advantage of providing a greater constructional stiffness, but also of providing protection against external influences, such as moisture. As a result of said additional stiffness, fewer layers of corrugated paper/cardboard are in principle needed in order to give the flat panel the required stiffness. Said impregnation preferably takes place by means of vapour deposition, spraying or otherwise, said vapour deposition or spraying taking place in a direction parallel to the direction of the “cell structure” of the corrugated paper/cardboard that is used. Said impregnation may also be effected with mechanical means, wherein toothed and/or flat rollers are used for pressing the impregnating medium into the paper/cardboard.

In a preferred embodiment of a wall panel according to the invention, the strengthening layer is made of wood, preferably multiply wood, in particular three-ply wood.

In another preferred embodiment of a wall panel according to the invention, the wall panel is at least substantially made of an even number of layers of paper/cardboard. In combination with the strengthening layer, this provides a planar material which is hardly deformable, if at all. Preferably, the wall panel is mirror symmetrical with respect to a central longitudinal plane of the wall panel so as to increase the dimensional stability thereof, so that “warping” is prevented at all times.

The invention also relates to a method for manufacturing a wall panel according to the specifications of the invention, wherein the wall panel is at least substantially made of layers of paper/cardboard, each layer at least substantially being made up of a corrugated sublayer and a flat sublayer provided on one side thereof, which layers of paper/cardboard are interconnected via an adhesive applied to the corrugations of the corrugated sublayers, wherein the wall panel is impregnated, in particular with a resinous material, and wherein at least one strengthening layer which is stiffer (i.e. less deformable) than the layers of paper/cardboard is provided, which strengthening layer is connected to a layer of paper/cardboard on one side of the wall panel via an adhesive.

It is noted that the term paper is usually used for lighter types of paper; in the case of a heavier quality, the term cardboard is frequently used. Within the framework of the invention, the terms paper, cardboard and weight are not intended to be limitations as regards the type of material to be used.

The aforesaid resinous material with which the wall panel according to the invention is impregnated, is preferably an epoxy resin, a polyurethane resin, a polyester resin or a phenol resin. Fire-resistant and/or fire-retarding agents may be added thereto. Preferably, the resinous material with which the wall panel according to the invention is impregnated also functions as an adhesive for adhering two layers of paper/cardboard together, so that a separate adhesive, such as a glue, is not required. To that end, sets consisting of a corrugated sublayer and a flat sublayer adhered to one side thereof, which sublayers are already impregnated with the resinous material, can be placed on top of each other so as to be adhered together (after the resinous material has dried).

BRIEF DESCRIPTION OF THE FIGURES

The invention will now be explained in more detail with reference to figures illustrating a preferred variant of the invention.

FIG. 1 shows a schematic, perspective view of the present wall panel.

FIG. 2 shows a schematic, detail view of the wall panel in FIG. 1.

FIG. 3 shows a schematic, exploded view of the wall panel in FIG. 1.

DETAILED DESCRIPTION

FIGS. 1-3 show a flat wall panel 1 according to the invention in the form of a “sandwich”, in the sense that a core 2 built up of several layers of corrugated cardboard is connected on either side to a stiffer strengthening layer 3 of multiply wood, in particular three-ply wood.

In this case, four layers of corrugated cardboard are depicted, which are each built up of corrugated sublayer 4 and a flat sublayer 5 adhered to one side thereof, using an adherant applied to the corrugations 6 of the corrugated sublayer 4. The core 2 is impregnated with a resinous material. The strengthening layers 3 are glued to both sides of the core 2.

The wall panel 1 is mirror symmetrical with respect to a central longitudinal plane 7 of the wall panel 1.

It is noted that the invention is not limited to the embodiment as shown in the figures, but that it also extends to other variants that fall within the scope of the appended claims. Thus it will be apparent to those skilled in the art that the wall panel may exhibit a (slight) curvature, whilst the wall panel may also comprise a curved longitudinal edge.

Claims

1. A wall panel comprising:

at least one layer including a corrugated sublayer and a flat sub layer wherein the flat sublayer is connected with the corrugated sublayer; and

a strengthening layer adhesively connected to the layer, wherein the wall panel is impregnated with resinous material.

2. A wall panel according to claim 1, wherein the wall panel is comprised of two or more layers and wherein the corrugated sublayer(s) and the flat sub layer(s) are composed of paper, cardboard or other material containing a high cellulose content.

3. A wall panel according to claim 2, wherein a second strengthening layer is adhesively connected to the paper/cardboard layer thereby sandwiching the paper/cardboard layer between the two strengthening layers.

4. A wall panel according to claim 2, wherein the said strengthening layer is made of wood.

5. A wall panel according to claim 3, wherein the said strengthening layers are made of wood.

6. A wall panel according to claim 2, wherein the said strengthening layer is made of multiply, preferably three-ply wood.

7. A wall panel according to claim 3, wherein the said strengthening layers are made of multiply, preferably three-ply wood.

8. A wall panel according to claim 2, wherein the wall panel comprises an even number of layers.

9. A wall panel according to claim 3, wherein the wall panel comprises an even number of layers.

10. A wall panel according to claim 4, wherein the wall panel comprises an even number of layers.

11. A wall panel according to claim 5, wherein the wall panel comprises an even number of layers.

12. A wall panel according to claim 6, wherein the wall panel comprises an even number of layers.

13. A wall panel according to claim 7, wherein the wall panel comprises an even number of layers.

14. A wall panel according to claim 8, wherein the wall panel is mirror symmetrical with respect to a central longitudinal plane of the wall panel.

15. A wall panel according to claim 9, wherein the wall panel is mirror symmetrical with respect to a central longitudinal plane of the wall panel.

16. A wall panel according to claim 10, wherein the wall panel is mirror symmetrical with respect to a central longitudinal plane of the wall panel.

17. A wall panel according to claim 11, wherein the wall panel is mirror symmetrical with respect to a central longitudinal plane of the wall panel.

18. A wall panel according to claim 12, wherein the wall panel is mirror symmetrical with respect to a central longitudinal plane of the wall panel.

19. A wall panel according to claim 13, wherein the wall panel is mirror symmetrical with respect to a central longitudinal plane of the wall panel.

20. A method for manufacuring the wall panel comprising:

interconnecting layers including a corrugated paper/cardboard sublayer and a flat paper/cardboard sublayer, wherein the layers are interconnected via adhesive applied to the corrugations of the corrugated sublayers, connecting at least one strengthening layer to the paper/cardboard layer via an adhesive, the strengthening layer being less deformable than the paper/cardboard layers, wherein the wall is impregnated with a resinous material.