Self-supporting calcium silicate panel and related prefabricated living module

Abstract

 New self-supporting panel for the production of filler panels, coverings, walls, ceilings, floors, partitions etc., comprising one or more layers in calcium silicate produced in an autoclave, surface-treated with sodium silicate, and on which one or more surface layers are glued made of sheet metal or plastic or fibre, or any material able to provide the necessary resistance, and related prefabricated living module complete with walls, ceiling, floor, technical installations etc., all factory assembled, tested and sealed so that it can be loaded on transport vehicles.

Description

[0001] The present patent concerns the field of prefabricated panels and in particular panels with characteristics suitable for the production of coverings, walls, ceilings, floors for buildings, ships, etc. and related construction of living compartments or modules intended for civil buildings and ships.

[0002] At present prefabricated panels for living compartments and/or cabins of ships are known comprising a central core made of polystyrene or foamed polyurethane or rock wool, which provides the necessary characteristics of insulation and sound absorption, and two outer layers made of metal or plastic laminate, able to provide the necessary static rigidity, with further metal covering if required, for example aluminium laminate, as a finish.

[0003] The above panels are sufficiently rigid and insulating to permit the production of walls of standard height, approximately 240-270 cm, but they have some drawbacks.

[0004] Said panels are generally not very robust, due to the presence of the polyurethane core which does not have any structural characteristic.

[0005] Furthermore, in particular due to the characteristics of the materials themselves and the joints between the panels, they often do not have the characteristics of fire resistance imposed by the current safety regulations.

[0006] Currently living modules and cabins are known constructed by assembling panels with core made of insulating material such as foamed polyurethane or polystyrene or rock wool suitably coated.

[0007] In this way living modules can be produced in various shapes and sizes but these have some drawbacks.

[0008] In particular said living modules or cabins are generally not very robust, due to the inner core made of polyurethane or similar, which has no structural function.

[0009] An important problem is constituted by the fact that generally said panels, and the joints between them, do not have the necessary characteristics of fire resistance and do not permit approval of the same in the highest classes provided for by the regulations for shipbuilding or civil buildings. This represents a serious problem, since it is highly desirable, especially for ships' cabins, to have fire-retardant characteristics such as to form optimal fire barriers to avoid the danger of fire spreading between the cabins.

[0010] A further drawback, particularly in the case of ships' cabins, derives from the fact that the supporting surfaces such as the decks of ships are not perfectly flat and regularly shaped. Said irregularities make correct positioning of the cabin complex and limit perfect adhesion of the floor of the cabin to the deck, so that it is not supported correctly, therefore endangering the stability of the cabin itself in the long term.

[0011] To remedy all the above drawbacks a new type of self-supporting panel has been designed and produced for filler panels, coverings, ceilings, floors, walls, partitions etc. for buildings, ships and related living modules in general.

[0012] The main aim of the new panel is to be self-supporting, i.e. have the necessary structural characteristics for use as wall or partition and a new living module or cabin made of self-supporting prefabricated panels particularly resistant and stable also on irregular supporting surfaces provided with joints such as to ensure maximum fire resistance and optimal heat insulation and soundproofing.

[0013] A further aim is to be lightweight, so that it can be assembled easily.

[0014] A further aim of the new panel and the new cabin or living module is to have excellent fire resistance such as to make it safe in the event of fire and so that it can be approved in the highest classes provided for by the law.

[0015] A further aim is to guarantee optimal heat insulation and soundproofing.

[0016] A further aim is to have a low ecological impact, i.e. not favour the release of any toxic or contaminating substance, and there be easy to dispose of.

[0017] A further aim of the new panel is to be able to absorb the excess humidity in the air and release it over time dry, without the formation of mould or alterations in general.

[0018] A further aim is to be very resistant from a static point of view, so as to constitute a self-supporting structure which can be easily and rapidly assembled.

[0019] A further aim is to guarantee stability also on supporting surfaces that are not flat or are uneven.

[0020] A further aim is to guarantee heat insulation and soundproofing between cabins and outer compartments.

[0021] These and other aims, direct and complementary, are achieved by the new self-supporting panel, made of calcium silicate produced in an autoclave, treated externally with sodium silicate and coated in a fine outer layer of plastic, or metal, or fibre or any other coating material able to provide the necessary mechanical resistance, also called mechanical panel.

[0022] These and other aims, direct and complementary, are achieved by the new cabin produced by assembling panels, as described above, with a high mechanical resistance and provided with maximum fire resistance, maximum soundproofing and heat insulation coupled by means of joint elements that guarantee stability, air tightness and continuity of the fire-retardant characteristics of the panels. The panels intended for flooring also feature holes to provide a system for levelling the supporting surface of the cabin.

[0023] The new self-supporting panel consists in its main parts of a core made of calcium silicate, the outer surfaces of which are treated with a layer of primer in sodium silicate, coated externally in a layer of metal, or plastic, or fibre or any material designed to resist traction.

[0024] The new cabin or living module consists in its main parts of a series of panels made of calcium silicate, coupled by means of supporting and joining elements preferably made of metal of suitable forms and dimensions.

[0025] The calcium silicate produced in an autoclave is an inert material with low density, which has excellent fire resistance and physical-chemical characteristics which do not vary with changes in temperature. It has low conductivity and is therefore able to provide optimal heat insulation over a wide temperature range.

[0026] It is also waterproof and therefore does not permit the formation of mould.

[0027] It is a completely non-toxic ecological material, does not contain asbestos fibres or other toxic or contaminating substances.

[0028] In addition the characteristics of this material remain unchanged in the long term, so that no maintenance is necessary.

[0029] An element made of calcium silicate produced in an autoclave is fragile, however: it has fairly good resistance to compression but poor resistance to traction, and therefore cannot be used as it is for the production of wall panels.

[0030] In order to make the new panel self-supporting and structural, said central core made of calcium silicate must be coupled with a layer of material able to resist traction. Glues able to bind the calcium silicate to metal, plastic or fibre sheets are not currently known.

[0031] For this reason the calcium silicate core is treated externally, preferably on both surfaces, with a sodium silicate-based primer. The sodium silicate acts like a root, penetrating the calcium silicate and permitting the adhesion of any glue and related coating. The sodium silicate therefore prevents slipping and detachment of the coating on the calcium silicate. In this way a solid structure is created, able to resist all the stress to which walls, ceilings and floors etc. are usually subjected.

[0032] In particular the panels made of calcium silicate surface-treated with sodium silicate and coupled, by means of glue, to metal, plastic or fibre layers are used for the purpose. Said panels can be provided, along the edges, with frame elements consisting preferably of metal section bars, preferably C or L-shaped and fixed to said panels for example by means of glues or resins with high fire-retardant characteristics.

[0033] The structural joining and supporting elements designed for assembly of the panels and production of the new cabin are preferably metal elements that can be fixed to said frame elements, or directly to the panel, preferably by inserting them in milled areas obtained in said panels and then gluing them to them with glues or resins with high fire resistance. The form of said structural joining and supporting elements guarantees the necessary characteristics of fire resistance and insulation between cabins, in addition to contributing to the mechanical resistance of the same.

[0034] Joints of various shapes and dimensions are envisaged and such as to permit coupling between two or more panels, or between two or more pairs of panels, also belonging to separate cabins, so as to fix said cabins one to the other. Said joints are also designed to produce not only flat panels, but angle-shaped panels, also with angles other than 90°.

[0035] For example, the joint between two pairs of panels square to each other, belonging to two separate cabins, is produced by using a C-shaped upright joint element and fixing the first pair of panels at the level of a first angle of a C-shaped section bar, and the second pair at the opposite angle. On the long side of the C two spaced parallel panels are therefore fixed. In said way the joint acts also as spacer between the two cabins, thus providing a gap between them, necessary for insulation.

[0036] The perfect bearing on the ground and the improved stability of the new cabin derive from the particular characteristics of the panels used for the floor. Said panels are in fact provided with holes uniformly distributed over the entire surface of the panel. Via said holes it is possible, once the floor panels have been assembled and positioned, to introduce an expandable glue or resin which, by filling the spaces between the floor panel and the supporting panel provides a system for ground levelling and fixing of the cabin.

[0037] Many advantages are obtained with the new panel.

[0038] It is a self-supporting panel, with high mechanical and static resistance.

[0039] It has excellent heat insulation and fire resistance; in particular the fire tests performed on said new panel provide values in the highest classes of the REI scale for civil buildings, and scale A-B for shipbuilding.

[0040] It is lightweight and therefore easy to transport and assemble.

[0041] Furthermore it is made entirely of non-toxic non-contaminating material and therefore has low ecological impact when disposed of.

[0042] The new panel can be coated externally in an additional layer in any material to give the required appearance.

[0043] Panel protection and closing frames are also provided, consisting of metal or plastic elements, positioned on the edges of the panel, to protect the sharp edges. Said elements are preferably in a C or L shape, or such as to cover, totally or partially, the edges of the new panel. Said frame elements are preferably coupled to said panel by applying between panel and frame elements a layer of glue or resin with suitable fire-retardant characteristics.

[0044] Said panels, with or without protection frame, can be positioned side by side and fixed by means of glue or resin with suitable fire-retardant characteristics.

[0045] In order to increase the heat insulation and soundproofing of the new panel, a sound-absorbent viscoelastic resin can be used, applied between the surfaces of the layer of calcium silicate treated with sodium silicate and the surface layers made of sheet metal or other.

[0046] Variations are also envisaged in which each panel comprises not one but two layers of calcium silicate, glued together with a layer of viscoelastic resin, provided with excellent sound absorption. In particular the new panel, according to this second method, comprises two layers of calcium silicate, each of which are treated on both surfaces with sodium silicate. Between said layers of calcium silicate a layer of viscoelastic resin is applied, which guarantees soundproofing between said two layers of calcium silicate. Externally the panel is coated on both surfaces, with a sheet layer made of metal, fibre or other.

[0047] The characteristics of the new panel and the new cabin or living module will be better clarified by the following description with reference to the drawings, attached as a nonlimiting example.

[0048] Figure 1 shows a section of the new panel: the central core (I) in calcium silicate, treated in the surface area (S) with sodium silicate, can be seen. On the treated surfaces (S) a layer of glue (C) is applied, to permit subsequent application of a layer (L) made of sheet metal, plastic or fibre. Said layer of glue (C) can, if necessary, be a layer of sound-absorbent viscoelastic resin.

[0049] Figure 2 shows the same panel furthermore comprising two C-shaped closing and protection frame elements (E1) with dimensions such as to cover and fully protect the edges of the new panel.

[0050] Figure 3 shows the same panel with a variation of the frame element (E2). In this case the frame element covers only half of the thickness of the edge. Total protection can be provided by coupling two of said frame elements (E2).

[0051] Figure 4 shows a variation of said panel, comprising two layers in calcium silicate (I). In particular the figure shows that said layers in calcium silicate (I), each treated on both surfaces (S) with sodium silicate, are glued together with a layer (V) of viscoelastic resin, provided with excellent sound absorption and therefore able to soundproof said layers (I) in calcium silicate. The panel is covered externally in two sheet metal layers, coupled to the calcium silicate layer by application of glue (C) on the surface (S) of said layers (I) treated with sodium silicate.

[0052] Figure 5 shows a plan view of an example of cabin (C), provided with bathroom compartment (V), produced according to the procedures described. The peripheral walls (A), the internal walls (D), the floors (K) and the ceilings are provided by assembling several panels (P). The panels (P) are assembled by means of joint elements, which have different characteristics depending on whether they are joints (GA) for coupling between panels (P) that are aligned, or joints (GB) for coupling between panels (P) positioned at right angles. The panels used can be flat or angle-shaped.

[0053] Figure 6 shows a detail of a joint element (GA) designed to provide connection between two aligned panels (P). Said joint element (GA), shaped in a double T, fixes the two panels (P) together. The connection between said joint element (GA) and said panels is made preferably by applying between said panels (P) and said joint element (GA) glue or resin with excellent fire resistance. Said joint element (GA) can consist of one single double T section bar or, alternatively, can be obtained by coupling, for example by means of screws or glue, two C-shaped elements (GA1), like those shown in fig. 2a.

[0054] Figure 7 shows the joint (GB) designed to provide the connection between two panels (P) positioned at right angles. Said joint element (GB) consists of two elements: a first Z-shaped element (GB1) slots into one of the two panels (P) and is fixed along part of the edge of the second, a further element (GB2), L-shaped, fixed to the two panels (P) and to the first joint element (GB1), defines and follows the angle created by the two panels (P).

[0055] The angles can be created not only by coupling two flat panels as described above but also by using angle-shaped panels. Said shaped panels are obtained from a flat panel via grooving and milling operations, and use of joints, as illustrated in figures 4-5.

[0056] Figures 8 a-8e show a first method of obtaining the angle panel.

[0057] Figure 8a shows the panel (P), with one surface layer made of metal sheet (M) and one multiaxial layer made of resin-bonded fibreglass (F). On said panel (P) a groove (T) has been obtained to interrupt the layer of calcium silicate (I), the layer in fibre (F), but not the metal sheet (M).

[0058] Figure 8b shows the same panel (P), after bending of the same. The two portions (P1, P2) of the panel, originating with the groove (T), are positioned at right angles.

[0059] Figure 8c shows an element (E) in the form of a parallelepiped of length equal to the length of the panel (P) and with square section with side equal to the thickness of said panel (P). Said element (E) is preferably made of calcium silicate and/or resin and/or metal.

[0060] Figure 8d shows the section of the joint (G1) consisting of a metal section bar bent in the shape of a hollow parallelepiped with form and dimension such as to perfectly contain said parallelepiped element (E).

[0061] Figure 8e shows how said joint (G1) containing the element (E) fits perfectly into the space formed between the two parts (P1, P2) of the panel (P). For further fixing and protection of the angle thus formed, a section bar (Z) preferably made of galvanised steel, bent at right angles, is fixed externally, for example by means of screws (V).

[0062] As shown in figure 8f the panel (P) in its final form is provided with a further layer made of fibre (B), to cover the metal section bar (Z) and protect the angle in general.

[0063] Figure 9 shows a second method of producing an angle panel.

[0064] Figure 9a shows a panel (P) with a calcium silicate core (I), a surface layer made of sheet metal (M), and a multiaxial layer made of resin-bonded fibreglass (F). On said panel (P) a V-shaped groove (T1) is made involving the surface layer (F) and the core (I). At the level of the longitudinal axis of the panel (P) and in each of the portions (P1, P2) of panel, originating with the groove (T1), two further grooves (T2, T3) or slots have been produced, for example by milling.

[0065] Figure 9b shows the same panel, after rotation of the portions (P3, P4), around the apex of the groove (T1). The panel (P) obtained in this case is shaped at an angle of 90°. Different angles can be obtained by producing grooves with different and suitable angle aperture.

[0066] Following bending, the two slots (T2, T3) come into contact and produce a fissured seat shaped at right angles.

[0067] Figure 9c shows the panel (P) complete. In the seat created by combination of the two slots (T3, T4) an angle joint (G2) is inserted, which joins the two portions (P3, P4). The angle thus produced is internally coated in a metal laminate (Z), fixed by means of screws, shaped at right angles and provided with a further fibre layer (B) to protect the angle.

[0068] Figure 10 shows an example of a wall of a cabin, formed of panels (P) comprising two layers made of calcium silicate (I1, I2), glued together with a layer of sound-absorbent viscoelastic resin (R). This precaution is very important for guaranteeing adequate soundproofing. Also in this case, the angles are produced according to one of the methods previously described.

[0069] Figure 11 shows in detail a joint (GC) which provides the connection between two pairs of panels (P5, P6) belonging to two separate adjacent cabins. Each of the panels (P) is provided with joint (GA1). The connection between the two pairs of panels is provided by fixing the first pair of panels (P5), square to each other, at one angle of the joint element (Gc), and the second pair (P6) at the opposite angle. The long side of the C-shaped upright (Gc) has a larger dimension than the sum of the thicknesses of two panels. In this way the joint element (Gc) also acts as a spacer between the two cabins, thus providing a gap (S) between the same, necessary for the insulation. Said insulation is fundamental for the safety of the cabin. In fact it guarantees non-transmission of noise, vibrations and heat between the cabins, thus acting as partition wall in the event of fire.

[0070] Figure 12 shows an example of compartment that can be produced according to the invention described here.

[0071] Figures 13-16 show various types of panel (P). The use of panels (P) of different widths is envisaged to obtain walls of different dimensions or angles other than 90°. In particular flat panels are envisaged like those shown in figure 13, or angle shaped like those shown in figures 14, 15, 16. The angle can be a right angle, as shown in fig. 14, or acute, or obtuse, like the one shown in figure 15. Panels with more than one bending point are also envisaged, like the one shown in figure 16, for example. In this way perimeter walls of any form can be easily produced, for example with angles that are not right angles.

[0072] Figure 17 shows an embodiment example of a ceiling of a new cabin. In this case the panels are supported by a metal framework (L), which also acts as a junction element.

[0073] Figure 17a also shows the fixing device (U) of the panels to the framework (L). The central panel (P) is provided with hole (O) for housing the light point.

[0074] The figures show said central panel with the detail of the fixing device (U) of the panel (P) to the framework (L), and a detail of an angle end of said framework (L).

[0075] Figure 17b shows how the framework (L) has greater longitudinal dimensions than those of the panel (P), so that said framework (L) protrudes from said panel by a stretch (Ls) designed to rest on the walls of the cabin (C).

[0076] Figure 18 shows the section of panels for producing a floor.

[0077] The first operation is fixing of the panels (P) for construction of the wall (A) to the supporting surface (H). Subsequently the panels (P) for producing the floor (K) are rested on the surface (H). Said panels (K) are provided with equidistant holes. Extractable screws (N) are inserted in the panel. Said screws (N) lift said panels (K) from the ground (H), so as to arrange them in a perfectly horizontal position, creating a gap (W) between said panels (K) and said supporting surface (H). At this stage a resin (Res) is injected into the holes (Kf) designed to expand in the gap (W) between supporting surface (H) and floor panels (K). In this way the floor panels (K) are rested and fixed on the surface (H). After hardening of the resin, the screws (N) are extracted and the floor is ready for final finishing with carpet or similar.

[0078] Said new cabins can be pre-fitted and/or prefabricated in the factory or on site, either completely or in separate blocks complete with furnishings and installations. Alternatively it is possible to construct the cabin with bare walls and assemble it in the final position of use.

[0079] The floor is preferably formed of panels provided with holes for insertion of expandable glue or resin for fixing to the ground. In particular the cabins are preferably provided inside with rolls of carpet or similar so that, once positioned in situ, first the glue or resin is inserted in the holes and then the floor is finished, laying the carpet or other covering.

[0080] The new cabin as described also has the considerable advantage that it can be completely assembled at the factory and not in the final place of use. Said complete assembly permits factory testing of said cabin and all the installations contained in it so that the product can be immediately adapted in the case of unsatisfactory test results. Once testing has been successfully performed, the manufacturer seals the cabin which will be opened only after final installation. The advantage deriving from this possibility consists in the fact that on-site testing is slower, more costly and more complex.

[0081] There are many advantages of the new cabin.

[0082] Due to the materials used the new cabin or living module is extremely lightweight, rigid, sturdy and self-supporting. It also provides very good soundproofing, heat insulation and fire resistance.

[0083] It is easy to transport, and can be assembled in loco or on site.

[0084] Therefore with reference to the preceding description and the attached drawings the following claims are made.

Claims

1. Self-supporting panel for the production of filler panels, coverings, walls, ceilings, floors, partitions, furniture, characterised in that it comprises one or more layers in calcium silicate produced in an autoclave, surface-treated with sodium silicate, and on which one or more surface layers are glued made of sheet metal or plastic or fibre, or any material able to provide the necessary resistance.

2. Self-supporting panel, according to claim 1, characterised in that said surface layers are made of metal or plastic or fibres or paper or cardboard or PVC film or other.

3. Self-supporting panel, according to claims 1, 2, characterised in that a layer of sound-absorbent viscoelastic resin is positioned between said surface layer and the surface made of calcium silicate treated with sodium silicate.

4. Self-supporting panel, according to claims 1, 2, 3, characterised in that it comprises two or more layers of calcium silicate surface-treated with sodium silicate and glued together with positioning of a layer of sound-absorbent viscoelastic resin in-between and two surface layers glued to the outer surfaces of said calcium silicate layers.

5. Self-supporting panel, according to claims 1, 2, 3, 4, characterised in that it comprises, to protect the edges, one or more C or L-shaped frame elements made of metal or plastic sheet, and such as to cover said edges totally or partially.

6. Self-supporting panel, according to claims 1, 2, 3, 4, 5, characterised in that said frame elements are coupled to said panel by application of a layer of glue or resin with suitable fire-retardant characteristics.

7. Self-supporting panel, according to claims 1, 2, 3, 4, 5, 6, characterised in that it can be positioned adjacent and fixed to an identical panel by means of glue or resin with suitable fire-retardant characteristics.

8. Self-supporting panel, according to claims 1, 2, 3, 4, 5, 6, 7, characterised in that it comprises a further outer covering layer made of metal or plastic or fibres or paper or cardboard or PVC film or other.

9. Living module for buildings and ships characterised in that it comprises walls, ceilings, floors consisting of panels, as claimed in the preceding claims, made of calcium silicate surface-treated with sodium silicate, on which covering layers are glued made of metal or plastic or fibre, assembled together.

10. Living module, according to claim 9, characterised in that said panels are flat or angle shaped.

11. Living module, according to claims 9, 10 characterised in that the angle shaped panels are obtained from a flat panel, producing in it a V-groove that divides the panel into two portions, thus providing a slot in each of said portions, then bending the panel and inserting an angle joint in the seat formed by joining of the two slots.

12. Living module, according to claims 9, 10, 11, characterised in that the angle shaped panels are produced from a flat panel by providing a groove in it which divides the panel into two portions, then bending said portions around said groove and inserting in the space between said portions a parallelepiped element, contained in a parallelepiped joint.

13. Living module, according to claims 9, 10, 11, 12, characterised in that the aligned panels are connected by means of double T shaped joints.

14. Living module, according to claim 13, characterised in that said double T joints comprise two adjacent C-shaped joints fixed securely together.

15. Living module, according to claims 9, 10, 11, 12, 13, 14, characterised in that the panels positioned at right angles are fixed by means of a joint comprising an L-shaped section and one section with two parallel wings and a square stretch.

16. Living module, according to claim 9, characterised in that the panels used for producing the floor are provided with holes distributed on their surface such as to permit the introduction through them of expandable glues or resins designed to fill the gaps present between said floor panels and the supporting surface of said living module.

17. Prefabricated living module, according to claim 16, characterised in that said floor panels are assembled by resting said panels on the supporting surface, inserting extractable screws in them in order to keep them in a horizontal position and raised with respect to said supporting surface, then introducing into said holes glues or resins, and removing, after hardening, said extractable screws.

18. Prefabricated living module, according to the preceding claims, characterised in that the panels used for the ceiling are sustained by a metal framework which rests on the wall panels of the cabin.

19. Prefabricated living module according to the preceding claims, characterised in that the joint between two pairs of panels square to each other, belonging to two separate cabins, is provided by using a C-shaped upright joint element and fixing the first pair of panels at the level of a first angle of a C-shaped section bar, and the second pair at the opposite angle.

20. Prefabricated living module according to the preceding claims, characterised in that it comprises walls, ceiling, floor, technical installations etc., all assembled in a self-supporting way and loadable on transport vehicles and lifting equipment.

21. Prefabricated living module according to claim 20, characterised in that it is factory assembled and tested and sealed for transport.

22. Prefabricated living module according to the preceding claims, characterised in that said self-supporting cabin contains the fixed furnishings and/or furniture.

Drawing