WO2008147178A2

WO2008147178A2 - Portable and one-piece structural panel

Info

Publication number: WO2008147178A2
Application number: PCT/NL2008/000140
Authority: WO
Inventors: Leendert Willem Cornelis De Jong
Original assignee: De Jong Leendert Willem Cornel
Priority date: 2007-05-29
Filing date: 2008-05-29
Publication date: 2008-12-04
Also published as: WO2008147178A3; NL1033902C2

Abstract

A portable and one-piece structural panel for the toolfree assembly of a self-supporting wall, ceiling or similar partition of a structure, in particular, for emergency accommodation, using multiple structural panels that are substantially identical and without using additional components. The structural panel includes a substantially rectangular and substantially flat main panel section, wherein the main panel section is provided on the inside, near the first side, with a plug-in clamp having a plug-in opening for inserting the second side of a second structural panel parallel to the surface of the main panel section in the plug-in opening in such a way that the main panel sections of these structural panels partially overlap.

Description

Portable and one-piece structural panel

The present invention relates to a portable and one-piece structural panel for the toolfree assembly of a self-supporting wall, ceiling or similar partition of a structure, in particular for an emergency accommodation in a disaster area with multiple substantially identical structural panels.

Aid organisations are aware of the problems related to supplying material for emergency accommodation during disasters such as, for example, earthquakes, floods, war refugees, etc. The supply of such material, usually tents, over land is often difficult partly due to the many intermediaries who must cooperate and/or offer their collaboration in such cases. Air shipment of tents is difficult, partly because tents cannot be thrown out of aircrafts. Many tents weigh between 60 - 80 kg in practice. In addition, tents are only suitable to a limited degree for the different climatic conditions in disaster areas and, ultimately, they offer little comfort to the occupants. Tents, for example, do not allow, or only to a limited extent allow, to make a fire in the tent and, therefore, this forms a restriction for heating, preparing food and/or boiling water.

The aid organisations are also aware of the phenomenon that in many situations those affected are not capable of setting up structures, for example, due to a lack of education (not being able to read) and/or a lack of tools. Those affected also often wish to have very different structures than a tent, for example, the need exists to have a walled area in which poultry, cattle or the like can be kept.

An object of the invention is to provide a portable and one-piece structural panel that has many applications and can at least be toolfree assembled to provide a self-supporting wall, ceiling or other partition for a structure with multiple substantially identical structural panels and without using additional components.

An object of the invention is also to provide such a panel that can be manufactured at a low cost price.

An object of the invention is also to provide such a panel that it is impact resistant and, preferably can be thrown out of an aircraft or helicopter. An object of the invention is also to provide such a panel that can be used by users to independently assemble a structure of their choice.

The invention achieves one or more of the above objects by providing a structural panel according to claim 1.

The structural panel according to the invention can be coupled together with the adjacent structural panels through a form fit and has, as is the preference, no movable parts whatsoever.

The design of the structural panel is such that the assembly of the structural panels into a wall or the like does not require any relevant knowledge, in fact, the design of the structural panel already points out the correct method. Preferably, every structural panel is provided with instructions based on simple images and, preferably without text.

The described "active parts" of the structural panel are stiff and, preferably robust to such an extent that no harmful damage will occur when the structural panel falls from a height of at least 50 metres.

Further advantageous details of the structural panel according to the invention are described in the subclaims and the following description based on the drawing.

The invention also relates to a system for the assembly of a structure, for example an emergency accommodation, comprising multiple structural panels.

The invention also relates to a structure that is assembled from multiple structural panels.

In the drawing:

Figure 1 shows an embodiment of the structural panel according to the invention from the outside;

Figure 2 shows the panel of Figure 1 from the inside;

Figure 3a shows the panel of Figure 1 in a side-view on the first side in the direction of arrow

A in Figure 2; Figure 3b shows the panel of Figure 1 in a side-view on the third side in the direction of arrow

B in Figure 2;

Figure 4 shows the panel of Figure 1 in a side-view on the second side in the direction of arrwo C in Figure 1 ;

Figure 5 shows a series of aligned panels according to Figure 1 from the outside;

Figure 6 shows the series from Figure 5 from the inside;

Figure 7 shows the stacking of a panel in the series from Figure 5; Figure 8 shows a detail of the series from Figure 5, wherein a rope secures the panels;

Figure 9 shows the series from Figure 5 in a side-view on the third side;

Figure 10 shows the series of Figure 5 in a by a rope secured state;

Figure 11 shows a wall surface assembled with panels according to Figure 1 from the inside;

Figure 12 shows the wall surface of Figure 7 with a securing rope; Figure 13 shows the ridge construction of a structure with two (still expandable) sloping roof surfaces that can be assembled with panels according to Figure 1 ;

Figure 14 shows a detail of Figure 13;

Figure 15 shows a scaled model of a structure with two sloping roof surfaces that can be assembled from panels according to Figure 1 ; Figure 16 shows the structure of Figure 15 from a different angle;

Figure 17 shows the structure of Figure 15 from yet another different angle;

Figure 18 shows the structure of Figure 15 with an opened tarpaulin on a side;

Figure 19 shows a second embodiment of a structural panel according to the invention seen from the inside; - Figure 20 shows the structural panel of Figure 19 from another direction;

Figure 21 shows the structural panel of Figures 19 and 20 from the outside.

Based on Figures 1-14, in particular Figures 1-4, an explanation shall now be provided of a first embodiment of the structural panel 1 according to the invention. Demonstration models of panel 1 are shown that have been made of wood here. The invention preferably provides for a model made of plastic material as will be explained below of which an embodiment is shown in Figures 20-22.

It is envisaged to produce the panel from metal, for example, steel plate such as used in the automotive industry or aluminium plate.

The portable and one-piece structural panel 1 is arranged for the toolfree assembly of a self- supporting wall, ceiling or similar partition of a structure, in particular for an emergency accommodation using multiple structural panels 1 that are substantially identical and without using additional components.

Figures 5-14 show that a self-supporting partition can be assembled with the structural panels 1, such as self-supporting roof surfaces for an accommodation as is shown as an example in Figures 15-18.

Each panel 1 has a substantially rectangular and substantially flat main panel section 2 with an inside (see Figure 2) and an outside (see Figure 1).

The main panel section 2 has a first and a second side, 3 and 4 respectively, that are located opposite to each other and a third and a fourth side, 5 and 6 respectively, that are located opposite to each other.

The main panel section 2 has an integral plug-in clamp 7 with a plug-in opening 8 for inserting the second side 4 of a second structural panel 1 on the inside, near the first side, parallel to the surface of the main panel section 2 in the plug-in opening 8. This is done in such a way that the main panel sections of these structural panels partially overlap.

The plug-in clamp 7 has a clamping plate 7a that lies substantially parallel to the main panel section 2 and at a distance that is approximately the same as the thickness of the main panel section 2. The clamping plate 7a is linked to the main panel section 2 through a spacer 7b at a distance from the first side 3.

The clamping plate 7a has been provided with an open recess 9 towards the first side 3, here a triangular recess that forms an alignment member.

There is a alignment contra-member on the inside of the main panel section 2, near the second side 4, that has a shape that is complementary to the recess 9. A triangular member in this example.

If a panel 1 with its plug-in clamp 7 is slid onto the second side of an adjacent panel 1 , the member 10 of that adjacent panel will get in the opening 9. This will ensure that the panels are in a mutually aligned arrangement and that they remain in this arrangement wherein the third and fourth sides of the panels 1 are in line.

Figures 5-9 show that a series of panels 1 can be built up in this overlapping way, wherein the mutual lateral movements of the panels 1 in the series are prevented by the recesses 9 and the members 10 that are received therein.

The overlapping of the main panel sections 2 provides a type of roof tile effect, which will stop the penetration of water (for example, by the inclined arrangement of a roof surface as in Figures 15-18).

The Figures further show that the main panel section 2 is provided with a hook member 12 on the inside, near the third side 5 and is provided with a contra-hook member 13 near the fourth side 6 in such a way that the hook member 12 is engageable with the contra-hook member 13 of a structural panel 1 to be arranged next to the third side 5. This ensures that the adjacent sides 5, 6 of these structural panels 1 are kept against each other through the cooperation between the hook member 12 and the contra-hook member 13.

The contra-hook member 13 of a panel is, in a similar way, engageable with the hook member 12 of a structural panel 1 to be arranged next to the fourth side 6, wherein the adjacent sides 5, 6 of these structural panels 20 are kept next to each other through the cooperation between said contra-hook member 13 and the hook member 12.

The Figures also show that the main panel section 2 is provided with an overlap strip 15 on the outside (see Figure 2) along at least a section of the fourth side 6 that protrudes towards the outside over the top of the fourth side in such a way that this overlap strip 15 covers the seam with a structural panel 1 adjacent to the fourth side.

The overlap strip 15 has a first axial end 15a at a distance past the first side 3 of the main panel section 2 and an opposite second axial end 15b in the area of the fourth side 6 at a distance from the second side 4 in such a way that the second axial end 15b of the overlap strip 15 will be adjacent to the first side 3 of a structural panel 1 adjacent to the second side (see Figures 5, 13).

The overlap strip 15 forms a seal of the seam and also contributes to the stability of the coupling between the panels, and, therefore, to the loadability of the formed partition.

The Figures show that the hook member 12 has been mounted here on the clamping plate 7a and that it protrudes past the third side 5 where the contra-hook member 13 has here also been mounted on the clamping plate 7a and protrudes past the fourth side 6.

You can also see that the overlap strip 15 on the fourth side 6 protrudes more than the contra-hook member 13.

The hook member 12 has a hook surface 12a that is directed towards the first side 2, wherein the contra-hook member 13 has a hook surface 13a that is directed to the second side 4. These hook surfaces 12a, 13a are under an equal slanting angle with respect to the sides of the main panel section 2.

The panel 1 is also provided with one or more rope eyes 18 or rope passageways so that the structural panels 1 that are adjacent and joined together can be secured through one or more ropes as can be seen in Figures 8, 10, 12.

Preferably, the weight of the structural panel 1 is between 1 and 4 kg so that it can be easily transported and handled.

Preferably, the structural panel 1 , in particular at least the main panel section 2 thereof, is substantially manufactured from plastic, preferably through injection moulding or rotational moulding, and possibly through blow moulding, preferably using impact-resistant plastic material, for example, polycarbonate, preferably resistant against a free fall from a height of 50 metres.

The plastic material can, for example, be polyethylene (PE).

The panels may be made as a sandwich construction.

The demonstration panels 1 shown in the Figures are on a smaller scale than the preferred choice.

In a preferred embodiment, a structural panel has dimensions of 50 x 90 centimetres. Smaller dimensions, preferably at least 30 x 50 centimetres, or, on the contrary, larger panels are also possible. Rotational moulding seems to be the preferred method for larger dimensions whilst, for smaller dimensions, injection moulding would be the preferred method.

In a preferred variant, the structural panel contains one or more metal, preferably, aluminium, sections, for example, a metal part that forms the plug-in clamp 7 and/or metal parts that form the hook members and contra-hook members 12,13, and/or the alignment member 10. These one or more metal parts are preferably embedded in the plastic material of the main panel section 2 during production, preferably during injection moulding.

The design of the structural panel 1 is such that the assembly of the structural panels up to a wall or similar does not require any relevant knowledge, in fact, the design of the structural panel already points out the correct method. Preferably, every structural panel should be provided with instructions based on simple images, preferably without text. These images could also be formed in the panel during the injection process.

Preferably, the structural panel 1 is such that the self-supporting wall, ceiling or similar partition of a structure can withstand a load, for example, a dry snow load, of at least 25 kg/m2.

In a possible variant, a structural panel could be provided with an integral solar cell assembly for generating electricity, for example, low voltage, so that, for example, (LED) lighting and/or a radio/telephone can be connected.

In a possible embodiment, provisions could be made such that a system of one or more solar cells are embedded on the outside in the plastic material of the main panel section 2 during injection moulding of the structural panel 1.

In a possible embodiment, for example, made from polycarbonate, provisions could have been made to make the structural panel 1 at least partially transparent.

The invention also relates a system for the toolfree assembly of a wall or the like of a structure, in particular an emergency accommodation, comprising a large number of structural panels 1. Such panels can, if required, be bundled (possibly in boxes) and can, for example, be thrown out of an aircraft should they be impact-resistant.

It may be advantageous when building an emergency accommodation according to Figures 15-18 to provide a stop 21 on the inside of the main panel section 2 , here an upright rib, against which a panel 1 can rest under a (square) angle, for example, for forming an angular structure.

A roof surface can, for example, be formed with panels 1 that may be very suitable for an arrangement under an angle so that rainwater runs downwards and does not penetrate inside due to the roof tile overlapping and the strip 15.

If, as in the Figures 15-18, two of such roof surfaces are realised (without any tools), they may be set up in a gable roof shape. The then still open sides that are more or less triangular of the accommodation can be closed with a further wall of panels 1. In a preferred embodiment provisions have been made to seal of those openings with a canvas as shown in Figures 15-18.

A system could be delivered to a disaster area or the like comprising a considerable quantity of panels 1 and furthermore one or more of the following elements: floor panels for the assembly of a floor, preferably toolfree linkable floor panels; a floorcloth; one or more canvases to cover a side opening in the structure, in particular, if the structural panels form a structure with two roof surfaces under an angle; - one or more ropes for securing the adjacent structural panels.

It should be clear that no tools or other components are required for the assembly of a partition with the panels 1.

It should, furthermore, be clear that the panels 1 can also be used for other objectives such as roofs that can be disassembled (to be used while carrying out work, during disasters, when making enclosures for poultry, horticulture, camping, play houses for children, market stalls, etc.). A carrier, for example, a stretcher, could also be made with panels 1. A raft could be made with the panels when using an embodiment of the panel that has considerable floating capabilities.

Figures 19, 20 and 21 show a second embodiment of the structural panel according to the invention. This panel 1' has been produced from plastic using a suitable mould. You can see that the main panel section 2 is relatively thinly walled with upright perimeter edges.

Components that correspond with the components of the previous described panel 1 with respect to their function have been provided with the same reference number provided with an accent in Figures 19-21.

A clearly observable difference is clamp T that here has been produced with a centrally lying alignment member formed by a recess 9' with, on each side, a plug-in opening 8' for a section of the side 4¹, here referred to as components 4a¹, 4b'.

The plug-in openings 8' are each formed by an upright wall section and a lying wall section in this example, wherein the upright wall section 7b' acts as a spacer and the lying wall section 7a' acts as a clamping plate. Another clearly observable difference are the hook members 12', 13'. This example shows that the hook member 12' (viewed from the outside) is designed as a cut-away while hook member 13' is designed as a projection formed together with the inside that fits into the cutaway 12'. You can see that the hook members 12" and 13' each have wall sections obliquely with respect to the nearby side to, thus, obtain the contemplated hooking action.

A strip 16' is provided in this example that can be found along the side 6' in the area between the axial end 15b' and the corner of the side 6' and the side 4'. This strip 16' extends under the adjacent panel 1' and, thus, forms an additional seal and provides stability.

Claims

C L A I M S

1. A portable and one-piece structural panel (1 ; 1 ') for the toolfree assembly of a self- supporting wall, ceiling or similar partition of a structure, in particular, for emergency accommodation using multiple structural panels that are substantially identical and without using additional components, which structural panel (1 ;T) comprises: a main panel section (2;2') that is substantially rectangular and substantially flat; which main panel section (2;2') has an inside and an outside as well as a first and a second side (3 4; 3' 4') that are opposite to each other and a third and a fourth side that are opposite to each other (5,6;5\6'); wherein the main panel section is provided on the inside, near the first side, with a plug-in clamp (7;7') having a plug-in opening (8;8") for inserting the second side of a second structural panel (1 ; 1") parallel to the surface of the main panel section (2;2') in the plug-in opening in such a way that the main panel sections of these structural panels partially overlap; which main panel section (2;2') furthermore near the first side (3) is provided with an alignment member (9; 9'), preferably integrated with the plug-in clamp, wherein the main panel near the second side (4;4'), preferably on the inside, is provided with an alignment contra-member (10; 10'), that is engageable with a corresponding alignment member (9;9') near the first side of the main panel section of a third structural panel (1 ;1') that is adjacent to said second side in such a way that, when the main panel section is slid into the plug-in clamp of said adjacent third structural panel (1 ;1'), the alignment member (9;9') and the alignment contra-member (10; 10') align the structural panels with respect to each other; wherein the main panel section (2;2') on the inside, near the third side (5;5'), is provided with a hook member (12; 12') and is provided with a contra-hook member (13; 13') near the fourth side (6;6') in such a way that the hook member is engageable with the contra- hook member of a fourth structural panel to be set up next to the third side, wherein the adjacent sides of these structural panels are kept next to each other by the combined action of the hook member (12; 12') and contra-hook member (13; 13'), and in such a way that the contra-hook member is engageable with the hook member of a fifth structural panel (1;1') to be set up next to the fourth side, wherein the adjacent sides of these structural panels are kept together by the combined action of said contra-hook member and hook member.

2. Panel according to claim 1 , wherein the main panel section is provided with an overlap strip (15; 15') on the outside along at least a section of the fourth side that protrudes to the outside over the fourth side in such a way that this overlap strip covers the seam with the structural panel adjacent to the fourth side.

3. Panel according to claim 2, wherein the overlap strip (15; 15') has a first axial end (15a) at a distance past the first side (3;3') of the main panel section and a second axial end (15b) on the opposite side in the area of the fourth side (6;6') at a distance from the second side (4) in such a way that the second axial end (15b) of the overlap strip will be adjacent to the first side of a second structural panel (1) adjacent to the second side.

4. Panel according to one or more of the preceding claims, wherein the plug-in clamp (7; 7') has a clamping plate (7a; 7a¹) that substantially lies parallel to the main panel section and at a distance that has been adjusted to the thickness of the main panel section, wherein the clamping plate is linked to the main panel section at a distance from the first side through a spacer (7b; 7b¹).

5. Panel according to claim 4, wherein the clamping plate is provided with an open recess (9; 9¹) towards the first side that forms the alignment member, wherein the alignment contra-member (10; 10') is provided on the inside of the main panel section and has a complementary shape.

6. Panel according to claim 5, wherein the clamping plate is provided with an open triangular recess (9; 9') directed towards the first side, and wherein the alignment contra- member (10; 10') has a complementary shape, preferably triangular.

7. Panel according to claim 4, wherein the hook member (12) is arranged on the clamping plate (7a) and protrudes past the third side (5), wherein the contra-hook member (13) also is arranged on the clamping plate (7a) and protrudes past the fourth side (6).

8. Panel according to claim 2, wherein the overlap strip protrudes more on the fourth side than the contra-hook member.

9. Panel according to one or more of the preceding claims, wherein the hook member (12; 12') has a hook surface that is directed towards the first side (3), and wherein the contra- hook member (13; 13') has a hook surface that is directed towards the second side (4).

10. Panel according to claim 9, wherein the hook surfaces are directed obliquely with respect to the sides (5, 6; 5, 6') of the main panel section.

11. Panel according to one or more of the preceding claims, wherein the structural panel is provided with one or more rope eyes or rope passages so that the structural panels that are adjacent and are linked to each other can be secured using one or more ropes.

12. Panel according to one or more of the preceding claims, wherein the weight of the structural panel is between 1 and 4 kg.

13. Panel according to one or more of the preceding claims, wherein the structural panel, in particular at least the main panel section thereof, is substantially produced from plastic material, preferably through injection or rotational moulding and preferably from impact- resistant plastic material, for example, polycarbonate, preferably resistant against a free fall from a height of 50 metres.

14. Panel according to one or more of the preceding claims, wherein the structural panel has a dimension of substantially 50 x 90 centimetres.

15. Panel according to one or more of the preceding claims, wherein the structural panel has one or more metal, preferably aluminium parts, for example, a metal part that forms the plug-in clamp and/or metal parts that form the hook members and contra-hook members and/or the alignment member and/or the alignment contra-member.

16. Panel according to claim 15, wherein one or more metal parts are embedded in the plastic material, preferably during injection or rotational moulding.

17. Panel according to one or more of the preceding claims, wherein the structural panel is such that the self-supporting wall, ceiling or similar partition of a structure can withstand a load, for example a dry snow load, of at least 25 kg/m2.

18. Panel according to one or more of the preceding claims, wherein the structural panel is provided with an integral solar cell assembly for generating electricity.

19. Panel according to claim 18, wherein a system of one or more solar cells is embedded in the plastic material during injection moulding of the structural panel.

20. Panel according to one or more of the preceding claims, wherein a structural panel is at least partially transparent.

21. System for the toolfree assembly of a wall or the like of a structure, in particular an emergency accommodation, comprising a large number of structural panels according to one or more of the preceding claims.

22. System according to claim 21 further comprising one or more of the following elements:

- floor panels for the assembly of a floor, preferably toolfree linkable floor panels;

- a floorcloth;

- one or more tarpaulins to cover a side opening in the structure, in particular if the structural panels form a structure with two roof surfaces under an angle; - one or more ropes for securing the adjacent structural panels.

23. Structure, such as an emergency accommodation, comprising a partition assembled with multiple structural panels according to claims 1-20.