Sandwichpaneel

Abstract

Sandwich panel (1) for forming a wall or ceiling of a building, comprising an outer sheet (2) and an inner sheet (3), between which an insulating core (4) is arranged, which in particular consists of rock wool or polyurethane foam, wherein the inner sheet (3) has at least one groove (5) for receiving a plastic conduit (6), characterized in that the groove (5) has a cross-section which has a semicircular region (7) with a diameter (8) and a tapered region (9) adjoining the semicircular region (7) with side edges (10) that taper at least in some areas, wherein a ratio of a minimum distance (11) between the side edges (10) to the diameter (8) is greater than 0.7, preferably greater than 0.8, in particular greater than 0.9.

Description

[0001] The invention relates to a sandwich panel for forming a wall or ceiling of a building, comprising an outer sheet and an inner sheet, between which an insulating core is arranged, which in particular consists of rock wool or polyurethane foam, wherein the inner sheet has at least one groove for receiving a plastic conduit.

[0002] The invention further relates to a method for manufacturing a sandwich panel.

[0003] Furthermore, the invention relates to a machine for the production of sandwich panels.

[0004] Sandwich panels of the type mentioned above are known from the prior art, in particular from WO 2024 / 197325 A1. Such sandwich panels have proven effective for forming walls and ceilings of buildings such as halls, which not only provide weatherproofing but also allow for heating or cooling of the interior. This is achieved via pipes embedded in the corrugations, which are pressurized with a fluid to transfer heat from the fluid to the interior, or, in the case of a cooling fluid, from the interior to the fluid. However, it has been shown that the production of such sandwich panels is comparatively complex and costly.

[0005] This is where the invention comes in. The object of the invention is to provide a sandwich panel of the type mentioned above, which can be manufactured in a particularly simple way.

[0006] Furthermore, a simple and feasible method for manufacturing such a sandwich panel should be specified.

[0007] Finally, a machine for manufacturing such a sandwich panel should be specified.

[0008] The first problem is solved according to the invention by a sandwich panel of the type mentioned at the outset, in which the corrugation has a cross-section which has a semicircular area with a diameter and a tapered area adjoining the semicircular area with side edges that taper at least in some areas, wherein a ratio of a minimum distance between the side edges to the diameter is greater than 0.7, preferably greater than 0.8, preferably greater than 0.85, in particular greater than 0.9.

[0009] Within the scope of the invention, it was recognized that the production of the sandwich panel shown in document WO 2024 / 197325 A1 is only possible with considerable effort due to the geometry of the depicted groove. At the same time, inserting a plastic conduit into the groove shown in that document is often difficult due to tolerances of the plastic conduits, and during prolonged operation, mechanical damage and / or undesirable deformations occur due to thermal stresses. These disadvantages are avoided in a sandwich panel according to the invention due to the optimized geometry of the groove, since the constriction, i.e., the ratio of the minimum distance between the side edges to the diameter, is significantly greater. This allows for simpler production, which also reduces the mechanical stress on the inner sheet.Furthermore, with a suitably designed groove, it is also very easy to insert or remove a plastic cable.

[0010] The semicircular area preferably has a semicircular segment; however, it is understood that the corresponding segment can also deviate from a circle and, for example, be elliptical. Even then, a surface contact between an inserted plastic pipe or conduit and the inner sheet metal in the semicircular area can be achieved in the groove.

[0011] Preferably, the sandwich panel is designed and manufactured in such a way that it complies with the standard DIN EN 14509. Accordingly, the inner and outer sheets preferably have a sheet thickness of 0.3 mm to 0.8 mm.

[0012] Materials suitable for the insulating core include, for example, rigid polyurethane foam, expanded polystyrene, extruded polystyrene foam, phenolic resin foam, foam glass and mineral wool, polyurethane (PUR) and polyisocyanurate (PIR).

[0013] It is advantageous if the ratio of minimum distance to diameter is less than 1.0, and especially less than 0.96. This easily prevents the plastic conduit from unintentionally falling out of the groove, for example, when the sandwich panel is used as a ceiling element and the groove is therefore open at the bottom. At the same time, simple and reliable manufacturing is possible.

[0014] Particularly long durability due to reduced mechanical stresses in the metal results when the side edges connect approximately tangentially to the semicircular area and transition into radii that connect the side edges to an inner sheet metal area, which is particularly parallel to an inner sheet metal plane. The inner sheet metal area thus corresponds to a region of the inner sheet metal in which the inner sheet metal is not deformed or has no beads.

[0015] The side edges connecting the semicircular area to the radii can be straight lines in cross-section. Alternatively, the side edges can have a curvature in cross-section, preferably less than the curvature of the semicircular area, to achieve favorable mechanical stress during manufacturing and a long service life. If the side edges have a curvature, it is preferably less than 1 / 2, preferably less than 1 / 5, and particularly less than 1 / 10 of the curvature of the semicircular area. Thus, a radius of curvature along the side edges can be, for example, more than twice, preferably more than five times, and particularly more than ten times the radius of the semicircular area, i.e., half the diameter.

[0016] For reliable manufacturing processes with good mechanical stress resistance of the sheet metal, it has proven effective to use a ratio of diameter to radius greater than 4, and especially greater than 10. For example, the radii can range from 1 mm to 4 mm.

[0017] It is advantageous if the groove has a depth where the ratio of the depth to the diameter is greater than 2, particularly greater than 2.1. This ensures, in particular, that a plastic conduit arranged in the groove with a nominal diameter that is at most equal to the diameter does not protrude from the groove. This prevents, for example, the conduit from touching the plastic conduit when the sandwich panel is placed on a support, thus avoiding potential damage to the conduit.

[0018] Preferably, a plastic pipe is arranged in the groove of such a sandwich panel. The plastic pipe can, for example, carry hot or cold water to heat or cool a space enclosed by the sandwich panel via the inner sheet, thus eliminating the need for separate radiators.

[0019] To achieve high process reliability and prevent mechanical damage caused by thermal stresses in the plastic conduit and the inner sheet metal, it has proven effective for the nominal diameter of the plastic conduit to be smaller than or equal to the diameter of the corrugated sheet, in particular by 0.1 mm to 1 mm smaller, preferably by 0.4 mm to 0.6 mm smaller. This ensures a large contact area between the plastic conduit and the corrugated sheet, resulting in good heat transfer, while simultaneously guaranteeing that the plastic conduit has sufficient space within the corrugated sheet, even considering manufacturing tolerances, thus preventing damage.

[0020] It is advantageous if the plastic conduit is completely enclosed in the groove, with a depth distance between an inner sheet metal plane and the plastic conduit being at least 1 mm, preferably at least 2.5 mm.

[0021] In principle, a suitable sandwich panel can be used for pipes of various types and diameters, for example, for all types of pipes and conduits used in heating systems. Particularly for use as a wall or ceiling element in a hall, it has proven advantageous for the plastic pipe to have a nominal diameter of 10 mm to 25 mm. To achieve particularly good heating or cooling performance, it is preferred that several parallel plastic pipes are arranged in several parallel grooves in the inner panel, with the plastic pipes connected on one side via a supply manifold and on the other via a return manifold. This ensures the most uniform possible heating of the inner panel.

[0022] It is particularly preferred that the supply manifold is connected to a supply line at one end and the return manifold is connected to a return line at the opposite end, so that the flow paths between the supply and return lines have approximately the same length across all the plastic pipes. In this way, approximately the same velocities are achieved in the individual plastic pipes, resulting in similar conditions with regard to temperature and heat transfer.

[0023] The further problem is solved according to the invention by a method of the type mentioned at the outset, in which a bead is first introduced into the inner sheet by roll forming, which has a semicircular area in cross-section with adjoining parallel or diverging side edges, after which the parallel or diverging side edges are deformed inwards to form a bead with at least partially converging side edges.

[0024] In this way, a sandwich panel can be manufactured in a particularly simple and reliable manner. Typically, a method according to the invention is used to manufacture a sandwich panel according to the invention.

[0025] In roll forming, also known as roll forming, a flat sheet metal strip is fed at speeds of up to 120 meters per minute through numerous, for example, more than 20, driven pairs of rollers arranged in a row until the strip is bent into the desired profile shape. The roller pairs have different profiles, with subsequent pairs along the direction of the strip's movement exhibiting profiles that increasingly closely resemble the desired shape. This distributes the potentially large deformation that roll forming is intended to induce in the flat sheet metal strip across the individual roller pairs, resulting in deformation at each pair that ultimately leads to the desired profile shape—in this case, a bead with straight edges in cross-section and a semicircular section.

[0026] It is understood that the term "cross-section" here refers to a cross-section in a plane normal to a longitudinal direction of the groove or of a plastic pipe arranged in the groove.

[0027] To create the undercut or the tapered side edges in the groove, the initially parallel or diverging side edges are deformed inwards in a later step, for example by means of angled rollers.

[0028] Since the groove in the area of ​​the inner sheet metal plane typically has a gap that is smaller than the diameter of a plastic tube to be positioned in the groove, thus preventing the plastic tube from unintentionally falling out, it is preferably provided that a plastic tube is inserted into the groove and fixed in place by deforming its side edges inwards. The plastic tube is inserted into the groove, particularly before or after this inward deformation of the side edges. The method can then be carried out, for example, by first creating a groove with a semicircular cross-section at its end in the inner sheet metal, after which the side edges are deformed inwards. The plastic tube is then inserted and fixed in the groove by the inwardly deformed side edges or the tapered section.When the plastic pipe is inserted into the groove through the tapered area, both the plastic pipe and the groove can be temporarily elastically deformed, especially since the nominal diameter of the plastic pipe is usually larger than a minimum distance between the side edges in the tapered area.

[0029] To achieve particularly low manufacturing costs, it is preferably provided that the sandwich panel is manufactured continuously, wherein, after profiling the inner sheet, an insulating core is arranged between the outer sheet and the inner sheet, in particular foamed onto the outer sheet, in order to achieve a good bond between the outer sheet and the insulating core.

[0030] It is understood that the outer and inner sheets are usually manufactured simultaneously and in parallel. Therefore, if the outer sheet also incorporates a profile, for example a trapezoidal shape to increase mechanical stability, this trapezoidal shape or profile of the outer sheet is also typically formed into the outer sheet by roll forming.

[0031] For manufacturing, it is preferably provided that the outer sheet is manufactured at the bottom, a foaming material is applied to the outer sheet, which then foams up, after which the inner sheet is moved onto the foamed material and held in place until the foaming material has hardened, for example, polyurethane foam. This also corresponds to manufacturing according to the aforementioned standard, although it is of course also possible in principle for the inner sheet to be arranged at the bottom and the outer sheet at the top.

[0032] The inner sheet and / or outer sheet can also be glued to the insulating core and, if necessary, pressed against the insulating core during the curing process to ensure a good bond.

[0033] It is advantageous if the side edges deform inwards due to angled rollers. This results in favorable mechanical stress distribution.

[0034] The third problem is solved by a machine of the type mentioned at the outset, which is designed to carry out a method according to the invention.

[0035] For this purpose, the machine typically has several pairs of rollers arranged in series to create a corresponding bead in a previously flat sheet metal strip. Furthermore, corresponding pairs of rollers can be provided for creating a profile in the outer sheet. The outer and inner sheets are usually cut automatically after roll forming, in a direction perpendicular to the direction of movement of the sheets, resulting in pieces with a length of, for example, 4 m. In the case of continuous production, it can also be provided that the sheets are cut together with the insulating core after the foaming or bonding and pressing process.

[0036] Following the production of the sheets, an insulating core is placed between the sheets, for example by foaming, so the machine can also be designed for this purpose.

[0037] Furthermore, it is advantageous if the machine has clamping devices to clamp the outer and inner sheets together, so that unwanted deformations caused by the foaming material between the outer and inner sheets are avoided.

[0038] Further features, advantages, and effects of the invention will become apparent from the exemplary embodiments described below. The drawings referenced therein show: Fig. 1 and Fig. 2 sandwich panels designed according to the invention; Fig. 3 a detail of a sandwich panel according to the invention; Fig. 4 another detail of a sandwich panel according to the invention; Fig. 5a to 5d Details of a machine for manufacturing an inner sheet metal panel; Fig. 6 a sandwich panel in a heating circuit.

[0039] Fig. 1 and Fig. Figure 2 shows sandwich panels 1 designed according to the invention, each comprising an outer sheet 2, an inner sheet 3, and an insulating core 4 arranged between the outer sheet 2 and the inner sheet 3. As shown, the inner sheet 3 has four grooves 5 in which plastic lines 6 are arranged to transfer heat from a fluid, for example water, transported in the plastic lines 6 to the inner sheet 3 and to release heat from the inner sheet 3 to the fluid, so that a space adjacent to the inner sheet 3 can be cooled.

[0040] Fig. Figure 1 shows a sandwich panel 1 with an outer sheet 2, which has trapezoidal ribs 24 that are particularly advantageous for mechanical stability. Furthermore, the following features are present in the Fig. 1 shown sandwich panel 1 in the grooves 5 plastic pipes 6 shown, while Fig. Figure 2 shows a sandwich panel 1 without plastic conduits 6. The corrugations 5 themselves are each identically designed.

[0041] An insulating core 4 arranged between outer sheet 2 and inner sheet 3 typically fills a space between outer sheet 2 and inner sheet 3 essentially completely to ensure good thermal insulation and can be formed, for example, by rock wool, polyurethane foam, expanded polystyrene, extruded polystyrene foam, phenolic resin foam, foam glass, mineral wool, polyurethane (PUR) and / or polyisocyanurate (PIR).

[0042] Fig. 3 and Fig. Figure 4 shows details of inner sheets 3 of sandwich panels 1, which according to Fig. 1 and Fig. 2 are trained, whereby Fig. Figure 3 shows an area of ​​an inner sheet metal 3 with a groove 5 in which no plastic conduit 6 is arranged. Fig. Figure 4 shows an area of ​​an inner sheet metal 3 with a groove 5, in which a plastic conduit 6 is also arranged.

[0043] As in Fig. Figure 3 shows that the groove 5, in a cross-section (i.e., a section perpendicular to a longitudinal axis 26 of the groove 5), has a semicircular region 7 and adjoining side edges 10, which converge towards an inner sheet plane 13, thus forming a tapered region 9. This easily prevents the plastic conduit 6 from falling out. The side edges are formed by straight lines, which provides good stability, but can also have a curvature, which is usually less than the curvature in the semicircular region.

[0044] As can be seen, the semicircular area 7 has a diameter 8 which is larger than a minimum distance 11 between the side edges 10, so that a plastic cable 6 arranged in the groove 5 is prevented from falling out even when the sandwich panel is installed upside down with the groove 5 open at the bottom. In the illustrated embodiment, the diameter 8 is 20 mm and a minimum distance 11 between the side edges 10 in the area of ​​the tapered section 9 is 16.5 mm, resulting in a ratio of minimum distance 11 between the side edges 10 to diameter 8 of 0.825.

[0045] Furthermore, it can be seen that a center point of the semicircular area 7 has a distance 11 from an inner sheet plane 13, which distance 11 corresponds to more than half the diameter 8, here about 13 mm, so that a depth 14 of the groove 5 of 23 mm results.

[0046] This ensures that a circular plastic pipe or plastic conduit 6 arranged in the groove 5 does not protrude from the groove 5. This situation is in the Fig. Figure 4 shows a plastic pipe 6 with a nominal diameter of 20 mm in groove 5. A pipe tolerance of, for example, +0.3 mm / -0.0 mm is used.

[0047] Due to the nominal diameter of the plastic conduit 6, which is smaller than the depth 14, a depth distance 15 of 3 mm is obtained between the inner sheet plane 13 and the plastic conduit 6. This depth distance 15 ensures that the plastic conduit 6 cannot be damaged if, for example, the sandwich panel 1 rests on a support or if a covering or the like is arranged on the inner sheet 3 in the inner sheet plane 13.

[0048] At the base of the groove 5, where the groove 5 transitions into an inner sheet plane 13, radii 12 are provided that connect the side edges 10 with an inner sheet area located in the inner sheet plane 13, i.e., a part of the inner sheet 3, and have a radius of, for example, 0.5 mm to 10 mm, in particular approximately 2 mm. This results in a secure hold for the plastic conduit 6 arranged in the groove 5 and favorable heat transfer.

[0049] Fig. Figures 5a to 5d show sections of a machine for producing an inner sheet 3 of a sandwich panel 1 according to the invention, namely rollers 21 or pairs of rollers. The illustrated sections follow one another in the machine in the direction of movement of the sheet, so that the Fig. 5a pair of rollers shown in front of the in Fig. The pair of rollers shown in 5b is arranged in front of the roller shown in Fig. The pair of rollers shown in 5c is arranged. The roller 21 and the rollers 23, which are in Fig. The 5d diagrams follow accordingly from the one shown in Fig. Figure 5c shows a pair of rollers. It is understood that further pairs of rollers or rollers 21 and rollers 23 may be arranged between the depicted sections and that the profile 22 shown here is only schematic and not necessarily to scale.

[0050] As in the Fig. As can be seen in Figures 5a to 5d, the profile 22, which is provided on the rollers 21, increases along one direction of movement of the sheet metal, so that, as is usual in roll forming, the sheet metal is continuously deformed during its movement over the pairs of rollers. The profile 22 is shown here only in the area where the rollers 21 adjoin each other; however, it is understood that the rollers 21 generally have the profile 22 along their entire circumference.

[0051] As can be seen, the process begins with the introduction of two central beads 5, whereby the introduction of the beads 5 pulls the sheet metal inwards. The rollers 21 of the Fig. 5a and Fig. 5b therefore only have two profiles 22 to introduce initial groove-like depressions into the inner sheet 3.

[0052] When the two inner beads 5 have reached a full depth 14 after passing through further pairs of rollers, later pairs of rollers create beads 5 located further outwards, which in Fig. 5c and Fig. 5D representation.

[0053] As can be seen, the beads 5 can initially only be created with parallel or diverging side edges 10 by the profiles 22 of the rollers 21. Therefore, in order to form an undercut or the tapered area 9 with the converging side edges 10 of the final beads 5, rollers 23 are provided in a later step, which press the inner sheet 3 inwards in the base area of ​​the beads 5, where the beads 5 border the inner sheet plane 13.

[0054] Fig. Figure 5d shows such inclined rollers 23 rotating about roller axes 25, by which the side edges 10 of the groove 5 are deformed inwards, after the groove 5 has initially been formed as in the Fig. 5c is evident with a semicircular area in cross-section and approximately parallel side edges 10.

[0055] The machine usually displays the in Fig. 5a to Fig. In the sub-areas shown in 5d, a system for cutting off the inner sheets 3 is located downstream, usually in a cutting direction perpendicular to a conveying direction of the sheets over the roller pairs, especially since production over the rollers 21 or roller pairs is generally continuous. The sheets are thus usually cut parallel to an axis of rotation of the rollers.

[0056] It may also be provided that, as part of continuous or discontinuous production, the insulating core 4 is also foamed onto the inner sheet 3 or the outer sheet 2, which can be profiled with an analogous system for forming ribs 24.

[0057] The system for cutting the sheets can also be downstream of a device for foaming the insulating core onto the outer sheet or the inner sheet, so that the outer sheet, inner sheet and insulating core can be cut in one go.

[0058] In this way, the production of a large number or large area of ​​sandwich panels 1 is possible in a particularly efficient manner.

[0059] Inserting a plastic conduit into the grooves therefore takes place after completion of the roll forming process, i.e., also after the inward deformation of the side edges according to Fig. 5d. In principle, however, it can also be provided that the plastic conduit is inserted before the side edges are deformed inwards, for example by additional rollers.

[0060] Fig.Figure 6 schematically shows the arrangement of a sandwich panel 1 according to the invention in a heating circuit, which can also be used analogously as a cooling circuit. As can be seen, plastic pipes 6 are arranged in the grooves 5 of the inner sheet 3, which are connected at their ends to a supply manifold 16 and a return manifold 17, respectively. The supply manifold 16 and the return manifold 17 are connected to the supply 18 and return 19 in such a way that the flow paths 20 from the supply 18 to the return 19 have approximately the same length via each of the plastic pipes 6, thereby achieving favorable conditions for good heat transfer.

[0061] A sandwich panel 1 according to the invention can be manufactured in a particularly simple and at the same time process-reliable manner and enables the formation of wall or ceiling elements of buildings that not only protect against the weather, but also allow heating or cooling in a particularly simple and cost-effective manner.

[0062] Such a sandwich panel 1 can be manufactured very easily using a method according to the invention. 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 2024 / 197325 A1 [0004, 0009]

Claims

[1] Sandwich panel (1) for forming a wall or ceiling of a building, comprising an outer sheet (2) and an inner sheet (3) between which an insulating core (4) is arranged, which in particular consists of rock wool or polyurethane foam, wherein the inner sheet (3) has at least one groove (5) for receiving a plastic conduit (6), characterized by , that the groove (5) has a cross-section which has a semicircular region (7) with a diameter (8) and a tapered region (9) adjoining the semicircular region (7) with side edges (10) that taper at least in some areas, wherein a ratio of a minimum distance (11) between the side edges (10) to the diameter (8) is greater than 0.7, preferably greater than 0.8, in particular greater than 0.

9. [2] Sandwich panel (1) according to claim 1, characterized by, that the ratio of minimum distance (11) to diameter (8) is less than 1.0, in particular less than 0.

96. [3] Sandwich panel (1) according to claim 1 or 2, characterized by , that the side edges (10) connect approximately tangentially to the semicircular area (7) and transition into radii (12) which connect the side edges (10) to an inner sheet area which is in particular parallel to an inner sheet plane (13). [4] Sandwich panel (1) according to claim 3, characterized by , that the ratio of the diameter (8) to the radii (12) is greater than 4, in particular greater than 10. [5] Sandwich panel (1) according to any one of claims 1 to 4, characterized by , that the groove (5) has a depth (14), wherein the ratio of the depth (14) to the diameter (8) is greater than 2, in particular greater than 2.

1. [6] Sandwich panel (1) according to any one of claims 1 to 5, characterized by , that a plastic conduit (6) is arranged in the groove (5). [7] Sandwich panel (1) according to claim 6, characterized by , that a nominal diameter of the plastic conduit (6) is smaller than the diameter (8), in particular by 0.1 mm to 1 mm, preferably 0.4 mm to 0.6 mm. [8] Sandwich panel (1) according to claim 6 or 7, characterized by that the plastic conduit (6) is completely enclosed in the groove (5), wherein a depth distance (15) between an inner sheet plane (13) and the plastic conduit (6) is at least 1 mm, preferably at least 2.5 mm. [9] Sandwich panel (1) according to any one of claims 6 to 8, characterized by , that the plastic conduit (6) has a nominal diameter of 10 mm to 25 mm. [10] Sandwich panel (1) according to any one of claims 6 to 9, characterized by, that several parallel plastic lines (6) are arranged in several parallel grooves (5) in the inner sheet (3), wherein the plastic lines (6) are connected on the one hand via a supply manifold (16) and on the other hand via a return manifold (17). [11] Sandwich panel (1) according to any one of claims 1 to 10, characterized by , that the supply manifold (16) is connected at a first end to a supply (18) and the return manifold (17) is connected at an opposite end to a return (19), so that flow paths (20) between supply (18) and return (19) have approximately the same length across all plastic pipes (6). [12] Machine for the production of sandwich panels (1), characterized by, that the machine is designed to carry out a method for manufacturing a sandwich panel (1), in particular a sandwich panel (1) according to one of claims 1 to 11, in which method a bead (5) is first introduced into the inner sheet (3) by roll forming, which has in a cross-section a semicircular area (7) with adjoining parallel or diverging side edges (10), after which the parallel or diverging side edges (10) are deformed inwards to form a bead (5) with at least partially converging side edges (10). [13] Machine according to claim 12, characterized by , that pairs of rollers are provided with which the groove (5) can be formed at least partially by roll forming. [14] Machine according to claim 12 or 13, characterized by , that inclined rollers (23) are provided, by which the side edges (10) can be deformed inwards.

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