A METHOD FOR ARRANGING ELEMENTS TO A COMPRESSED STRUCTURE, SUCH AS A BOARD STRUCTURE AND THE USE THEREOF

Abstract: The invention relates to a method for arranging reinforcing and/or fastening element(s) at a surface of a compressed structure such as a fibre board (1). The invention further relates to a compressed fibre board (1), said structure comprising a matrix material which is hardened during a compression step to constitute a firm structure, as well as to the use of such a structure. Said structure integrally comprises at least one elongated reinforcement and/or fastening element having a web portion (4a, 5a) and successive tongue- and/or finger-like attachment portions (7) embedded into the hardened matrix material during a compression step. Said elements are of a deformable sheet material, and said attachment portions (7) extend orthogonally with respect to the initial surface extent of the web portion (4a, 5a). Said matrix material is compressed to its final dimensions, whereby said attachment portions (7) will be embedded and integrally attached to said matrix material inside the resulting compressed structure (1). In such board structures having element(s) (5) extending along an edge area (2), at least one of said element(s) is used for attaching said board structure (1) to a fixed external structure.

Description: A method for arranging elements to a compressed structure, such as a board structure and the use thereof The present invention relates to a method for arranging studs, girders or the like essentially reinforcing and/or fastening element (s) at a surface of a compressed structure such as a fibre board or the like, wherein said compressed structure is manufactured by feeding and compressing a matrix material between press members and subjecting said material to a hardening process . The invention further relates to a compressed fibre board structure or the like structure comprising a matrix material hardened during a compression step to constitute a firm structure, as well as to the special uses of such a structure. In the building industry many kinds of fibre boards and the like are known. These are usually essentially flat structures which are used for various building purposes. Such fibre boards usually comprise a basic material of wood particles, grass, hair, paper, rags or the like essentially fibrous material. Said basic material is mixed with a bonding component like glue, gypsum, cement or the like curable bonding agent to form a matrix material, which during the production of the structure is compressed at least in one direction, usually to 1/2 to 1/10 of the dimension of the matrix material. In this process the curable bonding agent is cured using pressure, heat, catalytic materials, carbon oxygen, or the like to form, in conjunction with said basic material, a firm structure. In this manner various materials which usually are considered as waste can be used for building purposes . Such fibre boards have many advantageous properties and can be used for many purposes. One common disadvantage, however, is the difficulty to attach, in an easy and reliable manner, any external structures to the board, since due to the relatively low bonding forces between the separate fibres in the basic material screws and nails cannot find any good hold in the relatively thin board. For this reason a normal use of such boards requires that said boards themselves are attached to a framework made of some other material, such as wood or metal. The co-pending Finnish patent application FI- 962943 by the same inventor discloses a method for attaching fasteners to compressed fibre structures, wherein separate means for attaching such boards to external structures or for attaching external structures to said boards comprises tongue- like means which are embedded into the matrix material already during the production of said board. The disclosure of said FI patent application is considered enclosed herein by reference. The present invention discloses a similar arrangement for attaching studs, girders or the like load-bearing structures directly to a compressed fibre board, which thereafter as such can be used in the building industry e.g. for erecting walls or the like. In a corresponding manner the board itself can be reinforced to withstand any external forces directed to the board as it exists in a building. The inventive method, board structure and use thereof is characterized by the features indicated in the characterizing portion of the independent claims 1, 5 and 11, correspondingly. Other favorable embodiments are disclosed in the dependent claims. The invention is based on the realization that by attaching elongated studs, girders or the like elements made of sheet metal directly onto the board surface in an integrated manner using tongue- or finger- like attachment portions of said sheet metal element one can accomplish several essential advantages. The attachment as such is easily accomplished during the manufacturing of such boards. More specifically the inventive method is characterized in said method further comprising the steps of a) providing said element (s) of a deformable sheet material, said element (s) comprising i) at least one web portion adapted to extend along at least one intended surface of said compressed structure, and ii) successive tongue- and/or finger-like attachment portions arranged along the general extent of said web portion, said attachment portions extending essentially orthogonally with respect to an initial surface extent of said web portion. Said element (s) are arranged so that said web portion extends essentially flat at an intended surface of said compressed structure, said tongue- like attachment portions being arranged to extend from said intended surface into said matrix material, at least a section of said web portion being adapted to extending outside the general outer boundaries of said compressed fibre structure. Said press members are thereafter moved, in a manner known per se, towards each other in order to press, therebetween, said matrix material to its final dimensions, whereby said tongue-like attachment portions will be embedded and integrally attached to said matrix material inside the resulting compressed structure. The inventive fibre board structure is especially characterized in that said structure integrally comprises at least one stud, girder or the like elongated reinforcement and/or fastening element, said element comprising at least one web portion arranged to extend outside the general outer boundaries of said fibre board structure. Said element further comprises successive tongue- and/or finger- like attachment portions embedded into said hardened matrix material during said compression step. Such a structure being provided with one or several first element (s) extending along at and in the essential direction of at least one border area of said structure is favorably used so that at least one of said element (s) is used for attaching said board structure to a fixed external structure. Other corresponding elements are preferably used for interconnecting opposite ones of such structures. Initially a web portion of said sheet metal stud or girder element will lie flat against the board surface, actually normally so that the outer surface portion is flush to the outer board surface. Having the webs lying flush along the surface of the finished board facilitates an efficient and care-free transportation and storing of said boards. In use, e.g. during the erection of a wall said web portions of said studs or girders or the like enforcing elements are, at locations necessary for the purpose, bent out to form sheet metal beams extending substantially transversely in relation to the board surface. The webs are especially favorably located so as to run along at least some of the edges of said board . Said sheet metal stud or girder element will now comprise an elongated web portion having successive tongue- or finger-like attachment portions arranged along that edge of said web which is located towards said board, all of said attachment portions being integrally embedded in the matrix material of the board. Thus, said sheet metal web will, essentially along its whole length, have a firm load bearing contact with the interior of said board. Normally the web structure bent out from the board surface will leave an indent in said surface, but since this surface usually will be located towards the inner portion of a wall this indent will be of no significance. The invention will now be more closely described with reference, by way of example only, to some preferred embodiments disclosed in the appended drawings, wherein Figure 1 shows a general perspective view of a board adapted in accordance with the invention, Figure 2 in perspective shows an enlarged portion of a corner of said board, thus disclosing the ends of vertical and horizontal girders firmly attached to the board surface, Figure 3 partially shows an alternative stud structure attached to a board surface, Figure 4 shows a vertical sectional view of the attachment of two opposite boards to an upper (or lower) U-beam structure, and Figure 5 shows a horizontal section of the arrangement according to Fig. 4. Figure 1 shows a compressed fibre material board 1, e.g. a wood particle board, a cement particle board or the like, which board suitably has edges 2, 3 adapted for connection to an adjacent board by e.g. a tongue and groove connection. Said board 1 is provided with integrally attached studs, girders, beams or the like reinforcing and/or fastening elements 4, 5, some 4 of which run in a vertical direction and some others 5 horizontally. For the purpose of e.g. interior wall building one vertical beam 4 is normally arranged in the vicinity of a vertical board edge 2. Corresponding beams 5 or the like structures are favorably arranged at the horizontal edges 3. Further elements 6 may be arranged vertically, horizontally and/or diagonally in the mid area of said board to prevent it from buckling, or to allow fasteing of other means, as desired. Initially the web portions of all sheet metal elements 4, 5, 6 lie flat against the board surface as shown in Figure 1. Said Figure also discloses, in phantom, how successive tongue- and/or finger-like attachment portions 7 of said sheet metal elements 4, 5, 6 extend from an edge of said element into the inner portions of said board 1, thereby fixing each sheet metal element 4, 5, 6 along its entire length firmly to said board 1. Said attachment portions 7 are preferably arranged in groups, suitably in pairs and so that adjacent ones of said tongue- like attachment portions 7 will extend, after the com- pression of the board matrix material, slightly inclined in opposite directions inside said board matrix material. Referring now to Figure 2 the web portions 4a, 5a of said sheet metal beams, studs, girders or the like elements 4, 5, 6 can be raised, at locations appropriate for the individual use of said board, into positions where said web portions 4a, 5a extend essentially transversely (4a) with respect to the surface of said board 1, or even to positions (5a) turned nearly 180° with respect to the board 1 surface. In Figure 2 the original flat position, and any slight indent in the inner surface of said board 1 is shown in phantom. In order to facilitate the detachment of said webs portions 4a, 5a from the surface of said board 1 a thin sheet 20 of paper or the like material can be arranged between said board surface and said web. Said attachment portions 7 will extend through said sheet 20 into the board material. In certain cases said sheet 20 can cover the entire board surface, in which case said sheet favorably is used also for positioning said stud or girder elements 4, 5, 6 during the manufacture of said board. By selecting a suitable sheet material said sheet 20 can also be used as a vapor barrier or the like . In order to facilitate a bending of separate portions 4b of said web 4a e.g. in transverse directions with respect to the general extent of said web 4a, successive suitably elongated apertures 8 can be arranged in said web 4a. Said web may also comprise larger holes 9 for connecting means 10 and/or tubings (not shown) or the like to be arranged within the wall. In the embodiment disclosed in Figure 3 there are, replacing said elongated apertures 8 at the actual web portion 4a, thinned portions 11 at the border line between the actual web portion 4a and said web portion 4b, which portions 11 also facilitate a bending of said web 4a by hand or using simple tools. In the embodiment according to Figure 3 the sheet metal stud element 4, 5 comprises a defined flange portion 12 which will remain flat against the surface of said board 1 even when said web portions 4a are raised. Here successive holes 8 may be arranged for facilitating the bending up of said webs 4a from said flange 12. In the embodiment disclosed in Figure 3 said tongue- or finger-like attachment means comprise relatively short tongues 13 which in a suitable configuration are punched out from the material of said flange portion 12. Said tongues 13 will extend into the matrix material 14 of said board 1, while, correspondingly some matrix material usually will be pressed up through the punch holes 15 in the flange material, thus further improving the attachment of said structure 4, 5. Referring now to Figure 4 opposite boards 1, la are easily attached to a U-shaped beam 16 attached to a ceiling 17 and, correspondingly, to the floor or a wall (not shown) . Said beam 16 comprises flanges 18, 18a. Said boards 1, la are easily interconnected to constitute a wall structure (see also Figure 5) by interconnecting subsequent boards 1, lc and la, lb using appropriate means, e.g. said tongue and groove portions at said edges 2. Opposite webs 4 are interconnected using suitable connecting means 10 such as screws, rivets or the like. Thereafter the web portions 5a of the outermost studs 5 are bent over to partially enclose said flanges 18, 18a at said U-beams 16, as disclosed in Figure 4. Further studs 6 are thereafter bent into an essentially transversal direction to withstand any buckling of said boards 1, la, lb, lc. In the space between said boards a suitable insulation material 19 can be inserted, which will be kept in position by said studs 6. The disclosed wall structure is easy to erect and can also be easily removed, since contrary to a traditional wall all verti- cal posts are actually integrated with the boards 1 which constitute the wall. It should be understood that the above specification only shows some preferred embodiments of the invention, and that the invention can be modified in many other ways within the scope of the claims.

Claims: Claims 1. A method for arranging studs, girders or the like reinforcing and/or fastening element (s) (4, 5, 6) at a surface of a compressed structure such as a fibre board (1) or the like, wherein said compressed structure is manufactured by feeding and compressing a matrix material (14) between press members and subjecting said material to a hardening process, c h a r a c t e r i z e d in said method further comprising the steps of a) providing said element (s) (4, 5, 6) of a deformable sheet material, said element (s) (4, 5, 6) comprising i) at least one web portion (4a, 5a) adapted to extend along at least one intended surface of said compressed structure ( 1 ) , ii) successive tongue- and/or finger-like attachment portions (7, 13) arranged along the general extent of said web portion (4a, 5a), said attachment portions (7, 13) extending essentially orthogonally with respect to an initial surface extent of said web portion (4a, 5a) , b) arranging said element (s) (4, 5, 6) so that said web portion (4a, 5a) extends essentially flat at an intended surface of said compressed structure (1) , said tongue-like attachment portions (7, 13) being arranged to extend from said intended surface into said matrix material (14), at least a section of said web portion (4a, 5a) being adapted to extending outside the general outer boundaries of said compressed fibre structure (1) , and c) moving said press members, in a manner known per se, towards each other in order to press, therebetween, said matrix material (14) to its final dimensions, whereby said tongue- like attachment portions (7, 13) will be embedded and integrally attached to said matrix material (14) inside the resulting compressed structure (1) . 2. A method as defined in claim 1, c h a r a c t e r i z e d in providing, along a longitudinal extent of said element (4, 5, 6), weakened portions (8, 11) for facilitating bending of said element (4, 5, 6) . 3. A method as defined in claim 1 or 2 , c h a r a c t e r i z e d in arranging, between said intended board surface and said web portion (4a, 5a) , one or more sheets (20) of paper, thin plastic or the like sheet-like material, said tongue- and/or finger-like attachment portions (7, 13) extending through said sheet (s) (20) . 4. A method as defined in any one of claims 1 to 3 , c h a r a c t e r i z e d in bending said web portion (4a, 5a) to rise essentially transversely with respect to the general surface of said compressed structure (1) . 5. A compressed fibre board structure such as a fibre board (1) or the like, said structure comprising a matrix material (14) hardened during a compression step to constitute a firm structure, c h a r a c t e r i z e d in that said structure integrally comprises at least one stud, girder or the like elongated reinforcement and/or fastening element (4, 5, 6), said element (4, 5, 6) comprising at least one web portion (4a, 5a) adapted to extend outside the general outer boundaries of said fibre board structure (1), said element (4, 5, 6) further comprising successive tongue- and/or finger-like attachment portions (7, 13) embedded into said hardened matrix material (14) during said compression step. 6. A structure as defined in claim 5, c h a r a c t e r i z e d in that said successive tongue- and/or finger- like attachment portions (7) comprise preferably paired tongues extending from an inner edge of said web portion (4a, 5a) . 7. A structure as defined in claim 5, c h a r a c t e r i z e d in that said elements (4, 5, 6) comprise a flange portion (12) located along the general surface of said fibre structure (1) and said tongue- and/or finger-like attachment portions (7, 13) comprise tongues and/or fingers (7, 13) arranged at said flange portions (12), said web portion(s) (4a, 5a) extending along at least one edge of said flange portion (12) . 8. A structure as defined in claim 7, c h a r a c t e r i z e d in that said tongue- and/or finger-like portions comprise portions (13) which are punched out of said flange portion (12) and bent in an appropriate direction. 9. A structure as defined in any one of claims 5 to 8, c h a r a c t e r i z e d in said web (4, 5) and/or said flange (12) portion(s) comprising one or more weakened portion(s), suitably thinned portion (s) (11) and/or row(s) of preferably elongated apertures (8) , for facilitating the bending of said web (5, 6) along said weakened portion(s) (8, 11). 10. A structure as defined in any one of claims 5 to , c h a - r a c t e r i z e d in said web portion (s) (4a, 5a) extending in an essentially transversal direction with respect to the general surface of said fibre board structure (1) and/or said flange portion (12) . 11. The use of the fibre board structure according to any one of claims 5 to 10, said structure being provided with one or several first elemen (s) (5) extending along and in the essential direction of at least one edge area (2, 3) of said structure (1), wherein at least one of said element (s) (5) is used for attaching said board structure (1) to a fixed external structure (17) . 12. The use as defined in claim 11, c h a r a c t e r i z e d in that at least one of said element (s) (5, 5a) is bent to at least partially enclose an extending portion (18, 18a) of said fixed external structure (17) . 13. The use as defined in claim 11 or 12, c h a r a c t e r i z e d in that said board (1) is provided with one or several elongated second elements (4) , at least one of said second elements being arranged essentially transversely to at least one of said first elemen (s) (5), said second element (s) (4) being used for reinforcing purposes and/or for attaching opposing essentially similar fibre board structures (la) to said board structure (1) at a distance therefrom. 14. The use as defined in any one of claims 11 to 13, c h a r a c t e r i z e d in that further elongated elements (6) provided at an inner area of said fibre board structure (1) are raised for strengthening said board structure (1) especially against buckling.

Inventors: GUDMUNDSSON EDGAR, GUDMUNDSSON, EDGAR
Applicants: EELA HARRI, GUDMUNDSSON EDGAR, EELA, HARRI, GUDMUNDSSON, EDGAR
Application year: 1997
Main classification: E04C2
IPC codes: B27M3, B27N7, E04C2