AU623674B2 - Composite construction element and a method of forming same - Google Patents
Composite construction element and a method of forming same Download PDFInfo
- Publication number
- AU623674B2 AU623674B2 AU40394/89A AU4039489A AU623674B2 AU 623674 B2 AU623674 B2 AU 623674B2 AU 40394/89 A AU40394/89 A AU 40394/89A AU 4039489 A AU4039489 A AU 4039489A AU 623674 B2 AU623674 B2 AU 623674B2
- Authority
- AU
- Australia
- Prior art keywords
- matrix
- matrices
- composite
- reinforcement
- layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
- E04C2/243—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 one at least of the material being insulating
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
- E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0221—Vinyl resin
- B32B2266/0228—Aromatic vinyl resin, e.g. styrenic (co)polymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/02—Cellular or porous
- B32B2305/022—Foam
Description
OPI DATE 05/02/90 APPLN. I D 403941 89 P AOJP D 12?j0 3&0. Pf NUMBER PCT/FR89/00371 DEMANDE INTERNATIONALE 6 3I JRTLUITE D4OPERATION EN MATIERE DE BREVETS (PCT) (51) Classification internationale des brevets 5 (It) Nuniro de publication internationale: WO 90/00474 B32B 21/08 Al (43) Date de publication internationale: 25 janvier 1990 (25.01.90) (21) Numiro de la deinande~ internationale: PCT/FR89/00371 (81) Etats disigni~s: AT (brevet europ~en), AU, BE (brevet europ~en), CH (brevet europ~en), DE (brevet europ~en), FR (22) Date de dipfit internaticrnal: 12 juillet 1989 (12.07.89) (brevet europ~en), GB (brevet europ~en), IT (brevet europ~en), JP, LU (brevet europ~en), NL (brevet euroi a piort6:p~en), SE (brevet europ~en), US.
88/09472 l2juillet 1988 (12.07.88) FR Publiie Avec rapport de recherche internationale.
(71)X72) Diposants et inventeurs: VAN WILLIGEN, Willem, Arnold [NL/NL]; Kamp 22-03, NL-8225 DW Lelystad SORIA, Jean-Yves [FR/FR]; 13, rue de la Fraternit6, F-93130 Noisy-le-Sec (FR).
(74) Mandataire: NONY, Michel; Cabinet Nony Cie., 29, rue Cambac&rs, F-75008 Paris (FR).
(54) Title: COMPOSITE CONSTRUCTION ELEMENT IqN MET HO I= t 0 1tG S, C-_ (54) Titre: ELEMENTS COMPOSITES DE CONSTRUCTION A ARMATURES TRIDI MENSIONELLES 4 (57) Abstract4 The invention relates to a composite construction element of the type having at least one matrix made of cellular material and at least one internal and/or external armature layer consisting of plywood. The matrix or matrices are made of rigid foam having a compression resistance higher than I kg/cm 2 There is provided between the matrix or matrices and the armature or each of the armatures of plywood a transition layer consisting of a composite material of rigid foam /polyu rethane (4) having a thickness higher than that of the associated plywood armature and preferably comprised between 10 and 20 mm.
(57) Abr~g6 L'invention est relative Ai un 616ment composite de construction du type comportant au momns une matrice en mat~riau cellulaire et au momns une couche d'armature interne et/ou externe en contreplaqu6. La ou les matrices sont r~alis~es en une mousse igide pr~sentant une resistance A la compression sup~rieure A 1 kg/cm 2 II est pr~vu entre la ou les matrices et Ia ou chaune des armatures en contreplaqu6 une couche de transition en un mat~riau composite mousse rigide/polyur~thane (4) lune paisseur sup~rieure d celle de l'armature en contreplaqu6 associ~e, et de preference comprise entre 10 et 20 mm.
I-IY This invention relates to composite construction elements of the type comprising at least one matrix of cellular material, such as expanded polystyrene foam, and at least one layer of plywood reinforcement.
Composite elements of this type are described, for example, in European patent application EP-A-0164280 of the applicants.
That patent application also describes processes for the production of multidimensional structures by shaping and/or by assembly of such composite elements.
This invention proposes to produce composite elements exhibiting mechanical properties improved relative to the composite elements of the prior proposal as well as a process of production of such composite 15 elements making it possible to obtain complex structures, in particular three-dimensional, directly, without having coo• to use the cutting and assembly operations provided in eoo the process described in the prior patent application.
2 According to one aspect of the invention there is 20 provided a composite construction element comprising a matrix of cellular material and at least one layer of plywood reinforcement, wherein the matrix is produced r from a rigid foam exhibiting a compression resistance greater than 1 kg/cm 2 and adjacent the or each e 25 reinforcement layer a transition layer of a rigid foam/polyurethane composite material is formed by impregnating the matrix with a polyurethane resin to a depth greater than the thickness of the associated reinforcement layer.
By the invention, the or each transition layer of composite material is obtained by applying to a surface of a rigid foam matrix, in particular of expanded polystyrene, intended to comprise the core of the composite element and having to receive a plywood reinforcement layer, a suitable amount of a polyurethane resin, preferably of the precrosslinked monocomponent type. The polyurethane resin impregnates the matrix to 92D225,PIISPE.021,wllgenspe,1 -2depth which is preferably between 10 and 20 mm by penetrating the interstitial network formed by the blank spaces of the rigid foam. Where the rigid foam is formed from expanded polystyrene, this transition layer may therefore comprise polystyrene "balls" completely coated and connected to one another by the polyurethane resin once the hardening of the latter is achieved.
The composite element may comprise a plurality of matrices of said rigid foam and at least one plywood reinforcement layer is provided between adjacent matrices with one said transition layer between the reinforcement layer, or layers and each of the adjacent matrices.
To obtain the thickness of the transition layer specified above, an amount of polyurethane resin between o 15 about 25 and about 120% by weight of the rigid foam matrix or matrices is preferably applied.
The transition layer or layers, because of the adhesion properties of the polyurethane, achieve the bond between the or each matrix and the plywood reinforcement *i 20 or reinforcements.
The composite transition layer can produce, between the matrix of rigid foam, in particular of expanded polystyrene, and the reinforcement of plywood, a eeoc *transition with a coupling gradient in which the amount 25 of polyurethane in the transition composite material Se effectively decreases gradually from the reinforcement.
The matrix forming the core of the composite element according to the invention is produced preferably from an expanded polystyrene having a density between about and about 25 kg/m3, and preferably on the order of kg/m3.
The reinforcement or each reinforcement of plywood preferably has a thickness between about 4 and about mm. Preferably the plywood reinforcement or reinforcements present in the composite element represents 50 to 75% of the total weight of the element.
According to another aspect of the present 92I25,PHHSPE.021 wiligenspeM2 i invention, there is provided a process of producing a composite element in accordance with the first aspect, wherein the or each matrix is produced by cutting a rigid foam unit, a polyurethane resin in an amount between and 120% by weight of the matrix or matrices is applied to the face or faces of the matrix or matrices to receive the plywood reinforcement, the or each layer of plywood reinforcement is positioned on the respective matrix, the unit of matrix or matrices and reinforcement is placed in a mold consisting of remaining parts of the initial rigid foam unit, and the mold is compressed for a period between 5 minutes and 3 hours as a function of the hardening time of the polyurethane resin, after which the finished composite element is withdrawn from the mold.
V 15 By the process of the invention, a composite element can be produced directly which can form a threedimensional structure and whose shape is determined by the configuration of the matrix or matrices obtained by cutting the initial unit of rigid foam, the latter 20 constituting, during the hardening phase of the polyurethane, a counterform which can achieve, because of its conformation complementary to that of the matrix or matrices, a perfect distribution of the pressure exerted during the hardening phase of the polyurethane, as well 25 as a perfect keeping in place of the reinforcement(s).
Other advantages and characteristics of the invention will come out in reading the following description of embodiments, given by way of example only, with reference to the accompanying drawing in which: figure 1 illustrates a first embodiment of a composite element according to the invention, figure 2 illustrates two phases of use of the process 920225,PHHSPE.02,wlhigenjspe,3 for the production of such multiple elements as illustrated in figure 1, figures 4 to 6 illustrate three other embodiments of composite elements according to the invention.
i In figure 1. a composite element according to the invention has been illustrated in the form of a curved profile panel.
Illustrated composite element 1 comprises a core 2 consisting of a polystyrene matrix and two outer plywood reinforcements constituting outer skins 3.
Between polystyrene matrix 2 and each reinforcement 3, an interface layer of an expanded polystyrene/polyurethane composite material 4 is produced.
Figures 2 and 3 illustrate two stages of a simultaneous production process according to thc invention of several composite elements of the type of that illustrated in figure i.
For this purpose, a start is made from a parallelepipedic unit 5 of expanded polystyrene with in which multiple cutouts are made, in particular by the hot wire technique, to constitute multiple matrices, four in number in the example illustrated, 2a, 2b, 2c and 2d, each having the shape and the final dimension desired (matrix itself and zone(s) of expanded polystyrene/polyurethane composite material).
Two additional cutouts 6 also are produced in unit 5 to withdraw two zones of material on both sides respectively of matrices 2a and 2d, the total thickness of these zones corresponding to the total thickness of the reinforcements having to be placed on the matrices. Thus, as illustrated in figure 3, in remaining parts 5a and 5b of initial unit after cutting, four units can be placed consisting of matrices 2a, 2b, 2c, 2d each covered on each of their main faces with reinforcements 3 necessary to constitute four composite elements la, Ib, Ic, Id that are produced simultaneously by applying, as illustrated in the arrows of figure 3, a pressure 2 of 0.3 kg/cm for 4 period of 1 hour to achieve the adhesion of the reinforcements to the polystyrene matrices after placing I ~ulrr*prurren~r~ of the suitable amount of polyurethane resin to form transition zones of expanded polystyrene/polyurethane composite material 3, at a depth of about 10 mm.
Figure 4 illustrates a reinforced plane panel constituting a second embodiment of a composite element according to the invention.
The element designated as a whole by 10 comprises multiple matrices of expanded polystyrene 11 of parallelepipedic shape and of approximately square section between which are placed plywood reinforcements 12. expanded polystyrene/polyurethane composite material layers 13 being produced between each matrix 11 and the corresponding plywood reinforcements. The composite element further comprises, on its main faces and if necessary on its edges, outer plywood reinforcements with insertion of a composite material transition layer. These reinforcements and these transition layers have not been shown for a greater clarity of the drawing.
Figure 5 illustrates another embodiment of a composite element according to the invention globally designated by this composite element exhibiting a cylindrical unit shape and consisting of multiple matrices 21 in the shape of cylinder sectors to which plywood reinforcements 22 are attached, expanded polystyrene/polyurethane composite material layers 23 2s being produced between each armature and the corresponding matrix.
The unit of expanded polystyrene which serves ao_.
to the invent inn, as a counterform during the production of the composite element, also has been illustrated in figure Illustrated element 20 comprises a peripheral plywood reinforcement forming an outer skin (not shown), the latter being produced during the same molding stage as that illustrated in figure 5, by, as in the embodiment of figures 2 and 3, the removal from the initial unit of a zone corresponding to the thickness of the reinforcement having to form the outer skin.
Element 30 illustrated in figure 6 exhibits a left
I
I triangular shape formed by cutting from the expanded polystyrene unit (not shown) in the desired final shape of an expanded polystyrene matrix 31 on all of whose faces are placed outer reinforcements only some of which are shown in S32, expanded polystyrene/polyurethane composite material layers 33 being produced as in the preceding embodiments between reinforcements 32 and matrix Although the invention has been described in connection with particular embodiments, it is quite obvious that it is in no way limited and that many variants and modifications can be provided without thereby going outside its scope or its spirit.
In particular, although the various examples use expanded polystyrene as a rigid foam, other rigid foams exhibiting the exfrudcac polyc:hsne i1 specified mechanical properties, in particular/p-lystyrnte o or po/-r/enc -e--ca polyurethane foams, can be used according to the invention.
i F
Claims (9)
1. A composite construction element comprising a matrix of cellular material and at least one layer of plywood reinforcement, wherein the matrix is produced from a rigid foam exhibiting a compression resistance greater than 1 kg/cm 2 and adjacent the or each reinforcement layer a transition layer of a rigid foam/polyurethane composite material is formed by impregnating the matrix with a polyurethane resin to a depth greater than the thickness of the associated reinforcement layer.
A composite element according to claim 1 wherein the p or each transition layer has a thickness of between S. 15 and 20 mm.
3. A composite element according to claim 1 or claim 2 which comprises a plurality of matrices of said rigid foam and wherein at least one plywood reinforcement layer is provided between adjacent matrices with one said .•transition layer between the reinforcement layer, or i layers and each of the adjacent matrices. l
4. A composite element according to any one of claims 1 I 25 to 3, wherein said transition layer or layers comprise from 25 to 120% by weight of the matrix or matrices of polyurethane resin.
A composite element according to any one of claims 1 to 4 wherein the plywood reinforcement layer or layers comprise from 50 to 75% by total weight of the element.
6. A composite element according to any of claims I to wherein the matrix or matrices are of expanded polystyrene having a density of between 15 and 25 kg/m 3
7. A composite construction element substantially as 920225,PHHSPE.021,%illhgenspe,7 i -8- herein described with reference to the accompanying drawings.
8. A process of producing a composite element according to any one of the preceding claims, wherein the or each matrix is produced by cutting a rigid foam unit, a polyurethane resin in an amount between 25 and 120% by weight of the matrix or matrices is applied to the face or faces of the matrix or matrices to receive the plywood reinforcement, the or each layer of plywood reinforcement is positioned on the respective matrix, the unit of matrix or matrices and reinforcement is placed in a mold consisting of remaining parts of the initial rigid foam o unit, and the mold is compressed for a period between minutes and 3 hours as a function of the hardening time of the polyurethane resin, after which the finished composite element is withdrawn from the mold.
9. A process of producing a composite element 20 substantially as herein described with reference to the accompanying drawings. DATED this 25th day of February, 1992. o er WILLEM ARNOLD VAN WILLIGEN and JEAN-YVES SORIA By its Patent Attorneys DAVIES COLLISON CAVE 920225,H HSP E021,willgespea8 L
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| FR8809472 | 1988-07-12 | ||
| FR8809472A FR2634160B1 (en) | 1988-07-12 | 1988-07-12 | COMPOSITE CONSTRUCTION ELEMENTS WITH THREE-DIMENSIONAL FRAMEWORK COMPRISING AT LEAST ONE MATRIX OF CELLULAR MATERIAL AND METHOD FOR THE PRODUCTION THEREOF |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| AU4039489A AU4039489A (en) | 1990-02-05 |
| AU623674B2 true AU623674B2 (en) | 1992-05-21 |
Family
ID=9368370
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU40394/89A Expired - Fee Related AU623674B2 (en) | 1988-07-12 | 1989-07-12 | Composite construction element and a method of forming same |
Country Status (6)
| Country | Link |
|---|---|
| EP (1) | EP0383877A1 (en) |
| JP (1) | JPH03501592A (en) |
| AU (1) | AU623674B2 (en) |
| ES (1) | ES2014895A6 (en) |
| FR (1) | FR2634160B1 (en) |
| WO (1) | WO1990000474A1 (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105402910A (en) * | 2015-12-29 | 2016-03-16 | 山东小鸭新能源科技有限公司 | WIFI (Wireless Fidelity) long-distance intelligent controlled home solar split-type water heater and control method |
| FR3055638B1 (en) | 2016-09-06 | 2020-10-02 | Willigen Willem Arnold Van | ELEMENTS OF CONSTRUCTION, ASSEMBLY PROCEDURE OF SUCH ELEMENTS AND CONSTRUCTION THUS CARRIED OUT |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR1187291A (en) * | 1957-11-27 | 1959-09-09 | Prefabricated panels for construction and decoration | |
| EP0044286A2 (en) * | 1980-07-04 | 1982-01-20 | KemaNord AB | A method of securing adhesion |
| EP0164280A2 (en) * | 1984-04-16 | 1985-12-11 | Jonathan Christopher Mc Intosh | Enveloping composite comstruction elements and process for making multidimensional structures from these elements |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2294826A1 (en) * | 1974-12-16 | 1976-07-16 | Normac | Rigid lightweight polyurethane foam panels - and mouldings with foamed polystyrene particles as filler |
-
1988
- 1988-07-12 FR FR8809472A patent/FR2634160B1/en not_active Expired - Fee Related
-
1989
- 1989-07-11 ES ES8902953A patent/ES2014895A6/en not_active Expired - Fee Related
- 1989-07-12 JP JP1508350A patent/JPH03501592A/en active Pending
- 1989-07-12 AU AU40394/89A patent/AU623674B2/en not_active Expired - Fee Related
- 1989-07-12 WO PCT/FR1989/000371 patent/WO1990000474A1/en not_active Application Discontinuation
- 1989-07-12 EP EP89908835A patent/EP0383877A1/en not_active Withdrawn
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR1187291A (en) * | 1957-11-27 | 1959-09-09 | Prefabricated panels for construction and decoration | |
| EP0044286A2 (en) * | 1980-07-04 | 1982-01-20 | KemaNord AB | A method of securing adhesion |
| EP0164280A2 (en) * | 1984-04-16 | 1985-12-11 | Jonathan Christopher Mc Intosh | Enveloping composite comstruction elements and process for making multidimensional structures from these elements |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH03501592A (en) | 1991-04-11 |
| AU4039489A (en) | 1990-02-05 |
| FR2634160B1 (en) | 1991-02-15 |
| ES2014895A6 (en) | 1990-07-16 |
| EP0383877A1 (en) | 1990-08-29 |
| FR2634160A1 (en) | 1990-01-19 |
| WO1990000474A1 (en) | 1990-01-25 |
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