SANDWICH PANEL AND METHOD FOR MANUFACTURE THEREOF

Abstract

 The present invention relates to a sandwich panel for covering a roof. The sandwich panel comprises:
- a plate-like element provided with a length and a width;
- an insulation space arranged on a side of the element and filled at least partially with insulating material;
- a vapour-permeable film arranged parallel to the side of the insulation space remote from the plate-like element; and
- a cover arranged substantially parallel to the vapour-permeable film,
wherein a ventilation space is provided between the vapour-permeable film and the cover, and wherein the cover is arranged at an incline relative to the plate-like element.

Description

[0001] The present invention relates to a sandwich panel for covering a roof. The invention further relates to a method for manufacturing such a sandwich panel.

[0002] Sandwich panels are known in practice. Sandwich panels are for instance use as roof construction for garden sheds. Sandwich panels usually comprise a lower wall, an upper wall and a casing, such that the lower wall, upper wall and casing define an inner space. In order to increase the insulating value of the sandwich panels the inner space can be filled with an insulating material. Common insulating materials are polyurethane foam and polyisocyanurate foam.

[0003] A drawback of the known sandwich panels is that the insulating value of the sandwich panels is insufficient. A further drawback is that the standard insulating materials have an environmental impact.

[0004] The present invention has for its object to obviate or at least reduce the above stated problems. It can be a particular object of the invention to provide a sandwich panel with an improved insulating value.

[0005] This object is achieved with a sandwich panel for covering a roof, comprising:

• a plate-like element provided with a length and a width;
• an insulation space arranged on a side of the element and filled at least partially with insulating material;
• a vapour-permeable film arranged on the side of the insulation space remote from the plate-like element; and
• a cover arranged substantially parallel to the vapour-permeable film,
  wherein a ventilation space is provided between the vapour-permeable film and the cover.

[0006] Owing to the slope, water falling onto the sandwich panel, for instance due to rain, is carried in the direction of the slope. This prevents standing water on the sandwich panel. An advantage hereof is that the danger of the sandwich panel leaking is prevented.

[0007] The slope can be realized by providing the casing, which can be arranged round the insulation space, and/or the ventilation laths, which can be arranged between the insulation space and the cover, at an angle to the plate-like element. This can for instance be realized by removing material from the casing and/or the ventilation laths. An upper surface of the casing and/or the ventilation laths is thus placed at an incline relative to the plate-like element. The cover, which is thereby placed at an incline relative to the plate-like element, can then be placed on the upper surface. Because the cover rests (at least partially) on the ventilation laths or the casing, the cover is arranged at an angle, and therefore incline, relative to the plate-like element.

[0008] In traditional house building all roof frame constructions for flat roofs are provided with an sloping element so that the water runs off the roof. The slope is realized here by placing slope insulation on the cold side of the roof. This means that slope insulation is placed on the roof boarding. This is done to prevent the forming of condensation. The roof covering is then arranged on the slope insulation. A drawback of the slope insulation is that it always consist of highly polluting insulating materials such as polyisocyanurate (PIR), polyurethane (PUR) and expanded polystyrene (EPS). Slope insulation PIR, PUR and EPS are insulating materials which are made of petroleum products, and are therefore highly environmentally harmful elements in construction.

[0009] In the present invention the sandwich panel is provided with a preferably wooden construction, wherein the slope is realized by arranging an incline in the construction on the upper side. On this construction space is realized for a ventilated ventilation space, also referred to as air cavity. The cover, on which the roof boarding can be arranged, is arranged above the ventilation space. The roof covering can then be arranged on the roof boarding.

[0010] On the inside of the sandwich panel the insulation space is insulated entirely with ecological materials such as wood fibre or other ecological and/or circular materials. The sandwich panel is hereby insulated on the warm side.

[0011] In the current invention the warm side of the roof is the insulated side. Due to the prevailing vapour pressure, this results in the forming of condensation in the insulation space. In order to prevent this condensation the ventilation space is provided between the insulation space and the cover. The ventilation space provides the option of ventilating on the underside of the cover, so that condensation is prevented.

[0012] The ventilation space which is arranged between the vapour-permeable film and the cover gives the sandwich panel a greatly improved insulating value relative to standard sandwich panels. A further advantage of the ventilation space is that no moisture deposits on or at the vapour-permeable film. This prevents moisture from finding its way into the insulation space. This has the result that insulating material located in the insulation space remains dry and thereby retains its insulating properties. This results in a further improved insulating value of the sandwich panel.

[0013] The sandwich panel according to the invention has a layered structure. In use the sandwich panel can be used as roof covering, particularly as horizontal roof covering. The sandwich panel comprises, as seen in use from bottom to top, a plate-like element, an insulation space filled at least partially with insulating material, a vapour-permeable film, a ventilation space and a cover.

[0014] The insulation space being filled at least partially with insulating material increases the insulating value of the sandwich panel. The insulation space is a space which is defined at least partially by the plate-like element and the vapour-permeable film.

[0015] The vapour-permeable film and the cover are preferably arranged substantially parallel to the plate-like element. In the present application substantially parallel is understood to mean a maximum variation of 5 degrees from a plane or line running parallel to the plate-like element.

[0016] The vapor-permeable film is a film which is at least partially moisture-permeable.

[0017] In an embodiment according to the invention the slope is in the range of 1-10 mm per metre, preferably in the range of 3-7 mm per metre, and most preferably in the range of 4-6 mm per metre.

[0018] With the above stated slopes an effective discharge is achieved of the water or other liquid to the side in which the downward slope is directed.

[0019] In an embodiment according to the invention the slope is provided in the longitudinal direction.

[0020] By providing a slope in the longitudinal direction the water or other liquid is carried in the longitudinal direction in effective manner. In use the longitudinal direction spans the whole roof, whereby the water is carried directly off the roof.

[0021] In an embodiment according to the invention the insulation space is bounded by a casing, wherein strengthening elements are arranged inside the casing, wherein the strengthening elements and the plate-like element are connected, wherein the connection preferably comprises a milled connection.

[0022] The insulation space being bounded by the casing means that a casing is arranged round the insulation space. A robust sandwich panel is obtained with the casing. In an embodiment the casing comprises at least partially the side walls of the ventilation space. In an embodiment the casing is rectangular, preferably beam-like.

[0023] The strengthening elements are preferably planks. The strengthening elements can be cross-laths. The strengthening elements are preferably connected to the plate-like element and the casing. The width direction of the planks preferably extends in a direction substantially perpendicularly of the plate-like element. An advantage of the strengthening elements which are arranged inside the casing is that the strengthening elements connect at least the casing and the plate-like element more firmly. This reduces sagging of the plate-like element.

[0024] The milled connection comprises of the plate-like element being milled or a milled lath being arranged on the plate-like element, wherein the planks are arranged in the milled recess of the plate-like element or the milled planks. The strengthening elements which are connected to the plate-like element or milled laths with a milled connection reduce the chances of relative movement between the strengthening element and the plate-like element. This realizes a stable sandwich panel.

[0025] An advantage of the strengthening elements in combination with the milled connection is that the same structural demands can be met with 40% less wood. Alternatively or additionally, a 20% greater span can be realized with the sandwich panel according to the invention.

[0026] In an embodiment the milled connection comprises a plaster mortar, arranged in the milled recess, which connects the plank and the plate-like element to each other. This additionally strengthens the connection between the planks and the plate-like element.

[0027] In an embodiment according to the invention the strengthening elements extend in the longitudinal direction and width direction, such that sub-spaces are defined between the strengthening elements, wherein an insulation sub-space is preferably provided in each sub-space.

[0028] The insulation sub-spaces are preferably filled at least partially with insulating material. The insulation space is compartmentalized by the sub-spaces. Not all the insulating material will hereby be affected in the event of a leak, but only the insulating material located in the insulation sub-space. This preserves the insulating value of the panels in the event of leakage. Alternatively or additionally, the insulating material can be replaced in simpler manner since only the insulation sub-space need be filled with insulating material again.

[0029] In an embodiment according to the invention the sandwich panel comprises at least one ventilation opening, wherein the ventilation opening provides for fluid connection between the ventilation space and the area surrounding the sandwich panel.

[0030] Owing to the ventilation opening, the ventilation space can be ventilated with air carried from outside the sandwich panel, i.e. the area surrounding the sandwich panel, through the ventilation space and vice versa. This reduces the chances of moisture droplets depositing in the insulation space, this increasing the insulating value of the sandwich panel as a whole.

[0031] In an embodiment according to the invention the sandwich panel comprises spacers arranged between the vapour-permeable film and cover for the purpose of providing a predetermined distance between the vapour-permeable film and the cover plate, such that the ventilation space is defined between the vapour-permeable film and the cover.

[0032] The spacers can be any suitable element which provides a distance between the vapour-permeable film and the cover. Examples of suitable spacers are planks, slats, beams or blocks. The ventilation space is realized with the spacers. In an embodiment the spacers are a casing.

[0033] In an embodiment according to the invention the ventilation space has a predetermined distance in the range of 0.5-10 cm, preferably in the range of 1-5 centimetres, and most preferably in the range of 2-3 centimetres.

[0034] With said distances an effective ventilation space is created where sufficient ventilation is possible.

[0035] In an embodiment according to the invention the spacers comprise ventilation laths.

[0036] The ventilation laths create a robust ventilation space. This considerably increases the lifespan of the sandwich panel. Ventilation laths can also be understood to mean ventilation beams and/or ventilation planks.

[0037] In an embodiment according to the invention the ventilation laths extend in the longitudinal direction, wherein a plurality of ventilation spaces extending in the longitudinal direction are defined between the ventilation laths.

[0038] Each of the ventilation sub-spaces is preferably provided with a ventilation opening, so that each of the ventilation sub-spaces is in fluid connection with the space outside the sandwich panel. Owing to the ventilation sub-spaces the ventilation is uniformly distributed over the sandwich panel, this reducing the chances of moisture deposition further. This increases the insulating value of the sandwich panel.

[0039] In an embodiment according to the invention the vapour-permeable film is arranged in the casing, wherein the cover and the plate-like element are provided on the casing on opposite sides for the purpose of defining a substantially closed space.

[0040] The substantially closed space reduces the ability of the sandwich panel to let heat through. This increases the insulating value of the sandwich panel.

[0041] In an embodiment according to the invention the ventilation opening is arranged in the casing.

[0042] An advantage of the ventilation opening which is arranged in the casing is that, the moment that a plurality of sandwich panels are placed with their casings adjoining each other, a ventilation opening is provided between the casings of the sandwich panels. The ventilation space is hereby also ventilated when the sandwich panels are placed in adjoining manner.

[0043] In an embodiment according to the invention the sandwich panel comprises a plurality of modular cassettes, wherein each cassette comprises at least insulating material.

[0044] The cassettes can be formed or be defined by the strengthening elements.

[0045] In an embodiment according to the invention the insulating material is selected from a group of: insulating wool, hemp, cellulose and/or thermoflex.

[0046] Said materials impart a good insulating value to the sandwich panel. A further advantage of said materials is that they are natural materials, which are not detrimental to the surrounding area. Alternatively or additionally, the chances of toxic chemicals being released from the sandwich panel are reduced.

[0047] In an embodiment according to the invention a vapour-tight film is arranged between the plate-like element and the insulating material.

[0048] The vapour-tight film is a film that does not let moisture through.

[0049] In an embodiment according to the invention the plate-like element comprises wood, for instance pinewood.

[0050] The plate-like element preferably comprises veneered pinewood. The use of pinewood, particularly veneered pinewood, as it were reinforces the plate-like element from the underside. This increases the maximum span that can be achieved without the sandwich panel sagging.

[0051] In an embodiment according to the invention the cover comprises an Oriented Strand Board (OSB).

[0052] The invention further relates to a roof comprising at least one sandwich panel according to any one of the above described embodiments.

[0053] The roof has similar effects and advantages as stated for the sandwich panel.

[0054] The invention further relates to a building provided with a sandwich panel according to the invention or a roof according to the invention.

[0055] The building has similar effects and advantages as stated for the sandwich panel and the roof.

[0056] The invention further relates to a method for manufacturing a sandwich panel according to the invention, comprising of:

• providing a plate-like element;
• arranging insulating material between the plate-like element and a vapour-permeable film arranged substantially parallel to the plate-like element;
• arranging spacers on the vapour-permeable film; and
• arranging a cover on the spacers so that a ventilation space is defined between the vapour-permeable film and the cover.

[0057] The method has similar effects and advantages as stated for the sandwich panel, the roof and the building.

[0058] The method preferably comprises the step of arranging the vapour-tight film between the plate-like element and the insulating material.

[0059] The method preferably comprises the step of arranging a casing round the insulating material.

[0060] The method preferably comprises the step of dividing the insulation space into insulation sub-spaces, preferably by providing planks in the casing, wherein the planks preferably serve as strengthening elements.

[0061] The invention further relates to a method for arranging a roof for a building, comprising of:

• providing at least one of the sandwich panels according to the invention; and
• arranging the at least one sandwich panel on a number of walls for the purpose of forming a roof.

[0062] The method has similar effects and advantages as stated for the sandwich panel, the roof and the building.

[0063] Further features, advantages and details of the invention are described on the basis of embodiments thereof, wherein reference is made to the accompanying drawings, in which:

• figure 1 shows a perspective view of a portion of a sandwich panel;
• figure 2 shows a perspective view of a sandwich panel;
• figure 3 shows a cross-section of a sandwich panel; and
• figure 4 shows a garden structure provided with sandwich panels.

[0064] Sandwich panel 2 (figure 1) comprises plate-like element 4 having a length L and a width B, wherein casing 6 is arranged at the edges of plate-like element 4. Partition 8 is arranged in longitudinal direction L of plate-like element 4. Partition 8 is plank-like, wherein the width direction of partition 8 extends substantially perpendicularly of the plane in which panel-like element 4 extends. A vapour-tight film 10 is provided on plate-like element 4. Vapour-tight film 10 is a film that is moisture-tight. Arranged between casing 6 and partition 8 are milled laths 12 extending in width direction B. Milled laths 12 comprise milled recess 23.

[0065] Sandwich panel 2 (figure 2) comprises casing 6. Casing 6 comprises first wall 6a, second wall 6b, third wall 6c and fourth wall 6d. Arranged on first wall 6a of casing 6 are ventilation openings 18a, 18b. Ventilation opening 18 extends in height direction H over the whole height of casing 6. A fluid connection is hereby provided along casing 6 through ventilation openings 18a, 18b. Although ventilation openings 18a, 18b are in the shown embodiment arranged on first wall 6a, it will be apparent to the skilled person that ventilation openings 18a, 18b can also be arranged and second wall 6b, third wall 6c and fourth wall 6d.

[0066] Plate-like element 4 is formed by a plurality of planks 21. In the shown embodiment planks 21 are made of veneered pinewood. Planks 21 extend in longitudinal direction L. Vapour-tight film 20 is arranged on top of plate-like element 4. In the shown embodiment vapour-tight film 20 extends over the whole plate-like element 4. Partition 8 and stabilizing walls 22 are placed on plate-like element 4. Stabilizing walls are placed in milled recess 23 of milled laths 12. Stabilizing walls 22 divide insulation space 14 into insulation sub-spaces 16. Insulating material 24 is provided in insulation sub-spaces 16. In the shown embodiment insulating material 24 is insulating wool.

[0067] Vapour-permeable film 25 is arranged on insulating material 24. Vapour-permeable film 25 is a film that is moisture-permeable. Ventilation laths 26 are arranged on top of second wall 6b and fourth wall 6d. Ventilation laths 26 extend in longitudinal direction L. Cover 28 is provided on ventilation laths 26. With ventilation laths 26 ventilation space 30 is realized, this being located between insulating material 24 and cover 28. Because ventilation laths 26 extend over the whole longitudinal direction L, ventilation space 30 is divided into a plurality of ventilation sub-spaces 32a, 32b. Ventilation sub-space 32a is in fluid connection with ventilation opening 18a and ventilation sub-space 32b is in fluid connection with ventilation opening 18b.

[0068] Cover 28 is provided at an incline relative to plate-like element 4. In the shown embodiment the slope is about 5 mm over length L₁ of 1 metre. This means that height H₁ is 5 mm higher than height Hz, wherein the mutual distance between height H₁ and height H₂ amounts to about 1 metre in the longitudinal direction Li. In the shown embodiment the cover is realized by arranging the upper side of casing 6 at an angle relative to plate-like element 4. Ventilation laths 26 and subsequently cover 28 can be placed thereon, whereby cover 28 is placed at an incline relative to plate-like element 4. It will be apparent to the skilled person that it is also possible to keep casing 6 parallel to plate-like element 4 and to arrange the upper side of ventilation laths 26 at an angle to plate-like element 4. Cover 28 can subsequently be placed on ventilation laths 26, whereby cover 28 is placed at an incline relative to plate-like element 4.

[0069] Sandwich panel 2 (figure 3) comprises plate-like element 4. Vapour-tight film 20 is placed on plate-like element 4. Insulating material 24 is arranged on vapour-tight film 20. Vapour-permeable film 25 is arranged on insulating material 24. Ventilation lath 26 is provided between vapour-permeable film 25 and cover 28, such that ventilation sub-spaces 32a, 32b are realized between vapour-permeable film 25 and cover 28. Air from outside sandwich panel 2 can flow through ventilation sub-spaces 32a, 32b in that ventilation sub-spaces 32a, 32b are in fluid connection with the space outside sandwich panel 2 by means of ventilation openings 18a, 18b.

[0070] Garden structure 40 (figure 4) comprises a number of sandwich panels 2, wherein the number of sandwich panels 2 form roof 42 of garden structure 40. Sloping of cover 28 relative to plate-like element 4 automatically guides rainwater to gutter 44.

[0071] In an embodiment according to the invention plate-like element 4 is provided. Vapour-tight film 20 is subsequently arranged on plate-like element 4. Insulating material 24 is then arranged between plate-like element 4 and a vapour-permeable film 25 arranged substantially parallel to plate-like element 4. Spacers 26, for instance ventilation laths, are subsequently arranged on vapour-permeable film 25. Cover 28 is then arranged on spacers 26 so that ventilation space 30 is defined between vapour-permeable film 25 and cover 28.

[0072] The present invention is by no means limited to the above described embodiments thereof. The rights sought are defined by the following claims, within the scope of which many modifications can be envisaged.

Claims

1. Sandwich panel for covering a roof, comprising:

- a plate-like element provided with a length and a width;

- an insulation space arranged on a side of the element and filled at least partially with insulating material;

- a vapour-permeable film arranged on the side of the insulation space remote from the plate-like element; and

- a cover arranged substantially parallel to the vapour-permeable film,

wherein a ventilation space is provided between the vapour-permeable film and the cover,

and wherein the cover is arranged at an incline relative to the plate-like element.

2. Sandwich panel according to claim 1, wherein the incline is in the range of 1-10 mm per metre, preferably in the range of 3-7 mm per metre, and most preferably in the range of 4-6 mm per metre.

3. Sandwich panel according to claim 1 or 2, wherein the incline is provided in the longitudinal direction.

4. Sandwich panel according to claim 1, 2 or 3, wherein the insulation space is bounded by a casing, wherein strengthening elements are arranged inside the casing, wherein the strengthening elements and the plate-like element are connected, wherein the connection comprises a milled connection.

5. Sandwich panel according to claim 4, wherein the strengthening elements extend in the longitudinal direction and/or width direction, such that sub-spaces are defined between the strengthening elements, wherein an insulation sub-space is preferably provided in each sub-space.

6. Sandwich panel according to any one of the foregoing claims, wherein the sandwich panel comprises at least one ventilation opening, wherein the ventilation opening provides for fluid connection between the ventilation space and an area surrounding the sandwich panel.

7. Sandwich panel according to any one of the foregoing claims, further comprising spacers arranged between the vapour-permeable film and cover for the purpose of providing a predetermined distance between the vapour-permeable film and the cover, such that the ventilation space is defined between the vapour-permeable film and the cover, wherein the ventilation space preferably has a predetermined distance in the range of 0.5-10 cm, preferably in the range of 1-5 centimetres, and most preferably in the range of 2-3 centimetres.

8. Sandwich panel according to claim 7, wherein the spacers comprise ventilation laths, wherein the ventilation laths preferably extend in the longitudinal direction, wherein a plurality of ventilation spaces extending in the longitudinal direction are defined between the ventilation laths.

9. Sandwich panel according to claim 4, or any one of the claims 5-8 when dependent on claim 4, wherein the vapour-permeable film is arranged in the casing, and wherein the cover and the plate-like element are provided on the casing on opposite sides for the purpose of defining a substantially closed space, and/or wherein the ventilation opening is arranged in the casing.

10. Sandwich panel according to any one of the foregoing claims, wherein the sandwich panel comprises a plurality of modular cassettes, wherein each cassette comprises at least insulating material.

11. Sandwich panel according to any one of the foregoing claims, wherein the insulating material is selected from a group of: insulating wool, hemp, cellulose and/or thermoflex.

12. Sandwich panel according to any one of the foregoing claims, wherein a vapour-tight film is arranged between the plate-like element and the insulating material, and/or wherein the plate-like element comprises wood, for instance pinewood, and/or wherein the cover comprises an Oriented Strand Board (OSB).

13. Roof comprising at least one sandwich panel according to any one of the foregoing claims.

14. Structure provided with a sandwich panel according to any one of the claims 1-12 or a roof according to claim 13.

15. Method for manufacturing a sandwich panel according to any one of the foregoing claims, comprising of:

- providing a plate-like element;

- arranging insulating material between the plate-like element and a vapour-permeable film arranged substantially parallel to the plate-like element;

- arranging spacers on the vapour-permeable film; and

- arranging a cover on the spacers so that a ventilation space is defined between the vapour-permeable film and the cover,

further preferably comprising of:

- providing at least one of the sandwich panels according to any one of the claims 1-12; and

- arranging the at least one sandwich panel on a number of walls for the purpose of forming a roof.

Drawing