Structural sandwich panel

Abstract

The claimed technical solution relates to the field of building, and more particularly to prefabricated building elements for cladding buildings and other architectural structures. A structural sandwich panel comprises layers of a sheet metal casing having a main thermal insulation layer arranged therebetween, locking elements formed at the end faces of the panel for connection to another panel, and protective thermal insulation layers disposed at the end faces of the main thermal insulation layer, proximal to the locking elements, wherein the thickness (T) of a protective thermal insulation layer is less than the height (H) thereof, and the thickness of the sheet metal casing is 0.35-0.80 mm. The technical result of the claimed solution is an increase in the reliability and fire resistance of the structural sandwich panel.

Description

[0001] Construction sandwich panel

[0002] Field of technology

[0003] The claimed technical solution relates to the field of construction, namely to prefabricated building elements intended for cladding buildings and structures.

[0004] Prior art

[0005] A prior art solution comprises a façade sandwich panel for cladding and insulating structures. The panel comprises a cladding panel with fasteners located at its ends, capable of being joined to another panel using a tongue-and-groove lock, and a thermal insulation material attached to it, to which a vapor-permeable sheathing is attached. The thermal insulation material is formed from rows, each consisting of segments, and the joints of the segments of one row are offset relative to the joints of the next row. Grooves are formed on the surface of the thermal insulation material facing the cladding panel, forming ventilation ducts with the cladding panel. A protective mesh is fixed to the end surface of the panel, covering the ventilation ducts. Russian Federation Patent No. RU210168U1, IPC E04C 2 / 00, published March 30, 2022.

[0006] The closest alternative chosen is a sandwich panel, a three-layer structure with sheet metal skins and a middle insulating layer consisting of layers of mineral wool slab and expanded polystyrene foam bonded together. The expanded polystyrene foam layer is framed on the two sides adjacent to the locking section by a layer of mineral wool slab, the height of which is equal to the thickness of the expanded polystyrene foam layer, and the thickness of which is equal to the thickness of the mineral wool layer. The butt joint on the two sides adjacent to the locking section is additionally framed by a metal strip. Russian Federation Patent No. RU81229U1, IPC E04B 2 / 00, E04C 2 / 00, published March 10, 2009.

[0007] The objective of the stated technical solution is to create a construction sandwich panel with increased reliability.

[0008] Disclosure of the solution

[0009] The technical result of the claimed solution is to increase the reliability and fire resistance of the construction sandwich panel.

[0010] Increased reliability is achieved, in particular, by increasing durability, wear resistance, and fire resistance.

[0011] The claimed technical result is achieved due to the fact that the construction sandwich panel includes layers of cladding made of a metal sheet, between which a main thermal insulation layer is installed, locking elements made on the end sides of the panel for connection with another panel, protective thermal insulation layers placed on the end sides of the main thermal insulation layer on the side of the locking elements, while the thickness (T) of the protective thermal insulation layer is less than its height (H), and the thickness of the metal cladding sheet is 0.35-0.80 mm.

[0012] A sandwich panel consists of layers of metal sheet skins sandwiched between a primary thermal insulation layer. The presence of a thermal insulation layer between the skin layers reduces heat transfer from one skin layer to another, preventing the structure from freezing during cold weather and increasing its fragility, thereby increasing durability and, consequently, the reliability of the solution. Furthermore, the skin layers protect the primary thermal insulation layer of the panel, increasing the reliability of the solution, from moisture ingress. Moisture freezes when the ambient temperature drops, reducing the thermal insulation properties of the panel and damaging the primary thermal insulation layer from the inside due to expansion during freezing. The skin layers also protect the primary thermal insulation layer from mechanical impacts, rodents, birds, and insects, thereby preventing a reduction in the panel's thermal insulation properties and further damage, significantly increasing the reliability of the solution.Using sheet metal for the skin layers imparts high wear resistance and strength to the panel due to the inherent properties of metal, while also ensuring a highly reliable solution. The skin layers and the underlying thermal insulation layer installed between them can be bonded, for example, using an adhesive layer or a material with an adhesive surface. In specific embodiments of the proposed solution, the skin layers can be made of sheet metal appropriate for the intended function, such as aluminum, stainless steel, etc., and can be flat or profiled. The underlying thermal insulation layer can be made of a suitable thermal insulation material, such as expanded polystyrene, polyurethane foam, mineral wool, etc.The choice of material for the main thermal insulation layer, as well as for protective thermal insulation layers, may be determined, but not limited, by the specific conditions of application of the proposed solution, in particular, humidity, the location of the construction site on the terrain, temperature conditions throughout the year, etc.

[0013] The proposed technical solution includes interlocking elements on the end faces of each panel for joining to another panel, enabling the panels to be joined together to form a single structure when used for cladding buildings. The interlocking elements on the end faces of each panel allow for easy and secure joining of the panels, while protective thermal insulation layers ensure a tight fit, reducing installation gaps and preventing rodent and insect penetration, thereby increasing the durability and, therefore, reliability of the solution.Furthermore, the presence of locking elements reduces the need for various panel-to-panel joining elements that compromise the structural integrity of the panel, such as strips connecting panels with screws. This increases the risk of further panel damage, the formation of thermal bridges, and the reduction of its thermal insulation properties, contributing to the structure's freezing during the cold season and increasing its fragility. In specific embodiments, locking elements can be tongue-and-groove or Z-lock joints, and can be achieved, in particular, by bending the edge of the metal sheet of the cladding layer. In a specific embodiment of the proposed solution, the height of the locking element is 12-20 mm, which further improves the reliability of the panel connection and the resistance of the joint to mechanical stress.In the context of the proposed solution, the term "locking element height" refers to the height of the projection of one element of the locking joint, or the depth of the groove of the other element of the locking joint. Reducing the locking element height to less than 12 mm increases the risk of panel joint failure under various loads, further increasing the risk of moisture or insect penetration into the panel's thermal insulation material. Increasing the locking element height to more than 20 mm further increases the risk of thermal bridges forming at the panel joint.

[0014] The proposed sandwich panel also includes protective thermal insulation layers placed on the end faces of the main thermal insulation layer, on the side of the locking elements. These layers protect the main thermal insulation layer from various impacts from the end face of the panel. Due to their thermal insulation properties, they prevent the creation of "cold bridges" between the metal skins of the panel, which would facilitate heat transfer and, consequently, severe cooling of the panel and increased fragility, thereby increasing the reliability of the solution. Furthermore, the presence of protective thermal insulation layers on the side of the locking elements ensures better adhesion of the panels to each other when joined, without reducing the thermal insulation properties of the panel.In the context of the claimed solution, the term "protective thermal insulation layers" refers to layers of thermal insulation material different from the primary thermal insulation layer, which perform protective functions relative to it, in particular, against atmospheric conditions, rodents, and various loads. In certain embodiments, these layers may be made of a thermal insulation material, for example, with a higher density than the primary thermal insulation layer. As a specific, non-limiting example, the primary thermal insulation layer may be made of expanded polystyrene, while the protective thermal insulation layers may be made of mineral wool, which also improves the panel's fire resistance. The protective thermal insulation layers may be bonded to the primary thermal insulation layer via an adhesive layer or a material with an adhesive layer.

[0015] In the proposed solution, the thickness (T) of the protective thermal insulation layer is less than its height (H). This design feature ensures optimal protection of the main thermal insulation layer from various influences, including fire, moisture, and rodents, which can impair the panel's thermal insulation properties. Making the protective thermal insulation layer less than its height (H) also reduces the panel's weight while maintaining its protective properties. This reduces the load on the interlocking elements and the panel connection, thereby reducing the risk of stress in the material and damage to the interlocking elements, thereby increasing the durability and, consequently, the reliability of the solution.Furthermore, in this design, the junctions between the protective thermal insulation layers and the main thermal insulation layer are located closer to the end of the panel, further minimizing the bending moment in the metal cladding layer, thereby reducing the risk of damage during transportation, installation, and joining with other panels, increasing the reliability of the solution. The thickness of the metal cladding sheet in the proposed construction sandwich panel ranges from 0.35 to 0.80 mm, which also ensures optimal strength, wear resistance, durability, and, consequently, reliability. Reducing the cladding thickness to less than 0.35 mm reduces the strength and wear resistance of the metal sheet, increasing the risk of panel damage and compromising the integrity of the cladding layers. Furthermore, a thickness of less than 0.35 mm also increases the flexibility of the metal sheet, increasing the risk of cladding deformation under load, leading to subsequent damage.Increasing the sheet metal thickness above 0.80 mm will increase the weight of the entire panel, as well as the rigidity of the skin layers. This increases the risk of damage to the sheet metal skin layers if the panel flexes. Furthermore, increasing the sheet metal thickness above 0.80 mm increases the volume of the skin material, which, when frozen at low temperatures, increases the risk of cold bridges between the warmer and colder skin layers.

[0016] In one particular solution, the main thermal insulation layer is formed from rows, each of which consists of segments, and the joints of the segments of one row are offset relative to the joints of another row, which can further improve the thermal insulation properties of the panel by complicating the internal structure of the thermal insulation layer and the intersection of segments with each other, especially, for example, when using fibrous thermal insulation materials, which further reduces the risk of the formation of "cold bridges" and a decrease in the durability of the panel.

[0017] The locking elements can be made asymmetrical across the panel thickness. One of the skins can have a high profile (up to 40 mm).

[0018] Brief description of the drawings

[0019] The claimed technical solution is further explained with the help of a figure, which conditionally represents one of the specific variants of the claimed construction sandwich panel.

[0020] The following elements are indicated on the figure:

[0021] - layers (1) of sheathing;

[0022] - main thermal insulation layer (2);

[0023] - locking elements (3);

[0024] - protective thermal insulation layers (4);

[0025] - thickness (T) of the protective heat-insulating layer (4);

[0026] - height (H) of the protective heat-insulating layer (4). Implementation options

[0027] Below, one of the preferred embodiments of the claimed technical solution is described with reference to the figure.

[0028] The construction sandwich panel includes layers (1) of cladding made of a metal sheet, preferably steel with a polymer coating, between which a main heat-insulating layer (2) is installed, in particular polystyrene foam, locking elements (3) made on the end sides of the panel for connection with another panel, and protective heat-insulating layers (4) placed on the end sides of the main heat-insulating layer (2) on the side of the locking elements (3) and made, in particular, from mineral wool.

[0029] The thickness (T) of the protective thermal insulation layer (4) is less than its height (H). The thickness of the metal cladding sheet (1) is 0.35-0.80 mm, preferably 0.50 mm. The height of the locking element (3) is preferably 12-20 mm, in particular 18 mm. The main thermal insulation layer (2) is preferably formed from rows, each of which consists of segments, and the joints of the segments of one row are offset relative to the joints of the next row.

[0030] When using the claimed technical solution, construction sandwich panels are installed according to the building design and are connected to one another using locking elements (3) located on the end faces of the panels. Protective thermal insulation layers (4) ensure a tight fit between the panels. The primary thermal insulation layer (2) prevents heat transfer from one sheet metal cladding layer (1) to another, preventing freezing of the entire structure. The cladding layers (1) protect the primary thermal insulation layer (2) from external influences, such as moisture or impact loads. The protective thermal insulation layers (4) also protect the primary thermal insulation layer (2) from various influences, including rodents and insects.Due to the fact that the thickness (T) of the protective heat-insulating layer (4) is less than its height (H), and the thickness of the metal sheet is made within the range of 0.35-0.80 mm, the panel is easy to transport and install in the desired position due to the reduction in weight, and at the same time, the high durability and wear resistance of the panel is maintained, providing a highly reliable solution.

[0031] Industrial applicability

[0032] The claimed technical solution can be used for cladding and insulating building structures and is characterized by increased reliability, achieved in particular by durability and wear resistance. The claimed sandwich panel can be used, without limitation, as a wall or roof panel. The presented figure, description of the design, and use of the building sandwich panel do not exhaust the possible design options or in any way limit the scope of the claimed technical solution. Other design options are possible within the scope of the claimed formula.

Claims

FORMULA 1. A construction sandwich panel comprising layers of cladding made of a metal sheet, between which a main thermal insulation layer is installed, locking elements made on the end sides of the panel for connection with another panel, protective thermal insulation layers placed on the end sides of the main thermal insulation layer on the side of the locking elements, wherein the thickness (T) of the protective thermal insulation layer is less than its height (H), and the thickness of the metal cladding sheet is 0.35-0.80 mm.

2. A construction sandwich panel according to paragraph 1, characterized in that the height of the locking element is 12-20 mm.

3. A construction sandwich panel according to paragraph 1, characterized in that the main heat-insulating layer is formed from rows, each of which consists of segments, and the joints of the segments of one row are offset relative to the joints of another row.

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