Multi-layer ceiling panel for a building ceiling, building and method for manufacturing a multi-layer ceiling panel

Abstract

A multi-layer ceiling panel (3) for a building ceiling comprises a wood material layer (6) and a concrete material layer (7) with reinforcement (13), wherein the reinforcement (13) includes at least one prestressed strand (16) for forming prestressed concrete. Furthermore, a method for producing the multi-layer ceiling panel (3) is described.

Description

[0001] The invention relates to a multi-layer ceiling panel for a building ceiling. Furthermore, the invention relates to a building with such a multi-layer ceiling panel. The invention also relates to a method for manufacturing a multi-layer ceiling panel.

[0002] A multi-layer ceiling panel is known from WO 2022 / 232 851 A1. A disadvantage is that such a multi-layer ceiling panel is complex to manufacture and requires improvement with regard to material usage, transport costs, and strength.

[0003] The invention is based on the objective of providing an improved multi-layer ceiling panel for a building ceiling, which is particularly robust in use, has a low weight, and is particularly economical to manufacture, transport and assemble.

[0004] This problem is solved by a multi-layer ceiling panel with the features of claim 1. It has been recognized that a multi-layer ceiling panel for a building ceiling can have at least one prestressed tendon strand for forming prestressed concrete, thereby increasing the strength of the multi-layer ceiling panel, reducing its weight, saving material, and reducing transport and installation costs. The at least one tendon strand is preferably arranged in the lower region, particularly in the lower half, and especially in the lower third, of the concrete material layer, particularly of the multi-layer ceiling panel. This allows tensile forces due to bending loads, especially under the self-weight of the multi-layer ceiling panel, to be compensated.

[0005] Contrary to expectations, prestressing does not lead to increased stress in the interface between the wood and concrete layers, which should be avoided as much as possible. While increased forces do initially occur in the contact area between the wood and concrete layers, particularly immediately after fabrication, these forces are significantly reduced when the multi-layer floor slab is laid on the building walls, resulting in lower stresses than would occur without prestressing. Thus, not only is the concrete layer relieved of stress, but also the relevant contact area between the wood and concrete layers.

[0006] The tension of the at least one prestressing strand is preferably determined and adjusted such that the stress on the multilayer ceiling panel when resting on edge supports, particularly the building walls, is especially low. For this purpose, the prestressing can be determined taking into account the installation situation and / or the length and / or width and / or thickness of the multilayer ceiling panel.

[0007] Preferably, the multi-layer ceiling panel comprises at least two, in particular at least three, in particular at least four, in particular at least five, and / or a maximum of 20, in particular separately tensionable, prestressing strands. This ensures a particularly uniform stress distribution.

[0008] The connection between the concrete layer and the wood layer is preferably made by pouring the concrete onto the wood layer. For improved bond strength, connecting elements can bridge the concrete and wood layers, for example, pin-shaped connecting elements such as nails and / or screws, which can be inserted into the wood layer before the concrete is poured, preferably at an angle, and protrude from the wood layer to connect it to the concrete layer.

[0009] The wood material layer preferably has a wood content of at least 70%, in particular at least 80%, in particular at least 90%, in particular at least 95%, in particular 100%, especially by volume. Furthermore, the wood material layer may comprise a matrix material and / or an adhesive and / or wood glue and / or a decorative layer.

[0010] The wood material layer can consist of at least one, in particular several, plywood panels and / or OSB panels and / or laminated wood panels and / or chipboard and / or veneers.

[0011] The multi-layer ceiling panel can consist solely of the wood material layer and the concrete material layer. Alternatively, the multi-layer ceiling panel can have additional layers, for example, an insulation material layer. The volume fraction of the insulation material layer in the multi-layer ceiling panel is preferably a maximum of 60%, more particularly a maximum of 40%, and more particularly a maximum of 20%, and / or a minimum of 10%.

[0012] The concrete material layer may contain a filler, in particular a foamed material, in particular expanded glass, in particular to a volume fraction of at least 10%, in particular at least 20%, in particular a maximum of 60%.

[0013] The concrete used is preferably low-shrinkage concrete.

[0014] Preferably, the at least one prestressing strand is connected to the concrete layer by immediate bonding. Alternatively, the connection to the concrete can be made by subsequent bonding and / or without bonding.

[0015] The bearing surface for placing the multi-layer ceiling panel on the building walls is preferably provided by the wood material layer, or alternatively by the concrete material layer.

[0016] The reinforcement can comprise at least one reinforcing steel mesh and / or a support cage and / or the prestressing strand. The support cage is also referred to as a lattice girder.

[0017] The thickness of the concrete layer, in particular its maximum thickness, is preferably a maximum of 25 cm, in particular a maximum of 20 cm, in particular a maximum of 18 cm, in particular a maximum of 15 cm, in particular a maximum of 12 cm, and / or at least 6 cm, in particular at least 8 cm, in particular 10 cm. Alternatively or additionally, the wood layer may have this thickness, in particular this maximum thickness, and / or be 2 cm, 4 cm or 6 cm thinner.

[0018] The inclusion of at least one prestressing strand in the multi-layer ceiling panel is optional. Further aspects of the invention are described below, which can be provided alternatively or additionally to the at least one prestressing strand and result in a particularly robust, weight-reduced, and material-saving multi-layer ceiling panel.

[0019] It is also optional for the multi-layer ceiling panel to include the wood material layer. Alternatively, a layer of another material, preferably a renewable raw material and / or a lighter material than concrete, in particular an insulating material layer, can be provided.

[0020] According to one aspect, the multi-layer ceiling panel can have a positive-locking profile between the wood material layer and the concrete material layer. The positive-locking profile is preferably designed such that the wood material layer and the concrete material layer overlap in an orthogonal projection onto a plane perpendicular to the main extension plane of the multi-layer ceiling panel. The resulting positive-locking connection ensures that forces, in particular shear forces, can be reliably transferred between the wood material layer and the concrete material layer.

[0021] The interlocking profile can have at least one recess, in particular a groove and / or a bore and / or a wave-like shape, and / or at least one projection, in particular a rib, in particular a tongue, and / or a tenon. The at least one recess can be formed in the wood material layer and the at least one projection can be formed in the concrete material layer, or vice versa, or a combination thereof. The at least one groove is particularly preferably arranged in the wood material layer. The at least one groove can extend over the entire dimension of the wood material layer, in particular parallel to the main plane of extension, in particular to the longitudinal extension of the multi-layer ceiling panel.

[0022] The interlocking profile, in particular the at least one recess, and especially the at least one groove, may have at least one undercut, in particular a widening and / or a tapering, especially when viewed in the longitudinal direction of the groove and / or perpendicular to the main plane of extension of the multi-layer floor slab. The at least one rib that interacts with the at least one groove may have a corresponding design. Due to the undercut, forces in the longitudinal direction of the groove or in the orthogonal direction of the slab can be transferred particularly reliably between the wood material layer and the concrete material layer.The undercut, in particular the widening and / or the tapering, is preferably designed such that it has at least one, in particular at least two, in particular two opposing, flanks that form an angle of at least 10°, in particular at least 30°, in particular at least 45°, in particular at least 60°, in particular at least 70°, in particular 90°, to the longitudinal direction of the groove and / or to the orthogonal direction of the plate. This allows for interlocking in the longitudinal direction of the groove. It prevents forces in the longitudinal direction of the groove and / or to the orthogonal direction of the plate from causing the groove to spread or forces transverse to the longitudinal direction of the groove. This results in a particularly robust connection between the wood material layer and the concrete material layer.The at least one widening and / or tapering can alternatively or additionally be oval, in particular elliptical, in particular circular, and / or mirror-symmetrical, in particular with a plane of symmetry oriented parallel and / or perpendicular to the groove longitudinal direction, and / or arrow-shaped, with an arrowhead pointing in the groove longitudinal direction, in particular towards the center of the multilayer ceiling panel, in particular in a plan view of the multilayer ceiling panel.

[0023] Preferably, the at least one prestressing strand can be arranged in the interlocking profile, particularly in the at least one groove, and especially within the wood material layer. Preferably, at least one prestressing strand, and especially exactly one prestressing strand, is provided per groove. The at least one prestressing strand can, in particular, be arranged in a smallest convex envelope of the wood material layer. This advantageously reduces forces, especially shear forces, between the wood material layer and the concrete material layer. In particular, a stress-reduced area, especially the neutral axis, of the multi-layer ceiling panel can be shifted into the contact area between the wood material layer and the concrete material layer by means of the prestressing strand when the panel is bent under its own weight.

[0024] Preferably, the multi-layered slab has three-dimensional reinforcement, in particular comprising a reinforcing steel mesh and / or a support cage and / or at least one prestressing strand. The reinforcement, in particular the support cage, preferably extends into the interlocking profile, in particular into the at least one groove, and into a plate-shaped area of ​​the concrete material layer and / or bridges it.

[0025] According to another aspect, the multi-layer ceiling slab can be designed as a semi-precast slab. The concrete layer can, at least partially, be produced as cast-in-place concrete, particularly on-site for the construction of the building it will form.

[0026] According to a further aspect, the wood material layer and / or the concrete material layer each extend over at least 80%, in particular at least 90%, in particular 100%, of the total area of ​​the multi-layer ceiling slab, particularly parallel to its main plane of extension. In an orthogonal projection onto a main plane of extension of the multi-layer ceiling slab, the wood material layer and the concrete material layer preferably overlap over at least 80%, in particular at least 90%, in particular 100% of their areas.

[0027] Another aspect is that the surface of the concrete layer adjacent to the concrete layer can be made water-repellent, in particular hydrophobic. For this purpose, the wood layer, especially its surface, can be treated with silicone-based substances, particularly siloxane. This advantageously counteracts the loss of water from the concrete and prevents the wood layer from being damaged by the moisture of the freshly poured concrete.

[0028] Another objective of the invention is to create an improved building which is particularly robust, has reduced weight and can be manufactured with particularly low material, transport and assembly costs.

[0029] This problem is solved by a building with multiple walls and at least one, and in particular several, multi-layer ceiling panels on these walls, as described above. Preferably, the concrete layer is arranged above the wood layer. The wood layer, in particular a laminated timber panel and / or a veneer, is preferably visible in the installed state, especially from below. The advantages of the building preferably correspond to the advantages of the multi-layer ceiling panel. The building can be further developed with at least one of the features described above in connection with the multi-layer ceiling panel.

[0030] A further object of the invention is to provide an improved method for manufacturing a multi-layer ceiling panel, which in particular leads to a particularly robust, lightweight multi-layer ceiling panel that can be manufactured with particularly low material, transport and assembly costs.

[0031] This problem is solved by a method for producing a multi-layered slab, comprising the steps of: providing a layer of wood material, arranging reinforcement on the wood material layer, tensioning at least one prestressing strand of the reinforcement, and pouring concrete onto the wood material layer and the reinforcement, in particular the prestressing strand, especially to form prestressed concrete. Preferably, the prestressed concrete is produced with immediate bond. Alternatively, the prestressed concrete can be produced with post-tensioning or without bond. Accordingly, the tensioning of the at least one prestressing strand can take place before or after the pouring and / or curing of the concrete. The advantages of the method preferably correspond to the advantages of the multi-layered slab or the building. Preferably, the method is further developed with at least one of the features described above in connection with the multi-layered slab or the building.

[0032] In one respect, the multi-layer ceiling slab is manufactured as a semi-prefabricated slab. To complete the ceiling slab, cast-in-place concrete can be poured onto the concrete layer, particularly at the building's construction site.

[0033] Further features, advantages and details of the invention will become apparent from the following description of an exemplary embodiment with reference to the figure: Fig. 1 a sectional view of a building with a building wall and a multi-layer ceiling slab arranged on it, comprising a wood material layer and a reinforced concrete material layer.

[0034] Based on the Fig. Figure 1 describes an embodiment of a building 1. The building 1 comprises several building walls 2.1, 2.2 and at least one building ceiling, which is designed as a multi-layer ceiling panel 3 and rests on the building wall 2.1.

[0035] The building walls 2.1, 2.2 are designed as exterior walls in this case, but could also be interior walls. According to a typical construction, insulation 4 abuts a narrow side of the multilayer ceiling panel 3 located against the exterior wall. Alternatively, according to a further development, the insulation 4 can be formed as a single unit with the multilayer ceiling panel 3.

[0036] One exterior surface of the building walls 2.1, 2.2 has an exterior plaster 5.

[0037] The multi-layer ceiling panel 3 comprises a wood material layer 6 and a concrete material layer 7; in particular, the multi-layer ceiling panel 3 consists of these two layers. The concrete material layer 7 is in contact with the wood material layer 6.

[0038] In an orthogonal projection onto a principal extension plane 8 of the multilayer ceiling panel 3, the wood material layer 6 and the concrete material layer 7 preferably overlap each other by at least 70%, in particular at least 90%, and in particular completely. A contact surface 9 between the wood material layer 6 and the concrete material layer 7 preferably extends over at least 60%, in particular at least 80%, in particular at least 90%, and in particular 100% of the dimensions of the multilayer ceiling panel 3 along the principal extension plane 8.

[0039] The wood material layer 6 preferably has a wood content of at least 80%, particularly at least 90%, and particularly at least 98%. Preferably, the wood material layer 6 comprises a particleboard and / or an OSB board 11 and / or a plywood board 12 and / or a laminated wood board and / or a fiberboard and / or a face veneer 10. The face veneer 10 can form a surface of the multilayer ceiling panel 3. Particularly preferably, the wood material layer 6 comprises, particularly from the inside out and / or from top to bottom, at least one, and in particular several, OSB boards 11 and / or at least one, and in particular several, plywood boards 12 and / or laminated wood boards and / or the face veneer 10.

[0040] Optionally, the multi-layer ceiling panel 3, in particular the wood material layer 6, can have an insulating material layer (not shown). The insulating material layer can comprise a fibrous material, in particular a natural fiber material, and / or a foamed material, in particular a ceramic foam and / or a plastic foam.

[0041] The concrete layer 7 has reinforcement 13. The reinforcement 13 can comprise a reinforcing steel mesh 14 and / or support cages 15 and / or prestressing strands 16. The reinforcing steel mesh 14 is preferably attached to the support cages 15. The prestressing strands 16 can be formed separately. The reinforcement 13, in particular the reinforcing steel mesh 14 with the support cages 15, extends three-dimensionally in the multi-layered slab 3, particularly in the concrete layer 7, especially with a considerable extension perpendicular to the main extension plane 8, and in particular over a height h. Bof at least 3 cm, in particular at least 5 cm, in particular at least 8 cm, in particular 10 cm.

[0042] The prestressing strands 16 are embedded in the concrete layer 7 under prestress, specifically in a bonded configuration. The prestressing force per strand 16 can, for example, range from 5 kN to 250 kN. The prestressed concrete layer 7 makes the multi-layered floor slab 3 particularly robust. Surprisingly, it was also found that the prestressed concrete layer 7 leads to improved adhesion between the concrete layer 7 and the timber layer 6.

[0043] In particular, the robustness of the multilayer ceiling panel 3 is enhanced by arranging the prestressing strands 16 in a groove 17 within the wood material layer 6. This advantageously reduces expansion, especially static expansion, particularly due to the self-weight of the multilayer ceiling panel 3. Stress peaks, especially due to thermal expansion, are also reduced, particularly in the area of ​​the contact surface 9.

[0044] Preferably, the multi-layer ceiling panel 3 comprises a positive-locking profile 18. The positive-locking profile 18 can be designed such that the wood material layer 6 has a recess, in particular the groove 17. The concrete material layer 7 can have a corresponding projection, in particular a rib 19, which engages in the recess. Alternatively or additionally, the wood material layer 6 can have a projection and / or the concrete material layer 7 can have a corresponding recess.

[0045] The interlocking profile 18, in particular the groove 17 and the rib 19, form an undercut in the orthogonal direction 20 of the slab. This promotes the bond strength of the wood material layer 6 with the concrete material layer 7 along the orthogonal direction 20 of the multilayer ceiling slab 3.

[0046] Preferably, the positive locking profile 18 forms an undercut along the groove longitudinal direction 21. For this purpose, the positive locking profile 18, in particular the groove 17, has a widening 22 perpendicular to the groove longitudinal direction 21 and parallel to the main extension plane 8 of the multilayer ceiling panel 3.

[0047] The reinforcement 13 preferably extends into the area within a smallest convex envelope of the wood material layer 6, in particular into the interlocking profile 18, in particular into the at least one groove 17. In particular, the reinforcement 13 extends between the interlocking profile 18, in particular the groove 17 and a flat, in particular plate-shaped, section 23 of the concrete material layer 7.

[0048] Preferably, the contact surface 9 is treated to inhibit water transport, in particular to make it hydrophobic. This prevents the wood material layer 6 from being damaged by water and / or from drawing water from the liquid concrete material, which forms the concrete material layer 7 after hardening. For this purpose, the wood material layer 6 can have a silicone-based, in particular siloxane-based, hydrophobic coating.

[0049] The thickness H of the multilayer ceiling panel 3 is preferably in a range of 10 cm to 40 cm, in particular from 12 cm to 30 cm, and in particular from 15 cm to 25 cm.

[0050] The thickness H H , in particular the maximum thickness, of the wood material layer 6, in particular including the form-fitting profile 18, is preferably in a range of 4 cm to 25 cm, in particular from 6 cm to 20 cm, in particular from 8 cm to 18 cm, in particular from 10 cm to 15 cm.

[0051] The thickness H B, in particular the maximum thickness, of the concrete material layer 7, in particular including the form-fitting profile 18, is preferably in a range of 6 cm to 30 cm, in particular from 10 cm to 25 cm, in particular from 12 cm to 20 cm.

[0052] The height h of the positive locking profile 18, in particular of the groove 17 and / or the rib 19, is preferably in a range of 4 cm to 20 cm, in particular of 6 cm to 16 cm, in particular of 8 cm to 14 cm.

[0053] The length L of the multilayer ceiling panel 3 can be in a range from 3 m to 12 m, in particular from 4 m to 10 m.

[0054] The width B of the multilayer ceiling panel 3 can be in a range of 1 m to 5 m, in particular from 2 m to 4 m, in particular from 2 m to 3 m.

[0055] The multi-layer ceiling panel 3 can be designed as a semi-precast ceiling. To complete the ceiling panel, the semi-precast ceiling can be cast on-site with cast-in-place concrete. In the case of the semi-precast ceiling, concrete may initially be present only in the area of ​​the interlocking profiles 18 and / or the contact surface 9 may be completely wetted with concrete, with the final thickness H B The concrete material layer 7 is only achieved by means of the cast-in-place concrete.

[0056] Preferably the reinforcement 13, in particular the reinforcing steel mesh 14 and / or the support cage 15, protrudes from the precast concrete slab at least section by section for grouting with the cast-in-place concrete.

[0057] To manufacture the multi-layer ceiling panel 3, the wood material layer 6 is first provided. If the wood material layer 6 consists of several components, for example the top veneer 10, the OSB board 11 and / or the plywood board 12, these can first be joined together, for example by means of a positive connection, in particular by means of screws and / or nails, and / or by means of a material connection, for example by gluing.

[0058] The positive locking profile 18, in particular the respective groove 17 and / or the widening 22, can be produced by machining, especially by milling. Alternatively, the positive locking profile 18 can be produced by joining appropriately cut wood material panels together. By making suitable cuts, especially with exclusively panel-orthogonal cuts, both the widening 22 and the positive locking in the panel-orthogonal direction 20 can be produced.

[0059] The reinforcement 13 is placed on the wood material layer 6, in particular into the form-fitting profile 18, in particular into the respective groove 17.

[0060] The tension strands 16 are tensioned.

[0061] The prepared layer of wood material 6 with the reinforcement 13 is preferably arranged on a formwork table with side formwork.

[0062] Concrete is poured onto the wood layer 6, in particular onto the contact surface 9 and into the grooves 17, to create the concrete material layer 7. The concrete hardens and thereby forms a form-fit, and preferably also a material-fit, bond with the wood layer 6, thus forming the concrete material layer 7.

[0063] After the concrete has hardened, the prestressed tendons 16 can be disconnected from the fixing. The tensile stress of the tendons 16 causes a compressive stress on the concrete layer 7.

[0064] The multi-layer ceiling panel 3 is finished and can be transported to the site of building 1 to be constructed.

[0065] Alternatively, the multi-layer ceiling panel 3 can be manufactured as a semi-prefabricated ceiling. The ceiling panel is completed by pouring concrete on-site at the construction site of building 1.

[0066] The multi-layer ceiling panel 3, as described above, is particularly robust. The prestressing of the prestressing strands 16 generates compressive stresses on the underside of the concrete layer 7, which compensate for the bending stress in the installed state. This relieves the concrete layer 7 of stress. Of particular importance is the reduction of forces between the concrete layer 7 and the wood layer 6, resulting in a particularly strong connection between them. This is especially true under alternating stresses caused by thermal expansion.

[0067] The multi-layer ceiling panel 3 is exceptionally lightweight. The reduction in stress, particularly on the concrete layer 7 and / or the connection to the wood layer 6, allows for a reduction in material usage, especially the structural height H, while maintaining the same load-bearing capacity, particularly for a given length L. This reduction in material usage also lowers the transport costs of the multi-layer ceiling panel 3 to the manufacturing site of building 1. The multi-layer ceiling panel 3 is therefore particularly robust, economical to manufacture, and easy to transport and install. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] WO 2022 / 232 851 A1

[0002]

Claims

[1] Multi-layer ceiling panel (3) for a building ceiling, comprising 1.1 a layer of wood material (6) and 1.2 a layer of concrete material (7) with reinforcement (13) characterized by , that 1.3 the reinforcement (13) includes at least one prestressed strand (18) for forming prestressed concrete. [2] Multilayer ceiling panel (3) according to claim 1, characterized by a form-fitting profile (18) between the wood material layer (6) and the concrete material layer (7). [3] Multilayer ceiling panel (3) according to claim 2, characterized by , that the at least one prestressing strand (16) is arranged in the positive locking profile (18). [4] Multilayer ceiling panel (3) according to claim 2 or 3, characterized by , that the positive locking profile (18) has at least one groove (17) in particular in the wood material layer (6). [5] Multilayer ceiling panel (3) according to claim 4, characterized by, that the at least one groove (17) has an undercut, in particular a widening (22), in the longitudinal direction (21) of the groove. [6] Multilayer ceiling panel (3) according to claim 4 or 5, characterized by , that the at least one tension strand (16) is arranged within the at least one groove (17) formed in the wood material layer (6). [7] Multilayer ceiling panel (3) according to any one of claims 2 to 6, characterized by , that the form-fitting profile (18), in particular the at least one groove (17), forms an undercut in the plate orthogonal direction (20). [8] Multilayer ceiling panel (3) according to one of the preceding claims, characterized by a three-dimensional reinforcement (13). [9] Multilayer ceiling panel (3) according to one of the preceding claims, characterized by , that the reinforcement (13) extends into the interlocking profile (18) and / or into the plate-shaped area (23) of the concrete material layer (7). [10] Multilayer ceiling panel (3) according to one of the preceding claims, characterized by a design as a semi-precast ceiling, wherein the concrete material layer (7) is produced at least partially as cast-in-place concrete. [11] Multilayer ceiling panel (3) according to one of the preceding claims, characterized by that the wood material layer (6) and / or the concrete material layer (7) each extend over at least 80% of the main extension plane (8) of the multi-layer ceiling slab (3). [12] Multilayer ceiling panel (3) according to one of the preceding claims, characterized by , that the surface (9) of the wood material layer (6) adjacent to the concrete material layer (7) is made water-transport-inhibiting, in particular hydrophobic. [13] Building (1), comprising 13.1 several building walls (2.1, 2.2), and 13.2 on the building walls (2.1, 2.2) at least one multi-layer ceiling panel (3) according to one of claims 1 to 12. [14] Method for producing a multilayer ceiling panel (3), in particular according to one of claims 1 to 12, comprising the steps: 14.1 Providing a layer of wood material (6), 14.2 Arranging reinforcement (13) on the wood material layer (6), 14.3 Tensioning at least one prestressing strand (16) of the reinforcement (13) and 14.4 Pouring concrete onto the wood material layer (6) and the reinforcement (13) to form prestressed concrete. [15] Method according to claim 14, characterized by Pouring cast-in-place concrete onto the concrete material layer (7).

Images