BE1009396A5 - Element of strata construction, manufacturing method thereof and device for implementing the process. - Google Patents

Abstract

This element (1) consists of a layer (2) of flakes (3 to 5) of synthetic foam connected by a synthetic material (6) of primary material and of a covering layer (11) disposed at a surface (10) of the layer (2) and connected to it by force and by matching of the shapes. In zones, a framework or cellular structure of the flakes (3 to 5) is deformed in the layer (2). The covering layer (11) is embedded in a synthetic material (6) of the layer (2) formed in particular by a thermoplastic material and / or a synthetic material (16) with an intermediate layer (12) disposed between it and the covering layer (11) and / or is added by this synthetic material (6,16) at least on the layer (2) and is connected by force and / or by concordance of the shapes with the latter.

Description

       

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   "Multi-layer building element, method for manufacturing the same and device for implementing the method"
The invention relates to a multi-layer building element consisting of a layer of synthetic foam flakes bonded by a synthetic material of primary material and a covering layer arranged on a surface of the layer and connected to it. ci by force and by concordance of the forms, and by zones, a framework or cellular structure of the flakes in foam of synthetic material is formed in the layer. The invention also relates to the manufacturing process and the device for implementing this element.



   A method for manufacturing sandwich elements is already known from European patent 10 266 224. This sandwich element consists of a surface layer, for example an interlacing or a knitted fabric of polyester, viscose, fibers. of glasses or in a combination of these, a first reinforcing layer disposed behind and a thermally deformed cell core material, a second reinforcing layer and a covering layer. The assembly of the various layers, in particular of the surface layer with the core material takes place using an adhesive, and the first reinforcing layer is placed in the adhesive layer at the same time, and

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 the core element by an additional layer of glue the additional reinforcement layer.

   This multi-layer element is produced according to a continuous production process by unrolling the different layers partially from a roll and passing them through the processing machines, and the molding as well as the activation of the individual sticky layers in the multi-layer element taking place in a molding and marking tool and if necessary cutting during the continuous passage through the production line. This certainly makes it possible to speed up and simplify the manufacture of construction elements with several layers, however the solidities obtained in the vicinity of the covering layers are not sufficient in a large number of fields.



   Another multi-layer building element known from DE-Al-24 45 180 is formed on a support body made of light material, for example of polyurethane hard foam, comprising an upper covering layer of aluminum sheet d '' a thickness of 0.3 to 0.4 mm with a profiled belt and a lower cover layer, for example also made of aluminum sheet with a thickness of 0.3 to 0.4 mm which is divided into three parts by milling in the form of dovetail grooves.

   Even when hard polyurethane foams are used and the stable filling is obtained, even when choosing thicknesses of 0.3 to 0.4 mm for aluminum sheet, there is a great risk of damage to the surfaces of cover layers during manufacture, storage and transport.

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   The object of the present invention is to create a building element with several layers which can be provided with covering layers having sufficient own stiffnesses and which can be separated again into layers of individual materials after use.



   This object is produced according to the invention in that the covering layer is embedded in a synthetic material of the layer constituted in particular by a thermoplastic material and / or in a synthetic material of an intermediate layer arranged between the latter and the layer of covering and / or added by this synthetic material at least on the layer and connected by force and / or by concordance of the forms with this.

   The surprising and unpredictable advantages of this solution lie in that due to the use of a synthetic material between the layer and the covering layer, even when this layer consists of synthetic foam materials, in particular of a material recycling a reduced specific weight and a higher elasticity, one can manufacture a very hard support layer, capable of supporting loads, on the surface of the layer or between this layer and the covering layer.

   This is connected on the one hand tightly to the covering layer as well as to the layer and constitutes a support envelope for the covering layer, and thus it is possible in a simple way also to use layers of overlap which have extremely reduced wall thicknesses, for example sheets only 0.001 mm thick. This decreases both in the vicinity of these thin sheets and in the vicinity of layers

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 of a material thickness of between 0.2 and 0.8 mm, the compressive strength at the edges and the risk of damage during the manufacture, storage and transport of the construction elements.

   Since this synthetic material can be used at the same time to connect the layer and the covering layer, it is possible during a fixing and molding operation to create a covering layer capable of supporting high loads. In addition, thermoplastic synthetic material is advantageously used as synthetic material so that it can be liquefied in a temperature zone in which the layer or layers of foam forming the support body of a reduced specific weight do not lose not yet their solidity or in which the cellular structure of such mosses does not yet collapse.

   Another advantage when using a thermoplastic synthetic material resides in the reprocessing or the treatment of the recovery products of such construction elements, since it is possible to obtain the separation between the synthetic material or the foams of synthetic material of the layer. and of the covering layer in a simple manner by a sufficiently strong heating of the covering layer and a new liquefaction of the thermoplastic synthetic material.



   One can create in particular by such an embodiment and the reinforcement of the construction elements directly below the covering layer of the very rigid, self-supporting or suspended construction elements, with a

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 molded part, for example also in a foam of synthetic material of low specific weight which has a corresponding high number of air-filled cells which again have a very high insulation effect. Since it is possible to separate the different layers of the building element, it is possible to use recovery products obtained by such building elements to manufacture new building elements without harming the solidity characteristics or with thermal insulation characteristics.



   According to a further development of the invention, a molded part, in particular made of synthetic material, is fixed on a surface of the layer remote from the covering layer, whereby it can be applied advantageously, due to the possibility of production with its own stability. of the covering layer with the layer, the latter also by a subsequent bonding operation on previously formed molded parts. This allows production and storage, free from damage, of different covering layers in different colors and surface configurations, and the desired covering layer can then be applied, for example, to the mounting site respectively on the molded part which can already be fixed if necessary.



   According to another alternative embodiment, the plastic molded part is attached to the surface of the layer remote from the covering layer, in particular by a foaming operation. It is thus obtained that the layer with the covering layer placed on it can already be placed in the foaming mold and can

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 be fixed by the sticky effect of the plastic foam of the molded parts directly to the layer.

   Another advantage of this solution lies in the fact that, due to the use of this layer, it is certainly impermeable to solid liquid, not airtight and therefore, during the manufacture of large construction elements. with a large volume of the molded part of synthetic material foam, the air discharged during the foaming of the synthetic material can exit in the direction of the layer, and this can avoid the formation of hollow spaces in the transition zone between the layer and the molded part.

   This gives on the one hand a greater solidity of the construction element and, on the other hand, the bumps or hollows in such construction elements are reduced in the vicinity of the covering layers since there is no has no hollow spaces or bubbles, especially during solar radiation or strong heating on one side.



   According to another advantageous embodiment, the layer consists of flakes of foam of primary synthetic material or of recycling, in particular in hard or semi-hard foam and / or in flexible foam. It is therefore possible, in accordance with the recycling material used during the recovery of old materials, to also define the specific weight and the damping behavior as well as the solidity of the construction elements.



   According to a further development of the invention, the foam flakes of primary synthetic material or of recycling are provided with covers or covers, in particular in

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 textile, leather, synthetic material or synthetic leather. It is therefore possible, in connection with the application of the covering layer to the building element, also to use synthetic recovery materials provided with hard or semi-hard coatings, since the hard components of the covers do not pass through the covering layers and cannot lower the quality of the surfaces.



   According to an advantageous embodiment of the invention, the flakes consist of recovered textiles and / or paper and / or cardboard and / or fabric and / or leather and / or textile and / or metal remains , which makes it possible to vary the composition of the layer in a simple manner according to the application case and the recovery of recycling materials.



   According to an alternative embodiment of the invention, the layer comprises between 70% and 95%, preferably 85% of foam flakes of synthetic material, which makes it possible to obtain a close bond of the recycling materials or foam flakes synthetic material, and also allows to keep very low the share of primary material for the manufacture of the core, especially when using flakes of recycling material.



   According to a further development of the invention, 10 to 20% of the weight of the layer consists of a foam of synthetic material and / or a thermoplastic material of primary materials, for example polyurethane, which makes it possible to solidly drown the flakes in the nucleus while obtaining a proportionately reduced increase in specific weight.

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   According to another embodiment of the invention, the specific weight or the weight of free foam of the recycled plastic foam added to the layer is between 30 and 150 kg / m3, which makes it possible to obtain, apart from a sufficient solidity, still a satisfactory elasticity of the damping of the oscillations or an elastic arrangement between the two covering layers, even when the temperatures vary greatly.



   According to another advantageous embodiment, an intermediate layer of thermoplastic synthetic material is placed between the layer and the covering layer. Due to the adaptation of the thermoplastic material used, the construction elements can be universally adapted to different application cases. Another advantage of this solution resides in the fact that the thermoplastic materials exhibit, at temperatures usually encountered in the field of use of such construction elements, a high hardness and thus the compressive strength at the edges and the ability to withstand shots of the cover layer are greatly increased.



  In addition, during the reaction or the establishment of the connection between the layer and the covering layer by the liquefaction of the thermoplastic material, the foam structure and the plastics in recycling foam in the layer are not modified. disadvantageously, there is in particular no release of oil, and it is possible to maintain a sufficient solidity of this layer, but at the same time, due to the liquefaction of this thermoplastic material during assembly

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 of the covering layer with the layer, it is possible to balance possible surface inequalities between these two components, which makes it possible to manufacture construction elements with a very high surface quality of the covering layer.

   This increases the breaking strength under permanent load and in particular the risk of delaminations.



   According to other advantageous embodiments, there is disposed between the covering layer and the intermediate layer an intermediate layer and this is produced in the form of a sticky and / or adhesive layer which is preferably made of polyethylene and / or PVC or made of other synthetic or sticky materials with good adhesiveness. It is thus possible to durably connect different materials which are not stably connected by means of the additional intermediate layer.



   According to another advantageous characteristic of the invention, the thermoplastic synthetic material consists of polyethylene, polyamide, polypropylene, polystyrol, polyvinyl chloride, polyamide, synthetic resins type ABS or the like, which makes it possible to adapt the adhesion forces and hardness respectively necessary for the different conditions of use



   According to another further development, a support body made of fibers or threads is embedded in the intermediate layer of thermoplastic synthetic material. It is thus possible to reduce the drawbacks which arise in the case of certain thermoplastic materials, namely a high fracture capacity in the hardened state, since by reinforcing the thermoplastic material it is possible to

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 considerably increase the mechanical properties, in particular the resistance to deformation thereof.

   By using the thermoplastic material which is liquefied when the layer is assembled with the covering layer, it is also possible to prevent disadvantageous effects on the surface quality of the covering layer, since the liquefied thermoplastic material makes it possible to equalize the inequalities produced. by the support body between the layer and the covering layer.



   According to another characteristic of the invention, the support body consists of a net and / or knitted fabric and / or web of different fibers or threads made of glass and / or metal and / or Kevlar and / or graphite and / or textile. There is thus a large number of possibilities for producing the covering layer which allows universal use of construction elements produced in this way in the most diverse areas of soundproofing, for example for the interior lining of vehicles. , in the field of construction and the like.



   According to a further development of the invention, the fibers or threads of the support body consist of glass and / or metal and / or Kevlar and / or graphite and / or textile, which makes it possible to use such building components also in areas subject to high loads, where they are subjected to higher impacts and frictional stresses, such as for example the external coating of tanks or boilers.



   According to an advantageous alternative embodiment of the invention, the support body and / or the flakes of the material foam

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 synthetic are covered or filled with a granule, for example a powder or a sheet of thermoplastic synthetic material of a solid consistency. It is thus possible to coat the support body already with the necessary materials which, because of the powder used, can be handled simply in production and can be treated for example also without adhering to the rollers, so that the thermoplastic synthetic material only liquefies when it has been correspondingly reheated and thus a uniform distribution over the support body is ensured.

   We also recommend the provision of a sheet of thermoplastic synthetic material which will then be softened, then plasticized or liquefied in a corresponding manner, since this considerably simplifies the manufacture of the construction elements according to the invention.



   According to another advantageous embodiment of the invention, the support body and / or the flakes of the synthetic material foam are covered with a paste of the termoplastic synthetic material which is only weakly adhesive at room temperature, because thus the energy costs for liquefying the thermoplastic material are reduced and also the most diverse raw materials can be used for this thermoplastic synthetic material.



   According to a further development of the invention, the thermoplastic synthetic material, under pressure and at a temperature between 1200C and 1800C is at least semi-liquid, which makes it possible to use the thermoplastic synthetic material for the

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 molding or to drown the support body without exceeding the temperatures which could disadvantageously modify or cause cracking or release of oil from the cellular structure of the layer.



   According to an alternative embodiment, the thermoplastic synthetic material, at a temperature between 150 C and 2000 C is liquid and / or the adhesion is very weak, for example between 5 and 30 N / 5 cm. Elimination of such construction elements is thus possible relatively simply because the core structure, even when it is made of foam plastics, is not destroyed during separation, and thus the foam plastics, after tearing off. and a corresponding treatment can be used again as flakes for the manufacture of a new building element.



   According to another advantageous embodiment of the invention, the covering layer consists of a knit, a fabric, a tablecloth or a sheet of natural and / or synthetic materials and is added by the synthetic material consisting of the thermoplastic material or a layer formed by the latter to the support body and / or to the layer or adheres thereto. The thermoplastic synthetic material, apart from the establishment of the sufficiently rigid covering layer, allows at the same time a bonding and an application on the whole surface of a covering layer without additional glue layer.



   According to an advantageous alternative embodiment of the invention, it is arranged in the layer preferably made up of several

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 plates between the latter and a surface remote therefrom from the molded part or from the layer a reinforcing element. This creates possibilities of fixing with greater resistance to tearing or better introduction of forces than the use of the molded part as a fixing element.



   According to a further advantageous development of the invention, a reinforcing element (96) is arranged between the support body (13) and the layer (2) and a covering layer (11,21). preferably embedded in the layer (2) of synthetic material, for example in the thermoplastic material thereof, which makes it possible to apply still already prefabricated building elements, before the application of the covering layers, elements reinforcement in different surface areas where these are necessary.



   According to another characteristic of the invention, the covering layer consists of a plate or a sheet of natural or synthetic material, which makes it possible to adapt the construction elements in a simple manner to fields of use and stresses different. Plates and sheets of synthetic material are particularly suitable for use in post areas and in interior applications where the UV charge is relatively reduced.



   According to a further development of the invention, the plate or sheet is made of a metallic material, for example sheet steel or aluminum or cardboard, which allows the construction elements to be used

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 also outdoors, for example for thermal insulation of tanks, silos, reaction vessels, for example drop towers used for the disposal of waste water, etc.



   According to an alternative embodiment of the invention, the covering layer consists of a sheet of paper and / or of synthetic material and / or of synthetic material with vacuum metallization and / or of textiles, which allows a simple adaptation. of the outer covering layer of the building element for the most diverse purposes of use and an adaptation of the bonding characteristics to the materials of the flakes used for the layer.



   According to other advantageous characteristics of the invention, the thickness of the sheet of the plate is greater than 0.2 mm and the thickness of the sheet is between 0.001 and 0.2 mm and it is made of preferably aluminum, which makes it possible to adapt in a simple manner the stresses of the layer or of the synthetic material and the corrosion resistances to the respective requirements.



   According to a further development of the invention, the covering layer is provided on the side facing the layer with a coating, in particular of PVC and / or polyethylene and / or polyamide, which makes it possible to obtain good adhesion or stability during the subsequent bonding operation of the covering layer with the intermediate layer produced in the form of a hard layer.



   According to another advantageous characteristic of the invention, there is arranged on the molded part on the surface opposite the layer thereof.

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 additional covering layer, which makes it possible to obtain a high resistance and a higher overall solidity of the building element.



   According to an advantageous embodiment of the invention, the additional covering layer is added during the manufacture of the molded part thereon, which allows, during the manufacture of the molded part, to connect at the same time the overlapping layers to it.



   According to another characteristic of the invention, the layer is liquid-tight but permeable to gas on the surface remote from the covering layer. It is thus possible, during the molding of the molded part, when it is made of a synthetic material or a foam of synthetic material, to avoid the formation of bubbles since the air trapped during foaming between the foam of material synthetic and the covering layer can exit in the direction of the layer.



   According to a further development of the invention, the synthetic material is a polyol which is mixed with flakes into a hard or semi-hard polyurethane foam, and the flakes are embedded in the synthetic material after mechanical compaction relative to the weight of foam free, which makes it possible to advantageously use synthetic recovery materials, in particular building elements made of synthetic foam.



   According to another characteristic of the invention, an intermediate formation is arranged between the support body of fibers or threads and the covering layer,

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 in particular a PE sheet, constituted by an adhesive hot-melt sheet, which makes it possible to obtain better adhesion between the different layers.



   According to another characteristic of the invention, the fiber or yarn body is formed by a polypropylene sheet and is covered, where appropriate, with a powder-shaped thermoplastic material, for example a polypropylene powder, which allows to obtain a uniform hardness and a high compressive strength at the edges of the layer and a good filling of the covering layer.



   According to an alternative embodiment of the invention, the recycled plastic foam flakes are embedded in a catalytically and / or thermally blocked PU, and thus the polyurethane reacts only under predetermined conditions and it is possible to work until the time of the reaction with a dry mixture for the layer or the molded part.



   The invention also relates to a method of manufacturing a multi-layer building element, in which flakes of synthetic foam are mixed with a liquid primary material of synthetic foam and are formed into a plate or in a block which is caused to react under the effect of pressure and / or temperature and / or humidity, and thus the flakes of synthetic foam are bonded to each other by the foam of synthetic material made of primary material, after which a covering layer is applied to at least one surface of such a plate or of such a block, and under the effect of pressure and / or temperature, if applicable

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 if necessary under spatial deformation,

   the cover layer is connected to the plate or block to form a multi-layer construction element.



   This process is characterized in that, before the covering layer is laid on the layer, for example the plate or the block, there is applied to the latter and / or a support body made of fibers or yarns of an intermediate layer. , a granule and / or a sheet and / or a paste of a thermoplastic synthetic material, then the covering layer with the layer and / or the intermediate layer and the thermoplastic synthetic material, respectively, is heated at least up to becoming semi-liquid as a result of which the covering layer is pressed onto the core-forming layer of a multi-layer building element and, by pushing back the thermoplastic synthetic material, this is pressed into the surface areas of the layer, then the cover layer and the layer and / or the intermediate layer are directly cooled, and

   after sufficient hardening and / or after the temperature of the solidification point or the pour point of the thermoplastic synthetic material has been lowered downwards, the construction element is removed from the mold. Due to this type of manufacturing, it is now possible to manufacture such construction elements in large batches, which makes it possible to considerably simplify the handling of the various components necessary for the manufacture of the construction elements.



  In addition, we can now process some of the materials used directly by unrolling them from a roll and that frequently,

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 the application of liquid components, in particular adhesives and the like mixed with solvents is no longer necessary. In addition, with slight changes in the production process, construction elements can be produced according to a wide variety of requirements using the same system.



   According to an advantageous characteristic of the invention, the covering layer and / or the intermediate layer and / or the layer, simultaneously with the penetration of the thermoplastic synthetic material into the surface areas of the layer, are spatially deformed. The element can also be spatially configured using the temperature necessary for the liquefaction of the thermoplastic synthetic material, and it is also possible to ensure a different spatial form by compaction of different strength of the layer, in particular of foam elements. of synthetic material in the core without deforming or cracking the cellular structure of the layer, since by compression of the elastic core materials,

   these are somehow solidified in the pre-stretched state by the solidification of the covering layer of thermoplastic material and therefore, the elastic characteristics thereof, despite the higher density and specific gravity, are not destroyed and decommissioned. Thus, the damping characteristics of such construction elements, in particular for sound insulation, are very good.



   According to another characteristic of the invention, the layer is heated before or during the spatial deformation of the layers of

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 covering, which makes it possible to obtain an even greater spatial deformation and, where appropriate, a partial solidification of the cellular structure of the layer. Thus, in certain cases it is possible to obtain a spatial deformation of the building element with reduced pressure forces.



   According to other characteristics of the invention, a previously adjusted pressure is exerted on the layer and / or the intermediate layer and / or the intermediate formation and / or the covering layer before heating and following the loading of pressure, the intermediate layer is clamped between the layer and the covering layer and the intermediate formation, respectively, whereby a uniform distribution of the intermediate layer produced in the form of a hard layer is obtained over the entire bonding zone, which allows '' avoid withdrawal during the heating operation.



   According to yet another characteristic, the flakes of the layer are arranged in bulk on the intermediate layer, and thus it is simply necessary to reduce the recycling materials used to the corresponding size of the flakes and to bring them into the desired mixing ratio. bulk at the processing facility.



   According to another advantageous characteristic of the invention, the layer is brought in the form of individual plates and / or products in rolls to the laying station, and thus, in the working area of the installation, there is no additional dust accumulation.



   According to another characteristic of the invention, the device for manufacturing

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 construction elements operate intermittently, which allows a simpler construction of the installation as well as better control of the progress of the process.



   According to another characteristic of the invention, simultaneously with the spatial deformation of the covering layer, the cellular structure or the cells of the layer are cracked thermally and are fixed in the deformed position, which allows the element to be fixed. construction for example in fixing areas so that it has practically the structure of a solid material component with the advantages of a multi-layer construction.



   According to another characteristic of the invention, the thermoplastic synthetic material is heated to a temperature of between 1200 ° C. and 170 ° C., which makes it possible to use a large number of different materials for the layer without these losing their mechanical characteristics or chemicals.



   According to another characteristic of the invention, the multi-layer building element is heated at least in the areas of
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 surface at a temperature between 1500C and 2000C as a result of which the covering layer is removed from the core, which allows to ensure in a simple way a separate elimination of the different layers of the building element.



   According to an alternative embodiment of the invention, the thermoplastic synthetic material in the covering layer is heated to a temperature above 2000C and is removed in the liquid state from the support body of fibers or threads, in particular by suction, this

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 which allows the synthetic material to be eliminated almost completely from the support body.



   According to another characteristic of the invention, before the application of the covering layer to the layer, the support body is put in place, and the support body, by means of the thermoplastic synthetic material impregnating it is firmly connected to the covering layer or the layer, or else they are formed one on the other, and thus one can establish in a single working step by means of a support layer necessary for the mechanical characteristics of the building element simultaneously connects to the most diverse covering layers.



   The invention further relates to a device for manufacturing a building element with several layers, consisting of a layer of flakes connected by a foam of synthetic material of primary material and at least one covering layer disposed on one of the two opposite surfaces of the layer, connected to it by force and / or by matching of the shapes, with a support body made of fibers or threads, with a conveyor device for the support body coated or impregnated with the thermoplastic synthetic material which granule at room temperature, and which is in the form of a sheet or slightly adherent paste.



   This device is characterized in that the transport device consists of two conveyor belts extending parallel to one another at an adjustable distance one above the other, in particular in Teflon, and in that '' it is arranged following this device

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 transport a heating device and a mold, and in that it is arranged between the transport device and the molding device a device for handling the support body impregnated with the layer of thermoplastic synthetic material and / or the covering layer and / or the layer made of synthetic foam.

   This makes it possible to advantageously create an on-line process in which, especially when the same support body is used for the two covering layers, one can be satisfied with a manufacturing installation for supplying the covering layers and for the introduction of the thermoplastic synthetic material for the manufacture of the building element. However, it is also possible to provide, after the supply of the covering layer, several molding tools which can be loaded alternately by a continuous loading installation, which considerably increases the flow rate of such a device. manufacturing.



   Finally, according to an advantageous embodiment of the device of the invention, at least one of the two mold halves is provided with retaining devices, in particular vacuum slots for receiving and retaining a covering layer, which makes it possible to maintain the different covering layers during the molding and deformation operation and before hardening in an exact position, and displacement of these slots under vacuum can be prevented by bringing after compression and positioning of the covering layers and the layer in the mold through these vacuum slots where appropriate air from

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 cooling for rapid solidification of the molded part.



   The invention will be better understood, and other objects, characteristics, details and advantages thereof will appear more clearly during the explanatory description which follows, made with reference to the appended schematic drawings given solely by way of example illustrating embodiments of the invention, and in which: FIG. 1 represents the different layers of a construction element with several layers produced in accordance with the invention in a side view, in section and in an exploded view, simplified and schematic; - Figure 2 shows another constitution of a multi-layer construction element according to the invention in a side view, in section and in an exploded view, simplified and schematic;

     - Figure 3 shows another constitution of layers of a multi-layer building element according to the invention in a side view, in section, the different layers being shown at a certain distance from each other; - Figure 4 shows another possibility of achieving the constitution of a multi-layer construction element according to the invention in a side view, in section, where the different layers are also shown at a certain distance from each other others; - Figure 5 shows a possible construction of a building element with several layers in a schematic side view, in section and simplified;

   

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 - Figure 6 shows another embodiment of a building element according to the invention in a schematic side view, in section and simplified; - Figure 7 shows a tank coated with multi-layer construction elements produced according to the invention in a simplified graphic view; - Figure 8 shows a part of the tank provided with multi-layer construction elements produced in accordance with the invention in a top view, in section, along lines VIII-VIII in Figure 7; - Figure 9 shows two building elements with several layers according to Figure 8 in a schematic top view, in section and on a larger scale;

   - Figure 10 shows the construction elements with several layers in the joint area, in section along the lines X-X in Figure 7; - Figure 11 shows the building element with several layers with the covering layer, the intermediate layer and the layer after making the impressions with a tool shown schematically; - Figure 12 is an alternative embodiment of a boiler liner made from multi-layer construction elements according to the invention in a side view, partially in section; - Figure 13 shows a part of the boiler lining according to Figure 12 in the vicinity of the fixing device in a front view, in section, along the lines XIII-XIII in Figure 12;

   

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 - Figure 14 shows a device for manufacturing a multi-layer construction element according to the invention in a simplified schematic side view; and - Figure 15 shows another embodiment of a device for manufacturing a multi-layer construction element according to the invention in a schematic and simplified side view.



   There is shown in Figure 1 in a schematic and simplified manner the different layers separated from each other, of a building element with several layers 1.



   This multi-layer building element 1 consists of a layer 2 formed by flakes 3 to 5 made of recycled or primary synthetic materials, in particular of synthetic foam. Thus, the flakes 3 to 5 which are shown differently in Figure 1 can be made of different materials.



  The flakes 3 can be formed, for example, from foams of synthetic recycling material in a hard or semi-hard or flexible consistency. The flakes 4 can also be produced from thermosetting resins or from thermoplastic materials or from coating materials, such as for example textile, leather, synthetic material or synthetic leather.

   In addition, it is also possible to use as materials for the flakes 4, for example recovered textiles and / or paper and / or cardboard and / or fabric scraps and / or leather and / or metals and / or carbon fiber, ceramic, glass, graphite, Kevlar, metal or textile yarns or materials or a mixture of your choice from all of the above materials.

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 Finally, the flakes 5 made of different synthetic materials, in particular the synthetic foam flakes can be provided with textile, leather, synthetic material or synthetic leather covering. It is obviously also possible to mix the materials of the flakes 3 to 5 according to ratios of choice to form the layer 2.



   These various flakes 3 to 5 are connected by a synthetic material in a primary material, for example a foam of synthetic material in poylurethane or in polyethylene or the like in a coherent layer, for example in a plate or the like. This layer 2 can also be manufactured in that the flakes 3 to 5 are connected by the synthetic material 6 in a block of foam which can be divided by means of known cutting devices into individual plates, and it is also possible to prefabricate the different flakes 3 to 5 by the adhesive force which is specific to them in a roll product and to bring this then to the next manufacturing step.



   Preferably, the foam of synthetic material forming the synthetic material has a large number of open cells 7 which are separated from each other by arrays of cells 8. In the embodiment shown, the layer 2 is already represented in a position compacted where cells 7 and cell strips 8 have been deformed under the action of pressure and temperature and have been fixed in this deformed position by cooling.

   The specific weight of the layer 2 therefore depends on the weight of free foam and on the weight, respectively, and on the specific weight of the flakes 3 to 5 and of the synthetic material 6, and can be adjusted further by a

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 thermal cracking operation at desired values so as to create, for example following the fusion of the open cells in the vicinity of surfaces 9 and 10 opposite to each other of the layer 2, a construction part waterproof to the liquid but permeable to gas.



   This compaction of the layer 2 can take place before the assembly of the layer 2 with a covering layer 11 or simultaneously with the establishment of the connection with the covering layer 11. This connection between the covering layer 11 and the layer 2 takes place by an intermediate layer 12. This intermediate layer 12 is formed by a support body 13, for example a net, a knitted fabric, a mesh or the like made of fibers 14 and 15, respectively, which is embedded in a synthetic material 16 The synthetic material 16 can be applied to the support body 13 in a powder or paste consistency.



   When, for example, the covering layer 11 is now placed in a mold, the support body 13 provided with the synthetic material 16 is placed thereon and the layer 2 is placed thereon and that the mold is closed, one can obtain for example by exerting a pressure on this composite part on individual mold faces and under the action of the temperature that the synthetic material 16 thermally or chemically bonded becomes liquid and that at the same time the bars of cells 8 and cells 7 of layer 2 are spatially deformed, this deformation being able to be further reinforced by increasing the temperature.

   Because when layer 2 is exposed to a higher temperature, the plastic of layer 2 is also

  <Desc / Clms Page number 28>

 softened and there is therefore an even greater deformation of the cellular structure of layer 2 and a stronger liquefaction of the synthetic material 16 of the intermediate layer 12. When then stopped after sufficient liquefaction of the synthetic material 16 of the intermediate layer 12 the subsequent supply of heat and that the building element 1 is cooled to a temperature allowing sufficient solidification of the synthetic material 6 and of the synthetic material 16 of the intermediate layer 12, can remove the building element 1 in this compacted form and now spatially stable from the manufacturing mold.



   Obviously, it is also possible to introduce the different layers shown in FIG. 1, namely the covering layer 11, the intermediate layer 12 and the layer 2 loosely in a heating device, for example in a heating channel and to introduce them after sufficient heating in a cold mold tool in which then takes place the deformation of the covering layer 11, of the intermediate layer 12 and of the layer 2 according to the spatial form to be obtained and simultaneously the cooling so that the above layers are somehow solidified into the desired spatial form.

   Consequently, during the removal of the part, the cell bars 8 and the cells 7 in the layer 2 remain in their deformed compacted position, and the liquefied synthetic material 16 of the intermediate layer 12 is distributed uniformly between the cover layer 11 and layer 2 or has penetrated into the surface 10 of the

  <Desc / Clms Page number 29>

 layer 2 oriented towards the intermediate layer 12, and a durable and rigid, solid bond is thus obtained between the elastic layer 2 and the covering layer 11.



   Due to this hard intermediate layer 12 reinforced by the support body 13 it is now advantageously possible to use very thin covering layers, for example also sheets with a thickness of less than 0.2 mm up to '' to a thickness of only 0.001 mm, and the construction elements thus produced have a hardness at their covering layer which is substantially higher than in known construction elements where the covering layers 11 are provided directly with a foam. synthetic material.



   The semi-finished product thus prefabricated, namely the covering layer 11, the intermediate layer 12 and the layer 2 which now represent, after heating and compression, a unitary part, can then be placed in a foaming mold in which, by example by the introduction of a liquid synthetic material onto the surface 9 of the layer 2, a molded part 17, for example made of synthetic material foam, therefore of a synthetic material 18 which may be constituted by closed and open cells 19, 20 can be formed.



   During the production of this molded part from a cold PU foam or a synthetic foam otherwise endowed with a hard or semi-hard consistency, it is possible to connect, simultaneously with the assembly of the molded part 17 with layer 2 during a corresponding positioning of a covering layer

  <Desc / Clms Page number 30>

 additional 21 on a mold element, this additional covering layer 21 to the molded part 17.



   Depending on the purpose of use of the construction element to be manufactured 1, this additional covering layer 21 can be formed by cardboard, plates or sheets of synthetic material, metal or textiles, for example jute or knitted fabrics, tablecloths or fabrics made of fibers or yarns of synthetic material or natural materials.



   There is shown in Figure 2 another possible constitution of a building element 1 according to the invention. Here, the multi-layer building element consists of a covering layer 11, a layer 2 and the molded part 17. While the molded part 17, in terms of its constitution, as well as layer 2 and the covering layer 11 can be identical as has already been described with the aid of FIG. 1, the connection between the layer 2 and the covering layer 11 is established by the synthetic material 6. This is possible inter alia by the fact that, for example flakes 22, 23 made of hard or semi-hard polyurethane are mixed with a polyol, this polyol, by a chemical or thermal bond, may be at ambient temperature in a pulverulent state.



  Thus, the mixture consisting of the flakes 22, 23 and of the synthetic material 6 would constitute a dry mixture which, after the introduction of the covering layer 11 into a mold, is applied in a sufficient layer thickness. After application, this synthetic material 6 together with the flakes 22,23 can be activated under the effect of heat or under the effect

  <Desc / Clms Page number 31>

 of steam or other process steps, and it establishes a connection among the flakes 22,23 and at the same time between these flakes 22,23 and the cells 24 lying between them of the synthetic material 6 and the covering layer 11.



   This preferred construction variant therefore makes it possible to use, for example, a foam of synthetic recycling material obtained from damaged construction elements or manufactured before and dismantled to make layer 2, and the flakes 22, 23 between them and their connection. with the covering layer 11 can be carried out using the synthetic material 6, namely the polyol mixed with the flakes 22,23.



   During a corresponding dosage of the polyol, it is also possible that the polyol forms, between the surface 10 of the layer 2 oriented towards the covering layer 11 and the covering layer 11, a hard, impact-resistant support layer which opposes to a deformation of the covering layer 11 in the direction of the layer 2 in the case of stresses by blows or at the edges.



   Obviously in this case too, the molded part 17, after the manufacture of the semi-finished product constituted by the covering layer 11 and the layer 2 can be manufactured by foaming.



  However, it is also possible to glue the molded part 17 on the surface 9 of the layer 2 remote from the covering layer 11, and it is obviously possible to provide on the surface of the molded part 17 remote from the covering layer 11 of the layers. individual or additional overlap 21, as shown by dashed lines.

  <Desc / Clms Page number 32>

 



   There is shown in Figure 3 another alternative embodiment of a building element 1 according to the invention, and again the different layers are shown in the state separated from each other.



   In this exemplary embodiment, the covering layer 11 is connected to the layer 2 which can be produced in accordance with what has been explained in connection with FIGS. 1 or 2, by an intermediate layer 25 consisting of a ply 26 and of a synthetic material 16. The synthetic material 16 can be introduced into the ply 26 in that the ply 26 is impregnated with the synthetic material 16, or else that the synthetic material 16 is applied in the form of paste on the ply 26 or is applied on the surface or in the tablecloth in a solid form.

   Obviously it is also possible that individual yarns 27 of the ply are made of such a synthetic material 16, such as for example polypropylene, polyethylene etc., so that during the subsequent heating and if necessary under the action of the pressure, these threads 27 liquefy and impregnate the sheet with this synthetic material 16 while simultaneously establishing the connection between the layer 2 and the covering layer 11.



   It is also possible to envisage an embodiment where the whole of the ply 26 is constituted by wires 27 of synthetic material 16 so that during heating and under the action of pressure the whole of the ply 26 is liquefies and can be used to connect layer 2 to cover layer 11.



  The advantage of such an embodiment is that it can be used without problem for the

  <Desc / Clms Page number 33>

 manufacture of this sheet also of synthetic recycling materials, therefore of recovery materials which are prepared again by a corresponding preliminary treatment, since it is also possible to use thermoplastic resins mixed from different basic materials to manufacture yarns for the web, and thus certain son of the web of synthetic materials which have higher softening temperatures, form a trellis structure which then reinforces the intermediate layer 25 in the manner of a support body.

   In addition, it is advantageous to introduce into the sheet 26 made up of individual polypropylene wires or fibers in addition for reinforcement, individual wires or fibers of metal and / or Kevlar and / or carbon and / or graphite and / or glass and / or ceramic and / or textiles and / or synthetic material and / or natural materials which during the heating operation are embedded in the liquefied synthetic material 16 and reinforce or make more rigid the intermediate layer 25 after cooling. A hard thermoplastic layer is thus obtained.



   Such an embodiment also makes it possible to obtain very hard and resistant intermediate layers 25 and to obtain an extremely solid bond between the layer 2 and the covering layer 11.



   Can then be applied to layer 2, in accordance with the embodiments described before molded parts 17, if necessary one or more additional covering layers 21 in the manner described before by bonding or foaming or similar process.

  <Desc / Clms Page number 34>

 



   It should also be noted with regard to the molded part 17 that the thickness of the latter can vary perpendicular to the covering layer 11 depending on the different purposes of use of the construction element 1, and that the molded part 17 may obviously also consist of several different components or plates of identical or different synthetic materials of identical or different specific weights.



   There is shown in Figure 4 a building element 1 which is constituted essentially in the same way as the building element 1 shown in Figure 3. We will therefore use for the same parts the same reference numbers.



   In order to obtain an even better adhesion of the intermediate layer 25 to the covering layer 11, an intermediate formation 28 has been placed between the intermediate layer 25 and the covering layer 11, for example a sheet of PE or a covering in a such material or another sheet of synthetic material which can be used as a sticky fusible sheet or additional sticky layer and having good adhesion. This intermediate layer 28 can be used in the present embodiment as an adhesive between the synthetic material 16 of the intermediate layer 15 which constitutes the hard layer and a surface 29 facing the latter of the covering layer 11.

   Depending on the material of the intermediate layer 25, it is also possible to manufacture the intermediate layer 28, for example from polypropylene, polyamide, PVC or

  <Desc / Clms Page number 35>

 other synthetic or sticky materials, etc.



   When an aluminum plate or sheet is used as the material for the covering layer 11, it is also possible to apply this intermediate layer 28, as shown in part of FIG. 4, directly on the surface 29 of the covering layer 11. This prevents, in particular in the case of aluminum sheets or sheets, their oxidation so that a very stable and lasting bond can be established between the intermediate layer 12 and 25, respectively, and the cover layer 11.

   However, it is also possible to use as material for the covering layer 11 or 21 for example paper and / or sheets of synthetic material and / or sheets of paper and / or sheets of synthetic material metallized under vacuum, such as, for example, alumium and / or knitted fabrics and / or fabrics and / or trellises made of the most diverse materials. Such sheets or materials can be obtained commercially already provided with the most diverse coverings, such as for example PE coatings.



   Obviously, such an intermediate layer 28 consisting of a sheet capable of melting can be used for the construction elements in accordance with the exemplary embodiments of FIGS. 1 to 3.



   However, there is shown in Figure 5 a building element 1 whose different layers are linked.



   This building element 1 has a covering layer 11 which is wavy or noped, such a surface configuration of the

  <Desc / Clms Page number 36>

 covering layer 11 being particularly advantageous when this covering layer 11 is constituted by a sheet, for example an aluminum sheet with a thickness less than 0.2 mm, for example 0.009 mm. It is thus possible to avoid the formation of folds during the manufacture of the construction element 1, in particular during the application of the intermediate layer 25 since the sheet 30 produced correspondingly from the covering layer 11 can be sucked by vacuum to a molding wall after which the sheet 26 with the synthetic material 16 can be applied to connect the covering layer 11 to the layer 2.



   As shown schematically in this view, during the liquefaction of the synthetic material 16, during the connection of the layer 2 with the covering layer 11, the liquefied synthetic material 16 is diffused or partially flows into the hollow spaces of the layer 2 and hardens therein upon subsequent cooling.



  A good engagement is thus achieved between the intermediate layer 25 and the layer 2.



   In the same way, a close connection is obtained between the molded part 17 and the layer 2 when the molded part 17, as already described in the embodiment in FIG. 1, is formed directly on a surface 9 of the layer 2 by a foaming operation.



   Correspondingly, there is shown the line of separation between layer 2 and intermediate layer 25 and the molded part 17 only by a line in broken lines, because the different parts merge into one another. This also causes a bond

  <Desc / Clms Page number 37>

 narrow of these pal. ; <so that the stresses produced in the covering layers 11, 21, for example by different temperatures or strongly changing temperatures can be transferred for a long time to the layers behind without delaminations or detachments between these layers.



   In this embodiment as well as in the embodiments described with reference to FIGS. 1 to 4, it is possible to manufacture the molded part 17 by adding recycling materials, for example synthetic recovery materials of the most diverse types, such as, for example, thermosetting resins, thermoplastic resins, prepolymers, monomers and the like, mixed or exclusively made of these materials, by sintering or pressing processes.



   In the case of the building element 1 shown in FIG. 6, it has also been shown that after the various layers have been assembled, as described in connection with FIG. 4, the intermediate layer 28 under the effect of the temperature and pressure dissolves and forms a bonding element or a kind of sticky layer between the covering layer 11 and the intermediate layer 25. The assembly of the other layers, namely of the intermediate layer 25 with the layer 2 and of the layer 2 with the molded part 17 as well as of the molded part 17 with an optional additional covering layer 21 takes place in the manner described in detail already with reference to the previous exemplary embodiments according to FIGS. 1 to 5.

  <Desc / Clms Page number 38>

 



   FIG. 7 shows a possible use of the construction elements 1 for isolating a storage tank 31.



   The storage tank 31 has an approximately cylindrical shape and can be used as a tank, for example for liquid materials such as mineral oils, bitumen or liquefied gases such as liquid oxygen and nitrogen or as a tank sludge putrefaction. A longitudinal axis 32 of the storage tank 31 extends approximately perpendicularly to a ground contact surface 33. The storage tank 31 can be made of sheet steel or concrete or the like. For the thermal insulation of the storage tank 31, the outer side of the latter is coated by the construction elements 1 serving as an insulation body.



   The construction elements 1 are produced in the form of flat plates 34 and are provided in the vicinity of their longitudinal lateral edges 35,36 and in the vicinity of their shorter lateral edges 37,38 of connection and / or reinforcement elements.



   As shown in the detailed views according to FIGS. 8 and 10, the connecting and / or reinforcing elements are constituted in the vicinity of the shorter lateral edges 37, 38 by folds 40 arranged in a specularly symmetrical manner on the surfaces of the plates 39. The connecting and / or reinforcing elements in the vicinity of the longer lateral edges 35, 36 are formed by tongues 41 and grooves 42 which adapt by matching the shapes. A cross section of the tongue 41 has a longer arc length than a cross section of the groove 42. This allows

  <Desc / Clms Page number 39>

 to bring the plates 34 in different angular positions to each other which allows the use of plates of the same type 34 for coating storage tanks 31 of different outside diameters.



   As further shown in Figure 7, the plates 34 arranged one next to the other in the direction of the periphery are placed in the direction of the longitudinal axis 32 being offset respectively by a half-length of plate. There is thus obtained a joint "full joint" and a high inherent rigidity of the coating.



   It can also be seen in FIGS. 7 and 10 that it is arranged, at a distance approximately the same from the two narrower side edges 37, 38 of the plates 43, a connecting and / or reinforcing element for a tensioning device 44. This tensioning device 44 comprises a transverse tensioning element 45 which is introduced by foaming into the plate 34.



  The transverse tensioning element 45 may be provided with openings into which the synthetic material of the plate 34 enters during the foaming operation. The transverse tensioning element 45 can thus be firmly anchored inside the plate 34 and can receive higher tensile forces.



   The ends of the transverse tensioning element 45 are forcibly connected to coupling parts 46,47.



   The coupling parts 46, 47 of two neighboring transverse tensioning elements 45 can be connected together and constitute a coupling device 48. The coupling device 48 can be produced at the same time

  <Desc / Clms Page number 40>

 also as a tensioning element. However, it is also possible to provide in the vicinity of the bars 49 which remain next to the rebate a reinforcing element 50. In this case it is possible respectively to tension the transverse tensioning elements 45 and to connect them in the stretched state to the reinforcing element 50, for example by nails or screws, and by means of these nails or screws it is possible to connect the coupling parts 46 and 47 of two neighboring transverse tensioning elements 45 at the same time.

   A close and solid cohesion is thus obtained between the different plates 34.



   Figure 10 shows the coupling device 48 in section. The coupling parts 46 of neighboring transverse tensioning elements 45 are provided with the sides facing each other with transverse ribs or teeth. The coupling part 47 consists of a sleeve which surrounds the two coupling parts 46. By a deformation of the coupling device 48, the coupling parts 46, 47 are compressed and fixed in their relative position in the tense state.



  Obviously it is also possible to provide the coupling part 47 produced for example in the form of a sleeve on the side facing the coupling parts 46 with transverse ribs, grooves or the like so as to obtain, from the connection to friction, also an arrangement by matching the shapes of the position of the transverse tensioning elements 45 in the coupling device 48. It can also be seen in FIG. 10 that the plates 34, in the vicinity of their lateral edges 37 and 38, respectively, can be done in a way

  <Desc / Clms Page number 41>

 diametrically opposite. Thus, there has been associated with an extension 51 in the vicinity of the lateral edge 38 a rebate 52 of approximately the same thickness which however extends only over a part of a height 53 of the extension 51.

   This rebate 52 is followed by a recess 54, which constitutes a free space for the transverse tensioning elements 45 and the coupling device 48. The height 55 of an extension 56 in the vicinity of the lateral edge 37 is smaller d 'A measure 57 according to which the extension 51 and the rebate 52 overlap only the height 53 of the extension 51. In a side face of the extension 56 there is provided a roughly V-shaped groove 58 with which is associated a strip of support 59 in the vicinity of the lateral edge 37 of the plate 34 and which is produced in a diametrically opposite manner. A lateral face 60 of this support bar 59 is inclined in the direction of the plate surface 39, while a lateral face 61 is inclined towards the plate surface 39 in the direction of the lateral edge 38.

   As a result of the inclination of the side face 60, the plates 34 can be arranged without play on one another since, due to the inclined side face 60, a side face 62 of the rebate 52 is pressed against the side face opposite to this of the extension 51. Water or moisture possibly entering the slot between the opposite side faces 61 of the groove 58 and of the support bar 59, respectively, can flow towards outwards and downwards due to the inclination of the lateral face 61. Thus, the entry of moisture into the insulation is made even more difficult without devices

  <Desc / Clms Page number 42>

 expensive sealants are required.

   Obviously it is possible to have in the vicinity of the lateral face 61 additionally a seal consisting for example of a lip seal which closes any free space between the groove 58 and the support bar 59, or either this free space can be filled with plastic foam, or else one can introduce between the side face 60 of the support strip 59 and the side face opposite to it of the extension 56 an adhesive or a sealing mass.



   By using the support bar 59, it is avoided during the occurrence of a suction, in particular during a stress by the wind of the storage tank 31 that the lateral edges 37, 38 associated with each other detach or move , and thus, in addition to the action of the transverse tensioning elements 45, the risk that individual plates 34 are torn off by the depression or the suction of the assembly is reduced.



   In FIGS. 7 and 8, there have been arranged on the outer side of a cylindrical wall of the storage tank 31 with a vertical longitudinal axis, insulating bodies produced in the form of a plate 34, and this parallel to the generator of this cylindrical wall . Each plate 34 which can be provided at its outer side with a covering layer, for example of aluminum, has in a longitudinal longitudinal face or lateral edge 35 a groove 42 and on the opposite longitudinal narrow face or lateral edge 36 a projecting element link or a tongue 41 (Figure 8), the projecting connecting element, so the tongue

  <Desc / Clms Page number 43>

 and the groove 42 adapting by concordance of the shapes.

   Viewed in plan, the two parts, namely the tongue 41 and the groove 42, have a profile in the shape of an arc of a circle, the arc length of the groove 42 being greater than a semi-arc of a circle and the the arc length of the projecting connecting element being even greater than that of the cross section of the groove 42.



   For mounting such insulation, the projecting connecting element or the tongue 41 of a plate 34 is pushed into the groove 42 of the neighboring plate 34 in the longitudinal direction thereof, and the plates thus assembled 34 are placed around the wall of the storage tank 31, and thus the insulation is already half completed.



   As can also be seen in FIG. 8, each plate 34 has, transversely to the longitudinal direction of the step or the rebate 40, reinforcements protecting the hard foam against deformations, for example a plywood reinforcement element 50, and this only to the upper edge parts.



   To allow a corresponding engagement of the tongue 41 and the groove 42, as shown in FIG. 9, the two branches 63 delimiting the groove 42 project from a height 64 of between 2 mm and 15 mm, of preferably 7 mm on a diametrical line 67 parallel to the line 66 connecting the front faces 65 of the branches through a central point 68 of the semicircular cross section of the groove 42. As can be seen further, the connecting line 66 is inclined relative to an outer face 69 at an angle less than 900. Thus, by assembling elements

  <Desc / Clms Page number 44>

 of neighboring construction 1 or the plates 34, it is possible to surround a convex curved envelope.

   When it is necessary, for example, to coat a concave outer face with construction elements 1 or plates 34, it is also possible to arrange this assembly at an angle relative to the outer face 69 which is greater than 900.



   The construction element 1 or the plates 34 according to the invention can now be produced in accordance with the different construction variants shown in FIGS. 1 to 6.



   Thus, the plate 34 according to Figures 8 and 9 consists of a cover layer 11 of aluminum sheet provided with trapezoid-shaped recesses 70 to obtain greater rigidity at the outer face. This covering layer 11 is connected by an intermediate layer 12 and 25, respectively, according to the embodiments described above, to the layer 2. The molded part 17 is formed on this layer 2, for example by molding.



   To manufacture the plate 34, a semi-worked part is first produced, therefore a prefabricated semi-product, consisting of the covering layer 11, the intermediate layer 12 and 25, respectively, and the layer 2. In the regions where the covering layer 11, such as in the vicinity of the branch 63, or at the point of passage towards the tongue 41, must be spatially deformed, provision has been made in the corner areas 71,72, 73,74 and 75, as shown in FIG. 11, the prefabricated part consisting of the covering layer 11, the intermediate layer 12 and 25, respectively and of the layer 2, of impressions 76 where for example the

  <Desc / Clms Page number 45>

 intermediate layer 12,

  25 and the layer 2 are compressed to a wall thickness 78 smaller than a thickness 77. In these corner areas 72, 73 and 74, an articulation is thus made in the manner of a sheet hinge which makes it possible to proceed to the folding of the covering layer 11 with the intermediate layer li, 25 and the layer 22 in order to be able to insert this semi-finished product in a foaming mold or a mold for manufacturing the molded part 17.



   It is thus possible in a simple way to tilt edge bands 79.80 inwards so that they are inside the molded part 17. This prevents the covering layer 11 from being able to come off in the vicinity of the edge bands 79.80 from the surface of the molded part 17, and these edge bands 79.80 are firmly anchored in the interior of the molded part 17.



   As is also shown diagrammatically in FIG. 9, it is also possible that the plate 34 on its two surfaces 81, 82 opposite each other is equipped with a corresponding covering layer 11, provided with a layer and / or an intermediate layer. If necessary, it is also possible that the covering layers 11 or an additional covering layer 21, as shown in connection with another plate 34, may consist of only a layer of cardboard, aluminum, sheet metal. of steel or the like. Preferably, in the case of such covering layers 21, the edge bands 79.80 are folded so as to protrude into the interior of the molded part 17 so as to avoid delamination thereof.

  <Desc / Clms Page number 46>

 



   The covering layers 11, when they are connected to the intermediate layer 12,25 and / or the layer 2 and when they are arranged on surfaces 81, 82 opposite to each other of a plate 34 can be made of different materials, for example on the outside of sheet steel or aluminum foil and on the inside of a textile fabric or a thin sheet of synthetic material.



   Most often, the covering layers 11 which can be subjected to less stress are placed on the surface 82 oriented towards the storage container 31 of the plates 34 since they are not directly exposed to the weather and other stresses. On the contrary, the covering layers 11 and 21, respectively, arranged on the surfaces 82 can be adapted to the direct surrounding conditions in the vicinity of the storage container 31.

   Thus, it is advantageous to choose the storage tank 31 in which very hot gases or liquids are stored, in covering layers 11 resistant to temperatures, while for liquids or gases which are stored at very low temperatures in the storage tank 31, it is advantageous to use cover layers 11 and 21, respectively, which also have a certain minimum elasticity at low temperatures and which do not become brittle and burst.



   There is shown in Figures 12 and 13 another alternative embodiment of construction elements 83 to 85 according to the invention.



   These construction elements 83 to 85 constitute for example an insulating cap 86 for a hot water boiler which is heated by

  <Desc / Clms Page number 47>

 hot water, electricity or gas. In the present case, the construction elements 83, 84 constitute half-shells of the insulating cap 86 in the form of a hollow cylinder, and the cylindrical casing parts 87 have been formed in a frontal end region, preferably in one piece, front wall portions 88. In the opposite end zone, the assembled half-shell, that is to say the building elements 83,84, the building element 85 which is placed is produced in the form of a cover.

   The fixing of the two construction elements 83, 84 takes place in the vicinity of the front wall parts 88 by a ring of an L-shaped cross section and in the upper end region of the insulation cap 86, the element 85 which constitutes the cover 89 is held by a retaining ring 90 extending all around in the position shown.



   In order to obtain sufficient fixing of the construction elements 83 to 85 therebetween, there is disposed between the construction elements 83 and 84 a coupling device 91 which has a closure with interlocking strip. To this end, an interlocking strip 92 can be pivoted by an eccentric lever 93 in the direction of the circumference of the insulation cap 86 and it can be engaged in a stop element 94 to tension the two elements of construction 83, 84 in a position corresponding to the desired tension force. As coupling device 91, it is also possible to use, for example, an arrangement with a hooking strip.



   To obtain a flat outer surface of the insulation cap 86, the device

  <Desc / Clms Page number 48>

 coupling 91, as best seen in FIG. 13, can be embedded in a recess 95 in a surface of the construction elements 83, 84.



   As further emerges from Figure 12, the building elements 83 to 85 can be provided again at their outer face with a coating protecting the molded part 17 of synthetic foam, in particular of insulating foam, this coating being constituted a covering layer 11, a layer 2 and if necessary an intermediate layer 12 or 25 disposed between them. The covering layer 11 as well as the layer 2 and, where appropriate, the intermediate layers 12 and 25 can extend in one piece over the envelope parts 87 and the front wall parts 88.

   The building element 85, therefore the cover 89 can also be provided with a protective layer of the same type, consisting of the covering layer 11, the layer 2 and, where appropriate, an intermediate layer 12 or 25 for protection against damage from the outside, especially during transport, storage and assembly.



   Obviously, it is also possible to have, on the internal face facing the boiler, of the construction elements 83 to 85, a covering layer 21 or a similar protective layer formed by a covering layer 11, a layer 2 and, where appropriate, a '' an intermediate layer 12 or 25.



   Layer 2 in the different embodiments described before can comprise between 70% and 95%, preferably 85% of flakes 3 to 5 made of synthetic foam.

  <Desc / Clms Page number 49>

 Others 10% to 20% of the weight of layer 2 can be constituted by a foam of synthetic material 10, for example by a polyurethane and / or a thermosetting resin. Both synthetic foam and thermosetting resin can be made of recycling materials made from recovered synthetic materials as well as primary materials.



   Preferably, for the manufacture of the flakes 3 to 5 for the layer 2, foams of synthetic recycling material whose specific weight or the weight of free foam is between 30 kg / m 3 and 150 kg / m 3.



   The specific weight of the molded part 17 produced in particular from a cold molded foam can be between 30 kg / m3 and 80 kg / m3. By the arrangement of the intermediate layer 12.25 or the solidification of the layer 2 in the surface area oriented towards the covering layer 11, the specific weight can be lowered to 40 kg / m3 or less. In the construction elements known up to now it would be necessary, in order to obtain sufficient stability of the covering layer 11, to produce the molded part 17 with a higher specific weight.



   By using a thermoplastic synthetic material 6 and 16, in particular in the intermediate layer 12 or 25 which can be made of polyethylene, polyamide, polypropylene, polystyrol, polyvinyl chloride, synthetic resins such as ABS or the like, in particular when this intermediate layer 12, 25 is reinforced by a support body 13 made of fibers or threads, a hard shell is created for the building element which, when in use

  <Desc / Clms Page number 50>

 subsequent, especially when the temperatures change significantly or when there are large temperature differences in the vicinity of the covering layers 11 and 21 opposite one another, great stability is obtained under load and in particular low distortion.

   The fibers 14,15 or threads from which the support body 13 can be made can be made of glass and / or metal and / or Kevlar or graphite or textile. These fibers 14,15 or threads can be worked in a net or a knit or a mat, a grid or a tablecloth.



   In particular during the production of sheets of fibers 14, 15 and of threads which are made from recovered thermoplastic materials, such a support body will be treated simply because in the support body 13, the thermoplastic material is already there. in the form of threads or fibers and that the thermoplastic material provided in the sheet can be activated simply by pressurization and temperature. Preferably, the threads or fibers 14, 15 are made of polypropylene. The synthetic material 16 can also be introduced in the form of a pulverulent thermoplastic material into the sheet, in particular on the polypropylene fibers, in particular by a polypropylene powder.



   The thermoplastic synthetic material can also be applied in the form of granules or a sheet, therefore in a solid consistency, on the support body 13 or the flakes of the layer 2. Likewise, a paste-shaped application is possible.

  <Desc / Clms Page number 51>

 



   To allow dry mixing of the different parts of layer 2 or of intermediate layer 12, 25, the thermoplastic synthetic material 16 can be blocked chemically and / or thermally so as to achieve a semi-liquid or liquid consistency only at temperatures higher than 100 C. Advantageously, the thermoplastic synthetic material 16 is at least semi-liquid under pressure and at a temperature between 200C and 180 C, and liquid between 1500C and 200 C, or has only a very low adhesion between 5 N / 5 cm and 30 N / 5 cm.



   Likewise, the covering layers 11, 21 can be made of a wide variety of natural or synthetic materials, for example by knitting, fabric, tablecloth or a sheet. Preferably, for the covering layers 11, 21, plates are formed, for example of a thickness greater than 0.2 mm, of metallic materials, for example of sheet steel or aluminum or of synthetic materials or of cardboard.



   Due to the reinforcement or the greater rigidity of the covering layer 11 and 21, respectively, by the layer 2 or the intermediate layer 12.25 disposed behind it, it is advantageous to use sheets of very small thicknesses between 0.001 mm and 0.2 mm. These sheets can be made of synthetic material, preferably also of metallic materials, for example aluminum.



   In some application cases, the use of cardboard or textiles can be advantageous.

  <Desc / Clms Page number 52>

 



   As is shown diagrammatically in addition in FIGS. 12 and 13, it is possible to arrange, for example to fix the coupling device 91 between the support body 13 of the intermediate layer 12 and the covering layer 11, a reinforcing element 96 which can be made of synthetic material, wood or metal. It is obviously also possible to provide this reinforcing element 96 between the intermediate layer 12 and the layer 2.



   Preferably, this reinforcing element 96 will however be embedded in the synthetic material 6 or 16 of the intermediate layer 12.



   Likewise, such reinforcing elements 96, as shown in addition in FIG. 13 by dashed lines, can be arranged between the layer 2 and the molded part 17. When the molded part 17 consists of several layers or plates, it is also possible to arrange this reinforcing element 96 therebetween. Such reinforcing elements can be used to mount certain devices, such as for example the coupling device 91, in a manner resistant to being torn away from the construction element 1. As shown in FIG. 9, it is possible by example provide such reinforcing elements 96 also to fix the building element 1 for example to a facade of a building or the like.



   FIG. 14 shows a device 97 for manufacturing a construction element 1 in a simplified schematic view.



   The construction element 1 is in this case manufactured in what is produced in a foaming mold 98 or plates 99 individually

  <Desc / Clms Page number 53>

 for the diaper or, as also shown diagrammatically, a foam block 100 which is divided by means of a cutting device 101 into individual plates 99.

   This foaming mold 98 is constituted for example by a receiving tank 102 and a tank of raw material 103 containing the flakes 3 to 5 in different types of foam, namely hard, medium-hard and flexible-this is here so-called recycling foams or recovery materials which can also be provided with corresponding sheet parts or coatings and a primary material which can also be obtained by a recycling process - which are brought into a liquid consistency for the manufacture of the cell structure with a mixing device 104 by corresponding backing elements 105.



   In this mixing device 104, the flakes 3 to 5 are mixed with a liquid raw material 106 for the cells 19, 20 and are then introduced into a hollow mold space 107. Following the supply of a reactant, for example by a pump 108, if necessary a vapor, in particular a dry vapor between 1200C and 160oC, by a heat exchanger 109, the liquid raw material 106 reacts and is inflated for example by gases which are released so as to form a cellular structure, in particular cells 19, 20, in closed or open cells or partially closed or open cells.



   After a drying phase which follows the reaction phase and in which only dry air is blown, for example, the foam block 100 can be removed from the foaming mold 98. It could also be used instead of

  <Desc / Clms Page number 54>

 different plates 99 a roll product or an endless material of the corresponding shape or composition.



   The manufacturing of the construction element 1, for example on a clocked chain shown takes place now so that one unwinds in a first work station 110, for example from a roller 111, the support body 13 and that 'It is placed on a rotating belt conveyor 112, for example with a Teflon band or a band coated with an anti-friction agent. Preferably, a layer of thermoplastic synthetic material 16 in the form of a paste and / or in the form of a powder has been placed on the support body 13. It is also possible to apply directly to a heating device 113 the thermoplastic synthetic material 16 in liquid or pasty form by means of an application device 114.

   When passing through the heating device 113, the thermoplastic synthetic material 16 can be softened until it has reached its full adhesion property and can be displaced at least elastoplastically, that is to say it has a consistency plastic or liquid or pasty.



   A start of the support body 13 is gripped by a claw 115 of a handling device 116 and is pulled by a conveyor belt 117 to a subsequent conveyor device 118. To this end, the support body 13 can be gripped by a additional claw 115. When the plate 99 has the desired length 119, the support body 13 is separated by means of a cutting device 120 and it is placed with the two claws 115 directly on the conveyor belt 117 of the conveyor device 118 .

  <Desc / Clms Page number 55>

 



   Then, with another handling device 116 which is not shown in detail, using a plate 115, a plate 99 is placed on the support element and then, as described before, placed on the side upper of this plate 99 again a support body 13.



   Then, the conveyor device 118 can be transported for example along a guide path 121 from a laying station 122 to a heating station 123. In this heating station, layer 2 can now be heated or the synthetic material 6 or the synthetic material 16 of the intermediate layer 12 at a temperature sufficient to soften or liquefy the synthetic material 16.



   Then, the heated element previously made up of the covering layer 11, of the layer 2 and if necessary of the intermediate layer 12 or 25 is placed in the molding press 124 installed in succession.



   By closing or placing an upper part of the mold 125 on a lower part of the mold 126 by means of pressure controls 127, the construction element consisting of the covering layer 11, the layer 2 and, where appropriate, the layer intermediate 12.25 can be transformed to obtain the spatial form represented schematically by solid lines, the construction element 1 being held between the upper part of the mold 125 and the lower part of the mold 126 until the material thermoplastic 6 or 16 of layer 2 or of intermediate layer 12.25 in which the support body 13 is embedded

   is solidified or cooled enough for the

  <Desc / Clms Page number 56>

 molding rigidity is sufficient to maintain tablets or to fix layer 2 and the flakes 3 to 5 contained therein with cells 19, 20 and the arrays of cells deformed thereof into the desired spatial form.

   Since the different layers are heated in the heating station 123, the upper part of the mold 125 and the lower part of the mold 126 can be continuously cooled so that the cooling of the covering layer 11 as well as the layer 2 and, where appropriate, the intermediate layer 12.25 can take place quickly to obtain cooling which is sufficient to reduce the return forces inherent in the various parts, in particular of the layer 2 sufficiently so that the spatial form to be obtained can be maintained also after complete cooling of the building element 1.



   As a result of this molding press 124, a cutting station 128 can be arranged in which, for example, as shown in FIG. 14 by dashed lines, the hollows for forming the film hinges can be produced. corner areas. This cutting station 128 can be made so that the prefabricated part consisting of the covering layer 11, of the layer 2 and if necessary of the intermediate layer 12 and / or 25 is cut at its periphery to obtain the desired final shape. and, if necessary, by an additional thermal deformation operation the desired modified form.



   At the same time, this cutting station 128 can also be made as a foaming mold so as to finish, after cutting.

  <Desc / Clms Page number 57>

 of the part, the construction element by foaming the molded part 17 and if necessary by the simultaneous application of the additional covering layer 21.



   Obviously in the case of the device described 97 and the method described in connection with the device 97, this is one of the possible embodiments and arrangements, and the device 97 as well as the method can be modified by the skilled in the art, on the basis of knowledge resulting from the prior art, as long as they allow the desired characteristics of the construction element 1 to be achieved during manufacture.



   It is simply mentioned for the sake of order that different parts of the device 97 or of the building element 1 and of the layers thereof have been greatly exaggerated or are not shown to scale to facilitate understanding of the invention. The same applies to the thickness, width and length ratios chosen for the different layers, in particular of the support body 13 and the layers of thermoplastic material as well as of the molded part 17.



   In this embodiment of the construction element 1 it is advantageous that, due to the air absorption capacity of the layer 2 during the direct foaming of the molded part 17, the occurrence of bubbles or air bubbles, in particular between layer 2 and molded part 17 is prevented.



   Due to the liquefaction in particular of the thermoplastic material 6 or 16, the area directly following the surface of the covering layer 11 or 21 oriented towards layer 2 is completely filled so as to also prevent

  <Desc / Clms Page number 58>

 in this area the formation of bubbles or air bubbles.



   By the arrangement of the thermoplastic material on the surface of the covering layer 11 oriented towards the layer 2, when the finished construction elements 1 are damaged, for example during storage, transport or assembly, a simple recovery is possible because during heating of the covering layer 11, in particular when it is made of aluminum or another metallic material, by the expansion of air in the free space provided behind during heating, the thrust of the covering layer 11 in the initial shape is encouraged, and the latter is softened as a result of the liquefaction of the thermoplastic material, in particular when polypropylene is used, and after having brought the covering layer 11 into the configuration initially desired, this one,

   after the thermoplastic material has cooled and the rigidity thus produced therein is maintained in this restored position and is solidified.



   FIG. 15 shows another embodiment of a device 129 for manufacturing a construction element 1 in a simplified schematic view, using the same reference numbers for the same parts as in FIG. 14.



   The device 129, in this embodiment, consists of a feed station 130, a loading station 131, a finishing station 133 followed by the molding press 124 and the cutting station 128 These individual stations described before

  <Desc / Clms Page number 59>

 device 129 are preferably arranged one behind the other and are actuated in cadence intermittently or alternately.



   In the feed station 130, the various layers are retained, for example in the form of roll products, such as the intermediate layer 25 on the roll 111, the covering layer 11 on a roll 134 and possibly on another roll 135 the intermediate formation. 28 consisting for example of a PE sheet and inserted as an additional adhesive layer between the covering layer 11 and the intermediate layer 25.



   As already described, it is also possible to apply to the covering layer 11 which can be produced for example from a thin aluminum sheet, on one side a polyethylene coating as an additional sticky layer. It is also possible to apply to the side of the covering layer 11 opposite the intermediate layer 25 a printing or patterned layer to give the construction element 1 a corresponding appearance.



   Thus, the different bands of the intermediate layer 25, of the covering layer 11 and, if desired, of the intermediate layer 25 are transmitted from the supply station 130 by means of the claw 115 to the loading station 131 and there are placed on the conveyor belt 117 of the conveyor device 118. This conveyor device 118 extends in this embodiment of the loading station 131 to the finishing station 133 and is preferably made of a Teflon band unending. This Teflon strip will preferably be black for

  <Desc / Clms Page number 60>

 maintain its static charge in a minimum area.



   In the loading station 131, on the conveyor belt 117, the covering layer 11 coming from the feeding station 130, possibly the intermediate formation 28 as well as the intermediate layer 25 rest freely on each other. We now apply to these layers described before the flakes 3 to 5 in bulk by means of a metering device 136, the latter being stored for example in a storage container 137. The different flakes 3 to 5 can be made of the materials described before and be mixed as desired.



   To distribute the various flakes 3 to 5 regularly over the conveyor belt 117 and the layers placed on it, there is advantageously, following the metering device 136, a dressing device 138 to obtain a uniform height 139 of a layer 140 loose flakes. To control the metering device 136, all the elements or control devices known in the prior art can be used.



   Following the loading station 131, the processing station 132 has been arranged in which the layer of flakes 140 and the layers arranged below, such as the covering layer 11, the intermediate layer 25 and, where appropriate, the intermediate formation 28 are put under pressure by means of a pressure device 141.



   During the application of the pressure, the conveyor belt 117 of the conveyor device 118 is stopped in order to obtain in this treatment station 132 the assembly as well as the

  <Desc / Clms Page number 61>

 compaction of the flake layer 140 with the layer 2. We have associated with the pressure device 141 in addition to the upper and lower heating devices 142,143 in order to be able to heat the different layers or flakes 3 to 5. It is important that we can choose differently the temperatures of the upper and lower heating devices 142, 143 according to the material used for the covering layer 11, the intermediate layer 25 and the intermediate formation 28 as well as the flakes 3 to 5 in order to be able to obtain an optimal process sequence.

   The temperatures of the lower heater 143 may be between 900C and 1600C and will preferably be 120 C, and the temperatures of the upper heater 142 will be between 900C and 2200C and will preferably be between 1200C and 180 C. The rate in the treatment station 132, depending on the materials used, can be between 20 seconds and 3 minutes.



   It is also important, in the case where a mat of bulk polypropylene yarn with the reinforcing yarns introduced into it is used as the material for the intermediate layer 25, to exercise already before heating, by means of the device pressure 141, a corresponding surface pressure to stretch or maintain this intermediate layer 25 between layer 2, or the flakes 3 to 5 thereof and the covering layer 11 and, if provided, the intermediate formation 28 in their position. This applied pressure will be preselected according to the materials used. This avoids during the subsequent heating a withdrawal of natural voltages

  <Desc / Clms Page number 62>

 inherent in the material, thereby obtaining a continuous hard layer of thermoplastic material over the entire face of the covering layer 11.



   This inherent stress disappears during the transition to the plastic state of the material, and thus in this state there can no longer be any shrinkage. This heating in the treatment station 132 now leads, on the one hand, to compaction of the flake layer 140 towards layer 2 and, due to the intermediate layer 25 and the intermediate formation 28, a close connection with the covering layer 11. In doing so, the cell structure of the various flakes 3 to 5 is compacted correspondingly.



   Following the heating and compacting operation in the processing station 132, the strip material thus produced is cooled correspondingly to achieve solidification of the different layers of synthetic materials.



   This cooling, depending on the materials used, takes place at a temperature between 400C to 70 C. During this cooling, the intermediate layer 25 with the fibers or threads placed therein which can also be formed by the support body 13, constitutes a hard thermoplastic layer by obtaining by the intermediate formation 28 which can also be designated by additional sticky layer, a close adhesion to the covering layer 11.



   When the cooling operation is finished, the conveyor belt 117 of the conveyor device 118 transports the semi-finished product described before into the finishing station 133 in

  <Desc / Clms Page number 63>

 which it is cut to the desired length by means of a separation device 144.



   By means of the handling device 116, the prefabricated building element 1 can be transmitted to the molding press 124 arranged after it, whereby by closing or placing the upper part of the mold 125 on the part lower part of the mold 126 by means of the pressure controls 127 and additional heating, the building element 1 can be molded to obtain the spatial shape represented schematically by solid lines.

   The building element is held between the upper part of the mold 125 and the lower part of the mold 126 until, following the molding operation, the thermoplastic material 6 or 16 of the layer 2 or of the intermediate layer 12.25 in which the support body 13 can be embedded, for example, is solidified or cooled so that the shape resistance is sufficient to maintain or fix the various layers or flakes 3 to 5 in the desired spatial form. When the building element 1 is now cooled correspondingly and has a stable shape, it can be transmitted to the cutting station 128 comprising handling devices which are not shown in more detail in which the final cutting takes place or the cutting operation and therefore the final configuration.



   At the end of this configuration it is possible to form by molding or by foaming the molded part 17 in a separate molding operation with layer 2 to complete the building element to be obtained.

  <Desc / Clms Page number 64>

 



   It is also mentioned that it is obviously possible to perform additional processing or bending operations in the finishing station 133 to ensure corresponding processing of the construction element 1.



   Likewise, each of the exemplary embodiments may constitute its own inventive solution, and likewise certain combinations of the claims chosen may constitute its own inventive solutions, as well as of the individual characteristics of the exemplary embodiments, where appropriate in a combination of various different ones. examples of realization.



   In particular the different embodiments shown in Figures 1; 2; 3; 4; 5; 6; 7 to 11; 12.13; 14; 15 may constitute the subject of own inventive solutions. The related inventive objects and solutions emerge from the detailed descriptions of these figures.


    

Claims (51)

 CLAIMS 1. Multi-layer construction element consisting of a layer of synthetic foam flakes bonded by a synthetic material of primary material and a covering layer arranged on a surface of the layer and connected to it by force and by concordance of the shapes, with a framework or cellular structure of the flakes of synthetic foam in the layer, characterized in that the covering layer (11) is embedded in a synthetic material (6) of the layer (2) constituted nozammen:  by a thermoplastic material ec / or a synthetic material (16; an intermediate layer (12, 25 ′ disposed between the latter and the covering layer (11) and / or bonded by synthetic means (6,16) to the less on the layer (2) and connected by force and / or by concordance of the shapes therewith, the frame or the cellular structure being deformed by zones under the effect of pressure and heating.  2. Multi-layer building element according to claim 1, characterized in that it is fixed on a surface (9) of the layer (2) remote from the covering layer (11) a molded part (17), in particular made of synthetic material (18).  3. Multi-layer building element according to one of claims 1 or 2, characterized in that the molded part (17) of synthetic material (18) is attached to the surface (9) of the layer (2) remote from the covering layer (11) in particular by a foaming operation.  <Desc / Clms Page number 66>    4. Construction element with several layers according to one of claims 1 to 3, characterized in that the layer (2) consists of flakes (3 to 5; 22,23) made of foam of primary synthetic material or recycling , in particular in hard or semi-hard foams and / or in flexible foams.  5. Multi-layer building element according to one of claims 1 to 4, characterized in that the flakes (3 to 5; 22,23) made of primary synthetic or recycling foam are provided with covers or linings especially in textile, leather, synthetic material or synthetic leather.  6. Construction element with several layers according to one of claims 1 to 5, characterized in that the flakes (3 to 5; 22,23) are constituted by recovered textiles and / or paper and / or cardboard and / or fabric and / or leather and / or textile and / or metal scraps.  7. multi-layer building element according to one of claims 1 to 6, characterized in that the layer (2) comprises between 70% and 95%, preferably 85% flakes (3 to 5; 22,23) synthetic foam.  8. multi-layer construction element according to one of claims 1 to 7, characterized in that 10 to 20% of the weight of the layer (2) consists of a foam of synthetic material and / or a thermoplastic material primers, for example polyurethane.  9. multi-layer building element according to one of claims 1 to 8, characterized in that the specific weight or the weight of free foam of the foam material  <Desc / Clms Page number 67>  synthetic recycling added to the layer (2) is between 30 and 150 kg / m3.  10. multi-layer building element according to one of claims 1 to 9, characterized in that it is disposed between the layer (2) and the covering layer (11) an intermediate layer (12,25) of material thermoplastic synthetic (16).    11. multi-layer building element according to one of claims 1 to 10, characterized in that it is disposed between the covering layer (11) and the intermediate layer (12,25) an intermediate layer (28).  12. Multi-layer building element according to one of claims 1 to 11, characterized in that the intermediate layer (28) is produced in the form of a sticky and / or adhesive layer which is preferably produced in polyethylene and / or in PVC or other synthetic or sticky materials with good adhesiveness.  13. multi-layer building element according to one of claims 1 to 12, characterized in that the thermoplastic synthetic material (16) consists of polyethylene, polyamide, polypropylene, polystyrol, polyvinyl chloride, polyamide, synthetic resins such as ABS or the like.  14. multi-layer building element according to one of claims 1 to 13, characterized in that a support body (13) of fibers or son is embedded in the intermediate layer (12) of thermoplastic synthetic material.  <Desc / Clms Page number 68>    15. Construction element with several layers according to one of claims 1 to 14, characterized in that the support body (13) consists of a net and / or knitted fabric and / or ply of different fibers or son of glass and / or metal and / or Kevlar and / or graphite and / or textile.  16. Multi-layer building element according to one of claims 1 to 15, characterized in that the fibers (14,15) or wires of the support body (13) consist of glass and / or metal and / or Kevlar and / or graphite and / or textile.  17. Multi-layer building element according to one of claims 1 to 16, characterized in that the support body (13) and / or the flakes (3 to 5; 22,23) of the foam of synthetic material are covered or filled with a granule, for example a powder or a sheet of the thermoplastic synthetic material (16) of a solid consistency.  18. Multi-layer building element according to one of claims 1 to 17, characterized in that the support body (13) and / or the flakes (3 to 5; 22,23) of the foam of synthetic material are covered with a paste of thermoplastic synthetic material (16) which is only weakly adhesive at room temperature.  19. Construction element with several layers according to one of claims 1 to 18, characterized in that the thermoplastic synthetic material (16), under pressure and at a temperature between 1200C and 1800C is at least semi-liquid.  20. multi-layer construction element according to one of claims 1 to 19,  <Desc / Clms Page number 69>  characterized in that the thermoplastic synthetic material (16), at a temperature between 150 C and 2000 C is liquid and / or that the adhesion is very weak, for example between 5 and 30 N / 5 cm.  21. Multi-layer building element according to one of claims 1 to 20, characterized in that the covering layer (11) consists of a knitted fabric, a fabric, a tablecloth or a sheet of natural materials and / or synthetic and is attached by the synthetic material (16) consisting of the thermoplastic material or a layer (2) formed by the latter to the support body (13) and / or to the layer (2) or adheres to them.  22. multi-layer building element according to one of claims 1 to 21, characterized in that it is disposed in the layer (2) preferably consisting of several plates between the latter and a surface remote from the latter of the molded part (17) or of the layer (2) a reinforcing element (96).  23. multi-layer building element according to one of claims 1 to 22, characterized in that it is disposed between the support body (13) and the layer (2) and a covering layer (11,21) a reinforcing element (96) or that the latter is preferably embedded in the layer (2) of synthetic material, for example in the thermoplastic material thereof.  24. Multi-layer building element according to one of claims 1 to 23, characterized in that the covering layer (11,21) consists of a plate or a sheet of natural or synthetic material.  <Desc / Clms Page number 70>    25. Multi-layer building element according to one of claims 1 to 24, characterized in that the plate or the sheet is made of a metallic material, for example steel sheet or aluminum or cardboard.  26. Multi-layer building element according to one of claims 1 to 25, characterized in that the covering layer (11) consists of a sheet of paper and / or synthetic material and / or synthetic material with vacuum metallization and / or textiles.  27. multi-layer building element according to one of claims 1 to 26, characterized in that the thickness of the sheet of the plate is greater than 0.2 mm.  28. Multi-layer building element according to one of claims 1 to 27, characterized in that the thickness of the sheet is between 0.001 and 0.2 mm and that it is preferably made of aluminum.  29. Multi-layer building element according to one of claims 1 to 28, characterized in that the covering layer (11,21) is provided on the side facing the layer (2) with a covering, in particular of PVC and / or polyethylene and / or polyamide.  30. Multi-layer building element according to one of claims 1 to 29, characterized in that it is arranged on the molded part (17) on the surface opposite the layer (2) thereof a layer of additional covering (21).  31. Multi-layer building element according to one of claims 1 to 30, characterized in that the covering layer  <Desc / Clms Page number 71>  additional (21) is reported during the manufacture of the molded part thereon.  32. Multi-layer building element according to one of claims 1 to 31, characterized in that the layer (2) is liquid tight but permeable to gas on the surface (9) remote from the covering layer (11) .  33. Multi-layer building element according to one of claims 1 to 32, characterized in that the synthetic material (6) is a polyol which is mixed with flakes (3 to 5; 22,23) in a foam of hard or semi-hard polyurethane, and in that the flakes (3 to 5; 22, 23) are embedded in the synthetic material (6) after mechanical compaction relative to the weight of free foam.  34. Multi-layer building element according to one of claims 1 to 33, characterized in that it is arranged between the support body (13) of fibers or threads and the covering layer (11) an intermediate formation ( 28), in particular a PE sheet, consisting of an adhesive hot-melt sheet.  35. Multi-layer building element according to one of claims 1 to 34, characterized in that the fiber or son body (13) consists of a polypropylene ply (26) and is covered if necessary with a powder-shaped thermoplastic, for example a polypropylene powder.  36. Multi-layer building element according to one of claims 1 to 35, characterized in that the flakes (3 to 5; 22,23) made of recycled plastic foam are embedded in a catalytically blocked PU and / or thermally.  <Desc / Clms Page number 72>    37. Method for manufacturing a multi-layer building element, in which flakes of synthetic foam are mixed with a liquid primary material of synthetic foam and are formed into a plate or block which is caused to react under the effect of pressure and / or temperature and / or humidity, and thus the flakes of synthetic material foam are bonded to each other by the synthetic material foam of primary material, as a result of which a covering layer is applied to at least one surface of such a plate or of a block, and under the effect of the pressure and / or of the temperature if necessary under spatial deformation, the layer covering is connected to the plate or block to form a building element with several layers,  characterized in that, before the covering layer is laid on the layer, for example the plate or the block, a granule is applied to the latter and / or a support body made of fibers or yarns of an intermediate layer and / or a sheet and / or a paste of a thermoplastic synthetic material, then the covering layer with the layer and / or the intermediate layer and the thermoplastic synthetic material, respectively, is heated at least until it becomes semi- liquid as a result of which the covering layer is pressed onto the layer forming a core of a multi-layer building element and, by pushing back the thermoplastic synthetic material, this is pressed into the surface areas of the layer, then the cover layer and the layer and / or the intermediate layer are directly cooled, and  after sufficient hardening  <Desc / Clms Page number 73>  and / or after the temperature down from the solidification point or the pour point of the thermoplastic synthetic material has been lowered, the building element is removed from the mold.  38. Method according to claim 37, characterized in that the covering layer and / or the intermediate layer and / or the layer, simultaneously with the insertion of the thermoplastic synthetic material in the surface areas of the layer, are spatially deformed .  39. Method according to one of claims 37 or 38, characterized in that the layer is heated before or during the spatial deformation of the cover layers.  40. Method according to one of claims 37 to 39, characterized in that a pressure previously adjusted is exerted on the layer and / or the intermediate layer and / or the intermediate formation and / or the covering layer before heating .  41. Method according to one of claims 37 to 40, characterized in that following the pressure load, the intermediate layer is clamped between the layer and the covering layer and the intermediate formation, respectively.  42. Method according to one of claims 37 to 41, characterized in that the flakes of the layer are arranged in bulk on the intermediate layer.  43. Method according to one of claims 37 to 42, characterized in that the layer is brought in the form of individual plates and / or products in rolls to the laying station.  <Desc / Clms Page number 74>    44. Method according to one of claims 37 to 43, characterized in that the device for manufacturing the construction elements operates intermittently.  45. Method according to one of claims 37 to 44, characterized in that simultaneously with the spatial deformation of the covering layer, the cellular structure or the cells of the layer are cracked thermally and are fixed in the deformed position.  46. Method according to one of claims 37 to 45, characterized in that the thermoplastic synthetic material is heated to a temperature between 120C and 170 * C.  47. Method according to one of claims 37 to 46, characterized in that the multi-layer building element is heated at least in the surface areas to a temperature between 150 C and 2000C after which the layer cover is removed from the core.  48. Method according to one of claims 37 to 47, characterized in that the thermoplastic synthetic material in the covering layer is heated to a temperature above 2000C and is removed in the liquid state from the support body of fibers or threads , especially by aspiration.  49. Method according to one of claims 37 to 48, characterized in that before the application of the covering layer on the layer, the support body is put in place, and the support body, via thermoplastic synthetic material impregnating it is firmly connected to the covering layer or the layer, or else they are formed one to the other.  <Desc / Clms Page number 75>    50. Device for manufacturing a construction element with several layers, consisting of a layer of flakes connected by a foam of synthetic material of primary material and at least one covering layer disposed on one of the two opposite surfaces of the layer, connected thereto by ridge and / or by matching of shapes, with a support body of fibers or threads, with a conveyor device for the support body coated or impregnated with the thermoplastic synthetic material which granulates at room temperature , and which is in the form of a slightly adherent sheet or paste, characterized in that the transport device consists of two transport bands extending parallel to one another at an adjustable distance, one at a time. above the other, especially in Teflon,  and in that it is arranged after this transport device a heating device and a mold, and in that it is disposed between the transport device and the molding device a device for handling the support body impregnated with the layer of thermoplastic synthetic material and / or the covering layer and / or the layer consisting of foam of synthetic material.  51. Device for manufacturing a multi-layer building element according to claim 50, characterized in that at least one of the two mold halves is provided with retaining devices, in particular vacuum slots for receiving and retaining a cover layer.