Modified OSB board and its use in walls for house building systems

Abstract

The present invention relates to a modified OSB board (oriented strand board) with an upper side and a lower side. The upper and/or lower side of the board are coated with at least two paper layers. The first paper layer is impregnated with at least one resin and the second paper layer is a raw paper layer. The invention relates further to a construction wall for a house building system, to a partition wall for a house building system and a house building system.

Claims

1. A modified OSB board (oriented strand board) comprising an upper side and a lower side, wherein the upper side and/or the lower side of the OSB board are coated with at least two paper layers comprising a first paper layer and a second paper layer, wherein a paper layer being adjacent to a board surface as the first paper layer is impregnated with at least one resin, wherein the second paper layer is arranged on the first paper layer as a raw paper layer, wherein the raw paper layer is not impregnated with resin; and wherein the weight of the raw paper is between 100 and 300 g/m.sup.2.

2. The OSB board according to claim 1, wherein the upper side and the lower side are each coated with at least two paper layers.

3. The OSB board according to claim 1, wherein the paper layer being adjacent to the board surface as first paper layer is impregnated with at least one formaldehyde resin.

4. The OSB board according to claim 1, wherein the OSB board comprises a tongue-and-groove joint.

5. The OSB board according to claim 1, comprising chamfers and/or deepenings on at least one side of the OSB board.

6. A construction wall for a house building system comprising at least one modified OSB board according to claim 1.

7. The construction wall according to claim 6, wherein at least one wood frame with two long sides and two short sides continuing in each case parallel to each other is provided, wherein an area delimited by the frame is divided in at least two sub-areas using at least one beam extending within the frame vertical from one long side to the other long side of the frame parallel to the short sides of the frame; wherein the at least one wood frame is covered on both sides by at least one non-modified OSB board, respectively; and wherein the at least one modified OSB board is arranged on at least one non-modified OSB board.

8. The construction wall according to claim 7, wherein the at least one wood frame is made of wood like material.

9. The construction wall according to claim 7, wherein a space between the at least two non-modified OSB boards is filled with insulation material.

10. The construction wall according to claim 7, wherein the at least one modified OSB board is arranged on the non-modified OSB board by using laths which are mounted vertically on the at least one non-modified OSB board and onto which the at least one modified OSB board is placed, providing a space between the non-modified OSB board and the at least one modified OSB board.

11. The construction wall according to claim 10, wherein in the space between the non-modified OSB board and the at least one modified OSB board electrical equipment and/or plumbing components are installed.

12. A partition wall for a house building system comprising at least one of the modified OSB boards according to claim 1.

13. The partition wall according to claim 12, comprising an inner core comprising at least one LDF board.

14. The partition wall according to claim 13, wherein at least one side of the inner core is covered by the at least one modified OSB board.

15. A house building system, comprising: at least one construction wall according to claim 6; and at least one partition wall.

16. The construction wall according to claim 7, wherein the frame is divided into multiple sub-areas using multiple beams extending within the frame vertical from the one long side to the other long side of the frame parallel to the short sides of the frame.

17. The construction wall according to claim 9, wherein the insulation material comprises wood fiber insulation material.

18. A Modified OSB board (oriented strand board) comprising an upper side and a lower side, wherein the upper side and/or the lower side of the OSB board are coated with at least two paper layers comprising a first paper layer and a second paper layer, wherein the paper layer being adjacent to a board surface as the first paper layer is impregnated with at least one resin, wherein the second paper layer is arranged on the first paper layer as a raw paper layer, and wherein the weight of the raw paper is between 100 and 300 g/m.sup.2, wherein the modified OSB board comprises depressions at different positions along the OSB board on at least one side of the board, and wherein the depressions have a length between 10 and 30 mm and a width that corresponds to a width of the OSB board.

19. The OSB board according to claim 1, wherein the OSB board includes depressions at different positions along the OSB board on at least one side of the OSB board.

20. The OSB board according to claim 19, wherein the depressions have a length between 10 and 30 mm and a width that corresponds to the width of the OSB board.

21. The OSB board according to claim 20, wherein the pattern of the depressions and the distance between the depressions along the OSB board matches a lath grate to which the OSB boards are fastened.

22. The OSB board according to claim 21, wherein fastening means are arranged within the depressions that can be covered by putty or primer mass.

23. The OSB board according to claim 1, further comprising a layer of construction material secured to the raw paper wherein the raw construction material consists of one of wallpaper glue, putty and gypsum.

24. Modified OSB board (oriented strand board) comprising an upper side and a lower side, wherein the upper and/or lower side of the OSB-board are coated with at least two paper layers comprising a first paper layer and a second paper layer, wherein a paper layer being adjacent to the board surface as first paper layer is impregnated with at least one resin, and wherein the second paper layer is arranged on the first paper layer as a raw paper layer, wherein the raw paper layer is not impregnated with resin, wherein the weight of the raw paper is between 100 and 300 g/m.sup.2, wherein the modified OSB board comprises depressions at different positions along the OSB board on at least one side of the board, wherein the depressions have a length between 10 and 30 mm and a width that corresponds to a width of the OSB board, and wherein the OSB board is configured to match a lath grate to which the OSB boards are intended to be fastened, wherein the pattern of the depressions and the distance between the depressions along the OSB board matches said lath grate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention is further explained in more detail by means of the following examples with reference to the following Figures. It shows:

(2) FIG. 1A a schematic sight view of a modified OSB board according to a first embodiment of the invention;

(3) FIG. 1B a schematic sight view of a modified OSB board according to a second embodiment of the invention;

(4) FIG. 1C a schematic sight view of a modified OSB board according to a third embodiment of the invention;

(5) FIG. 1D a schematic sight view of a modified OSB board according to a fourth embodiment of the invention;

(6) FIG. 1E a schematic sight view of a modified OSB board according to a fifth embodiment of the invention;

(7) FIG. 1F a schematic sight view of a modified OSB board according to a sixth embodiment of the invention;

(8) FIG. 1G a schematic sight view of a modified OSB board according to a seventh embodiment of the invention;

(9) FIG. 1H a schematic sight view of a modified OSB board according to an eighth embodiment of the invention;

(10) FIG. 1I a schematic sight view of a modified OSB board according to a ninth embodiment of the invention;

(11) FIG. 1J a schematic sight view of a modified OSB board according to a tenth embodiment of the invention;

(12) FIG. 1K a schematic sight view of a modified OSB board according to an eleventh embodiment of the invention;

(13) FIG. 1L a schematic sight view of a modified OSB board according to a twelfth embodiment of the invention;

(14) FIG. 1M a schematic sight view of a modified OSB board according to a thirteenth embodiment of the invention;

(15) FIG. 2A a schematic cross view of a construction wall according to a first embodiment;

(16) FIG. 2B a detailed view of a section of a construction wall according to a further embodiment;

(17) FIG. 2C a schematic cross view of laths for use in a construction wall;

(18) FIG. 3 a side view of a construction wall according to another embodiment of the invention,

(19) FIG. 4 a schematic side view of a partition wall according to an embodiment according to the invention;

(20) FIG. 5 a schematic side view of a house building system according to an embodiment of the invention.

DESCRIPTION OF THE INVENTION

(21) Modified OSB Board

(22) FIG. 1A shows a modified OSB board 10 according to the invention, which is made on the basis of conventional OSB boards with a thickness of 9 mm to 22 mm. The conventional OSB panel 1 is coated on each side with two layers of paper. The first layer 2 consists of paper having the basis weight ranging from 50 g/m.sup.2 to 120 g/m.sup.2 impregnated with melamine resin, urea resin or melamine urea resin. The outer layer 3 is a raw paper having the basic weight ranging from 50 g/m.sup.2 to 220 g/m.sup.2. The panel or board is pressed on the tray press in short cycle or alternatively on the ContiRoll press.

(23) Due to the outer layer 3 comprising raw paper a suitable substrate for direct application of gypsum, patty and wall paper glue is obtained. Onto the outer layer of the raw paper hydrophobic agents can be applied in order to harden the panel against external weather conditions. It is also possible to press the paper together with the layer of an aluminum film in order to obtain a good heat reflection effect.

(24) These OSB boards are widely used in construction of low energy houses or in assembling floor heating. The modified OSB boards are produced either with sharp edges with dimensions of 12502800 mm or with tongue-and-groove joints in dimensions of 6202600 mm.

(25) In another second embodiment of the present modified OSB boards shown in FIG. 1B the board 10 has chamfers 4a, b or bevels near the lateral or abutting edges of the board. The dimension of each chamfer 4a,b differs and is adapted to the tongue-and-groove joints. Thus, a chamfer 4a at the tongue edge of the modified OSB board may have a length of about 28-33 mm while a chamfer 4b at the groove edged of the modified OSB board may have a length of about 10-12 mm. The chamfer height is about 1 mm. When connecting two modified OSB boards provided with said chamfers 4a,b using the tongue-and-groove joints a depression or deepening is formed extending over the abutting edges of the two OSB boards joined together. Said depressions are used for receiving a putty or filler and provide more space for covering screws or optionally a fiberglass mesh reinforcement with a plaster board. In order to obtain said depressions a cut was made on the edges and middle part of the board.

(26) Cutting length is 60 mm or 40 mmm to a depth of 1 mm (see also embodiments of FIGS. 1d-n). After cutting, four layers of paper are applied onto the board and compressed by a specially shaped die. The boards can be finished with a straight edge for a butt joint or with a tongue-and-groove edge. Through the modification of the system of cavities a smoother surface is obtained after plastering the joints. In this modification, a new format of the 12002800 mm wall board was also introduced to match popular 8002800 mm plasterboards and ceiling boards.

(27) In a third embodiment of the present modified OSB boards shown in FIG. 1C the boards or panels comprise further depressions 5 at different positions along the OSB board on at least one side of the board. The distance between two depressions 5 is about 680 mm and corresponds thus to the distance between the laths of the lath grate to which the modified OSB board is fastened. The length of such a depression 5 is about 25 mm and the depth is about 1 mm. The depressions 5 allow an exact positioning of the modified OSB boards on the lath grate and fastening (for example by using appropriate screws) on the lath grate. Within the depressions 5 the fastening means (such as a screw) are arranged that can be covered by putty or primer mass.

(28) The embodiments shown in FIGS. 1D-M illustrate different dimensions of the joints between two OSB-boards.

(29) The embodiment of FIG. 1D shows a tongue-and-groove-joint wherein the depression on the groove side is 12 mm and on the tongue side is 28 mm, respectively. After connecting both OSB boards a deepening with a total length (or width) of 40 mm is obtained over the joint (FIG. 1E).

(30) The embodiment of FIG. 1F shows a tongue-and-groove-joint wherein the depression on the groove side is 28 mm and on the tongue side is 12 mm, respectively (i.e. reversed to the embodiment of FIG. 1D). After connecting both OSB boards a deepening with a total length (or width) of 40 mm is obtained over the joint (FIG. 1G).

(31) The embodiment of FIG. 1H shows a tongue-and-groove-joint wherein the depression on the groove side is 30 mm and on the tongue side is 30 mm, respectively. After connecting both OSB board a deepening with a total length (or width) of 60 mm is obtained over the joint (FIG. 1I).

(32) The embodiment of FIGS. 1J, K show a blunt joint. Here two blunt OSB boards with depressions on both sides with a length (or width) of 20 mm, respectively, are connected to each other thereby forming a deepening with a total length (or width) of 40 mm.

(33) The embodiment of FIGS. 1L, M show another blunt joint. Here two blunt OSB boards with depressions on both sides with a length (or width) of 30 mm, respectively, are connected to each other thereby forming a deepening with a total length (or width) of 60 mm.

(34) Construction Walls

(35) The modified OSB board is used to cover a conventional construction wall 20. The construction wall system of the present invention (shown in FIGS. 2A, 2B, 3) is made of one wood frame 14, which is covered on both sides with non-modified OSB-boards (OSB/3) 11, 12. The modified OSB board 10 is placed on the OSB board 12 facing the interior of the building. The space between the OSB boards 11, 12 is filled with a wood fiber insulation material 13.

(36) The wood frame 14 has two long sides and two short sides continuing in each case parallel to each other is provided, wherein the area delimited by the frame is divided in multiple sub-areas using multiple beams 14a extending within the frame 14 vertical from one long side to the other long side of the frame parallel to the short sides of the frame.

(37) The construction wall 20 contains cut-through laths 15 having dimensions of 50 mm2600 mm and a thickness ranging from 18 mm to 22 mm with drilled, chamfered holes which are ready for quick installation (see FIG. 2C).

(38) Laths 15 are made of OSB-material (OSB/3). The laths 15 (see FIG. 2C) are 15, 18 or 22 mm thick wherein each single lath comprises a hole allowing a ready use of the laths. The hole is arranged with a distance of 50 mm from the lateral edge of the lath and about 25 mm (the hole center) from the longitudinal edge (in case of a 50 mm wide lath). Each lath may comprise multiple holes. In such a case the distance between each hole is about 400 mm (not shown).

(39) The single laths may be combined together to form one singular lath of different thicknesses allowing for an adaptation of the space created between the boards of the construction wall.

(40) Laths 15 are mounted vertically on the wall to obtain ventilation of the build-up area and furthermore space for routing electrical wires or water piping. Depending on the diameter of the plumbing pipes one or two laths 15 are used. The spacing of a lath 15 is selected in order to ensure the tongue and groove joint being in the axis of a in the case of a OSB board or panel is used with a tongue and groove joint. The distance between the laths 15 in the axis is 680 mm. After the laths 15 are installed on the wall the installation of the modified OSB panels 10 begins. The installation starts at the corner of the wall by screwing the modified OSB board 10 to a lath 15 and drive in the screws on the other side in the bottom of the groove. When putting the tongue of the next board 10 the head of the screw are staple is covered. The tongue and groove joint is subsequently glued with polyurethane adhesive. Following the installation and the gluing of all wall elements a gypsum mix is applied to the joints. After the gypsum has dried the joints are abraded and coated with acrylic paint.

(41) Due to the installation of the modified OSB boards 10 the interior finishing is faster and easier. Furthermore, due to the use of the present tongue and groove joints the heads of the screws or staples are hidden, the consumption of gypsum mix is reduced what in turn optimized the interior finishing process. Smaller panel formats reduce the weight which is important for work ergonomics.

(42) Partition Walls

(43) The partition walls 30 (shown in FIG. 4) are made from modified OSB boards 10 or conventional OSB boards (OSB/3 panels) having a thickness of 9 mm. The interior of the wall, i.e. its core consists of two LDF panels 16 with a density of 280 kg/m.sup.3. The individual layers are glued together using a polyurethane adhesive.

(44) The wall 30 has a profile tongue and groove joint which is used for quick installation of the partition wall in any room. The wall is a light weight construction that does not transfer the structural loads of the building.

(45) For wall installation at first the position of the partition wall 30 on the ceiling and floor is marked. Subsequently, an OSB power panel is installed on the floor and wall. OSB Power Panel parameter properties are obtained by arranging bigger strands and adequately gluing them together.

(46) The installation starts by setting the element on the floor panel, then slide the element with its groove to the OSB power panel mounted to the wall. A polyurethane adhesive is applied to all joints. A metal element connecting the wall with the ceiling is installed on the upper edge of the tongue. In a similar manner the next wall element is mounted to fill the entire surface. The space between the wall and the ceiling and the end wall is filled with a polyurethane foam. All joints are finally filled with a coat of gypsum, which is reinforced with fiber glass and the surface is covered with acrylic paint or wall paper.

(47) House Building System (40)

(48) FIG. 5 shows a schematic side view of a house building system 40 with a construction wall 20 and partition walls 30 (not shown).

(49) The house system 40 comprises further a foundation 50, a floor 60, a ceiling 70 and a roof system 80.

(50) Foundation (50)

(51) In a first embodiment, the foundation base is made of steel and solid concrete. The foundation walls are built of concrete blocks and are cemented with mortar. The upper part of the foundation wall is topped with steel and solid concrete comprising steel anchor and ventilation pipes. The whole system of ventilation pipes ventilates the area between ground and the ceiling.

(52) In a second embodiment, the foundation is made in form of a pile foundation. Due to the light structure of the house it is possible to create appropriately designed pile foundation; the drilling machine makes a round hole below the freezing zone, when the pile is shuttered with a paper form, steel and solid concrete with thread anchors is inserted. Between the piles precast concrete walls are mounted. This pile system is cheaper since it uses less concrete and steel, can be constructed faster, precast concrete elements can be mounted in all weather conditions and it may be built on every kind of ground.

(53) Floor Construction (60)

(54) I-beams are covered by a tongue and groove 25 mm conventional OSB board and from the bottom by a 12 mm conventional OSB board. The whole structure is isolated. On the top floor surface a sill plate made of solid wood (KWH wood) is installed.

(55) First Level Floor Construction (70)

(56) If the first level of the attic of the house is usable, then the ceiling is made of i-beams covered with 25 mm thick conventional OSB boards (OSB/3) from the top and 12 mm thick OSB boards (OSB/3) from the bottom with an insulation inside. From the zero level the ceiling system ready to plaster and paint is mounted.

(57) Roof Construction (80)

(58) The roof construction in the present house building system is made of i-beams mounted to the beam by the Simpson adjustable steel fittings. The outer roof sheaving is made of conventional OSB board (OSB/3) or MDF DP 50 board, and the bottom sheaving is made of a 12 mm thick conventional OSB board (OSB/3). Subsequently, a structure ready to plaster and paint, preferably the modified OSB board 10 according to the invention, is mounted to the board. The space between the rafters is insulated. In case of one-story houses the roof construction is made of precast truss, covered with conventional OSB/3 board. The bottom belt of the truss is used as the ceiling. The space between bottom belts is insulated and the ceiling is finished with a ready to plaster and paint system.

(59) The enlarged view in FIG. 5 illustrates the connection of construction wall and ceiling.