Sandwich panel, sandwich panel construction, housing and production method

Abstract

The invention relates to a sandwich panel having a foam layer (30) with a first foam layer surface (31) and a second foam layer surface (32) substantially parallel to the first foam layer surface (31), a first cover plate (10) which extends parallel to the first foam layer surface (31) and is connected thereto, and a second cover plate (20) which extends parallel to the second foam layer surface (32) and is connected thereto. The first cover plate (10) and / or the second cover plate (20) are / is formed from at least two layers (11, 12; 21, 22) which are spaced apart from one another in parallel and are connected to one another by means of connection pieces (13; 23) in such a way that one or more cavities (14; 24) are formed between the two layers (11, 12; 21, 22). The invention further relates to a sandwich panel construction, a housing and a production method for producing sandwich panels.

Description

[0001] Sandwich panel, sandwich panel construction, housing and manufacturing process

[0002] Description:

[0003] The invention relates to a sandwich panel, a sandwich panel construction, a housing made of such sandwich panels and / or sandwich panel constructions, as well as a manufacturing method for producing sandwich panels.

[0004] Common panels have a foam core, which is bonded on both sides with a thin layer of metal, wood, cement, other composite materials, or plastic. Due to the so-called sandwich effect, such a sandwich panel (also called a sandwich board) exhibits high flexural strength. However, these plastic sandwich panels typically lack the necessary load-bearing capacity to be used for constructing buildings. To improve load-bearing capacity, the thickness of the outer plastic layer can be increased, but this then leads to an increase in the panel's weight.

[0005] The object of the invention is to provide a sandwich panel and corresponding constructions which have improved load-bearing capacity, as well as a manufacturing process for their efficient production.

[0006] The problem is solved according to the invention by a sandwich panel with the features of claim 1, by a sandwich panel construction with the features of claim 12, by a housing with the features of claim 13, and by a manufacturing method with the features of claim 14. Advantageous embodiments of the invention are listed in the dependent claims.

[0007] The invention is based on the idea of ​​replacing at least one of the thin plastic layers with a cover plate formed from two parallel layers spaced apart from each other, which are spaced apart and connected to each other by webs. Here, the expression "two parallel layers spaced apart from each other" means that one of these two layers forms a parallel surface to the other. The webs stabilize the cover plate and give the sandwich panel thus assembled increased strength and load-bearing capacity.

[0008] Thus, according to a first aspect, a sandwich panel is proposed which comprises a foam layer with a first foam layer surface and a second foam layer surface that is essentially parallel to the first foam layer surface. A first cover sheet is applied to the first foam layer surface. The first cover sheet extends parallel to the first foam layer surface and is bonded to it. This means that the first cover sheet essentially follows and replicates the surface contour of the first foam layer surface. If the first foam layer surface extends along a plane, then the first cover sheet extends parallel to this plane. However, if the first foam layer surface is curved, for example in the case of a sandwich panel running along a curve, then this also applies to the first cover sheet.A second cover plate is arranged on the second foam layer surface, which is opposite the first foam layer surface. This second cover plate extends parallel to the second foam layer surface and is connected to it. The features of the first cover plate mentioned in the preceding paragraph also apply accordingly to the second cover plate.

[0009] The cover plates can be bonded or welded to the corresponding foam layers. In this context, "welded" specifically means that the surfaces of the two elements to be joined are first heated, and then the elements are placed or pressed together. This melts the surfaces, and after solidification, a strong bond forms. Heating can be achieved, for example, by irradiation with strong infrared radiation. Bonding is accomplished by applying an adhesive layer.

[0010] According to the invention, either the first or the second cover plate is formed from at least two parallel, spaced-apart layers connected to each other by means of webs such that one or more cavities are formed between the two layers. The two layers, the webs, and the cavities of the first cover plate are hereinafter referred to as the first layers, first webs, and first cavities, and those of the second cover plate are referred to as the second layers, second webs, and second cavities. Preferably, and to further increase strength, both cover plates are each designed as two-layer components with webs and cavities. Such cover plates are also referred to as multi-wall sheets, multi-wall panels, or multi-wall sheets.The term twin-wall sheet is also common when an additional intermediate layer is inserted between and parallel to the two layers of a cover sheet, which is designed similarly to the webs, for example with the same layer thickness.

[0011] Preferably, the foam layer, the first face sheet, and / or the second face sheet are formed essentially entirely from the same material. If the first face sheet is formed from two first layers with first ribs, then the two layers and the ribs are preferably formed from the same material. The same applies to the second face sheet and its components. Preferably, all three elements of the sandwich panel—the foam layer and the two face sheets—are formed from the same material. In particular, this means that the material is first melted and processed into the face sheets, for example, by extrusion, and the same material is then foamed to produce the foam layer. The more elements of the sandwich panel are formed from one material, the simpler and more efficient the recycling of the material can be.If all three elements are made from one material, especially a polymer, the entire sandwich panel can be reused as a whole so that new sandwich panels or other objects can be made from the material.

[0012] The foam layer, the first cover plate and / or the second cover plate are / are preferably made of one type of polymer material. A suitable polymer material is, in particular, polyethylene terephthalate (PET), polypropylene (PP), polystyrene (PS), polyethylene (PE), high-density polyethylene (HDPE), low-density polyethylene (LDPE), and / or polyvinyl chloride (PVC).

[0013] The material is preferably present in its respective elements with a purity of at least 90%, 95%, or 98%. Preferably, it is present with a purity between 90% and 98%. Essentially, this means that only potentially manufacturing-related impurities are present in the material, for example, due to a recycling process for material recovery. Furthermore, flame retardants may be added to the material, particularly the foam. Color pigments, UV protection, and / or some other stabilizing substances may also be added, but their total proportion is preferably less than a few percent.

[0014] When polyethylene terephthalate (PET) is used as the material, it can be present entirely or partially in the form of coPET (GPET) or rPET; an admixture of virgin PET is also possible. In this context, coPET refers to the copolymer of polyethylene terephthalate with one or more glycols or polyols. rPET means recycled PET or coPET. rPET can be obtained from PET bottles (also rPET) or from other potential PET sources (also rPET), such as sandwich panels, which are recycled using established processes. These processes include shredding the materials to be recycled into small PET particles that can be washed and cleaned, removing all non-PET components. These PET particles can then be used in a manufacturing process to produce the sandwich panel.It should be noted that polyester materials are equivalent to PET materials, although the term "polyester" is usually used for textile products or the like.

[0015] Manufacturing all three layers from plastic materials, especially from the same plastic materials, has the advantage that instead of bonding by means of an adhesive layer between the foam surface and the respective cover plates, the foam layer can be directly welded to the cover plates by means of surface heating.

[0016] The foam layer can be made of closed-cell foam, open-cell foam, or a foam containing both open and closed cells. The foam layer preferably has a foam density of more than 10 kg / m³. 3 , 20 kg / m 3 or 50 kg / m 3On the other hand, the foam density should preferably be less than 100 kg / m³. 3 , 200 kg / m 3 or 400 kg / m 3 be.

[0017] While the material-to-air / gas ratio in the foam layer is preferably between 5% and 50%, the layers and / or struts from which the cover plates are formed are more compact, with a material-to-air / gas ratio of preferably over 80% or over 90%.

[0018] The polymer material can be commercially obtained as granules or flakes. During recycling, the sandwich panel can again be processed into such granules or flakes. In particular, the foam core, the first face sheet, and the second face sheet are preferably made of the same polymer material. A sandwich panel made of such a mono-plastic or mono-polymer has the advantage that it can be melted down as a whole for reuse. Preferably, the first face sheet has a thickness perpendicular to the first foam layer surface of at least 1 cm, 1.5 cm, or 2 cm and / or at most 5 cm, 8 cm, or 10 cm. Alternatively or cumulatively, the second face sheet preferably has a thickness perpendicular to the second foam layer surface of at least 1 cm, 1.5 cm, or 2 cm and / or at most 5 cm, 8 cm, or 10 cm.Furthermore, the foam layer preferably has a thickness, measured from the first to the second foam layer surface, of more than 0.5 cm, preferably between 3 cm and 30 cm, preferably between 5 cm and 20 cm.

[0019] The first cover plate and / or the second cover plate are / are preferably formed from first or second layers, each having a layer thickness of between 0.5 mm and 10 mm, preferably a layer thickness of more than 0.5 mm, preferably of less than 10 mm or 5 mm.

[0020] The first cavity(ies) and / or the second cavity(ies) may be filled with air or another gas and / or partially or completely filled with a foam, hereinafter referred to as filling foam, in particular a foam made of the same material as the foam layer. The filling foam may, in particular, have a higher density than the foam layer. For example, the filling foam may have a density that is at least two, three, or four times that of the foam layer. For example, the filling foam may have a density between 20 and 80 kg / m³. 3 exhibiting a density between 100 and 200 kg / m³. 3 exhibits.

[0021] In a preferred embodiment, the first cover plate is formed in cross-section from the two first layers, which are spaced apart from each other by means of the filling foam and connected to each other at the two edges of the filling foam by means of two webs. The second cover plate can have the same shape. In this embodiment, the first cover plate and / or the second cover plate would each have a cavity filled with the filling foam. To produce such a cover plate, the two first layers and the webs at the edges can be extruded in an extrusion process, while simultaneously filling the cavity with foam.

[0022] The first and second webs can be configured such that the first and second cavities are interrupted along the length and / or width of the respective cover plate. In preferred embodiments, however, the first cavities comprise at least one first cavity which extends substantially over the entire length or width of the first cover plate. Alternatively or additionally, the second cavities comprise at least one second cavity which extends substantially over the entire length or width of the second cover plate.

[0023] The first or second webs preferably lie perpendicular to the first or second layers, respectively. Alternatively, it can also be advantageous if the webs are arranged at an angle to the respective layers, for example, at an angle of approximately 45°. The first webs can also include an intermediate layer parallel to the first two layers. This can also apply accordingly to the second webs of the second cover plate.

[0024] According to a preferred embodiment, the first cavities comprise at least one first cavity configured as a fluid channel for the flow of a fluid, or which includes a fluid channel for the flow of a fluid, and / or the second cavities comprise at least one second cavity configured as a fluid channel for the flow of a fluid, or which includes a fluid channel for the flow of a fluid. Such fluid channels can be, for example, pipes configured to transport fluids, in particular liquids or gases, for heating or cooling a respective side of the sandwich panel. If the sandwich panel is used as part of a building, then such fluid channels can serve as part of a heating and / or cooling system for the building.

[0025] Preferably, the sandwich panel has one or more spacers arranged between the two face sheets. Such a spacer can, in particular, serve to maintain a gap between the two face sheets. More preferably, however, the spacer serves to protect the foam layer from forces acting parallel to the first or second foam layer surface. The spacer thus serves, in effect, to protect the edges of the foam layer in such a way that lateral forces can be applied to the sandwich panel, for example, to fasten the sandwich panel to another building element.

[0026] The spacers can be offset laterally, either inwards or outwards. If they are offset outwards, this means, in particular, that they are not covered by the cover panels. Part of the foam layer can also extend beyond the edge of the cover panels, regardless of whether this edge has spacers or not. The outward projection of the foam layer and / or spacers on one side of the panel can be accompanied by an inward projection of the foam layer and / or spacers on the other side of the panel, allowing tongue-and-groove joints to be created with two or more such panels to form a larger wall element.

[0027] Preferably, the spacers partially or completely delimit the foam layer laterally. Lateral delimitation means that the foam layer is partially or completely covered by the spacers in the area between the cover plates. In particular, the spacers can completely cover the foam layer. Preferably, the foam layer is in contact with the spacers, i.e., it extends laterally to the spacers. The foam layer can then preferably be glued or bonded to the spacers in some other way, for example, by welding.

[0028] Advantageously, the two cover plates and the spacers are designed such that they partially or completely enclose the foam layer laterally. This means, in particular, that in a cross-sectional view of the sandwich panel, the foam layer is partially or completely surrounded by the two cover plates and the spacers.

[0029] In a preferred embodiment, a first spacer element is formed on the first cover plate and a second spacer element is formed on the second cover plate, the spacers being connected to each other. The two spacers can be connected using coupling elements, for example, by means of a snap-fit ​​connection. Alternatively or additionally, the two spacers can be glued or welded together.

[0030] In an alternative embodiment, a first spacer element on the first cover panel and a second spacer element on the second cover panel may be positioned opposite each other, but may or may not touch, leaving a gap between them. The foam layer may be visible through this gap. Such a gap can serve to ensure that the two cover panels rest securely on the foam layer. In this case, the spacers do not necessarily maintain a gap between the cover panels; this is achieved by the foam layer. The gap, perpendicular to the surface of the foam layer, can have a size, for example, between 1 mm and 100 mm. The sandwich panel preferably has a width of at least 5, 10, 45, 60, or 120 cm. Its length is preferably at least one meter or more.In particular, a sandwich panel can first be manufactured as a continuous strand and then cut into the desired size. To create larger sandwich panel structures from finished panels, two or more panels can be joined together at their edges.

[0031] To join two sandwich panels at their edges to form a larger sandwich panel, or to connect the sandwich panel to another structural element, such as the floor or a wall, the sandwich panel preferably includes a connecting element. Hereinafter, the side of the sandwich panel that abuts the other sandwich panel to be joined or the structural element is referred to as the proximal end, and the other side as the distal end. Such a connecting element comprises a pressing element arranged between the two face sheets at a distal end of the sandwich panel and a clamping element extending through the foam layer from the distal end to the proximal end. The clamping element is configured to exert a mechanical force on the pressing element in the direction of the foam layer.In other words, the sandwich panel is held at its distal end by the pressing element, which in turn is held by the clamping element and pressed towards the proximal end, i.e., towards the joint. Two sandwich panels can also be laterally joined by gluing or welding.

[0032] Preferably, the pressing element extends longitudinally along the length or width of the sandwich panel, and in particular over substantially the entire length or width of the sandwich panel. If a spacer element is provided at the distal end of the sandwich panel, the pressing element preferably rests on this spacer element and presses against it. The pressing element can, for example, comprise one or more plates. One or more further plates can be arranged at an angle, for example perpendicular, to the plate forming part of the pressing element, which then, for example, forms another pressing element for a further sandwich panel, which is arranged at an angle, for example perpendicular, to the sandwich panel and connected to it by means of these two pressing elements.In general, two or more pressing elements can be connected to each other, each connecting a distal end of one sandwich panel to a distal end of another sandwich panel.

[0033] The pressing element can have a C-profile in cross-section, with either the closed or the open side of the C-profile resting on the side of the foam layer or on the spacer element. The pressing element can also have an I-profile, an H-profile, a double-T profile, or the like. Preferably, it can have a rectangular or square profile. Suitable materials for the pressing element include steel, aluminum, or another appropriate metal. Alternatively, the pressing element can also be made of wood, for example, in the form of a wooden slat.

[0034] The clamping element can be an element extending along the length or width of the sandwich panel. The clamping element can be a rod that is connected to the pressing element, for example, by means of screws. For this purpose, the rod can have a thread at one or both ends. Alternatively, the rod can act as a spacer between the two pressing elements, which are only screwed together at their respective ends.

[0035] Preferably, two or more sandwich panels can be connected to each other to form a sandwich panel construction using such a connecting element. In this case, in particular, one sandwich panel is connected longitudinally to another sandwich panel by means of the connecting element such that a proximal longitudinal side of the sandwich panel abuts a proximal longitudinal side of the other sandwich panel. The pressing element abutting a distal longitudinal side of the sandwich panel and a further pressing element abutting a distal longitudinal side of the other sandwich panel are connected to each other by means of the clamping element extending through the foam layer from the distal longitudinal side of the sandwich panel to the distal longitudinal side of the other sandwich panel.

[0036] According to another aspect, a structure is proposed consisting of wall elements, roof elements, and floor elements, which enclose an interior space. This structure can be, in particular, a living space, an office space, or a modular unit. One or more of the wall elements, roof elements, and floor elements can be formed, at least partially or entirely, from one or more of the sandwich panels and / or sandwich panel constructions described herein.

[0037] According to a further aspect, a manufacturing process for producing a sandwich panel is proposed in which a foam layer is provided as a first and a second foam layer surface. A cover plate is placed on each of the two foam layer surfaces and connected to it. This can be done in particular by gluing, welding or by other suitable joining methods. One or preferably both cover plates are designed according to a cover plate described above or below.

[0038] Preferably, the first or second cover plate is produced in an extrusion process as a continuous strand. According to a convenient embodiment, both cover plates are formed in this way as continuous strands. Alternatively or additionally, the foam layer can also be produced in a foaming process as a third continuous strand. The first and second cover plates can then be cut from such continuous strands before being placed on top of and bonded to the foam layer, which has also been previously cut from the third continuous strand. Advantageously, the first and second cover plates can be cut from the same continuous strand.

[0039] However, according to an alternative design, the three continuous strands are locally joined at a connection area and connected to each other to form a continuous strand of a sandwich panel, for example by gluing or welding, before the continuous strand of the sandwich panel is divided into individual sandwich panels.

[0040] The features and advantages listed above and below in connection with the sandwich panel and the sandwich panel construction may also apply accordingly to the housing and / or the manufacturing process.

[0041] In the past, the use of pure plastics in structural components such as beams, boards, and wall supports was limited due to their insufficient strength, tendency to creep, and difficult fastening methods. The present invention, particularly in its embodiment as mono-plastic composite panels made primarily from recycled plastic packaging such as PET or PP, addresses these problems and provides a versatile and robust solution for construction. These panels are not only load-bearing but also serve as thermal and acoustic insulation, a vapor barrier, and cladding, thus simplifying material use and installation. Since they are made from a single plastic, they are 100% sustainable and recyclable, supporting the industry's transition to a circular economy.Furthermore, the thermoplastic formability of these panels allows for complex outer layers with defined vertical chambers, providing increased structural strength and multifunctionality. This enables the transformation of passive walls into active walls capable of capturing and storing energy by absorbing solar heat or dissipating it through air or liquid cooling. These sandwich panels are compatible with conventional construction methods and offer easy installation, design flexibility, and new application possibilities, such as small temporary structures. Moreover, they are cost-effective compared to traditional materials like wood and steel and can be produced quickly to meet high demand.

[0042] The invention will be explained below with reference to exemplary embodiments and the figures. These schematically show:

[0043] Fig. 1 shows an exploded view of a sandwich panel according to a preferred embodiment;

[0044] Fig. 2 shows the sandwich panel assembled according to Fig. 1;

[0045] Fig. 3 shows a sandwich panel with edge-arranged spacers, in a side view;

[0046] Fig. 4 shows a sandwich panel according to a further embodiment with a curved surface;

[0047] Fig. 5 shows a sandwich panel with cover plates filled with foam according to a further embodiment;

[0048] Fig. 6 shows a sandwich panel with cover plates filled with foam and spacer elements, according to a further embodiment;

[0049] Fig. 7 two sandwich panels connected laterally;

[0050] Fig. 8 shows the connection of two spacers of two cover plates by means of a latching mechanism;

[0051] Fig. 9 shows a sandwich panel similar to that shown in Figs. 1-3, with fluid lines arranged in cavities of one of the cover plates; Fig. 10 shows a sandwich panel according to a further embodiment for purely conceptual illustration of different web designs;

[0052] Fig. 11 shows a manufacturing process for producing a sandwich panel;

[0053] Fig. 12 shows a detailed view of a sandwich panel construction consisting of two sandwich panels joined at their edges according to a preferred embodiment;

[0054] Fig. 13 shows a sandwich panel construction consisting of two sandwich panels connected to each other by means of a connecting element according to a further advantageous embodiment;

[0055] Fig. 14 shows a sandwich panel which is attached to a floor element by means of a connecting element;

[0056] Fig. 15 shows a sandwich panel construction consisting of four interconnected sandwich panels;

[0057] Fig. 16 Illustrations of different pressing elements, each of which can be used as part of a connecting element;

[0058] Fig. 17 shows a housing composed of several sandwich panels according to a preferred embodiment;

[0059] Fig. 18 shows a dwelling composed of several sandwich panels according to a further preferred embodiment;

[0060] Figure 1 schematically shows an exploded view of a sandwich panel 1 according to a preferred embodiment, while Figure 2 shows a perspective view of the fully assembled sandwich panel 1. The sandwich panel 1 has a foam layer 30 with a first foam layer surface 31 and a second foam layer surface 32. A first cover plate 10 is arranged on the first foam layer surface 31, and a second cover plate 20 is arranged on the second foam layer surface 32. The cover plates 10 and 20 are bonded to the foam layer 30 over their entire surface, for example, by gluing or welding. The first cover plate 10 is formed from two first layers 11 and 12, which are arranged parallel to each other and connected to each other by means of first webs 13 arranged perpendicular to the layers 11 and 12.By means of the first webs 13, the first cover plate 10 has first cavities 14 between the first layers 11, 12, which extend completely in one direction over the entire length of the first cover plate 10. Thus, the cover plate 10 can be produced by means of an extrusion process.

[0061] On one side facing the second cover plate 20, the first cover plate 10 has two spacer elements 15, which have a height of approximately half the thickness of the foam layer 30. The second cover plate 20 is constructed identically to the first cover plate 20, so that in the resulting sandwich panel 1, the spacer elements 15, 25 of the different cover plates 10, 20 lie on top of each other and confine the foam layer 30 between them.

[0062] In the sandwich panel 1 shown in Figures 1 and 2, the spacers 15, 25 are offset slightly inwards laterally, so that the face sheets 10, 20 have an overhang at their edges where neither the foam layer 30 nor the spacers 15, 25 are arranged between the two face sheets 10, 20. In the sandwich panel 1 shown in Figure 3 in a cross-sectional view or a top view of an end face, the foam layer 30 extends almost to the edge of the face sheets 10, 20, where the spacers 15, 25 are arranged. Here, the spacers 15, 25 are therefore flush with the respective edges of the face sheets 10, 20. In both cases, the foam layer 30 is completely surrounded in the cross-sectional plane by the face sheets 10, 20 and the spacers 15, 25.

[0063] Figures 1-3 and most of the other figures described here, with the exception of Figure 18, show only sandwich panels 1 that extend essentially along a plane, i.e., where the first foam layer surface 31 runs along one plane and the second foam layer surface 32 runs along another plane parallel to the plane of the first foam layer surface 31. In contrast, Figure 4 shows a curved sandwich panel 1' in which the first and second foam layer surfaces 31, 32 are curved. Here, the curvature is designed such that the sandwich panel 1' can serve as an edge element of a housing. However, the sandwich panel 1 can be curved in a different way, for example, to fulfill certain functions or for aesthetic reasons. For example, the sandwich panel 1 can have a wave shape or a zigzag shape.Curved sandwich panels 1 can exhibit all the features mentioned above and below in connection with flat sandwich panels 1.

[0064] Unlike the sandwich panels 1 shown in Figures 1-3, the spacer elements 15, 25 shown in Figure 4 extend in one piece from the first cover plate 10 to the second cover plate 20, and thus do not consist of two parts extending from the respective cover plates 10, 20 to each other. Furthermore, the spacer elements 15, 25 are offset outwards here, so that they form part of a tongue-and-groove connection. Such a curved sandwich panel 1' can be readily joined, in particular, with the sandwich panel 1 shown in Figure 2 to form a sandwich panel structure and, for example, a housing.

[0065] In the two sandwich panels 1 shown in Figures 5 and 6, the cover plates 10, 20 each have webs 13, 23 only at their edges, so that each cover plate 10, 20 has only a single cavity 14, 24. The cavities 14, 24 are filled with a foam which, instead of webs, ensures the stability of the cover plates 10, 20. This foam can have any combination of properties described herein in connection with the foam layer 30. While the sandwich panel 1 shown in Figure 6 has spacers 15, these are not present in the embodiment shown in Figure 5. Figure 7 shows a sandwich panel construction consisting of two interconnected sandwich panels 1. The sandwich panels 1 are joined at their narrow sides.

[0066] A possible way of connecting two spacers 15, 25 of two cover plates 10, 20 is illustrated in Fig. 8. Here, the spacers 15, 25 each have interlocking locking elements that form a snap-fit ​​connection. This allows for a secure connection with a simple movement. In particular, this ensures correct alignment of the two cover plates 10, 20 relative to each other. Preferably, the foam layer 30, which is not shown in Fig. 8, should also be placed between the cover plates 10, 20 before the spacers 15, 25 are joined.

[0067] Figure 9 shows a sandwich panel 1 according to an advantageous embodiment, in which fluid lines 16 run in the first cavities 14 of the first cover plate 10. These serve to transport fluids, i.e., liquids and / or gases. These fluids can be used for the operation of a building that is composed of or incorporates such sandwich panels 1. The fluid can also be used to cool or heat the corresponding side of the sandwich panel 1. Preferably, the fluid lines 16 are designed such that two or more identically constructed sandwich panels 1 can be connected to each other in such a way that the fluid lines 16 of different cover plates can be connected and sealed.

[0068] In the sandwich panel shown in Fig. 10, the first cover panel 10 is divided into three sections with different first webs 13. These sections serve only to illustrate the possible variation in web types. In the first section, the webs consist of a wave-shaped curved intermediate layer between the first layer and the second layer of the first cover panel 10. In the second section, the webs are arranged in a herringbone pattern, while the third section shows webs arranged in a cross shape. In the second cover panel 20, the webs have a flat intermediate layer arranged with respect to the two second layers 21, 22, so that the second cover panel 20 is designed as a twin-web panel.

[0069] Figure 11 schematically illustrates the production of a sandwich panel according to a preferred embodiment. A first continuous strand 51, a second continuous strand 52, and a third continuous strand 53 are fed together to a press 55. Previously, an adhesive film was applied to both sides of the third continuous strand 53 using an applicator 56, here in the form of applicator rollers. The press 55 then ensures that the first continuous strand 51 is coated on one side and the second continuous strand on the other.

[0070] The first continuous strand 52 is bonded to the third continuous strand 53 on one side, creating a sandwich structure in the form of a continuous strand. This can then be cut into sandwich panels. In this case, the first continuous strand 51 is constructed according to the first cover sheet, the second continuous strand 52 according to the second cover sheet, and / or the third continuous strand 53 according to the foam layer, as described above and / or below. Alternatively, the adhesive film can be sprayed onto the respective continuous strands. In any case, the adhesive film can be applied in the form of a hot-melt adhesive (HMA). The use of a suitable polymer melt, for example, a polyester melt, is also possible.

[0071] As explained above, instead of bonding using the adhesive film, a welding connection can be made between the three endless strands 51, 52,

[0072] 53 are heated and thus melted by heating the respective surfaces. This can be achieved, for example, by replacing the previously referred to as application material 56 as heating elements, such as heating rollers, which heat the two surfaces of the third continuous strand 53. Alternatively or additionally, heating can also be achieved by irradiation, for example, by infrared heaters. A possible way of joining two sandwich panels 1 to form a sandwich panel construction is schematically illustrated in Fig. 12. Here, the first cover plate 10 of the first sandwich panel 1 is connected to the first cover plate 10 of the second sandwich panel 1 by means of a fastener, for example, by means of an adhesive or by welding. The fastener joins the two first cover plates 10 along one edge each.Likewise, the two second cover plates 20 of the two sandwich panels 1 are joined together at their edges.

[0073] An alternative advantageous joining method for connecting two sandwich panels 1 is shown in Fig. 13, and this method can be combined with the edge-jointing method according to Fig. 12. The following explains how the two sandwich panels 1 in Fig. 14 are joined together at their respective proximal sides or edges to form the sandwich panel structure. A pressing element 41 is placed on the spacer elements 15, 25 at their respective distal sides, pressing against the spacer elements 15, 25 in the direction of the foam layer 20. The pressing force is generated by a clamping element 45, which extends through the two foam layers 20 of the two sandwich panels 1 and connects and clamps the two outer clamping elements 41 together. The clamping element 45 can, in particular, be a metal rod with threads at both ends.The ends pass through holes in the two pressing elements 41 and are screwed to the two pressing elements 41 by means of nuts. In the embodiment shown here, the pressing elements 41 are designed as C-profiles, although other shapes may also be advantageous, for example closed profiles, to achieve greater rigidity.

[0074] The same device, consisting of two pressing elements 41 and one clamping element 45, can be used to attach a sandwich panel 1 to another building element, such as a wall or a floor. This is shown schematically in Fig. 14. For this purpose, the pressing element 41 that rests against the building element is provided with a fastening element, in this case a screw, which secures the pressing element 41 to the building element.

[0075] Two sandwich panels 1 can be joined at an angle to each other using a press element 41, which is designed as an angle element 42. The angle element 42 shown in Fig. 15 serves as a press element 41 for holding together two horizontally arranged sandwich panels 1, for holding together two vertically arranged sandwich panels 1, and simultaneously for holding these two sandwich panel constructions together to form an angled sandwich panel construction consisting of four sandwich panels 1. Fig. 16 shows, by way of example, a series of possible angled press elements 42 made of different materials and their possible construction from individual elements, for example, from two metal C-profiles or from two wooden boards. Joining two sandwich panels at an angle to each other allows for the simple assembly of complete structures, in particular residential buildings, etc., including roof, floor, corner joints and the like.

[0076] The sandwich panels described herein can form parts of a housing. Housings can even be composed predominantly or essentially entirely of such sandwich panels. Such housings are shown schematically in Figures 17 and 18. The housing shown in Figure 17 features sandwich panel constructions in which the panels are joined at angles to each other to form the edges of the housing. In contrast, the housing shown in Figure 18 uses curved sandwich panels 1' as explained in connection with Figure 4. Reference numerals:

[0077] 1 sandwich panel

[0078] 10 first cover plate

[0079] 11, 12 first layers

[0080] 13 first bridges

[0081] 14 first cavities

[0082] 15 spacers

[0083] 16 fluid lines

[0084] 20 second cover plate

[0085] 21, 22 second shifts

[0086] 23 second bridges

[0087] 24 second cavities

[0088] 25 spacers

[0089] 30 foam layers

[0090] 31 first

[0091] 32 second foam layer surface

[0092] 41 Press element

[0093] 42 additional pressing element

[0094] 45 clamping element

[0095] 51 first endless strand

[0096] 52 second endless strand

[0097] 53 third endless strand

[0098] 55 Pressing device

[0099] 56 On carrying equipment

Claims

Patent claims:

1. Sandwich panel (1) comprising: - a foam layer (30) with a first foam layer surface (31 ) and a second foam layer surface (32) substantially parallel to the first foam layer surface (31 ), - a first cover plate (10) which extends parallel to and is connected to the first foam layer surface (31), - a second cover plate (20) which extends parallel to and is connected to the second foam layer surface (32), wherein the first cover plate (10) is formed from at least two first layers (11, 12) spaced apart from each other and connected to each other by means of first webs (13) such that one or more first cavities (14) are formed between the two layers (11, 12), and / or wherein the second cover plate (20) is formed from at least two second layers (21, 22) spaced apart from each other and connected to each other by means of second webs (23) such that one or more second cavities (24) are formed between the two layers (21, 22).

2. Sandwich panel according to claim 1, wherein the foam layer (30), the first cover plate (10) and / or the second cover plate (20) are substantially entirely made of the same material.

3. Sandwich panel according to claim 1 or 2, wherein the foam layer (30), the first cover plate (10) and / or the second cover plate (20) are formed from one or more polymer materials, in particular polyethylene terephthalate (PET), polypropylene (PP), polystyrene (PS), polyethylene (PE), high-density polyethylene (HDPE), low-density polyethylene (LDPE), and / or polyvinyl chloride (PVC).

4. Sandwich panel according to one of the preceding claims, wherein the first cover panel (10) has a panel thickness perpendicular to the first foam layer surface (31) of at least 0.5 cm, 1 cm, 1.5 cm or 2 cm and / or of at most 5 cm, 8 cm or 10 cm and / or wherein the second cover panel (20) has a panel thickness perpendicular to the second foam layer surface (32) of at least 0.5 cm, 1 cm, 1.5 cm or 2 cm and / or of at most 5 cm, 8 cm or 10 cm.

5. Sandwich panel according to one of the preceding claims, wherein the first cavities (14) comprise at least one first cavity (14) which extends substantially over an entire length or width of the first cover plate (10) and / or wherein the second cavities (24) comprise at least one second cavity (24) which extends substantially over an entire length or width of the second cover plate (20).

6. Sandwich panel according to one of the preceding claims, wherein the first cavities (14) comprise at least one first cavity (14) which is designed as a fluid conduit for the flow of a fluid or which has a fluid conduit for the flow of a fluid and / or wherein the second cavities (24) comprise at least one second cavity (24) which is designed as a fluid conduit for the flow of a fluid or which has a fluid conduit for the flow of a fluid.

7. Sandwich panel according to one of the preceding claims, further comprising one or more spacer elements (15, 25) which are arranged between the two cover plates (10, 20).

8. Sandwich panel according to claim 7, wherein the spacer elements (15, 25) laterally limit the foam layer (30).

9. Sandwich panel according to claim 7 or 8, wherein the two cover plates (10, 20) and the spacer elements (15, 25) enclose the foam layer (30).

10. Sandwich panel according to one of claims 7 to 9, wherein a first spacer element (15) is formed on the first cover plate (10) and a second spacer element (25) is formed on the second cover plate (20) and wherein the spacer elements (15, 25) are connected to each other.

11. Sandwich panel according to one of the preceding claims, wherein the first cavity or cavities and / or the second cavity or cavities are partially or completely filled with a foam, in particular a foam made of the same material as the foam layer.

12. Sandwich panel according to one of the preceding claims, further comprising a connecting element for connecting the sandwich panel (1) at a proximal end of the sandwich panel (1) to another sandwich panel (1) or to another component, wherein the connecting element comprises a pressing element (41) arranged between the two cover plates (10, 20) at a distal end of the sandwich panel (1) and a clamping element (45) extending through the foam layer (30) from the distal end to the proximal end, which is configured to exert a mechanical force on the pressing element (45) in the direction of the foam layer (30).

13. Sandwich panel construction comprising a sandwich panel (1) according to claim 12, which is connected longitudinally to a further sandwich panel (1) by means of the connecting element such that a proximal longitudinal side of the sandwich panel (1) abuts a proximal longitudinal side of the further sandwich panel (1), wherein the pressing element (41) abutting a distal longitudinal side of the sandwich panel (1) and a distal longitudinal side of the further sandwich panel (1) The adjacent further pressing element (42) are connected to each other by means of the clamping element (45) which extends through the foam layer (30) from the distal longitudinal side of the sandwich panel (1) to the distal longitudinal side of the further sandwich panel (1).

14. Housing, in particular living space, office space or room module, comprising wall elements, roof elements and floor elements enclosing an interior area of ​​the housing, wherein the wall elements, roof elements and floor elements are formed partially or completely from one or more sandwich panel(s) (1) according to one of claims 1 to 12 and / or from one or more sandwich panel construction(s) according to claim 13.

15. Manufacturing process for producing a sandwich panel (1) wherein: - a foam layer (30) with a first foam layer surface (31 ) and a second foam layer surface (32) that is substantially parallel to the first foam layer surface (31 ), - a first cover plate (10) is arranged on the first foam layer surface (31) and connected to it, - a second cover plate (20) on the second foam layer surface (32) is arranged and connected to it, and wherein the first cover plate (10) is formed from at least two first layers (11, 12) spaced apart from each other in parallel, which are connected to each other by means of first webs (13) in such a way that one or more first cavities (14) are formed between the two layers (11, 12), and / or wherein the second cover plate (20) is formed from at least two second layers (21, 22) spaced apart from each other in parallel, which are connected to each other by means of second webs (23) in such a way that one or more second cavities (24) are formed between the two layers (21, 22).

16. Manufacturing process according to claim 15, wherein: - the first cover plate (10) is produced in a first extrusion process in the form of a first continuous strand 51, - the second cover plate (20) is produced in a second extrusion process in the form of a second continuous strand 52, and / or - a foam layer (30) is produced in a foaming process in the form of a third continuous strand 53.

17. Manufacturing process according to claim 16 wherein: - the three continuous strands are locally joined together at a connection area and connected to each other to form a continuous strand of a sandwich panel (1 ) before the continuous strand of the sandwich panel (1 ) is divided into individual sandwich panels (1 ), or - the three continuous strands are first each broken down into individual first cover plates (10), individual second cover plates (20) and individual foam layers (30), and then each first cover plate (10), second cover plate (20) and foam layer (30) is joined to form a sandwich panel (1 ).

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