WALL ELEMENT AND STRUCTURE CONSTRUCTED THEREWITH

Abstract

Wall element for separating two areas situated on either side of a wall, wherein the wall element is made by extrusion from a composite material having a synthetic matrix and incorporated therein wood particles, such as wood fibers or other cellulose-containing particles, wherein the wall elements are panel-shaped and comprise a first main plate, a second main plate spaced therefrom and transverse plates for connecting both main plates to each other, wherein both main plates and the transverse plates define hollow spaces, wherein the wood particles comprise a high fraction of elongated wood particles, which elongated wood particles are predominantly oriented in the profile direction, wherein the wall element has first and second, opposite longitudinal edges extending in the profile direction, which longitudinal edges are provided with first and second coupling members, respectively, wherein the first coupling members define an accommodation recess space for a protrusion formed at a second longitudinal edge of another, similar wall element, wherein the accommodation recess space is defined by plate continuations of both main plates.

Description

REFERENCE TO A RELATED APPLICATION

This application is a continuation-in-part of PCT application PCT/NL2005/00198 filed Mar. 16, 2005 which is relied on and incorporated herein by reference.

INTRODUCTION AND BACKGROUND

The invention relates to a wall element for use in constructing separating walls, such as earth retaining walls, water-retaining walls, such as sheet pile walls or revetment walls, noise barrier walls, room separating walls, such as walls of buildings. In other words, walls for separating substances or stopping physical phenomena.

There is a need for wall elements with which one or more of the above-mentioned walls can be constructed fast and easy.

There is furthermore a need for wall elements that can be reliably positioned and/or disposed, and for walls with a wood-like appearance for replacing walls made of durable wood like oak or tropical hardwoods for applications like sea or shore line barriers.

There is furthermore a need for wall elements that are versatile in use.

There is furthermore a need for wall elements that have a high durability in outdoor conditions, in particular very wet conditions.

SUMMARY OF THE INVENTION

From one aspect the invention provides a wall element for separating two areas situated on either side of a wall, wherein the wall element is made by extrusion using available equipment from a composite material having a synthetic matrix and incorporated therein wood particles, such as wood fibers or other cellulose-containing particles, wherein the wall elements are panel-shaped and comprise a first main plate, a second main plate spaced therefrom and transverse plates or ribs connecting both main plates to each other, wherein both main plates and the transverse plates define channels or chambers, wherein the wood particles comprise a fraction of elongated wood particles, which elongated wood particles are predominantly oriented in profile direction, wherein the wall element has first and second, opposite longitudinal edges extending in profile direction, which longitudinal edges are provided with first and second coupling members, respectively, wherein the first coupling members define an accommodation space for a protrusion formed like second coupling members at the second longitudinal edge of another, adjoining similar wall element, wherein the accommodation space is defined by plate continuations of both main plates.

Such wall elements have a wood-like appearance and can have sufficient strength for various uses. They are easy to assemble into a wall.

The plastic-based composite material having a synthetic matrix and incorporated therein wood particles used for purposes of making the wall elements described herein is described in detail in U.S. Pat. No. 6,929,841, granted Aug. 16, 2005, the disclosure of which is relied on and incorporated herein.

The wall elements according to the invention are strong and do not need to be filled with concrete or other substances in order to provide a sufficiently strong wall. Instead, if so desired, they can be filled with an insulating material, such as insulation foam, so that the wall elements acquire increased sound-insulating and/or heat-insulating properties. They can be directly connected or coupled to each other, so that with few actions extended walls can be made without using coupling profiles. A further advantage is that the presence of wood fibers provides the wall or the building with a finished wood-like appearance, as a result of which covering layers do not need to be provided. The particles are embedded in the synthetic material and do not protrude from the surface. Should a rough surface or a decorated surface be wanted, however, then this may optionally be achieved by brushing or embossing. Many types of surface modifications are possible to give the panels any type of desired appearance.

Moreover, the presence of wood fibers will result in a natural graying of the surface of the profiles when exposed to outdoor conditions. The wall elements of the invention can also be painted with any kind of paint due to the high content of wood fiber and low moisture absorption of the composite material resulting in an extremely good adhesion and long lasting paint durability.

A wall constructed with hollow profiles according to the invention has a minimum number of joints.

Preferably both plate continuations extend over a same distance.

Preferably per side the main plates and plate continuations have a same thickness. Both main plates may also have a same thickness. Furthermore, both plate continuations may have a same thickness.

In one embodiment the protrusion ends in a transverse wall that is parallel to the other transverse walls.

Preferably the length of the wall element in profile direction is larger than the width of the wall element.

In one embodiment the thickness of the main plates and the transverse walls is the same.

In order to give room for expansions, particularly as a result of moisture absorption, the first and second coupling members may be provided with a dilatation provision or expansion joints. Thus, water tight constructions can be made by assembling a plurality of the wall elements which will undergo some moisture absorption and swell, thereby forming a tight connection between adjacent elements.

In one embodiment the first and second coupling members can be brought into operative connection with each other by sliding them into each other in profile direction. The wall elements may then, for instance, be vibrated in a vertical profile direction into a substrate, such as earth.

In an alternative or additional embodiment the first and second coupling members can be brought into operative connection with each other by sliding them into each other transverse to the profile direction, parallel to the main plates.

In a constructively simple way, the first coupling means are provided on projections that extend from the first end edge and that may be provided with hooks and the second coupling means are provided in areas that are recessed from the second end edge with grooves into which the hooks may engage by a snapping action.

Preferably the first and second end edge are provided with a transverse plate, so that extra stability is provided to the first and second coupling means and after coupling a double transverse plate is present at that location.

The first and second coupling means can advantageously be formed with the material used for the construction elements in order to form a snap-together coupling.

The wall element may comprise several parallel hollow chambers or channels.

The first and second edges are preferably formed so that adjacent panels will fit into each other.

The first edge may form a narrowed protrusion and the second edge an accommodation space for the first edge of an adjacent similar wall element, wherein the recess is disposed in the second edge.

The wall element can be stackable with similar wall elements having the corresponding main plates in at least almost the same plane. It is, for instance, possible to place the wall elements lying horizontally onto each other in order to form a separating wall.

The wall elements of the invention are grease resistant and grease spots are easily removed. The panels also have good scratch resistance since they are far more hard than natural wood and especially WPC composites. The panels of the present invention can be pressure washed whereas natural wood can be heavily damaged.

In an embodiment suitable for placement in pitched roofs, the first main plate can be formed with crests and valleys, preferably corrugated in shape, due to which the water discharging function is enhanced and locations for attachment means such as bolts are provided that are situated relatively high on the crest and free from water.

In a further embodiment of the construction system according to the invention, the first main plate and the second main plate form separate parts that can be coupled to each other. The first and second main plate can then be transported in mutually offset condition, wherein the width or height is temporarily reduced, so that less air is transported along or in other words per volume unit (TEU container) more construction elements can be transported.

Preferably the transverse plates are divided into a first part that is formed as a one piece unit with the first main plate and a second part that is formed as a one piece unit with the second main plate. The transverse parts prevent mutual shifting in one direction and the transverse parts allow for forming coupling means for coupling both main plates.

It is preferred here that the first and second main plates are coupled to each other by means of a rigid coupling. Such rigid couplings can easily be formed with the said wood composite material.

In another aspect, the invention provides a construction element for walls, such as upright walls, ceilings or roofs of buildings, made by extrusion from a composite material having a synthetic matrix and incorporated therein wood particles, such as wood fibers or other cellulose-containing particles, wherein the construction elements are panel-shaped and comprise a first main plate, a second main plate spaced therefrom and transverse plates or ribs connecting both main plates to each other, wherein both main plates and the transverse plates define hollow spaces therebetween, wherein the wood fibers are predominantly oriented in the profile direction, wherein the first main plate and the second main plate form separate parts that can be coupled to each other.

Preferably the transverse plates are then divided again into a first part that is formed as a one piece unit with the first main plate and a second part that is formed as a one piece unit with the second main plate, wherein preferably both transverse plate sections are provided with third and fourth coupling members, respectively, for mutual coupling.

In a further aspect the invention provides an earth or water-retaining head wall structure constructed with wall elements according to the invention. The profile direction can then advantageously be vertical. Due to the slight swelling of the composite material under the influence of moisture uptake by the wood fibers, the connections between adjacent profiles will become water tight.

As the wall panel is constructed with two cover plates at a relatively large distance from each other, high values are achieved for the moment of inertia against bending and the section modulus for loading in bending. In combination with the high elasticity modulus and the high strength of the material itself, this results in profiles having a high load-bearing capacity and a high resistance against deformation. Moreover, as a result, the profiles have a large degree of elastic stability which is of importance when long profile lengths are used. No buckling or torsion will therefore occur when using said profiles. This is of particular importance when vibrating long profiles into the ground. Due to the high rigidity of the profiles, vibrations from the hammer type vibrator are properly transmitted to the lower end of the wall panel, in order to be as effective as possible when having the lower end of the wall panel penetrate into the ground. The vibration energy here only deforms the wall panel to a slight degree.

Advantageous here is that due to the rectilinear chamber structure which can be generally rectangular in shape, despite the fact that the wall panels are made of the said thermoplastic composite with wood particles, a high moment of inertia is achieved, due to which lateral forces can also be absorbed well.

Several wall panels can be joined together beforehand, for instance three pieces in a row, and then be jointly vibrated in for installation.

After a while an inclined position may arise when the plates are vibrated in for making revetments. According to the invention this can be counteracted by bevelling off a corner at the lower end of a wall panel intended to be vibrated into position, which corner faces away from the edge that is slid in into the wall panel already placed, so that as a result during vibrating a horizontal force oriented towards the wall panels already placed is exerted on the wall panel that is being vibrated into position.

Preferably a cap covers the upper side of the wall elements, wherein the cap is preferably U-shaped. The cap can also be made by extrusion from said composite material having a synthetic matrix and wood particles, such as wood fibers or other cellulose-containing particles, incorporated therein.

In case the hollow profiles are used partly in water that can freeze during cold periods, foam profiles can be used to prevent damage by expansion due to freezing of the water inside the hollow profiles. By inserting foam profiles, particularly made of closed cell synthetic foamed material, into the hollow profiles at the locations where the water may freeze during cold periods, the foam can absorb the expansion of the water due to freezing.

In a further aspect the invention provides a noise barrier structure constructed from wall elements according to the invention. The wall elements form an effective noise-reflecting surface. In that application the walls elements for ease of placement can be horizontally fitted or fixed in the profile direction.

Columns can be placed between a series of wall elements in a lengthwise direction. The columns may form accommodation spaces for accommodation of the longitudinal ends of the wall elements. In the accommodation spaces, between the column in question and the longitudinal end of the wall elements, sealing elements can be placed, which prevents noise leakages. The sealing elements can be formed by an element of closed-cell synthetic foamed material.

In an aesthetic embodiment the columns are made of the same material as the wall elements so as to have a uniform appearance.

In case noise absorption is desired, the main plate situated at the retaining side may be provided with through-holes. The chambers can then be filled with sound-insulating or sound-muffling material, for instance mineral wool or other sound-deadening material.

Preferably the content of wood particles or cellulose-containing particles is more than 50% by weight, preferably 70% by weight or more, more preferably between 70 and 85% of wood by weight, due to which a high strength is achieved, also at the location of the coupling means, and the woody nature of the product is enhanced thereby.

The synthetic material used to form the synthetic matrix preferably is a thermoplastic synthetic resin material particularly a polyolefin, preferably polypropylene or polyethylene, or PVC or polycarbonate. A variety of such synthetic resins are available for that purpose.

In a further development, the wall element according to the invention can be provided with continuous reinforcement elements extruded along in the wall element, which reinforcement elements are incorporated in the composite material, preferably in the main plates. Such reinforcement elements can be rod, cable, wire, strip or other flat profile. The reinforcing elements can be made of steel, carbon, glass fibers, hemp, as well as other material used for such purposes.

The invention furthermore provides profiles for a building with a pitched roof. Such a roof is relatively rigid and easy to place.

The roof may have a pitched roof shape, wherein the upper edges of the roof elements meeting at the ridge of the roof are oriented transverse to the main plates and in between them define a discharge opening that is in open connection with the hollow chambers of the profile. The wall elements having an undulatory corrugated or comparable first main plate are advantageous, as in case of a first main plate that is turned to the outside the ridge can be covered with a straight ridge strip and then as if of its own accord ridge ventilation passages leading to the outside have been formed between the ridge strip and the first main plate. The ventilation achieved in that way is suitable for very hot areas, wherein the roof surface can be strongly heated up by the sun during the day. This is advantageous when the eaves are kept open, that means accessible to air that will flow upward through the wall elements in the roof for cooling it down and is able to leave there, in both roof planes. The ridge strip can be kept simple here. Therefore, the present invention can produce air cooled roof elements due to the fact that air in the open channels heated by the sun will create an upward draft of air thereby pulling in cooler air from the lower end of the profile panel and releasing hot air at the top ridge. On the other hand in cold areas the cavities in the roof profiles can be used for partially or fully filling them with foam or in another way, as a result of which the roof surface is provided with larger heat insulation capability.

BRIEF DESCRIPTION OF DRAWINGS

The invention will be elucidated on the basis of an exemplary embodiment shown in the attached drawings, in which:

FIGS. 1A and 1B show end views of an embodiment of a wall panel wall element according to the invention, in solitary condition and in mutually joined condition, respectively;

FIG. 1C shows the wall panel of FIGS. 1A,B having individual reinforcement elements embedded in the material of the panel;

FIGS. 2A and 2B show a second embodiment of a panel/wall element according to the invention in solitary condition and in mutually joined condition, respectively;

FIG. 3 shows a schematic, diagonal front view of a wall composed from a plurality of wall elements according to the invention;

FIG. 3A shows a diagonal front view of the wall of FIG. 3, in an arrangement as a shore/bank, head wall or sea wall and provided with a cap;

FIG. 3B shows a cross-section of a cap of the arrangement according to FIG. 3A;

FIG. 3C shows an alternative embodiment of a wall in cross section constructed with wall elements according to the invention having another embodiment of a cap;

FIG. 3D is a schematic representation of the arrangement with the shore/bank head wall according to FIG. 3A in cross-section;

FIG. 3E is a cross-section schematic view showing details of FIG. 3D;

FIG. 4 shows a schematic arrangement of a wall composed of a plurality of wall elements according to the invention, as a noise barrier;

FIGS. 4A-C show a front view, a horizontal cross-section and a vertical cross-section, respectively, of the wall of FIG. 4;

FIG. 4D shows a wall panel according to the invention suitable for incorporation in noise barrier structures;

FIGS. 5A and 5B show a further embodiment of a panel according to the invention, without and with, respectively, individual reinforcement elements embedded in the material of the panel;

FIG. 6A shows a third embodiment of a wall panel according to the invention consisting of two unassembled parts; and

FIG. 6B shows an alternative embodiment of parts similar to the unassembled panel to form an assembled panel.

The panel 1′ in FIG. 1A is made by extrusion from a composite of a thermoplastic synthetic material, particularly polyolefin, such as polyethylene or polypropylene, or PVC or polycarbonate. The preferred material is polypropylene. In the polypropylene matrix wood particles comprising wood fibers or other cellulose-containing particles are embedded. The content of wood particles is more than 50% by weight, preferably more than 70% by weight, more preferably between 70-80% by weight, and the content of polypropylene is complementary thereto, preferably 20-30% by weight. A particularly preferred ratio is approximately 72/28% by weight. Such a material is available from the applicant under the trademark TECH-WOOD® and has proven its strength, rigidity and durability. The material has a wood-like appearance and after extrusion already has a smooth surface. The material has a E-modulus of at least 4000 MPa, preferably 4000-8000 MPa. FIG. 1B shows two panels of the type shown in FIG. 1A in assembled condition.

Further increase of the constructional strength and rigidity of the panel can be achieved when continuous reinforcement elements are extruded along in the panel for accommodation in the composite material, extending in the direction of extrusion, as seen in FIG. 1C. The E-modulus can then be considerably higher, between 6000-12000 MPa.

FIG. 1C shows the panel 1′ of FIG. 1A with continuous reinforcement elements 3a incorporated therein for increasing the rigidity and the strength.

The wall element 1′ shown in the FIGS. 1A and 1B is made of the thermoplastic-wood particle material described herein above. The method of manufacturing has been described in U.S. Pat. No. 6,929,841. In this case, reinforcement elements can also be incorporated therein, see FIG. 1C.

At a first traverse edge 5′, the wall element 1′ of FIGS. 1A and 1B is provided with a recess R of a depth for instance of 24 mm, defined by transverse edge 5′ and by extensions 10′ of the main plates 2′, 3′. The thickness of the wall continuations 10′ and the main plates 2′, 3′ is usually the same, for instance 7 mm. The thickness of the transverse edges 5′, 6′ and 4′ is typically the same, and preferably also the same as the main plates 2′ and 3′. The main plates 2′, 3′ and the transverse end 4′ and the transverse edges or ribs 6′, 5′ enclose generally rectilinearly shaped hollow chambers 40′. The chambers are elongated in the direction perpendicular to the plane of drawing: the largest length of the wall element 1′ is in the direction transverse to the end surface indicated, for instance, several meters. The effective width is for instance 250 mm and the depth 76 mm.

The second edge of the panel 1′ with transverse end 4′ forms a protrusion of for instance 24 mm that may be fittingly accommodated in the accommodation recess space R defined by the wall continuations 10′, as can be seen in FIG. 1B.

In the wall parts 8′ parallel to the main plates 2′, 3′ raised portions 9′ have been disposed at the outside surface of the panel and are dimensioned in order to leave slits 60a, 60b between two adjacent wall panels 1′ when assembled, in order to thus provide room for expansions caused by, for instance, moisture absorption in the wall panels 1′.

The wall panel 1″ in the FIGS. 2A and 2B for a large part corresponds to wall panel 1′ of FIGS. 1A,B wherein the thickness of the transverse walls 4″, 5″, 6″, at least in the center area thereof, is slightly smaller (e.g. 6 mm) than the thickness of the main plates 2″ and 3″. Furthermore, the panel projections 9″ are provided on the outside of the transverse end wall 4″, for abutment against the outside of the transverse wall 5″ of the adjacent wall panel 1″ when assembled together (see FIG. 2B). The wall panel 1″ can be made similarly, of the same material as wall panel 1′.

In case the wall panels 1′ are used for a noise barrier a resilient sound-sealing strip 61 can be disposed between the projections 9″ by clamping in order to close off the slit 60a thereby preventing air leakages and thus noise leakages.

Depending upon the intended use, the wall panels 1′ and 1″ can also be joined by approaching in a direction transverse to the direction of the chambers or according to a direction parallel to those of the chambers, depending on what the best approach is for the desired use.

For instance, a wall 90 as shown in FIG. 3 can be created, wherein the profile direction is vertical. This may be of particular use in noise barriers, earth retaining walls and water retaining walls. A bank/shore covering wall of a water body, such as a lake, fresh water or sea or sea channel or canal, will be discussed below by way of example, wherein a plurality of the wall panels 1; etc., have to be driven into the ground far below the water line.

The placed wall elements 1′ may, at the top, be covered by a cap, as shown in FIG. 3A, where U-shaped caps 70 (FIG. 3B), of wood composite material comparable to that of which the wall panel 1′ has been made, also obtained by extrusion, are placed over the upper end of the wall panels 1′. The legs of the U-profile may be provided with pilot edges. The inner surface of the upper wall may be provided with spacing ribs 71 to prevent the cap from resting with its rounded corners inside on the sawn edges of the wall profiles.

In FIG. 3C an alternative cap is shown, again made by extrusion of the same material, albeit in three parts, screwed together in order to form a cap 80, as shown.

In the FIGS. 3A and 3D the wall of FIG. 3A is shown in an arrangement functioning as a bank/shore wall or head wall, wherein the bank/shore wall is kept vertical by means of a purlin 42, an anchor rod 43, and an anchor plate 44, see FIG. 3D. In the common parlance, anchor rod and anchor plates are called “dead man tie back”. In that case, water may also penetrate the chamber 40 of the wall element 1′. When there is question of frost conditions the water in the chamber 40 may also freeze, and the chamber walls might get damaged by ice expansion. According to the invention, this is prevented by providing the chamber 40 at the location of the freezing area of the water with a filling, as a result of which the volume of water present can expand during freezing without building up material stresses that can cause damage. Preferably the filling is compressible, in order to buffer the expansion of the remaining water at that location, and thus to safeguard the walls of the chamber from too high expansion forces. A suitable filling material is a closed-cell synthetic foam, schematically shown in detail in FIG. 3E, in the form of polyethylene foam tube 41 having closed cells, of which the end can be turned and inserted into the chambers 40 in order to properly remain in place.

The wall elements according to the invention can also be used for noise absorption, see FIGS. 4 and 4A. The wood-like appearance of the wall panels in this embodiment can ensure a proper fit with the surroundings. The mass of the wall panels in this case is preferably at least 10 kg/m² or more, which can easily be achieved. Possible air leakage due to the connections between the wall panels that cause noise leakages can be prevented by a snug fit of the groove/tongue and optionally by sealing material, preferably strip-shaped.

In FIG. 4 an arrangement is shown with a noise barrier wall 90′ assembled from a plurality of wall elements 1′ according to the invention. The wall 90′ is placed between the building X and motorway Y and reflects the noise of the traffic. The wall 90′ in FIG. 4A is built up from a number of columns 91 having an H-shape. The columns 91 can be made of the same material as the wall elements 1′. Alternatively they can be made of steel. The columns 91 are fixed on concrete pedestal footings that are not further shown. Wall elements 1′ are stacked horizontally (see FIGS. 4A and 4C) between the columns 91, wherein the direction of the coupling is vertical. The longitudinal ends of the wall elements 1′ are in this case accommodated in the accommodation spaces defined by the H-profiles. In said accommodation spaces, tubes or hollow or round or square foamed elements with a closed cell structure 92 such as polyethylene foam with closed cells, comparable to pipes 40 of FIG. 3E, are placed, with which noise leakages can be prevented. The tubes or hollow, round or square foamed elements pressed between the ends of the wall elements 1′ and the H-profiles 91′ (See FIG. 4B), ensure permanent sealing due to their elasticity and are protected from UV radiation by the legs of the H-profiles. Due to their resilience, the foam tubes or hollow, round or square foamed elements 92 also ensure that an expansion provision is provided for the wall elements when they expand in their longitudinal direction due to gradual absorption of moisture.

Particularly for noise absorption, it may be advantageous to provide the noise barrier side of the wall panels, see wall panel 201 in FIG. 4D, with holes 241 connecting with the chambers 240. The holes form at least 15% of the overall surface at that side. The chambers 240 may function as sound muffling casing. Sound-absorbing material 242, such as mineral wool is placed in the chambers.

FIG. 5A shows a wall panel 31 that is particularly suitable for use as roof element for pitched roofs. In the example the first main plate 32 is formed undulatory or corrugated, but optionally can be a zig-zag shape or sheet pile wall shape. The first main plate 32 is intended to be situated at the outside or exterior of the roof, and the second main plate 33, which is straight, at the base and adjacent sub-roof structure. The main plates 32 and 33 are connected to each other by means of transverse walls or ribs 34, 35 and 36, which also define the rectilinear spaces 41 therebetween.

At its end edges, the panel 31 is provided with accommodation spaces 39, 42 and 43, respectively. The accommodation space 39 is a recess and is limited by confining edge 37 at one side, which confining edge 37 fits into the notch space 42 of an adjacent panel (not shown), wherein confining edge 44 of the adjacent panel is able to engage behind and interlock with confining edge 37. In the same way, confining edge 38 fits in the space 43 of the adjacent panel. The confinement connection can be realized by sliding in two panels 31 along each other in the profile direction to accomplish a mating engagement of two adjacent panels.

Sliding in the longitudinal direction is advantageous when arranging a roof consisting of panels 31, as after placing a first panel 31 in a desired location the next panel can simply be slid from the bottom up while coupling the end edges that are facing each other.

The valleys in the main plate 32 may be intended for water discharge. Attachment means may be passed through at the location of the crests (not shown), in order to remain free of discharged water. It is observed that the transverse walls 36 are situated offset with respect to the crests of the main plate 32, in order to offer room to the fastening bolts passed through the crests.

The main plate 33 is level so that mounting to the supporting parts of the roof structure is easy.

In FIG. 5B the panel 31 of FIG. 5A is shown with continuous reinforcement elements 33a accommodated therein, in order to increase the rigidity and strength.

The panels according to the invention may, depending on the intended use, for the sake of efficiency of transport also consist of two parts, as shown in the FIGS. 6A and 6B. At the main plate 312 transverse wall members 314b, 315b and 316b are formed that end in snap accommodation spaces 318. The main plate 313 for mating engagement with plate 312 is formed with transverse wall members 314a, 316a and 315a and end in snap protrusions 317. The transverse wall member 314a and the transverse wall member 315a at the location of 319 are offset to the inside for letting the transverse wall members 314a, 314b, 315a and 315b, become substantially aligned after connecting both panel members by insertion of the snap protrusions 317 in the snap spaces 318.

As can be seen in FIG. 6A the main plate 312 can be supported offset on main plate 313, so that transport height hi is much smaller than the height in mounted assembled condition, namely h2+h3. Thus, the unassembled panel member can be transported efficiently by saving loading and storage space.

The dimensions h2 and h3, and thus h1, may be varied as desired, shown in FIG. 6B with h4 and H. Comparable parts have comparable reference numbers, increased by 10. For instance, a h1 and h4 of 40 and 80 cm respectively may be provided and a height of h3 and h5 of 40 and 80 cm, wherein panel thicknesses of 80, 120 and 160 cm, respectively, can be made.

The snap connection such as between protrusions 317 and accommodation spaces 318 is formed such that there is question of an at least almost rigid constraint. After joining together by snapping, which is easy to do at the building site without using tools, an assembled panel is obtained which, as regards strength, can be compared with panel 1′, yet which due to the possibility of transport in the arrangement as shown in FIG. 6A requires less transport volume.

Further variations and modifications of the foregoing will be apparent to those skilled in the art and are intended to be encompassed by the claims appended hereto.

Claims

1. Wall element wherein the wall element is made from a composite material having a synthetic matrix and incorporated therein wood particles, wherein the wall element is panel-shaped and comprises a first main plate, a second main plate spaced therefrom and a plurality of transverse plates connecting both first and second main plates to each other, wherein both main plates and the transverse plates define hollow spaces, wherein said first and second plates have a major dimension and a minor dimension, said major dimension being a profile direction, wherein the wood particles comprise a fraction of elongated wood particles, which elongated wood particles are predominantly oriented in the profile direction, wherein the wall element has first and second opposite longitudinal edges extending in profile direction, which longitudinal edges are provided with a first and second coupling member, respectively, wherein the first coupling member defines an accommodation recess space for receiving a protrusion formed on a second coupling member at a second longitudinal edge of another wall element when assembled therewith, wherein the accommodation recess space is defined by plate continuations of each first main plate and second main plate.

2. Wall element according to claim 1, wherein each first and second plate continuations extend over the same distance.

3. Wall element according to claim 2, wherein the first and second the main plates and plate continuations have the same thickness.

4. Wall element according to claim 1, wherein each first and second main plates have the same thickness.

5. Wall element according to claim 1, wherein each first and second plate continuations have the same thickness.

6. Wall element according to claim 1, wherein a protrusion extends from an end transverse wall opposite to said accommodation recess space.

7. Wall element according to claim 1, wherein the length of the wall element in profile direction is larger than the width of the wall element.

8. Wall element according to claim 1, wherein the thickness of the first and second main plates and the transverse walls is the same.

9. Wall element according to claim 1, wherein the first and second coupling members are provided with an expansion joint.

10. Wall element according to claim 1, wherein the first coupling member can be brought into mating operative connection with a second coupling member of an adjacent wall element when assembled by sliding said first coupling member into said second coupling member of an adjacent similar wall element.

11. Wall element according to claim 1, further comprising continuous reinforcement elements incorporated with the composite material.

12. Wall element according to claim 1, which has been surface treated by brushing or embossing to provide enhanced wood-like appearance.

13. Wall element according to claim 1, which has been brushed to obtain enhanced adhesion for water-based paints.

14. Wall element according to claim 1, wherein the first coupling member can be brought into operative connection with a second coupling member by sliding said first coupling member transverse to the profile direction, parallel to the first and second main plates.

15. Wall element having a major dimension and a minor dimension made from a composite material having a synthetic matrix and incorporated therein wood particles, wherein the wall elements are panel-shaped and comprise a first main plate, a second main plate and a plurality of transverse plates for connecting both first and second main plates to each other, wherein said first and second main plates and the transverse plates when assembled define hollow spaces therebetween, wherein the wood particles of the composite comprise a fraction of elongated wood particles, which elongated wood particles are predominantly oriented in a profile direction, wherein the wall element is provided with first and second end edges extending substantially in a profile direction conforming to said major dimension, which end edges are provided with first and second cooperating coupling means, respectively.

16. Wall element according to claim 15, wherein the first coupling means are provided with projections having hooks that extend from the first end edge and the second coupling means are provided with grooves in recessed areas of the second end edge.

17. Wall element according to claim 15, wherein the first and second end edge are provided with a transverse plate.

18. Wall element according to claim 15, wherein the first and second coupling means are formed for forming a snap coupling.

19. Wall element according to claim 15, wherein the transverse walls or transverse plates are provided with openings for passing a tensioning element.

20. Wall element according to claim 15, provided with recesses at the first and/or second longitudinal edges, near the longitudinal ends of the wall element.

21. Wall element according to claim 15, wherein the height of the recess at least almost corresponds to half the height of the wall element.

22. Wall element according to claim 21, wherein the wall element comprises several parallel hollow chambers.

23. Wall element according to claim 21, wherein the first and second edges are formed for mutually fitting in each other.

24. Wall element according to claim 21, wherein the first edge forms a narrowed protrusion and the second edge an accommodation space for a first edge of an adjacent second similar wall element when assembled with said wall element, wherein the recess is arranged in the second edge.

25. Wall element for partitions, retaining walls and barrages, made by extrusion from a composite material having a synthetic matrix and incorporated therein wood particles, such as wood fibers or other cellulose-containing particles, wherein the wall elements are panel-shaped and comprise a first main plate, a second main plate spaced therefrom and transverse plates connecting both main plates to each other, wherein both main plates and the transverse plates define one or more hollow spaces, wherein the wood particles comprise a fraction of elongated wood particles, which elongated wood particles are predominantly oriented in profile direction, wherein the wall element is provided with first and second end edges extending substantially in profile direction, wherein the first and second edges are formed for mutually fitting into each other.

26. Wall element according to claim 25, wherein the first edge forms a narrowed protrusion and the second edge an accommodation space for the first edge of an adjacent similar wall element.

27. Wall element according to claim 26, stackable with similar wall elements having the corresponding main plates in at least almost the same plane.

28. Wall element according to claim 27, wherein the first main plate and the second main plate form separate parts that can be coupled to each other, wherein the transverse plates are divided into a first portion that is formed as a one piece unit with the first main plate and a second portion that is formed as a one piece unit with the second main plate.

29. Wall element according to claim 28, wherein the first and second main plates are coupled to each other by means of a rigid coupling.

30. Wall element according to claim 1 for a roof, wherein the first main plate is formed with crests and valleys in a corrugated manner.

31. Wall element for walls, such as head walls, ceilings or roofs of buildings and noise barriers, made by extrusion from a composite material having a synthetic matrix and incorporated therein wood particles, such as wood fibers or other cellulose-containing particles, wherein the wall elements are panel-shaped and comprise a first main plate, a second main plate spaced therefrom and transverse plates connecting both main plates to each other, wherein both main plates and the transverse plates define hollow spaces, wherein the wood particles are predominantly oriented in profile direction, wherein the first main plate and the second main plate form separate parts that can be coupled to each other.

32. Wall element according to claim 31, wherein the transverse plates are divided into a first part that is formed as a one piece unit with the first main plate and a second part that is formed as a one piece unit with the second main plate, wherein preferably both transverse plate sections coupling.

33. Wall element according to claim 31, wherein the first and second main plates are coupled to each other by means of a rigid coupling.

34. Wall element according to claim 1, wherein the content of wood particles is between 50 and 85% by weight.

35. Wall element according to claim 1, wherein the synthetic material is a thermoplastic synthetic resin material.

36. Wall element according to claim 1, wherein the thermoplastic synthetic material is a polyolefin, PVC or polycarbonate.

37. Wall element according to claim 36, wherein the synthetic material is polypropylene or polyethylene.

38. Wall element according to claim 37, wherein the hollow sections are filled with tubular foam elements.

39. Building having a pitched roof constructed with wall elements according to claim 1.

40. Building according to claim 39, wherein the roof has a pitched shape, and wherein the upper edges of wall elements meeting at the ridge of the roof are oriented transverse to the main plates and in between them define a discharge opening that is in open connection with the hollow spaces.

41. Building according to claim 40, wherein the discharge opening is upwardly covered by a ridge strip.

42. Earth or water-retaining structure constructed with wall elements according to claim 1.

43. Earth or water-retaining structure according to claim 42, wherein the upper side of the wall elements is covered by a cap, wherein the cap is U-shaped.

44. Noise barrier structure constructed with wall elements according to claim 1.