阅读说明：本技术 结构板 (Structural panel ) 是由 穆加达姆·莫尔塔扎 于 2018-04-18 设计创作，主要内容包括：本发明涉及一种结构板(100),包括：具有两个纵向边(24A、24B)和至少一个横向边(20A)的三维形状的空间框架组件(16)；一对桁架构件(10A、10B),其中,一个桁架构件(10A、10B)附接至空间框架组件(16)的每个纵向边(24A、24B)；一对壁骨构件(32A、32B),其中,一个壁骨构件(32A、32B)附接至空间框架组件(16)与一对桁架构件(10A、10B)的组合的每个纵向边(24A、24B)；以及填充材料(50),所述填充材料设在空间框架组件(16)、一对桁架构件(10A、10B)和一对壁骨构件(32A、32B)的整个组合中。此外,还描述了一种建筑物(200),包括根据本发明的多个结构板(100)。(The invention relates to a structural panel (100) comprising: a three-dimensionally shaped space frame assembly (16) having two longitudinal edges (24A, 24B) and at least one transverse edge (20A); a pair of truss members (10A, 10B), wherein one truss member (10A, 10B) is attached to each longitudinal edge (24A, 24B) of the space frame assembly (16); a pair of stud members (32A, 32B), wherein one stud member (32A, 32B) is attached to each longitudinal edge (24A, 24B) of the combination of the space frame assembly (16) and the pair of truss members (10A, 10B); and a filler material (50) provided in the entire combination of the space frame assembly (16), the pair of truss members (10A, 10B), and the pair of stud members (32A, 32B). Furthermore, a building (200) comprising a plurality of structural panels (100) according to the invention is described.)

1. Structural panel (100), characterized in that it comprises:

a three-dimensionally shaped space frame assembly (16) having two longitudinal edges (24A, 24B) and at least one transverse edge (20A);

a pair of truss members (10A, 10B), wherein one truss member (10A, 10B) is attached to each longitudinal edge (24A, 24B) of the space frame assembly (16);

a pair of stud members (32A, 32B), wherein one stud member (32A, 32B) is attached to each longitudinal edge (24A, 24B) of the combination of the space frame assembly (16) and the pair of truss members (10A, 10B); and

a filler material (50) provided in the entire combination of the space frame assembly (16), the pair of truss members (10A, 10B) and the pair of stud members (32A, 32B), the filler material (50) having a density of 50kg/m³～100kg/m³。

2. The structural panel (100) according to claim 1, wherein the space frame assembly (16) comprises a plurality of support members (18) arranged in parallel along at least one lateral edge (20A) and a plurality of top stiffeners (28A) and a plurality of bottom stiffeners (28B) arranged in parallel along two longitudinal edges (24A, 24B), respectively, wherein the top stiffeners (28A) and the bottom stiffeners (28B) are attached to the top and bottom edges of the support members (18), respectively.

3. The structural panel (100) of claim 2, wherein the plurality of top stiffeners (28A) and bottom stiffeners (28B) are oriented perpendicular to the plurality of support members (18).

4. The structural panel (100) according to any of claims 1 to 3, wherein each truss member (10A, 10B) comprises a force-bearing element (14) and a top beam member (12A) and a bottom beam member (12B), wherein the top beam member (12A) and the bottom beam member (12B) are attached to the top edge and the bottom edge of the force-bearing element (14), respectively, along the length direction thereof.

5. The structural panel (100) according to any one of claims 1 to 4, wherein each support member (18) comprises a carrier element (25) and a top support member (26A) and a bottom support member (26B), wherein the top support member (26A) and the bottom support member (26B) are attached along their length to the top and bottom edges, respectively, of the carrier element (25).

6. The structural panel (100) according to any of claims 1 to 5, wherein each stud member (32A, 32B) includes a plurality of holes (34) distributed along its longitudinal length.

7. The structural panel (100) of claim 6, further comprising a plurality of first cavities (60) extending through the body of the structural panel (100) along at least one lateral edge (20A), wherein each first cavity (60) is aligned with a corresponding pair of holes (34) in a pair of stud members (32A, 32B).

8. The structural panel (100) according to any one of claims 6 or 7, further comprising a plurality of second cavities (70) extending through the body of the structural panel (100) along both longitudinal edges (24A, 24B).

9. The structural panel (100) according to any of claims 1 to 8, wherein the filler material (50) is selected from the group consisting of mineral materials, inorganic materials, polymeric materials, plant materials and mixtures or composites thereof.

10. The structural panel (100) according to any of claims 1 to 9, wherein the density of the filler material (50) is 60kg/m³～70kg/m³。

11. The structural panel (100) according to any of claims 1 to 10, characterised in that it has a tensile strength of 100kg/m²～1400kg/m²Preferably 900kg/m²～1100kg/m²。

12. The structural panel (100) according to any of claims 1 to 11, characterised in that it has a dimension in the direction of the longitudinal edges (24A, 24B) of 240cm to 300cm, a dimension in the direction of at least one transverse edge (20A) of 20cm to 60cm and a thickness dimension of 7cm to 15 cm.

13. The structural panel (100) according to any of claims 1 to 12, wherein the filler material (50) constitutes a plane to be finished on both sides of the structural panel (100).

14. Building (200) comprising a plurality of structural panels (100) according to any one of claims 1 to 13, characterized in that

A first number of structural panels (100) is provided as at least one wall (201) of a first storey of the building (200),

a second number of the structural panels (100) being arranged as a floor (203) of the building (200), and

optionally, a third number of structural panels (100) are provided as a roof (205) of the building (200),

wherein each individual structural panel (100) is interconnected by a connector (207), the connector (207) engaging a corresponding aperture (34) of a respective stud member (32A, 32B) of an adjacent structural panel (100).

15. Building (200) according to claim 14, characterized in that at least in the respective cavities (60) of those structural panels (100) provided as at least one wall (201) there are provided electric supply lines and/or water and/or gas conduits.

Technical Field

The present invention relates to a structural panel and its use, as well as a building constructed from several such structural panels.

Background

In general, there is provided a structural panel for constructing a building, and more particularly, to a lightweight structural panel using a space frame assembly having a pair of truss members disposed in a longitudinal direction and a plurality of support members disposed in a transverse direction, and having a lightweight foam filling layer and an outer skin.

One known type of construction method for panel construction involves modular wall panels which can be prefabricated and connected in a particular manner to build a building. These panels are constructed of materials such as wood, concrete, foam, and plastic. However, none of these materials are ideal because concrete is too heavy and foam is too light to support the necessary weight loads. These wall panels are also made of heavy materials, making them difficult to construct off-site and difficult to transport.

Historically, it has been difficult to manufacture load-bearing walls that also have a finished appearance, due to the need for wall panels that can accommodate wiring, air ducts and water ducts. These boards either do not have enough room to make the necessary additions or do not have a finished appearance after installation to add wires and pipes.

Thus, structural panels are generally well known in the art, and are described in detail below.

Us patent 3,992,835 describes a self-supporting structural element formed from a unitary sheet of material characterized by alternating ridges and valleys that vary sinusoidally about a neutral plane or curved surface. The structural elements are said to be suitable for use as the core of a composite shell structure in which sinusoidal core elements continue in a curved fashion from the top of the raised features through the neutral plane to the bottom of the adjacent depressions, thereby avoiding stress-induced discontinuities. Core elements, which may be formed of any rigid material, such as steel, may be used alone or in a multi-layer stack between boundary layers. However, without the filler material, the structural element does not appear to be coherent. Furthermore, the individual components of the structural element are not connected to one another to form a rigid frame. The primary structure acts as a kind of mould and therefore cannot provide a complete load-bearing structure, since the entire structural element does not seem to be suitable for load-bearing. The structural element appears to be very heavy and requires an existing building structure for its insertion when installed.

Us patent 4,494,349 discloses a truss structure consisting of interconnected wires of different shapes. The structure comprises a plurality of elongated spaced apart wire assemblies including first and second elongated wire members, each wire member being formed into a continuous generally triangular shape. Each individual triangular wire member is staggered with respect to the vertices of the other triangular members, the first and second consecutive triangular member planes at an angle to each other, and the second and third longitudinal wire members coupled thereto. A layer of concrete partially buries the wire members, and a layer of polyurethane foam formed for the purpose of heat preservation is buried in the concrete layer. However, triangular wire members do not appear to be able to bear weight without a strong embedding material such as concrete. Furthermore, the individual triangular wire members are not interconnected to form a rigid frame. The final structures appear to be heavy and, since they appear not to be load bearing, a building structural frame is required for their insertion.

Us patent 4,614,013 relates to a method of forming a reinforced structural building panel having a plurality of parallel trusses connected together by cross wires. Each truss is triangular in cross-section and a layer of polyurethane foam is disposed in the panel and spaced from both the front and back of the panel. One surface of the foam is provided with a layer of cured adhesive material, such as asphalt or thermoplastic. The cross wires of opposite faces of the plate are offset from each other along the axis of the truss flow channel line to which they are weld connected. However, such structural building panels appear to be heavy and do not provide a finished piece for building construction. These building panels, being not finished products, must be brought to the construction site and must be finished at the construction site by forming an outer layer of mortar or concrete or the like.

Us patent 5,079,890 describes a space frame structure and a method of construction thereof. The space frame structure has parallel spaced apart lower and upper subframes connected by interconnecting members, wherein each subframe comprises a plurality of members connected in a grid. A concrete layer is fixed on top of the upper subframe, the mesh members of the upper subframe being buried in the concrete layer to form a composite upper substructure. This space frame structure also does not seem to be able to bear load, since the space inside the frame is empty under the thinner concrete layer in which the upper subframe is embedded. Although these space frame structures do not appear to be heavy, they require separate building structures for their installation.

Us patent 2002/0043045 a1 relates to modular panels for building construction, said to have thermal and acoustic insulation properties. These modular panels comprise at least one contoured plate-like element made of an insulating material. The plate-like elements are provided on their surfaces with a first reinforcing mesh and a second reinforcing mesh, respectively, which are connected to each other by means of connecting elements passing through the plate-like elements. Such modular panels seem to be suitable as partition walls, but there seems to be no load-bearing member, since the core material is an insulating material and only the reinforcing mesh is provided thereon. These reinforcing meshes do not appear to have any resistance to load bearing forces. These modular panels can be transported to the construction site and must then be finished, for example by stacking two panels with a space between them, and then filling this space with concrete, or covering the outside with concrete or mortar, etc. In order to construct a building, a support frame into which modular panels can be inserted must be provided. In particular, such modular panels appear to gain load bearing capacity only when the concrete structure is provided at the construction site.

A major drawback of the house elements of the known type is that they require delicate engineering work and are generally not unified by identical or compatible dimensions. Precast concrete panels, although heavy, have been introduced to the market, almost every panel is made specifically for a single purpose, i.e. wall panels are designed for walls, floor panels for the ground and roof panels for the roof. Most panels on the market all require heavy equipment to be installed, cannot be operated by a single person, and require delicate engineering work to be performed at the job site because most panels all have unique dimensions.

Summarizing the known prior art, to date, no structural panel has been able to provide alone the load-bearing capacity that can be used to construct a building without the need to install it into a prefabricated building structure.

Therefore, there is a need to provide a new structural panel. It is therefore an object of the present invention to provide a structural panel which is itself capable of bearing weight and which is lightweight so as to be operable by a single person to construct a wall, floor or roof of a building without relying on existing building structures. It is a further object of the present invention to provide a building which can be constructed substantially from the structural panels according to the invention.

Disclosure of Invention

In a first aspect of the invention, this object is achieved by: a structural panel (100) comprising:

-a space frame assembly (16) of three-dimensional shape having two longitudinal edges (24A, 24B) and at least one transverse edge (20A);

-a pair of truss members (10A, 10B), wherein one truss member (10A, 10B) is attached to each longitudinal edge (24A, 24B) of the space frame assembly (16);

-a pair of stud members (32A, 32B), wherein one stud member (32A, 32B) is attached to each longitudinal edge (24A, 24B) of the combination of the space frame assembly (16) and the pair of truss members (10A, 10B); and

-a filler material (50) provided in the entire combination of the space frame assembly (16), the pair of truss members (10A, 10B) and the pair of stud members (32A, 32B).

In a second aspect of the invention, the above object is achieved by: a building (200) comprising a plurality of structural panels (100) as described above, wherein:

a first number of structural panels (100) is provided as at least one wall (201) of a first storey of the building (200),

a second number of the structural panels (100) being arranged as a floor (203) of the building (200), and

a third number of the structural panels (100) are arranged as a roof (205) of the building (200),

wherein each individual structural panel (100) is interconnected by a connector (207), the connector (207) engaging a corresponding aperture (34) of a respective stud member (32A, 32B) of an adjacent structural panel (100).

The advantage of the present invention is that the structural panel (100) is lightweight, easy to assemble, but able to support a greater weight load. Thus, the structural panel may be used as a structural load bearing member in building construction, as part of a non-structural partition, floor and/or roof. The present invention provides a structural panel (100) that can be processed without the use of heavy lifting equipment. The structural panel (100) has heat, fire, moisture, insect/rat crack and noise resistant properties and is highly resistant to earthquakes and extreme climates.

The structural panel (100) is easily formed and modified by conventional construction cutting tools and is solid and substantially unbreakable. The structural panel (100) completes a rough stage of building construction without any post-installation construction work.

The present invention will be described in detail hereinafter.

A first aspect of the invention relates to a structural panel (100), in particular to a structural panel (100) configured for building installation.

The term "structure" as used herein means that the structural panel (100) is self-supporting and load-bearing due to its arrangement as described below.

The structural panel (100) includes a three-dimensionally shaped space frame assembly (16) having two longitudinal edges (24A, 24B) and at least one transverse edge (20A). Specific embodiments of the space frame assembly (16) are described in detail below. The space frame assembly (16) provides, at least in part, strength and consistency to the structural panel (100).

In the context of the present invention, a "three-dimensional shape" is understood to include a length, a width and a height, wherein two longitudinal sides (24A, 24B) extend in the length direction and at least one transverse side (20A) corresponds to the width. The length dimension is greater than the width dimension, which in turn is greater than the height dimension.

The structural panel (100) forms at least one triangle by having two longitudinal edges (24A, 24B) and at least one transverse edge (20A). In practice, the structural panel (100) of the present invention is generally formed as a rectangle. However, depending on the intended use, several other external shapes, such as the aforementioned triangular, pentagonal, rhomboid, etc., may be produced in addition to the rectangular shape.

The structural panel (100) further comprises a pair of truss members (10A, 10B), wherein one truss member (10A, 10B) is attached to each longitudinal edge (24A, 24B) of the space frame assembly (16). The truss members (10A, 10B) are used, at least in part, to impart load-bearing characteristics to the structural panel (100). The truss members (10A, 10B) are made of a load-resistant material, preferably a metallic material, in particular steel.

Furthermore, the structural panel (100) further comprises a pair of stud members (32A, 32B), wherein one stud member (32A, 32B) is attached to each longitudinal edge (24A, 24B) of the combination of the space frame assembly (16) and the pair of truss members (10A, 10B).

The stud members (32A, 32B) represent the outer sides of the structural panel (100) in the longitudinal direction. The stud member is also used, at least in part, to impart weight-bearing characteristics to the structural panel (100). The stud members (32A, 32B) are made of a load-resistant material, preferably a metallic material, in particular steel.

Preferably, each stud member (32A, 32B) is generally C-shaped and has one web member (3201), two flange members (3203a, 3203B) extending in the same direction from the upper and lower ends of the member (3201), and two lip members (3205a, 3205B) extending from the flange members (3203a, 3203B) inwardly of the structural panel (100). In particular, the two flange members (3203a, 3203b) extend towards the space frame assembly (16) of the structural panel (100).

Finally, the structural panel (100) includes a filler material (50) disposed in the entire combination of the space frame assembly (16), the pair of truss members (10A, 10B), and the pair of stud members (32A, 32B).

The term "combination" is used for the hollow portion of a structural panel (100) comprising a space frame assembly (16), a pair of truss members (10A, 10B) and a pair of stud members (32A, 32B). The combination is made prior to introducing the filler material (50) to finish the structural panel (100).

The present invention provides an inexpensive, simple and efficient method for manufacturing a structural panel (100) for building construction. Further, the structural panel (100) is provided for off-site assembly and easy transfer to the construction site of the construction project. The structural panel (100) has high processing capabilities including heat resistance, fire resistance, moisture resistance, noise resistance, and protection from the rat. Therefore, the structural panel (100) has a long pre-construction life with weather resistance.

In a preferred embodiment of the invention, the space frame assembly (16) comprises a plurality of support members (18) arranged in parallel along the direction of at least one transverse edge (20A) and a plurality of top stiffeners (28A) and a plurality of bottom stiffeners (28B) arranged in parallel along two longitudinal edges (24A, 24B), respectively, wherein the top stiffeners (28A) and the bottom stiffeners (28B) are attached to the top and bottom edges of the support members (18), respectively.

The support member (18) is substantially two-dimensional, i.e. its thickness is much smaller than its length and width. The support member (18) is at least partially used to impart load bearing characteristics to the structural panel (100). Specific embodiments of the support member (18) are described in detail below.

The top stiffener (28A) and the bottom stiffener (28B) are substantially one-dimensional, i.e. their thickness or diameter is much smaller than their length. In a particular embodiment, the top reinforcement (28A) and the bottom reinforcement (28B) are made of a bar or thick wire of load-resistant material, preferably a metallic material, in particular steel.

By attaching a plurality of top stiffeners (28A) and a plurality of bottom stiffeners (28B) to a plurality of support members (18), a mechanical communication is provided, creating a three-dimensional network, which in the present invention is defined as a space frame assembly (16). The space frame assembly (16) itself already has load bearing properties which help to improve the load bearing properties of the finished structural panel (100).

Preferably, the connection of the reinforcement (28A, 28B) to the support member (18) is a form-locking connection. In particular, the connection of the reinforcement (28A, 28B) to the support member (18) is a material-locking connection, specifically by welding or brazing.

Thus, a very secure connection between the elements is ensured.

The plurality of top stiffeners (28A) and bottom stiffeners (28B) are preferably oriented perpendicular to the plurality of support members (18). The advantage of the vertical orientation is better machinability, provided that the structural plate (100) is made rectangular.

In another development of the present structural panel (100), each truss member (10A, 10B) comprises a force-bearing element (14) and a top beam member (12A) and a bottom beam member (12B), wherein the top beam member (12A) and the bottom beam member (12B) are attached along their length to the top and bottom edges, respectively, of the force-bearing element (14).

The force-bearing element (14) is essentially two-dimensional, i.e. its thickness is much smaller than its length and width. The force-bearing elements (14) are used at least in part to impart load-bearing properties to the structural panel (100).

The force-bearing element (14) preferably has an open structure, i.e. is not solid, but comprises parts extending alternately between its top and bottom edges. Particularly preferred are force-bearing elements (14) having a sinusoidal shape, i.e. rods or wires which extend in the form of a sine wave between the top and bottom edges of the force-bearing element (14). However, other shapes of the force-bearing element (14) are also contemplated by the present invention, such as a zig-zag shape, etc., if desired.

The top beam member (12A) and the bottom beam member (12B) are substantially one-dimensional, i.e., their thickness or diameter is much smaller than their length. In a particular embodiment, the top reinforcement (28A) and the bottom reinforcement (28B) are made of a bar or thick wire of load-resistant material, preferably a metallic material, in particular steel.

By attaching the top beam member (12A) and the bottom beam member (12B) to the load bearing element (14), a mechanical communication is provided. Preferably, the connection of the beam member (12A, 12B) to the messenger element (14) is a form-locking connection. In particular, the connection of the beam component (12A, 12B) to the force-bearing element (14) is a material-locking connection, specifically by welding or soldering. Thus, a very secure connection between the elements is ensured.

A further development provides a structural panel (100), wherein each support member (18) comprises a carrier element (25) and a top support member (26A) and a bottom support member (26B), wherein the top support member (26A) and the bottom support member (26B) are attached along their length to the top and bottom edges, respectively, of the carrier element (25).

The carrier element (25) is substantially two-dimensional, i.e. its thickness is much smaller than its length and width. The carrier element (25) is at least partially used to impart load-bearing properties to the structural panel (100).

The carrier element (25) preferably has an open structure, i.e. if made of metal, is not solid but comprises parts extending alternately between its top and bottom edges. Particularly preferred are carrier elements (25) having a sinusoidal shape, i.e. rods or wires extending in the form of a sinusoidal wave between the top and bottom edges of the carrier element (25). However, other shapes of the carrier element (25) are also contemplated by the present invention, such as zig-zag shapes and the like, if desired.

The top support member (26A) and the bottom support member (26B) are substantially one-dimensional, i.e., their thickness or diameter is much smaller than their length. In a particular embodiment, the top support member (26A) and the bottom support member (26B) are made of a bar or thick wire of load-resistant material, preferably a metallic material, in particular steel.

By attaching the top support member (26A) and the bottom support member (26B) to the carrier element (25), a mechanical communication is provided. Preferably, the connection of the support member (26A, 26B) to the carrier element (25) is a form-locking connection. In particular, the connection of the support member (26A, 26B) to the carrier element (25) is a material-locking connection, specifically by welding or soldering. Thus, a very secure connection between the elements is ensured.

In a preferred embodiment of the structural panel (100), each stud member (32A, 32B) includes a plurality of apertures (34) distributed along its longitudinal length.

A plurality of holes (34) are provided on the web (3201) of each stud member (32A, 32B), preferably within the central axis along its length. The holes (34) are preferably arranged at equal distances from each other. The apertures (34) may have different shapes as desired, but are preferably longitudinal apertures having an aspect ratio of about 2: 1.

The holes (34) may be used to interconnect two adjacent structural panels (100), particularly using the holes (34) that are outermost in the length direction.

In a further development of the preferred embodiment described above, the structural panel (100) further comprises a plurality of cavities (60) extending through the body of the structural panel (100) along at least one transverse edge (20A), wherein each cavity (60) is aligned with a corresponding pair of holes (34) on a pair of stud members (32A, 32B).

In other words, each cavity (60) extending between the corresponding holes (34) forms a passage through the structural plate (100) which can be used in different ways, for example to provide electric and/or water and/or gas supply lines.

The cavity (60) preferably has a circular or elliptical cross-section, but other cross-sectional shapes are possible if desired.

In another embodiment of the invention, the filler material (50) of the structural panel (100) is selected from the group consisting of mineral materials, inorganic materials, polymeric materials, plant materials, and mixtures or composites thereof.

Among them, the mineral material is selected from concrete, mortar, clay, etc., and particularly preferred is a mineral material or lightweight concrete.

The polymer material is selected from Polyurethane (PU), Polystyrene (PS), polypropylene (PP), etc., and particularly preferred are Expanded Polyurethane (EPU) and Expanded Polystyrene (EPS).

The plant material is selected from wood, straw, wool, cotton, coconut fiber, hemp fiber, etc.

Mixtures or composites of these filler materials (50) are particularly preferably foamed polyurethane mixed with minerals. In addition, a mixture of clay and straw or a composite material of a polymer material and a natural fiber material can be selected.

In addition, additives such as flame retardants, preservatives, fungicides, herbicides, antifouling agents, and the like may be added to the filler material (50) depending on the intended use of the structural panel (100).

In this regard, the structural panels (100) are typically made of lightweight materials. More specifically, by combining the above-described filler material (50) with a combination of a space frame assembly (16), a pair of truss members (10A, 10B), and a pair of stud members (32A, 32B), the lightweight characteristics can be adjusted, and a balance can be found between the load-bearing characteristics and the lightweight characteristics of the structural panel (100).

The filler material (50) is not a factor in the weight bearing calculation of the lightweight structural panel (100). If the lightweight characteristic is not a relevant factor, the filler material (50) can be considered in the weight bearing calculation.

The density of the filling material (50) is preferably 50kg/m³～100kg/m³Preferably 60kg/m³～90kg/m³。

With such a density, the total weight of a single structural panel (100) is within a range that can be handled by a single person alone. In particular, the weight of the individual structural panels (100) according to the preferred embodiment is from 20kg to 40kg, preferably from 25kg to 35kg, and particularly preferably 30 kg.

Further, when horizontally installed, the tensile strength of the structural panel (100) is preferably 800kg/m²～1400kg/m²Preferably 900kg/m²～1100kg/m²。

More specifically, the structural panel (100) of the present invention has a compressive strength of 100kg/m when vertically installed². If each edge is horizontally fitted with appropriate rail members to form a floor, the load-bearing capacity of the structural panel is 625kg/m². Multiplied by 3 to yield 1875kg/m²。

With tensile strength, compressive strength and load-bearing capacity in these ranges, the structural panel (100) according to the invention is suitable as a self-supporting load-bearing construction element in building construction.

The dimension of the structural panel (100) in the direction of the longitudinal edges (24A, 24B) may be 240-300 cm, the dimension in the direction of at least one transverse edge (20A) may be 20-60 cm, and the thickness/height dimension may be 7-15 cm.

Such dimensions allow a single structural panel (100) to be carried and handled by a single person alone. Furthermore, the preferred dimensions allow for efficient building construction through the use of the structural panels (100) of the present invention.

In a preferred embodiment of the invention, the filling material (50) forms a plane to be finished on both sides of the structural panel (100).

The term "planar to be finished" means that the outermost layers on both sides of the structural panel (100) are substantially flat and mechanically stable, so that no further work is required after installation.

In a particular further development, the structural panel (100) is covered by a planar extending skin. In detail, the surface defined as the inner surface may be covered by a layer of inner wall plaster having a thickness of 2mm to 4mm, in particular 3 mm.

On the opposite side, the surface defined as the outer surface may be covered by a layer of outer wall plastering having a thickness of 2mm to 10mm, in particular 6 mm.

Such interior wall plasters and/or exterior wall renders may be applied not only for aesthetic reasons, but also in particular for reasons of weather resistance, fire resistance, etc.

Alternatively, both sides of the structural panel (100) may be covered by panels, suitable for interior or exterior applications. Alternative materials are wood, ceramic tiles, metal sheets, glass, solar panels, etc. These panels may be of different size than the structural panels. These panels may be primarily of small thickness.

In a second aspect of the invention, the above object is achieved by: a building (200) comprising a plurality of structural panels (100) as described above, wherein:

a first number of structural panels (100) is provided as at least one wall (201) of a first storey of the building (200),

a second number of the structural panels (100) being arranged as a floor (203) of the building (200), and

optionally, a third number of structural panels (100) are provided as a roof (205) of the building (200),

wherein each individual structural panel (100) is interconnected by a connector (207), the connector (207) engaging a corresponding aperture (34) of a respective stud member (32A, 32B) of an adjacent structural panel (100).

The building (200) has substantially similar advantages to the structural panel (100) described in detail above. With the prefabricated construction panels (100), a building (200) according to the invention can be built very quickly. A single person can complete most of construction work, and the whole building can be completed with the help of another person.

As mentioned above, preferred embodiments of the structural panel (100) include apertures (34) that have multiple uses. In the construction of a building (200), special holes (34) are used to engage the connectors (207) to securely connect two adjacent structural panels (100). In particular, the outermost holes (34) (in the longitudinal direction) are used to engage the connectors (207), while the inner holes (34) are aligned with the cavities (60).

By arranging a number of structural panels (100) in a vertical direction and then connecting them, it is possible to quickly construct a wall (201) of a building (200). After the first floor of the building (200) is constructed, a greater number of structural panels (100) may be arranged in the horizontal direction in order to construct the floor (203) of the building (200). Alternatively, another number of structural panels (100) may be disposed at an angle as a roof (205) of the building (200).

The building (200) of the present invention can be constructed in 1-8 floors, preferably 1-4 floors, using technical software. For a building with 4-8 floors, engineering calculations may be required.

In a preferred embodiment of the building (200), at least in the respective cavities (60) of those structural panels (100) provided as at least one wall (201) are provided electrical supply lines and/or water and/or gas conduits.

Since the structural panel (100) according to one embodiment is provided with cavities (60), the supply line installation of the entire building can be performed in a simple and fast manner.

To create doors, windows and stair openings, all structural panels are first installed quickly. Holes are then marked in the installed walls and floors according to the building plan. The opening is cut with a common construction cutting tool. Further, appropriate lintels and attachments are used above and around the opening depending on the size of the opening. The attachment may be made of a U-shaped rail member.

Further objects, features, advantages and possible uses of the invention will become apparent from the following description of working examples of the invention with reference to the accompanying drawings. All features described and/or shown in the figures constitute the subject-matter of the invention individually or in any combination, even independently of their combination in the claims or in the dependent references.

Description of the drawings:

figure 1 is a perspective view of a pair of truss members 10A, 10B of a structural panel 100 according to one embodiment of the invention,

figure 2 is a perspective view of a space frame assembly 16 of structural panels 100 according to one embodiment of the present invention,

figure 3 is a perspective view of the space frame assembly 16 of figure 2 provided with a pair of truss members 10A, 10B of figure 1 of a structural panel 100 according to one embodiment of the invention,

figure 4 is a perspective view of a pair of stud members 32A, 32B of a structural panel 100 according to one embodiment of the present invention,

figure 5 is a perspective view of the combination shown in figure 3 of the space frame assembly 16 and a pair of truss members 10A, 10B of the structural panel 100 in combination with a pair of stud members 32A, 32B shown in figure 4 according to one embodiment of the present invention,

figure 6 is a perspective view of a finished structural panel 100 according to one embodiment of the present invention,

figure 7 is a cut-away perspective view of the finished structural panel 100 of figure 6 according to one embodiment of the present invention,

figure 8 is a perspective view of the combination of the space frame assembly 16, the pair of truss members 10A, 10B and the pair of stud members 32A, 32B of figure 5 of a structural panel 100 according to one embodiment of the present invention,

figure 9 is a schematic view of a building 200 according to one embodiment of the present invention,

FIG. 10 is a schematic illustration of a connection between two structural plates 100, according to one embodiment of the present invention, an

Figure 11 is a stress-strain diagram of a structural panel 100 according to one embodiment of the present invention,

reference numerals

10A, 10B truss member

12A roof rail component

12B bottom beam member

16 space frame assembly

18 support member

20A at least one transverse edge

24A, 24B longitudinal edges

25 carrier element

26A Top support Member

26B bottom support member

28A roof stiffener

28B bottom stiffener

32A, 32B stud member

3201 Web member

3203a, 3203b flange member

3205a, 3205b lip members

34 holes

50 filling material

60 cavity

200 building

201 wall

203 ceiling

205 roof covering

207 connecting piece

209H-shaped beam

211 edge beam

Detailed Description

Fig. 1 illustrates a pair of truss members 10A, 10B for use with a structural wall panel 100 (see fig. 7), wherein each truss member 10A, 10B includes a top beam member 12A and a bottom beam member 12B. In this embodiment, the force-bearing elements 14, which have a sinusoidal shape, extend along the length of the top and bottom beam members 12A, 12B of each truss member 10A, 10B. In addition, each sinusoidal load bearing element 14 is welded to the top and bottom beam members 12A, 12B where they are in physical contact with each other.

Figure 2 illustrates one embodiment of a space frame assembly 16 for building a structural panel 100. In the present embodiment, the space frame assembly 16 includes a plurality of support members 18 having a sinusoidal shape disposed in a lateral direction (i.e., along at least one lateral edge 20A). Further, a plurality of top stiffeners 28A and a plurality of bottom stiffeners 28B are disposed longitudinally, i.e., along both longitudinal sides 24A, 24B. The plurality of top and bottom stiffeners 28A, 28B are disposed in a direction perpendicular to the plurality of support members 18, preferably opposite each other at the top and bottom edges of the support members 18.

In the present embodiment, the support member 18 includes a top support member 26A and a bottom support member 26B. In addition, a carrier element 25 having a sinusoidal shape extends along the length of the top and bottom support members 26A, 26B of each support member 18. Furthermore, each carrier element 25 is welded to the top and bottom support members 26A, 26B, where they are in physical contact with each other.

Further, in the present embodiment, each top stiffener 28A is in mechanical communication with each top support member 26A of each support member 18 by welding. Accordingly, each bottom stiffener 28B is in mechanical communication with each bottom support member 26B of each support member 18 by welding.

In fig. 8, a cross section of the space frame assembly 16 with the stud members 32A, 32B attached is illustrated. A specific combination of carrier elements 25 with top and bottom support members 26A, 26B is shown. The cross-sections of the top and bottom stiffeners 28A, 28B are shown only in smaller dots.

Fig. 3 illustrates one embodiment of the space frame assembly 16 provided, wherein a pair of truss members 10A, 10B are attached to each longitudinal edge 24A, 24B of the space frame assembly 16. In the present embodiment, each truss member 10A, 10B is preferably welded to a plurality of support members 18 at its top and bottom beam members 12A, 12B.

Fig. 4 illustrates a pair of stud members 32A, 32B, wherein each stud member 32A, 32B includes a plurality of holes 34 distributed along its length.

Fig. 5 illustrates one embodiment of a combination of space frame assemblies 16 in which a pair of truss members 10A, 10B and stud members 32A, 32B are each attached to a longitudinal edge 24A, 24B. In the present embodiment, the truss members 10A, 10B are welded to each side of the stud members 32A, 32B (i.e., the sides of the stud members 32A, 32B are referred to in the art as web members) along with the plurality of support members 18. In another embodiment, welding is performed approximately every 15cm along the length of each stud member 32A, 32B. The combination shown in fig. 5 is mechanically stable in itself and ready to receive a filler material 50.

It is clear from fig. 8 how the substantially C-shaped stud members 32A, 32B are attached to the combination of the space frame assembly 16 and the truss members 10A, 10B, wherein the web members 3201 are the lateral extremities of the structural panel 100 and the flange members 3203a, 3203B partially enclose the combination of the space frame assembly 16 and the truss members 10A, 10B. Two lip members 3205a, 3205b extend from the flange members 3203a, 3203b inward of the structural panel 100. Even smaller lip members 3205a, 3205b of about 6mm help to increase the load bearing capacity of the structural panel 100, and thus its strength. By being substantially C-shaped, the mechanical properties of the stud members 32A, 32B themselves, as well as the load-bearing properties of the structural panel 100 as a whole, are enhanced. As an example, a C-shape is only a simple shape of a stud. Other shapes may also be used in accordance with the present invention.

Fig. 6 illustrates one embodiment of a fully assembled structural panel 100, wherein the structural panel 100 further comprises a filler material 50. To fully assemble, the combination of the space frame assembly 16 with the truss members 10A, 10B and stud members 32A, 32B as shown in fig. 5 is placed in a mold, and the combination is then filled, submerged, and/or covered with a liquid precursor of the filler material 50. After filling, immersing and/or covering the combination, the liquid precursor is hardened to form the solid filler material 50.

In this embodiment, the filler material 50 may be composed of polyurethane, polystyrene, or a mixture of polyurethane and mineral additives having fire-resistant and other properties, and fills the voids of the combination shown in fig. 5 (i.e., space frame assembly 16, truss members 10A, 10B, and stud members 32A, 32B). The filler material 50 preferably forms the outer skin of the construction panel 100 ready for finishing by interior wall plaster or exterior wall plastering. In one particular embodiment, the filler material 50 may include 70% polyurethane and 30% minerals.

Fig. 7 illustrates a cross-sectional view of one embodiment of a structural panel 100 partially filled or covered with a filler material 50. The assembled structural panel 100 includes a space frame assembly 16, a set of truss members 10A, 10B, a plurality of support members 18, and a pair of stud members 32A, 32B. In addition, there is a corresponding cavity 60 aligned with each hole 34 and extending laterally from one stud member 32A to the other stud member 32B. In one embodiment, when the fill material 50 is introduced into the combination of space frame assemblies 16, 16 temporary tubes (not shown) are placed in the combination of space frame assemblies 16 to form each cavity 60. After the filler material 50 is applied and cured, the tube is removed. In particular, inserting two split tubes from both sides of the structural panel 100 allows for easier removal than a full tube.

In addition, the truss members 10A, 10B are welded to the stud members 32A, 32B along with the plurality of support members 18 to improve the strength and performance of the structural panel 100.

In certain other embodiments, the structural panel 100 may be fabricated from a suitable material such as metal, concrete, plastic, or any combination thereof.

For commercial purposes, the structural panel 100 according to the present invention is referred to as a "lightweight structural panel" (LSP).

Fig. 9 schematically illustrates a building 200 assembled from a plurality of structural panels 100. In order to construct a building 200 according to the present invention, a flat and mechanically stable area is generally required. The area may be a solid concrete slab foundation.

Thereon, a first number of structural panels 100 are provided as at least one wall 201 of a first floor of the building 200. The individual structural panels 100 are aligned in an upright (vertical) position adjacent to each other and are securely, but preferably releasably, interconnected at their top and bottom by screws within the U-shaped rails. Since each individual structural panel 100 has a standardized shape, various forms of buildings can be constructed. The structural panel 100 may be used for an outer wall of the building 200 as well as an inner partition wall.

As an alternative, the (cold-formed) channel guide can be provided in the already produced foundation according to a plan view. The structural plates 100 are then installed into the rail adjacent to each other (with the required reinforcement if necessary) and their bottom and top are connected to the channel rail (e.g., screwed).

After the first floor of the building 200 is constructed using the first number of structural panels 100, a second number of structural panels 100 may be provided as the floor 203 of the building 200. In the simplest way, the structural panels 100 may be placed side by side in a horizontal direction on top of the wall 201.

Alternatively, another (cold-formed) channel rail may be provided at a desired height on the top of the wall 201 or on one side thereof. Next, the structural panels 100 of the floor are installed adjacent to each other into the channel rails and connected thereto.

It is preferable to provide H-beams 209 between each individual structural panel 100 forming the floor 203 to further improve stability and construction ability. In a similar manner, vertical stiffening beams may be provided.

This combination of walls 201 and floor 203 typically constitutes a very simple building 200.

Of course, a third number of structural panels 100 may be provided as the roof 205 of the building 200, wherein, more specifically, the structural panels 100 are aligned in an inclined position, as shown in fig. 9.

Alternatively, to install the roof, another (cold-formed) channel rail may be provided uppermost on top of the wall 201, and the structural panel 100 is again installed into and connected to the channel rail.

In a particular embodiment, the walkway guide serves as an edge beam 211 around each storey, further improving the stability of the entire building.

To provide a door or window opening in the building 200 of the present invention, a corresponding wall 201 is constructed and then an opening for receiving a door or window is cut by a conventional construction cutting tool or the like. Doors with normal widths between 80cm and 120cm may be provided, but the maximum width of the window may be arbitrary by engineering calculations. To improve overall stability, lintels may be provided within the openings for receiving doors or windows.

Fig. 10 illustrates schematically the interconnection of two structural plates 100 by means of a connecting piece 207. The connectors 207 engage the corresponding apertures 34 of the stud members 32A, 32B of adjacent structural panels 100.

In a particularly preferred embodiment, the structural panel 100 has a length of 300cm, a width of 60cm and a height of 10 cm.

The assembly of the structural panels 100 according to the present invention for the purpose of constructing the building 200 is referred to as a "lightweight structural panel construction system" (LSPCS) for commercial purposes.

Fig. 11 depicts a mechanical evaluation of a structural panel 100 according to the present invention. The exemplary structural panel 100 has a length of 300cm, a width of 60cm, and a height of 10 cm. The exemplary structural panel 100 is made of steel rods, steel wires, galvanized studs, and polyurethane foam mixed with mineral materials. The load was applied to the top by two 5cm wide members with a parallel gap of 70cm, while being spaced 115cm from the ends of the exemplary structural panel 100. The ends of the exemplary structural panel 100 are supported from below at the outermost edges.

In detail, a stress-strain diagram is shown, wherein force (in kg) is expressed in relation to displacement (in mm). The solid line represents theoretical finite element calculations, while the dashed line represents actual measurements. It can be seen that the exemplary structural panel 100 mechanically exhibits a linear characteristic of maximum displacement of 18mm before deformation occurs at a maximum load of about 800 kg.