Pre-manufactured wall element

Abstract

According to an example aspect of the present invention, there is provided a pre-manufactured wall element (1) comprising a plurality of panel layers (5a, 5b) glued to one another, wherein adjacent panel layers (5a, 5b) overlap each other, wherein each panel layer (5a, 5b) comprises a plurality of laminated veneer lumber panels (2), wherein two adjacent panels of the plurality of laminated veneer lumber panels (2) are glued to one another, and wherein 10 % - 30 % of the wood veneers of each laminated veneer lumber panel (2) are oriented in a crosswise direction, at least one opening (3) provided through the plurality of panel layers (5a, 5b), and a laminated veneer lumber beam (4) arranged on top of a first panel layer (5a) of the plurality of panel layers (5a, 5b) and above the at least one opening (3), wherein a first surface of the laminated veneer lumber beam (4) is glued to an end surface of the first panel layer (5a) and a second surface of the laminated veneer lumber beam (4) is glued to a side surface of a second panel layer (5b), and wherein the wood veneers of the laminated veneer lumber beam (4) are oriented in a single direction or 10 % - 30 % of the wood veneers of the laminated veneer lumber beam (4) are oriented in a crosswise direction.

Description

PRE-MANUFACTURED WAEE EEEMENTFIELD

[0001] The present invention relates to a pre-manufactured wall element. In particular, certain embodiments of the present invention relate to a pre-manufactured wall element comprising a plurality of panel layers glued to one another, wherein adjacent panel layers overlap each other, and wherein each panel layer comprises a plurality of laminated veneer lumber panels.

[0002] Further, the present invention relates to a method of manufacturing a wall element.BACKGROUND

[0003] Use of prefabricated wall elements is a well-known technique in erecting a variety of structures. Such prefabricated wall elements are easy to install as well as offer improved quality and construction time.

[0004] For example, laminated veneer lumber, EVE, products can be used in wall elements in many different ways. LVL is a structurally laminated veneer lumber used in all types of construction projects, from new buildings to renovation and repair. LVL may be, for example, produced from 3 mm thick rotary-peeled strength graded softwood veneers. The veneers are bonded with weather- and boil-resistant phenol formaldehyde adhesive to form a continuous billet of up to 20 mm length, for instance. The billet is then cut to length and sawn into LVL beams, planks or panels according to customer's requirements.

[0005] Known wall elements may, for example, comprise a plurality of overlapping panel layers, each panel layer comprising a plurality of large and rigid panels. The panels are used to carry vertical loads and as a bracing structure simultaneously, thus saving material, time and workload. The panels may be glued to each other or provided with ready-made half-lap joints for easy installation. The wooden components in the wall elements are strong and stiff, as well as lightweight. Additionally, it is easy to machinewall elements due to straightness and dimensional stability. For example, CNC machining can be used for lead throughs and connections. Such prefabricated wooden wall elements are further easy to handle at the construction site.

[0006] Panels are beneficial for load-bearing applications that can be used both in horizontal and vertical structures. Using a large panel ensures material efficiency and minimizes installation time. Panels are typically provided having a thickness of 27-75 mm or 21-24 mm. The width of a panel may be, for example, in a range between 900 mm and 2500 mm.

[0007] The wall-floor-knot is one of the most complex details for designers and builders, particularly above windows, doors or other openings in the wall element. Loads above windows, doors or other openings in the wall element typically have to be transferred utilizing an additional high-performance component such as a lintel or an additional beam for reasons of stability.

[0008] In view of the foregoing, it would be beneficial to provide a premanufactured wall element comprising a plurality of panel layers, each panel layer comprising a plurality of laminated veneer lumber panels, wherein the pre-manufactured wall element is capable of transferring loads above windows, doors or other openings in the wall element.SUMMARY OF THE INVENTION

[0009] The invention is defined by the features of the independent claims. Some specific embodiments are defined in the dependent claims.

[0010] According to a first aspect of the present invention, there is provided a premanufactured wall element comprising a plurality of panel layers glued to one another, wherein adjacent panel layers overlap each other, wherein each panel layer comprises a plurality of laminated veneer lumber panels, wherein two adjacent panels of the plurality of laminated veneer lumber panels are glued to one another, and wherein 10 % - 30 % of the wood veneers of each laminated veneer lumber panel are oriented in a crosswise direction, at least one opening provided through the plurality of panel layers, and a laminated veneer lumber beam arranged on top of a first panel layer of the plurality of panel layers andabove the at least one opening, wherein a first surface of the laminated veneer lumber beam is glued to an end surface of the first panel layer and a second surface of the laminated veneer lumber beam is glued to a side surface of a second panel layer, and wherein the wood veneers of the laminated veneer lumber beam are oriented in a single direction or l0 % - 30 % of the wood veneers of the laminated veneer lumber beam are oriented in a crosswise direction.

[0011] Various embodiments of the first aspect may comprise at least one feature from the following bulleted list:• the pre-manufactured wall element comprises at least three panel layers• the panels of the plurality of laminated veneer lumber panels are arranged parallel to each other• the laminated veneer lumber beam serves as a boundary of a part of the at least one opening• a thickness of each of the plurality of laminated veneer lumber panels is in a range between 25 mm and 75 mm• a width of at least some of the plurality of laminated veneer lumber panels is in a range between 900 mm and 2500 mm• a length of each of the plurality of laminated veneer lumber panels is in a range between 2500 mm and 3000 mm• a thickness of the laminated veneer lumber beam is in a range between 25 mm and 75 mm• a thickness of the laminated veneer lumber beam is identical with a thickness of the first panel layer• 15 % - 25 %, 18 % - 22 %, 20 % or about 20 % of the wood veneers of each laminated veneer lumber panel are oriented in a crosswise direction• 15 % - 25 %, 18 % - 22 %, 20 % or about 20 % of the wood veneers of the laminated veneer lumber beam are oriented in a crosswise direction• the first panel layer is an intermediate layer between adjacent second and third panel layers• all or most veneers of the laminated veneer lumber beam are oriented perpendicular or substantially perpendicular to the majority of veneers of the laminated veneer lumber panelsat least some of the laminated veneer lumber panels are Kerto® LVL Q-panels the laminated veneer lumber beam is a Kerto® LVL S-beam the laminated veneer lumber beam is a Kerto® LVL Q-beam

[0012] According to a second aspect of the present invention, there is provided a method of manufacturing a wall element, the method comprising gluing a plurality of panel layers to one another, wherein adjacent panel layers overlap each other, wherein each panel layer comprises a plurality of laminated veneer lumber panels, wherein two adjacent panels of the plurality of laminated veneer lumber panels are glued to one another, and wherein 10 % - 30 % of the wood veneers of each laminated veneer lumber panel are oriented in a crosswise direction, machining at least one opening through the plurality of panel layers, arranging a laminated veneer lumber beam on top of a first panel layer of the plurality of panel layers and above the at least one opening, and gluing a first surface of the laminated veneer lumber beam to an end surface of the first panel layer and a second surface of the laminated veneer lumber beam to a side surface of a second panel layer, wherein the wood veneers of the laminated veneer lumber beam are oriented in a single direction or 10 % - 30 % of the wood veneers of the laminated veneer lumber beam are oriented in a crosswise direction.

[0013] Various embodiments of the second aspect may comprise at least one feature from the following bulleted list:• the method comprising utilizing polyurethane adhesive for at least one of: gluing the plurality of panel layers to one another, gluing two adjacent panels of the plurality of laminated veneer lumber panels to one another, gluing a first surface of the laminated veneer lumber beam to an end surface of the first panel layer, and gluing a second surface of the laminated veneer lumber beam to a side surface of a second panel layer• the method comprising hardening of the adhesive under external pressure• the method comprising machining the at least one opening through the plurality of panel layers by a CNC machine

[0014] Considerable advantages are obtained by certain embodiments of the invention. A pre-manufactured wall element comprising a plurality of panel layers isprovided, wherein each panel layer comprises a plurality of laminated veneer lumber panels, wherein the pre-manufactured wall element is capable of transferring loads above windows, doors or other openings in the wall element. Large openings can be provided in the wall element according to the present invention without the need of utilizing separate beams, lintels or other reinforcements. Additionally, a stiff wall element having a large opening can be provided. In other words, stiffness of the wall element can be maintained due to the laminated veneer lumber beam, even though a large opening is present in the wall element.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIGURE 1A illustrates a schematic view of a commonly known premanufactured wall element,

[0016] FIGURE IB illustrates a schematic view of a cross-section of the commonly known pre-manufactured wall element shown in FIGURE 1 A,

[0017] FIGURE 2A illustrates a schematic view of a pre-manufactured wall element in accordance with at least some embodiments of the present invention,

[0018] FIGURE 2B illustrates a schematic view of a cross-section A-A of the premanufactured wall element shown in FIGURE 2A, and

[0019] FIGURE 2C illustrates a schematic perspective view of a detail of the premanufactured wall element shown in FIGURE 2A.EMBODIMENTS

[0020] In FIGURE 1A a schematic view of a commonly known pre-manufactured wall element 1 is illustrated. The pre-manufactured wall element 1 comprises a plurality of laminated veneer lumber panels 2. Adjacent panels of the plurality of laminated veneer lumber panels 2 are glued to one another or provided with ready-made half-lap joints in order to form the wall element. Each of the laminated veneer lumber panels 2 is a structurally laminated veneer lumber produced from 3 mm thick rotary-peeled strength graded softwood veneers. The veneers are bonded with weather- and boil-resistant phenolformaldehyde adhesive to form a continuous billet. The billet is cut to length and sawn into LVL panels according to customer's requirements.

[0021] The laminated veneer lumber panels 2 are used to carry vertical loads, for example vertical loads caused by a floor. However, providing at least one opening through the shown wall element 1, for example a window, a door or another opening, causes stability problems, particularly in the area of the wall-floor-knot. As a consequence, the wall element 1 illustrated in FIGURE 1 A does typically not fulfil the stability requirements when having such at least one opening, because loads above windows, doors or other openings in the wall element 1 cannot be properly transferred. In FIGURE IB a crosssection of the commonly known pre-manufactured wall element of FIGURE 1A is illustrated. As can be seen, adjacent panel layers 5a, 5b, 5c overlap each other.

[0022] In FIGURE 2A a schematic view of a pre-manufactured wall element 1 in accordance with at least some embodiments of the present invention is illustrated. The premanufactured wall element 1 comprises a plurality of panel layers 5a, 5b, 5c glued to one another. In other words, pre-manufactured wall element 1 comprises two or more than two panel layers 5a, 5b, 5c, for example 2 to 8 panel layers, glued to one another. The wall element 1 may, for example, comprise three overlapping panel layers 5a, 5b, 5c as shown in FIGURE 2B illustrating a cross-section of the wall element 1 along A-A of FIGURE 2A. In other words, the intermediate second panel layer 5b may be arranged such that the laminated veneer lumber panels 2 of the second panel layer 5b are overlapping the connections between adjacent veneer panels 2 of the first panel layer 5a and overlapping the connections between adjacent veneer panels 2 of the third panel layer 5c. Connections between adjacent laminated veneer lumber panels of the first panel layer 5a and adjacent laminated veneer lumber panels of the third panel layer 5 c are not necessarily in the same plane as shown in FIGURE 2B. The panel layers 5 a, 5b, 5 c are stacked on top of each other and bonded by an adhesive. Hardening of the adhesive typically takes place under external pressure to form a strong, stiff and lightweight structure. An example adhesive is polyurethane adhesive.

[0023] Each panel layer 5 a, 5b, 5 c comprises a plurality of laminated veneer lumber panels 2. The laminated veneer lumber panels 2 may be, for example, produced from 3 mm thick rotary-peeled strength graded softwood veneers. The veneers are bonded with adhesive to form a continuous billet having a length of up to 20 m, for instance. Hardeningof the adhesive typically takes place under external pressure to form a strong, stiff and lightweight panel 2. An example adhesive is weather- and boil-resistant phenol formaldehyde adhesive. The billet is then cut to length and sawn into panels 2 according to customer's requirements. Each laminated veneer lumber panel 2 may, for example, have a thickness in the range between 27 mm and 75 mm. The width of at least some of the laminated veneer lumber panels 2 may be, for example, in a range between 900 mm and 2500 mm. The length of each laminated veneer lumber panel 2 may be, for example, in a range between 2500 mm and 3000 mm. 10 % to 30 % of the wood veneers of each laminated veneer lumber panel 2, for example 15 % - 25 %, 18 % - 22 %, 20 % or about 20 %, are oriented in a crosswise direction, i.e. perpendicular to the remaining wood veneers, thus providing excellent strength-to-weight ratio and dimensional stability improved against warp and twist. Two adjacent panels of the plurality of laminated veneer lumber panels 2 are glued to one another, for example utilizing polyurethane adhesive. At least some of the laminated veneer lumber panels 2 may be Kerto® LVL Q-panels, for instance.

[0024] Additionally, the wall element 1 comprises at least one opening 3 provided through the plurality of panel layers 5a, 5b, 5c. The opening 3 may be provided by CNC machining, for instance.

[0025] Further, the wall element 1 comprises a laminated veneer lumber beam 4. The laminated veneer lumber beam 4 may be, for example, produced from 3 mm thick rotary-peeled strength graded softwood veneers. The veneers are bonded with adhesive to form a continuous billet having a length of up to 20 m, for instance. Hardening of the adhesive typically takes place under external pressure to form a strong, stiff and lightweight beam 4. An example adhesive is weather- and boil-resistant phenol formaldehyde adhesive. The wood veneers of the laminated veneer lumber beam 4 are oriented only in a single direction or l0 % - 30 % of the wood veneers of the laminated veneer lumber beam 4, for example 15 % - 25 %, 18 % - 22 %, 20 % or about 20 %, are oriented in a crosswise direction, i.e. perpendicular to the remaining wood veneers, thus providing excellent strength-to-weight ratio and dimensional stability improved against warp and twist.

[0026] The billet is then cut to length and sawn into panels according to customer's requirements. The thickness of the laminated veneer lumber beam 4 may, for example, be identical with the thickness of the first panel layer 5 a. The width of the laminated veneerlumber beam 4 may be, for example, identical with the width of the plurality of panel layers 5a, 5b, 5c. The laminated veneer lumber beam 4 is arranged on top of the first panel layer 5 a of the plurality of panel layers 5 and above the at least one opening 3. A first surface of the laminated veneer lumber beam 4 is glued to an end surface of the first panel layer 5 a and a second surface of the laminated veneer lumber beam 4 is glued to a side surface of the second panel layer 5b as shown in FIGURE 2C. Alternatively, two or more laminated veneer lumber beams 4 may be arranged adjacent to each other as well as each positioned on top of the first panel layer 5 a and glued to the end surface of the first panel layer 5 a and to the side surface of the second panel layer 5b. All or most veneers of the laminated veneer lumber beam 4 are oriented perpendicular or substantially perpendicular to the majority of veneers of the laminated veneer lumber panels 2.

[0027] The laminated veneer lumber beam 4 is stacked on top of the first panel layer 5a and bonded by an adhesive. Hardening of the adhesive typically takes place under external pressure to form a strong, stiff and lightweight structure. An example adhesive is polyurethane adhesive.

[0028] It should be noted that the first panel layer 5 a is not necessarily an outer layer of the wall element 1 as shown in FIGURES 2A-2C. Instead, the first panel layer 5a may be an intermediate layer between adjacent second and third panel layers 5b, 5c. In such a case, a first surface of the laminated veneer lumber beam 4 is glued to an end surface of the first panel layer 5 a, a second surface of the laminated veneer lumber beam 4 is glued to a side surface of the second panel layer 5b and a third surface of the laminated veneer lumber beam 4 is glued to a side surface of the third panel layer 5 c.

[0029] The pre-manufactured wall element 1 is capable of transferring loads above windows, doors or other openings in the wall element due to the integrated laminated veneer lumber beam 4. Parameters of the laminated veneer lumber beam 4 such as width, length, thickness, number of wood veneers, adhesive used, etc. can be pre-determined and / or calculated prior to manufacturing of the wall element 1. As a consequence, large opening can be provided in the wall element 1 according to the present invention without the need of utilizing separate beams, lintels or other reinforcements. According to certain embodiments of the present invention, the laminated veneer lumber beam 4 may serve as a boundary of a part of the at least one opening 3.

[0030] It is to be understood that the embodiments of the invention disclosed are notlimited to the particular structures, process steps, or materials disclosed herein, but are extended to equivalents thereof as would be recognized by those ordinarily skilled in the relevant arts. It should also be understood that terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting.

[0031] Reference throughout this specification to one embodiment or an embodiment means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Where reference is made to a numerical value using a term such as, for example, about or substantially, the exact numerical value is also disclosed.

[0032] As used herein, a plurality of items, structural elements, compositional elements, and / or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary. In addition, various embodiments and example of the present invention may be referred to herein along with alternatives for the various components thereof. It is understood that such embodiments, examples, and alternatives are not to be construed as de facto equivalents of one another, but are to be considered as separate and autonomous representations of the present invention.

[0033] Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the description, numerous specific details are provided, such as examples of lengths, widths, shapes, etc., to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.

[0034] While the forgoing examples are illustrative of the principles of the present invention in one or more particular applications, it will be apparent to those of ordinary skill in the art that numerous modifications in form, usage and details of implementationcan be made without the exercise of inventive faculty, and without departing from the principles and concepts of the invention. Accordingly, it is not intended that the invention be limited, except as by the claims set forth below.

[0035] The verbs “to comprise” and “to include” are used in this document as open limitations that neither exclude nor require the existence of also un-recited features. The features recited in depending claims are mutually freely combinable unless otherwise explicitly stated. Furthermore, it is to be understood that the use of "a" or "an", that is, a singular form, throughout this document does not exclude a plurality.INDUSTRIAL APPLICABILITY

[0036] At least some embodiments of the present invention find industrial application in construction projects.REFERENCE SIGNS LIST wall element laminated veneer lumber panel opening laminated veneer lumber beam a first panel layer b second panel layer c third panel layer

Claims

CLAIMS:

1. A pre-manufactured wall element (1) comprising:- a plurality of panel layers (5a, 5b) glued to one another, wherein adjacent panel layers (5 a, 5b) overlap each other, wherein each panel layer (5 a, 5b) comprises a plurality of laminated veneer lumber panels (2), wherein two adjacent panels of the plurality of laminated veneer lumber panels (2) are glued to one another, and wherein 10 % - 30 % of the wood veneers of each laminated veneer lumber panel (2) are oriented in a crosswise direction,- at least one opening (3) provided through the plurality of panel layers (5a, 5b), and- a laminated veneer lumber beam (4) arranged on top of a first panel layer (5 a) of the plurality of panel layers (5a, 5b) and above the at least one opening (3), wherein a first surface of the laminated veneer lumber beam (4) is glued to an end surface of the first panel layer (5a) and a second surface of the laminated veneer lumber beam (4) is glued to a side surface of a second panel layer (5b), and wherein the wood veneers of the laminated veneer lumber beam (4) are oriented in a single direction or l0 % - 30 % of the wood veneers of the laminated veneer lumber beam (4) are oriented in a crosswise direction.

2. The pre-manufactured wall element (1) according to claim 1, wherein the premanufactured wall element comprises at least three panel layers (5a, 5b, 5c).

3. The pre-manufactured wall element (1) according to claim 1 or 2, wherein the panels of the plurality of laminated veneer lumber panels (2) are arranged parallel to each other.

4. The pre-manufactured wall element (1) according to any one of claims 1 - 3, wherein the laminated veneer lumber beam (4) serves as a boundary of a part of the at least one opening (3).

5. The pre-manufactured wall element (1) according to any one of claims 1 - 4, wherein a thickness of each of the plurality of laminated veneer lumber panels (2) is in a range between 25 mm and 75 mm.

6. The pre-manufactured wall element (1) according to any one of claims 1 - 5, wherein a width of at least some of the plurality of laminated veneer lumber panels (2) is in a range between 900 mm and 2500 mm.

7. The pre-manufactured wall element (1) according to any one of claims 1 - 6, wherein a thickness of the laminated veneer lumber beam (4) is in a range between 25 mm and 75 mm.

8. The pre-manufactured wall element (1) according to any one of claims 1 - 7, wherein a thickness of the laminated veneer lumber beam (4) is identical with a thickness of the first panel layer (5a).

9. The pre-manufactured wall element (1) according to any one of claims 1 - 8, wherein 15 % - 25 %, 18 % - 22 %, 20 % or about 20 % of the wood veneers of each laminated veneer lumber panel (2) are oriented in a crosswise direction.

10. The pre-manufactured wall element (1) according to any one of claims 1 - 9, wherein 15 % - 25 %, 18 % - 22 %, 20 % or about 20 % of the wood veneers of the laminated veneer lumber beam (4) are oriented in a crosswise direction.

11. The pre-manufactured wall element (1) according to any one of claims 1 - 10, wherein the first panel layer (5a) is an intermediate layer between adjacent second and third panel layers (5b, 5 c).

12. The pre-manufactured wall element (1) according to any one of claims 1 - 11, wherein all or most veneers of the laminated veneer lumber beam (4) are oriented perpendicular or substantially perpendicular to the majority of veneers of the laminated veneer lumber panels (2).

13. Method of manufacturing a wall element (1), the method comprising:- gluing a plurality of panel layers (5a, 5b) to one another, wherein adjacent panel layers (5 a, 5b) overlap each other, wherein each panel layer (5 a, 5b) comprises a plurality of laminated veneer lumber panels (2), wherein two adjacent panels of the plurality of laminated veneer lumber panels (2) are glued to one another, andwherein 10 % - 30 % of the wood veneers of each laminated veneer lumber panel (2) are oriented in a crosswise direction,- machining at least one opening (3) through the plurality of panel layers (5a, 5b),- arranging a laminated veneer lumber beam (4) on top of a first panel layer (5 a) of the plurality of panel layers (5a, 5b) and above the at least one opening (3), and- gluing a first surface of the laminated veneer lumber beam (4) to an end surface of the first panel layer (5 a) and a second surface of the laminated veneer lumber beam (4) to a side surface of a second panel layer (5b), wherein the wood veneers of the laminated veneer lumber beam (4) are oriented in a single direction or l0 % - 30 % of the wood veneers of the laminated veneer lumber beam (4) are oriented in a crosswise direction.

14. The method of manufacturing a wall element (1) according to claim 13, the method comprising utilizing polyurethane adhesive for at least one of:- gluing the plurality of panel layers (5 a, 5b) to one another,- gluing two adjacent panels of the plurality of laminated veneer lumber panels (2) to one another,- gluing a first surface of the laminated veneer lumber beam (4) to an end surface of the first panel layer (5a), and- gluing a second surface of the laminated veneer lumber beam (4) to a side surface of a second panel layer (5b).

15. The method of manufacturing a wall element (1) according to claim 14, the method comprising hardening of the adhesive under external pressure.

16. The method of manufacturing a wall element (1) according to any one of claims 13 - 15, the method comprising machining the at least one opening (3) through the plurality of panel layers (5a, 5b) by a CNC machine.

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