Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
  • B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
  • B29C44/0461—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities by having different chemical compositions in different places, e.g. having different concentrations of foaming agent, feeding one composition after the other
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/34—Auxiliary operations
  • B29C44/36—Feeding the material to be shaped
  • B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
  • B29C44/44—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length in solid form
  • B29C44/445—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length in solid form in the form of expandable granules, particles or beads
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/34—Auxiliary operations
  • B29C44/36—Feeding the material to be shaped
  • B29C44/46—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length
  • B29C44/54—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length in the form of expandable particles or beads
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/34—Auxiliary operations
  • B29C44/56—After-treatment of articles, e.g. for altering the shape
  • B29C44/5627—After-treatment of articles, e.g. for altering the shape by mechanical deformation, e.g. crushing, embossing, stretching
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
  • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
  • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
  • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
  • B32B3/263—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer having non-uniform thickness
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
  • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
  • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
  • B32B5/32—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed at least two layers being foamed and next to each other
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
  • B32B7/02—Physical, chemical or physicochemical properties
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
  • E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
  • E04C2/205—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
  • B29C37/0078—Measures or configurations for obtaining anchoring effects in the contact areas between layers
  • B29C37/0082—Mechanical anchoring
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/34—Auxiliary operations
  • B29C44/3415—Heating or cooling
  • B29C44/3426—Heating by introducing steam in the mould
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
  • B29K2025/04—Polymers of styrene
  • B29K2025/06—PS, i.e. polystyrene
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
  • B29K2995/0037—Other properties
  • B29K2995/0063—Density
  • B29K2995/0064—Non-uniform density
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2007/00—Flat articles, e.g. films or sheets
  • B29L2007/002—Panels; Plates; Sheets
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/776—Walls, e.g. building panels
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2250/00—Layers arrangement
  • B32B2250/03—3 layers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2250/00—Layers arrangement
  • B32B2250/22—All layers being foamed
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2250/00—Layers arrangement
  • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2266/00—Composition of foam
  • B32B2266/02—Organic
  • B32B2266/0214—Materials belonging to B32B27/00
  • B32B2266/0221—Vinyl resin
  • B32B2266/0228—Aromatic vinyl resin, e.g. styrenic (co)polymers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/72—Density
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2419/00—Buildings or parts thereof
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2607/00—Walls, panels
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2002/001—Mechanical features of panels
  • E04C2002/004—Panels with profiled edges, e.g. stepped, serrated

Definitions

• the present invention relates generally to moulded products made of expanded polystyrene beads, and in particular to panel-shaped products having a multi-ply, or multi-layer structure, each layer having a predetermined density.
• Such multi-density moulded products are known generally in the art. For example,
• EP0177621A1 discloses the basic principle of a multi-density moulded expanded polystyrene product, for example a panel, a process for its manufacture and corresponding apparatus.
• Two different expandable polystyrene bead materials are introduced into two different mould sections of a mould and expanded via the introduction steam into the mould, thereby forming a multilayer product.
• the multi-density product is obtained by introducing the expandable polystyrene starting materials into their respective mould sections one after the other, applying steam, and then removing, either completely or partly, a movable separating wall provided in the mould between the two types of material to allow the lighter density layer to expand into part of the width of the mould.
• the first layer has a final density of less than
• Figure 4 shows a sandwich structure composed of two outer layers of higher density, with an inner core layer sandwiched between the outer layers, said core layer having a lower density than the two outer layers.
• the surface area of the panels produced is approximately 1 square meter, so the panels are both relatively short and thin, in relation to the desired densities.
• any deformation is limited to at most a 5 to 10 mm deviation or equivalent angle from the normal or vertical axis, which remains acceptable for this dimension of panel when used in building construction or secondary building structures, such as inner or outer walls used for insulation.
• expanded polystyrene bead panels having densities of between about 10 kg/m 3 to greater than about 30 kg/m 3
• the applicant has noticed that deformation of the moulded panel starts to be more of a concern with panel lengths greater than or equal to about 3 meters, and when panel lengths with the above density ranges exceed 4 meters, such moulded expanded polystyrene bead panels show deformation as described above that renders them either unsuitable for the purpose for which they were intended, e.g.
• reinforcing means in polystyrene panels having a length of between 3 meters to more than 6 meters, and densities of between 14 to 30 kg/m 3 .
• Such reinforcing means generally take the form of struts or other pre-shaped elements made of steel or composite materials separately added or inserted into the panel.
• the major disadvantage of incorporating such reinforcing means into panels of this size and range of densities, is that as a result, the panels can no longer be shaped, sculpted or cut without recourse to mechanical saws capable of cutting the additionally inserted steel or composite reinforcing means.
• the processes currently known in the art for producing multi-density expanded polystyrene panels do not allow for prevention of deformation of the panel along its length.
• continuous moulding usually results in the worst deformations of the end product, especially where multi-density panels are involved.
• the basic principle of the moulding process involves introducing expanded polystyrene beads with differing expanded particle size distributions, or introducing unexpanded polystyrene particles into a mould.
• the polystyrene is formed into a uniform layer within the mould, expanded and then a further layer is separately and subsequently moulded onto the existing layer. Even if the materials are the same, as in the case of a panel entirely comprised of expanded polystyrene, the major disadvantage of such a process is that the differing internal resulting densities each create different sets of internal tensions within the expanded product. As mentioned above, with panel lengths of between 1 to 2 meters, any deformation caused by internal tension within the expanded layers was negligible or inexistent. Such processes were thus limited to the manufacture of small articles, such as cycle helmets for motorcycles or pedal cycles, or other smaller dimensioned shock absorbing products.
• one object of the present invention is a multi-density moulded product panel comprising at least two outer layers of expanded polystyrene beads, each of said at least two outer layers having a first density, and an inner core layer of expanded polystyrene beads having a second density lower than said first density, wherein said inner core layer of said second density is sandwiched between said outer layers of said first density, and wherein said multi- density moulded product panel :
• the multi-density moulded product panel has an average density greater than, or equal to, about 10 kg/m ; has a curved deformation measured against a normal running parallel to the height, perpendicular to the length, and centered at a midpoint in the thickness, of the multi-density moulded product panel, of less than or equal to 10%, substantially over the entire length of said product.
• the multi-density moulded product panel has an average density greater than, or equal to, about 10 kg/m 3 . It should be noted that this is the average density of the product measured with regard to its dimensions and total volume, in other words, its apparent average density.
• the first, inner, core layer advantageously has a density comprised between about 1 to about 199 kg/m 3 and the outer layers advantageously each have a density comprised between about 2 to about 200 kg/m 3 .
• the multi-density moulded product panel preferably has a first, inner, core layer having a thickness greater than or equal to, 10 mm, and even more preferably, greater than 100 mm, whereas the two outer layers each have a thickness which is preferably greater than or equal to 5 mm, and even more preferably greater than 30 mm.
• Another object of the present invention is therefore extremely long multi-density moulded product panels in accordance with the object defined above, wherein the length of such a panel exceeds 2 meters in length and is preferably greater than or equal to 2 meters in length and up to about 12 meters in length.
• the types of expanded polystyrene material suitable for use in the multi-density moulded product panel are those known generally in the art as suitable for use in moulding and expansion of polystyrene beads.
• the multi-density product panel is advantageously and preferably obtained using the same type of expanded polystyrene material for each layer, but with differing pre- expanded or partially expanded starting densities, which under constant conditions of applied temperature and/or steam pressure during expansion and moulding, lead to the desired final differing densities.
• the finished product having core and outer layers with fairly significantly different final densities, the core and outer layers adhere completely to each other at their respective contacting surfaces without any signs of interfacial separation.
• the multi-density moulded product panel has a curved deformation of less than or equal to 5%, substantially over the entire length of said product.
• the multi-density moulded product panel has a curved deformation of less than or equal to 2%, substantially over the entire length of said product. According to yet another object of the present invention, the multi-density moulded product panel has a curved deformation of less than or equal to 1%, substantially over the entire length of said product.
• the multi-density moulded product panel as indicated above can advantageously be batch moulded, semi-continuously moulded, or continuously moulded, with continuous moulding being the preferred kind of moulding.
• the outer layers of the multi-density moulded product panel comprise internal tension modulation means for modulating the internal tensions of the multi-density continuously moulded product panel created within the inner core layer by the difference in densities between the inner core layer and the outer layers having a density greater than the density of the inner core layer.
• the internal tension modulation means serve to modulate inner tensions created during the moulding process by the expansion of the inner core, for example at convergence points, the inner tensions of the material are thus redirected to a precise point, where they are more easily managed or compensated for.
• the internal tension modulation means are integrally moulded, or shaped, as part of the respective outer layers.
• tension modulation means enable the production of a multi-density panel product that is significantly reduced in weight compared to a standard multi-density panel product.
• the internal tension modulation means comprise a plurality of spaced apart and alternating tongues and grooves, integrally formed within the outer layers along the height of said panel.
• the series of spaced-apart and alternating ridges and troughs project from an outer surface of said outer layer through a thickness of said outer layer towards an outer surface of said inner core layer.
• each of said ridges or said troughs has a height, respectively a depth, equal to, or less than, two-thirds of the total thickness of said outer layer.
• the internal tension modulation means have an angular or a rounded shape, for example, a polygonal shape which in three dimensions corresponds to a substantially polyhedral or a substantially or partially spherical shape, such as, for example, a teardrop shape, a globe shape, a pyramidal shape, a three-dimensional star shape, and the like.
• each of said ridges or said troughs has a shape substantially corresponding to three contiguous sides of a hexagon.
• the outer layer comprises an equal number of ridges and troughs.
• the outer layer comprises a greater number of ridges compared to the number of troughs.
• the outer layer comprises a greater number of troughs compared to the number of ridges.
• the internal tension modulation means further comprises at least one tension blocking key.
• the at least one tension blocking key is located proximate to an outer edge of said outer layer.
• the outer layer comprises two tension blocking keys, one located at each outer edge of said outer layer.
• the outer layer comprises two tension blocking keys, one located at each outer edge of said outer layer, each key being contiguous with at least one of the spaced apart and alternating ridges or troughs.
• each tension blocking key extends from a maximum height of said ridge, or a maximum depth from said trough, through the thickness of the outer layer from the outer surface towards an inner surface of said outer layer proximate to an edge of said outer layer.
• the inner core layer also comprises tension modulation means that are complementary in shape to the internal tension modulation means of the outer layers.
• These complementary shapes are designed and configured to redirect the internal tensions to a precise point within the panel, and within the combined inner and outer layers, but they also play a role in uniformly dissipating and reducing said internal tensions, which in turn enables the use of outer layers having reduced thickness or reduced density in comparison to panel products where the inner core does not have any tension modulation means located within the core layer.
• Such a configuration advantageously results in a lower overall mass for a given unit volume of panel, making manipulation thereof, for example, in construction and assembly of the panels, easier, and requiring less manpower.
• tension modulation means included in the outer layers inclusion of tension modulation means into the core, for example, by integrally moulding such tension modulation means, enables a resulting product panel to have significantly reduced weight in comparison to a standard multi-density panel.
• a first of said outer layers has a density greater than the density of said inner core layer
• a second of said outer layers opposite to said first outer layer has a third density greater than either the density of the inner core layer or the density of the first outer layer.
• the outer layer has a substantially planar outer surface.
• the outer layer has an inner surface configured in shape and size to mate with an outer surface of the inner core layer.
• a multi-density moulded product panel comprising at least two outer layers of expanded polystyrene beads, each of said at least two outer layers having a first density, and an inner core layer of expanded polystyrene beads having a second density lower than said first density, wherein said inner core layer of said second density is sandwiched between said outer layers of said first density, and wherein:
• said multi-density moulded product panel has a total length greater than both a total height and a total thickness such that it is substantially oblong in shape ;
• said outer layers comprise internal tension modulation means for modulating the internal tensions of the multi-density moulded product panel created within the inner core layer by the difference in densities between the inner core layer and the outer layers having a density greater than the density of the inner core layer.
• the internal tension modulation means comprise a plurality of spaced apart and alternating ridges and troughs, integrally formed within the outer layers along the height of said panel.
• the series of spaced-apart and alternating ridges and troughs preferably project from an outer surface of said outer layer through a thickness of said outer layer towards an outer surface of said inner core layer.
• Each of said ridges or said troughs also preferably has a height, respectively a depth, equal to, or less than, two-thirds of the total thickness of said outer layer. Even more preferably, each of said ridges or said troughs has a shape substantially corresponding to three contiguous sides of a hexagon.
• the outer layer comprises an equal number of ridges and troughs. In another preferred embodiment, the outer layer comprises a greater number of ridges compared to the number of troughs.
• the outer layer comprises a greater number of troughs compared to the number of ridges.
• the internal tension modulation means further comprises at least one tension blocking key.
• the at least one tension blocking key is located proximate to an outer edge of said outer layer.
• said outer layer comprises two tension blocking keys, one located at each outer edge of said outer layer.
• the outer layer comprises two tension blocking keys, one located at each outer edge of said outer layer, each key being contiguous with at least one of the spaced apart and alternating ridges or troughs.
• each tension blocking key extends from a maximum height of said ridge, or a maximum depth from said trough, through the thickness of the outer layer from the outer surface towards an inner surface of said outer layer proximate to an edge of said outer layer.
• a first of said outer layers has a density greater than the density of said inner core layer, and a second of said outer layers opposite to said first outer layer has a third density greater than either the density of the inner core layer or the density of the first outer layer.
• the outer layer also has a substantially planar outer surface.
• the outer layer also has an inner surface configured in shape and size to mate with an outer surface of the inner core layer.
• the product panel has a length greater than or equal to 2 meters, and preferably a length of up to 12 meters.
• the multi-density continuously moulded product panel further has a degree of curvature measured against a normal running parallel to the height, perpendicular to the length, and centered at a midpoint in the thickness, of the multi-density moulded product panel, of less than 5° substantially over the entire length of said product. Even more preferably, the degree of curvature is less than 2° substantially over the entire length of said product.
• the degree of curvature is less than 1° substantially over the entire length of said product.
• the degree of curvature is less than 0.5° substantially over the entire length of said product.
• the resulting multi-density panel has a degree of curvature measured against a normal running parallel to the height, perpendicular to the length, and centered at a midpoint in the thickness, of the multi-density moulded product panel, of less than or equal to 10%, substantially over the entire length of said product.
• the degree of curvature is less than 5% substantially over the entire length of said product.
• the degree of curvature is less than 2% substantially over the entire length of said product.
• the degree of curvature is less than 1% substantially over the entire length of said product.
• the outer layers and the inner core layer are continuously, or semi-continuously, co-moulded.
• the process further comprises initially displacing the at least partially hardened and expanded outer layers along said longitudinal axis for a predetermined distance before introduction of the partially expanded polystyrene beads having a second density into the central chamber.
• the process further comprises opening the first moulding chamber walls at a downstream end of said first moulding chamber to allow longitudinal displacement of the at least partially hardened and expanded outer layers from said first moulding chamber along said longitudinal axis.
• the opening of the first moulding chamber walls at the downstream end of said first moulding chamber is effected outwards from said longitudinal axis.
• the process further comprises displacing the inner core layer supported on one longitudinal edge of said inner core layer along a longitudinal axis of the moulded product panel simultaneously to moulding the two outer layers onto said core layer. The applicant has found that displacing the panel product as it is formed along one of the longitudinal edges of the panel and along the panel's longitudinal axis is particularly advantageous.
• the process further comprises forming internal tension modulation means in the outer layers for modulating the internal tensions created within the inner core layer due to the difference in densities between said inner core layer and said outer layers.
• forming internal tension modulation means within the outer layers of the panel product enables one to control and substantially eliminate any distortions that might otherwise occur during expansion and cooling of the moulded product, and which would otherwise be noticeable over lengths of panel equal to, or exceeding 2 meters.
• the process further comprises forming internal tension modulation means in the outer layers as a plurality of spaced apart and alternating ridges and troughs, integrally formed within the outer layers along the height of said panel.
• the process further comprises forming tension modulation means within the inner core which are complementary to the internal tension modulation means formed in the outer layers.
• the process further comprises providing a first cutting station configured to cut locating or seating nipples in a longitudinal edge of said panel adjacent to a longitudinal extremity of said panel.
• This cutting station can be provided so that the panel's upper longitudinal edge can be formed with seating nipples at, or near, the longitudinal end of said panel.
• Such nipples are generally formed pairwise, on either side of the longitudinal axis of the panel, and serve to facilitate seating of a subsequent panel when these are assembled together, one on top of the other.
• the fourth cutting station can also be configured to provide seating recesses, such that the nipples from an underlying panel will align and seat within the recesses of an overlying panel during assembly.
• the first cutting station is further configured to form an overlap portion in said panel at a longitudinal extremity of said panel.
• the first cutting station can also advantageously be configured to cut the longitudinal ends of the panels in such a way that an overlap of panel material is provided.
• Such an overlap is useful when assembling panels to form a building construction, as it provides a means for joining said panels together longitudinally without having to glue them together, or alternatively as a means of providing a substantially orthogonal assembly of a first panel with a second panel, whereby the overlap of a first panel is laid over or under, and mates with, a corresponding overlap of a second panel.
• the seating nipples can also advantageously be of assistance here to facilitate seating of the overlaps.
• the panels can be cut to the desired final length, for example, to form part of a made to measure kit of parts containing each and every panel element required to construct a building with said panels, according to the measurements provided by a client or end-user or building construction configuration method, for example, implemented by a software program.
• the process further comprises providing a second cutting station configured to remove a portion of a lower longitudinal edge of said panel as said panel is moved along said longitudinal axis.
• This step is optionally and advantageously provided to compensate for the advantageous option of producing a panel which has an additional height of moulded expanded material integrally moulded onto the lower longitudinal edge of the panel, and after removal via cutting, for example, by hot wire cutting, of said additional material, the panel attains its definitive height for further processing.
• the addition of such extra moulded material is useful for enabling the panel to be pushed out of, and advanced through, the moulding apparatus whilst maintaining said panel on its longitudinal edge, thereby gready simplifying both the handling of said panel and the construction and functioning of the moulding apparatus.
• the process further comprises providing a third cutting station configured to cut vertical tunnels through said panel thickness from one longitudinal edge to the other opposing longitudinal edge.
• a cutting station is particularly useful for providing the possibility of internal conduits within the panels, such tunnels or internal conduits thereafter being available in the finished product, for example, for the pouring of concrete therein, or the introduction therein of reinforcement structures such as steel trellises or the like, or even simply for enabling the introduction of cabling or piping into the moulded panels via said tunnels or conduits, thereby facilitating use of the panels when assembled into a building structure.
• the tunnels are cut using a laser cutter.
• a laser cutter shaped so as to provide the necessary tunnel shape, pushing down through the thickness of the panel from an upper longitudinal edge towards a lower longitudinal edge, from which the cut out material would be withdrawn or ejected.
• a laser cutter avoids the need to provide an extraction means for the cut out material, as such material is necessarily small in dimension than the limits of the laser cut, whereas with say, a hot wire cutter, it is possible for the cut out material to get wedged in the panel as the wire cutter descends, thereby making it obligatory to provide an extraction means to at least hold and withdraw said cut out material as the cutter moves through the panel's height Of material.
• the shape of the laser cut-out can be anything one might deem appropriate, from straight channels with vertical parallel sides to spherical or cylindrical channels, square channels, or any other substantially polygonal shape.
• the process further comprises providing a fourth cutting station configured to cut oblique tunnels through said panel thickness from one longitudinal edge to the other opposing longitudinal edge.
• This optional stage of the process is also useful for providing further conduits or tunnels within the panel, especially, for example, for providing space for the passage of cables and piping, or even oblique reinforcing elements when the panels are assembled.
• the process further comprises providing a fifth cutting station configured to remove at least a portion of the core layer to form a gutter along said longitudinal axis within said core layer.
• Such a gutter is useful, for example, in panels which might require a hydraulic binding agent, such as concrete, to be poured into the gutter for providing reinforcement to a building structure comprising the multi-density panels of the invention, for example, in between stories of a building, and also to provide extra mass for any such building structure.
• a hydraulic binding agent such as concrete
• the fifth cutting station can be further configured to remove at least a portion of one of the outer layers along said longitudinal axis to form a sill. Such an option is useful, for example, when the multi-density product panels are to be used to form window openings.
• tension modulators enables a multi-density product panel to be produced that is significantly lighter than corresponding'multilayer, multi-density polystyrene panels.
• the outer layers each have a respective density of 40 kg/m 3
• an inner core layer with a density of 17 kg/m 3
• each layer having a thickness of 10 centimeters
• the total weight or mass would be 88.8 kg.
• a product panel that would meet the same structural rigidity and technical performance requirements would need to have a density of 40 kg/m3, and a resulting total mass of 144 kg.
• An overall lighter product panel according to the present invention also saves on total polystyrene material used, making the production process more economical for a given rigidity and technical performance rating.
• a multi-density product panel according to the invention provides generally for improved phonic insulation.
• One further unexpected advantage is that the tailoring of the shape and form of the tension modulation means enables such phonic insulation properties to be optimized for absorbing and deviating sound waves travelling through the panel.
• the panels can be designed so that the internal tension modulation means redirect sound waves in such a manner that they do not pass through from one side of the multi-density panel to the other, but rather are redirected either to be absorbed internally within the mass of the inner core, or else can, for example, advantageously be redirected to the outer edges of the panel, rather than through the faces.
• Yet another advantage to the panels of the invention is that when both inner and outer layers are made of the same polystyrene material, the product panel can be worked post-moulding, for example, cut into other shapes, using a hot wire cutter.
• Such cutting systems are generally inapplicable or unusable when comparative product panels containing different materials or inserts, for example, strengthening inserts of steel, are used within the panel.
• Being able to use a hot wire cutter is a particular advantage for the product panels of the invention, as it allows much greater variety in end shaping of the product panels, and complex cuts to be made along three orthogonal axes, for example, seating or locating nipples, or overlapping ends that allow panels to be mated or overlaid orthogonally one atop the other.
• Such cuts require millimeter scale precision, which is simply not available with traditional mechanical saws or other cutting systems, such as pressurized water cutters, or even laser cutters, used in the majority of multi- density panel production today, laser cutting generally being of interest in the present invention for removing material from within the multi-density panel, for example, for forming interior conduits or channels or runnels.
• the panel can be provided with gutters, conduits, channels or tunnels that allow for flow of a hydraulic binder introduced therein, such as concrete, whilst maintaining structural integrity of the panel.
• gutters, conduits, channels or tunnels can be cut out from the inner material of the product panel, to provide passageways with a dimension of for example, 15 centimeters by 20 centimeters.
• Such gutters, channels or conduits are preferably created in the product panels of the invention via a laser cutter, the cuts being made vertically through the height of the panel, and preferably in proximity or near to the positions of the internal tension modulation means.
• the multi-density product panels of the present invention displayed increased solidity over comparative products, as it has been unexpectedly found by the applicant that the internal tension modulation means optimize the mechanical efficiency of the panel by concentrating internal tensions within the panel product. This is comparable to a similar known effect found in concrete beams that are poured into a reinforcing steel ring scaffold.
• the optimization of the inner tensions via the tension modulation means contribute to an increase in mechanical performance in excess of 10% compared to known panels. This increase in mechanical strength or resistance allows for pouring of hydraulic binders such as concrete into the gutters, channels or conduits formed within the panel without the concern that the panels might rupture.
• the product panels of the present invention when incorporating tension modulation means, provide a mechanical resistance of greater than 3 bars internal pressure exerted on the inner walls formed by the conduits, which is more than sufficient to resist the pressure caused by hydraulic binders such as concrete bearing down on said walls.
• metal reinforcements within the panel, for example, within the conduits or channels, if so desired, in a manner more akin to traditional building processes to form a metal framework surrounded by hydraulic binder.
• multi-density product panels of the invention can directly accept load bearing screw threads, bolts, e.g. expandable or regular, or other fixation means for supporting or mounting, e.g. furniture or appliances, or heavy fittings, that could never have been imagined previously.
• Known polystyrene panels have insufficient resistance to applied traction, and even attempting to screw in a fixation means such as a threaded bolt often results in said threaded bolt pulling out, and/or destroying part of the panel, along with polystyrene bead material. Such is not the case with the product panels according to the invention, which will easily accept such load bearing screw threads.
• the time to build a construction that is 13 meters in length by 10 meters in width, i.e. a for building surface of 130 m 2 in terms of ground cover, with approximately 20 product panels according to the invention is less than one hour.
• a wall that is 10 meters in length and 2.9 meters high can be built using only 4 product panels according to the invention that are 10 meters in length.
• Handling each of said panels according to the invention takes approximately 3 minutes per panel per person with 2 handlers, in other words, only 12 minutes total for a wall with a surface area of 29 m 2 , which corresponds to a mean construction time of about 25 seconds per square meter.
• the multi-density product panels containing the internal tension modulation means according to the invention are so resistant that it is possible to directly use screw threaded mounting fixtures on them, and while furniture and appliances were mentioned above, especially, for example, for indoor usage, the panels can also be assembled so that one of the faces forms the outer wall of the construction.
• the advantageous capability of being able to affix heavy items using screw threaded fixation means is a noticeable gain of time and an economy of financial investment, because outer facings can be directly mounted via said fixation means onto the surface of the panel.
• the lightness of the panels enables constructors to assemble the panels without recourse to an exterior scaffolding such as one would find on a traditional building site.
• an exterior scaffolding such as one would find on a traditional building site.
• a multi- density product panel according to the present invention, and as such, said panels can be used as constitutive elements of a wall, either load-bearing or simple, or as filling material between blockwork, or roofing panels, flooring and ceiling panels, and just generally as a primary or secondary construction material.
• This versatility in applications is a distinct advantage over fixed polystyrene blocks requiring filling with hydraulic binder, as such blocks have pre-configured internal recesses and walls obtained during moulding that can not easily be altered post- moulding, and therefore are less flexible in actual use.
• the panels according to the present invention can be provided with internal conduits and channels in accordance with the design of the construction to be assembled, e.g. enabling precise location and positioning of the channels required for pouring and forming concrete support posts therein.
• Such conduits can be provided freely, for example with a precise spacing between conduits of anything from 1 millimeter to 10.5 centimeters to 928.8
• Figure 1A is a schematic representation of an illustrative known commercially available expanded polystyrene moulded product panel
• Figure IB is a schematic representation of a perspective view of a panel similar to that of Figure 1A, showing warping, or deviation from a normal along a longitudinal axis;
• Figure 2A is a schematic cross-sectional representation viewed along the longitudinal axis of a multi-density moulded expanded polystyrene product panel according to the invention;
• Figure 2B is a schematic cross-sectional exploded representation viewed along a longitudinal axis of a multi-density moulded expanded polystyrene product panel according to the invention
• Figure 3A is a schematic cross-sectional representation viewed along the longitudinal axis of a multi-density moulded expanded polystyrene product panel according to the invention which has been further shaped post-moulding by cutting;
• Figure 3B is a schematic cross-sectional representation viewed along the longitudinal axis of a multi-density moulded expanded polystyrene product panel according to the invention which has been shaped post-moulding by cutting in a similar, but different manner to the panel of Figure 3A;
• Figure 4A is a schematic representation viewed from a lateral side of a multi-density moulded expanded polystyrene product panel according to the invention in which an end of said panel has been shaped post-moulding to form an overlapping portion and seating or locating nipples positioned on an upper longitudinal edge;
• Figure 4B is a schematic representation viewed from a lateral side of two multi-density moulded expanded polystyrene product panels according to the invention in which
• complementary overlapping ends have been shaped post-moulding to form a first upper overlapping portion having seating nipples of a first panel and a first lower overlapping portion of a second panel;
• Figure 5A is a schematic two-dimensional representation viewed from a lateral side of an assembly of multi-density product panels according to the present invention, forming a wall section of a building construction and also showing a window placement with a sill;
• Figure 5B is a schematic three-dimensional perspective representation of the assembly of
• Figure 5A showing post-moulded shaped extremities of the panels in which a first extremity of each panel has been shaped to form upper overlapping portion and a second extremity has been shaped to form a lower overlapping portion, the overlapping portions having hollowed-out or cut out sections throughout part of the thickness of the panel.
• Figure 1A illustrates a commercially available expanded polystyrene panel product (1), having a length (L), a thickness (t), a height (h), and comprising a first and second longitudinal edges (2a, 2b), first and second longitudinal end faces (3a, 3b), and first and second lateral faces or sides (4a, 4b), forming a generally oblong shape in three-dimensional space.
• Such panels are typically approximately 2 meters in length, approximately 1 meter in height (h), and approximately 30 centimeters in thickness (t).
• FIG. IB A similar known, prior art single-density expanded polystyrene product panel is illustrated in a perspective view in Figure IB, however this product has a length L greater than about 2 meters, for example between about 4 and about 12 meters in length.
• this panel displays significant deformation measured against a normal (5) running parallel to the height (h) of the panel, and perpendicular to a longitudinal axis (6) along the length (L) of the panel, centered at a midpoint (7) in the thickness (t) of the single-density continuously-molded product panel. It is hypothesized that such deformation is substantially due to recrystallisation constraints and tensions introduced into the panel as the material making up the panel cools down with the increasing length of the panel during moulding.
• Panels having such significant deformation are to all intents and purposes either completely useless, or else require shaving or planing, or thickness correction by addition of matter, generally once the panel has been assembled with others into a building construction, as the degree of nuisance of such deformation will depend on the placement of the panel in the assembly. Naturally, this makes any use of such a deformed product not only more time consuming, but also more costly in terms of man hours to provide a correctly assembled structure that might use such a panel.
• Figure 2A in contrast, illustrates a schematic cross-sectional representation of a multi-density moulded expanded polystyrene product panel (8) according to the invention, the cross-section being shown through the height (h) of the panel orthogonal to the longitudinal axis (6), with a normal (5) running parallel to the height (h) also being indicated, and the panel stood on one of its longitudinal edges.
• the panel (8) according to the invention has two outer layers (10,11) of expanded polystyrene that each have a density greater than the density of an inner core layer (9) sandwiched between the outer layers (10,11).
• the thicknesses of each layer are indicated as tl, t2, and t3 respectively, with tl and t3 corresponding respectively to the thicknesses of the two outer layers (10, 11), and t3 to the thickness of the inner core layer (9).
• the densities of each of the outer layers (10, 11), which are both greater than the density of the inner core layer (9) can each respectively be anywhere between about 3 to about 5 times as dense as the inner layer (9).
• the internal tensions (12) produced within the panel (8) are illustrated by multi-directional arrows having a centre-point (13) generally located within the inner core layer (9), near a halfway point across the thickness t2, spaced along the height (h) of the panel (8) and also along the length (L) of the panel.
• the panel also comprises seating nipples (14), located on an upper longitudinal edge (2b) of the panel (8), on the surface of each of the outer layers (10, 11), the nipples (14) projecting away, in this case, upwards, from the body of the panel (8), and a pair of grooves (15) cut into the lower longitudinal edge (2a) of the panel each of the outer layers (10, 11) each groove being adapted in shaped and dimension and configured to received the seating nipples (14) of another panel (8) onto which the latter has been seated.
• the nipples (14) enable a first panel to be seated on an underlying panel, whereby the nipples (14) engage the grooves (15) provided in the panel laid on top of the underlying panel, and prevent the panel from moving laterally, keeping them aligned, or alternatively, providing for a right-angled layering of interlocking panels when the panels are assembled into a building structure.
• Figure 2A also displays internal tension modulation means (16a, 16b), and tension blocking keys (17a, 17b), a fuller description of which will be given in regard to Figure 2B.
• Figure 2B represents a schematic cross-sectional view similar to that of Figure 2A, the main difference being that the inner core layer (9) and outer layers (10, 11) of the panel (8) have been artificially separated for the purposes of illustration to provide greater detail of the various aspects of the invention.
• the panel is provided with internal tension modulation means (16a, 16b) and tension blocking keys (17a, 17b), which serve to counteract the tensions or constraints that are exerting pressure within the core layer, and which if left unchecked, cause the panel to deform or warp along its length.
• the internal tension modulation means are represented as a series of troughs, or grooves, and ribs, or ridges, of moulded expanded polystyrene material.
• the internal tension modulations means extend from an outer surface (18) of the lateral sides (4b) of the outer layers (10,11) through the thickness (tl, t3) of said outer layers (10,11) towards an inner-facing surface (19) of said outer layers.
• the internal tension modulation means (16a, 16b) are in contact with an outer surface (20) of the inner core layer.
• the inner core layer also comprises internal tension modulation means (21a, 21b), which are formed by moulding the expanding polystyrene during the moulding phase of the inner core layer.
• the shapes and form of the internal tension modulation means (21a, 21b) of the inner core layer complement completely the shapes and form of the internal tension modulation means (16a, 16b) of the outer layers, such that in the finished product panel (8), there is no separable interface between the outer surface (20) of the inner core layer (9), and the inner surface (19) of the outer layers (10,11).
• the outer layers (10, 11) are also provided with tension blocking keys (17a, 17b), which are contiguous with the troughs and ridges, and substantially located in proximity to each longitudinal edge (2a, 2b) of the panel.
• tension blocking keys (17a, 17b) extend from the outer surface (18) of the outer layers, towards the inner surface (19) of the outer layers, but extend further towards the inner core (9), and additionally further towards the longitudinal edges (2a, 2b) of the panel than any of the troughs or ridges (16a, 16b), and are generally shaped to form an extended oblique contact surface (22), giving the tension blocking keys shape not dissimilar to a claw.
• a corresponding complementary oblique or sloping outer surface (23) is provided on the inner core layer (9) to match that of the tension blocking key.
• the internal tensions exerted by the inner core layer are compensated for, redirected or absorbed, by the design and shape of the ridges (16b), troughs (16a), corresponding inner layer ridges (21a) and troughs (21b), and the blocking keys (17a, 17b).
• the shape of the internal tension modulation means, and blocking keys can be adapted in size and dimension, and configured to provide the optimum control and modulation of the internal tensions created within the inner core layer. As such, the shapes can be fairly wide ranging.
• the shapes of the troughs and ridges corresponds, in the two- dimensional view to at least part of a polygon, and in this case, part of a hexagon, for example three sides of a hexagon.
• a polygon for example three sides of a hexagon.
• these shapes become polyhedra.
• Suitable polyhedral shapes can thus be designed for the mould such that a variety of different polyhedral tension modulation means and blocking keys can be produced, and integrally formed of the same material as, and with, the remainder of the outer and inner layers.
• FIG 3A an illustration of a variation of the multi-density moulded expanded polystyrene product panel is shown, similar to Figures 2A and 2B, only the differences being described here.
• a part of the core layer has been removed post-moulding along the longitudinal axis, or length, of the product panel, for example by hot wire or laser cutting, to form a gutter, conduit or channel (24) that has an opening (25) towards the upper longitudinal edge 2b.
• the gutter or channel (24) formed within the core layer has side walls (26, 27) which extend from a closed end (28) of the channel, or bottom, towards the opening (25) Additionally, a part of the outer layer (10) and corresponding inner core (9) has been completely removed to leave one lateral side (4a) of the panel lower than the opposing lateral side (4b) of the panel, with the inner core layer side wall and corresponding outer layer (10) on that side extending only partly towards to the longitudinal edge (2a), thereby forming a longitudinal sill or lip (29).
• a product panel shaped in this way can conveniently be used to form a window opening that is directly provided with a corresponding sill or lip (29).
• FIG 3B a similar panel to that in Figure 3A is illustrated, except that in this panel, only the gutter or channel (25) has been cut or shaped into the material of the core, and the inner core walls (26, 27) formed by the removed core material extend all the way up to the longitudinal edge (2b), as do the outer layers (10, 11).
• a panel is ideally suited to receiving cables, or metallic tresses, and/or a hydraulic binder such as concrete, which can be poured into the gutter or channel to form, for example, a lintel.
• FIG 4A a schematic side view of an embodiment of the product panel of the invention is shown.
• the panel has been shaped or cut, for example, using a hot wire cutter post- moulding, to form an overlap (30) in the upper part (32) of the panel, which extends beyond the extremity of an otherwise straight-cut panel.
• the panel further comprises a ridge (31) situated substantially along the upper longitudinal edge of the panel, this ridge providing further means, in addition to the seating or locating nipples (14), for facilitating the seating the panel with respect to a panel placed on top of it, and especially with regard to the grooves (15) provided in the lower longitudinal edge (2a).
• each panel which is designed in a manner similar to that of Figure 4A, can interlock with an adjacent panel (33) having a corresponding overlap (34) in the lower part (35) of the panel, such that the two panels sit one on top of the other at their respective overlaps.
• panels according to the invention can be produced that can be interlocked end to end, along a longitudinal axis, but also orthogonally one with regard to the other.
• the respective overlaps (30, 34) are preferably dimensioned and configured so that no material of either panel sticks out over the edge of an adjacent panel when laid on top orthogonally, or when laid longitudinally end to end, and such that no gap occurs between the respective ends of each adjacent panel.
• FIG 5A illustrates a schematic side view of a wall constructed of assembled panels according to the invention, in which successive panels have been laid one on top of the other to form a wall surface, said wall surface being provided with a placement for a window.
• the top and bottom panels (36) are identical in this illustration, and similar to that illustrated in Figure 4A.
• panels (37a, 37b) as shown here are two separate panels, each with a straight edge at one end of the panel, which end defines the respective side boundaries of the window frame.
• panel (38) laid above the bottom panel (36) has been shaped, for example by hot wire cutting, to form a recess that defines respective side boundaries of the window frame, and the lower edge boundary of said window frame.
• the upper edge boundary of the window frame is defined by the lower longitudinal edge of top panel (36).
• FIG 5B a schematic illustration of a perspective view of the panel assembly of Figure 5A is shown.
• top panel (36) has been provided with a gutter (39), the panel therefore being similar to the one illustrated by Figure 4B.
• each of the overlaps (30, 34) has been provided with a vertical conduit (40) formed, for example, by laser cutting, in the core layer of the overlap.
• Partially expanded polystyrene beads having a first density are introduced into a first moulding chamber, comprising walled moulding areas, which walls form two distinct moulding areas capable of forming the outer layers of the multi-density panel product, around a second, central chamber.
• each moulding area of the first moulding chamber could receive beads of polystyrene with a different density to the other moulding areas, which although different, would nonetheless be greater than the density of the beads used for the inner core. In this way, it would be possible to produce a panel that had an outer layer with a first density, a second outer with a second density different from the first density, and an inner core layer with a density lower than either of the outer layers.
• the first moulding chamber is aligned with and located either side of a longitudinal axis which traverses the centre of the second, central moulding chamber.
• the partially expanded polystyrene beads are further expanded by the introduction of steam under controlled conditions of pressure and temperature into the first moulding chamber to cause the partially polystyrene beads to completely expand and then allowed to cool within the confines of the first moulding chamber to a point where the outer layers are expanded, but only partially hardened, in other words, they still have relatively pliable and adhesive external surfaces.
• the at least partially hardened layers are then partly displaced by a predetermined distance along the longitudinal axis, downstream of the first moulding chamber, via a series of hydraulic pistons which act on the moulding walls of the first moulding chamber to push said moulding walls along the longitudinal axis.
• said chamber can be equipped with means allowing the opening of said moulding walls at a downstream longitudinal end of the first moulding chamber.
• Such means can comprise jaw-like sections of the walls of the first moulding chamber, which can be configured, for example, to open outwards to an angle of at most 5% from the normal as defined by the longitudinal axis.
• Internal tension modulation means and corresponding blocking keys are formed in the outer layers by adapting the design of the mould walls of the first mould chamber to allow for expansion of the polystyrene beads into corresponding negative ridges and troughs such that the final shape of said outer layers facing inwards and extending from an outer surface of said outer layer provides the required tension modulation means. It has been found to be particularly advantageous to shape the internal tension modulation means such that each of said ridge or said trough has a height, respectively a depth, equal to, or less than, two-thirds of the total thickness of said outer layer. Furthermore, optimal internal tension modulation has been determined to be achieved through the use of ridges and troughs in which the shape thereof substantially corresponds to three contiguous sides of a hexagon.
• these three sides of a hexagon form a nodule-shaped projection of expanded high density material which extends from the outer facing surface of an outer layer through the thickness of said outer layer towards the outer surface of the inner core layer, with which it engages once the product expanded polystyrene has completely hardened.
• the particles introduced into the second, central moulding chamber expand, they come into contact with both the inner and partly adhesive surfaces of the already formed, at least partially hardened outer layers, and at the same time the further outer layers undergoing expansion.
• the expanded beads of the inner core espouse the shape of the inner surfaces of the outer layers, so the inner core forms its own corresponding internal tension modulation means which essentially mate with the internal tension modulation means of the outer layers.
• the outer layer blocking keys which are formed integrally along with the material of the outer layers, have a shape similar to an extended finger or fingers of material, which finger or fingers clamps down on, and is bonded to, an area of the inner core's outer surface proximate to a longitudinal side edge of said core as the product panel cools. These blocking fingers thereby prevent any tensions being displaced outwards through the upper and lower longitudinal edges of the core, which would otherwise cause the core to warp.
• both the internal tension modulation means of the outer layers, and those of the inner core contribute to modulating the internal tensions created within the inner core as the expanded polystyrene cools down, these tensions being due to the polymer nature and resolidification properties of the polystyrene itself.
• the internal tension modulation means prevent the internal pressures of the resolidified lower density polystyrene of the inner core from causing deviation of the core along the length of the panel, by redirecting and equalizing said pressures or internal constraints.
• the blocking keys complete the stabilization by preventing, or at least, significantly reducing, any outwardly directed forces from acting to cause warping on the longitudinal side edges of the panel.
• the whole moulding unit comprising the first and second moulding chambers and cooling chamber can be constructed to fit into a linear length not exceeding approximately 4 meters.
• Each cycle of bead introduction, expansion, displacement, cooling is repeated as often as desired, with the result that a corresponding multi-density panel product is formed of any length from about greater than or equal to 2 meters to up to about 12 meters, and the resulting product panel shows substantially no deformation of curvature.
• the hardened product panel After leaving the cooling chamber, the hardened product panel is advanced along a conveyor by the bottom edge of the panel to a series of post-molding shaping operations described hereafter.
• the panel At a first cutting station, the panel is shaped at the leading end to provide seating or locating nipples on an upper longitudinal edge of the panel.
• this cutting station can also cut the panel into the required final length, and shape the respective overlaps of two contiguous panels.
• a second cutting station removal of an excess of material provided during moulding of the inner core layer along the lower longitudinal edge of the panel is carried out.
• the excess core layer material is included during the moulding and expansion of the inner core layer in order to facilitate transport of the panel along a conveyor system as the panel is displaced along the longitudinal axis towards the post-moulding processing steps. Once the panel has hardened, this excess material can be removed.
• the second cutting station provides for removal of this excess material.
• the process comprises passing the panel through several other cutting stations:
• the panels can be provided with suitably shaped vertical tunnels that allow for hydraulic binder such as concrete to be poured into them when the panels are assembled into a building construction. Once hardened, the concrete will form reinforcing pillars to the overall building structure, as required by many building regulations;
• the panels can be provided with oblique or diagonally inclined tunnels through the core layer of the panel, which can either be filled with hydraulic binder, for example, or used to pass electrical wiring and/or piping through the panel once it has been assembled into a building structure;
• a fifth cutting station configured to to remove at least a portion of the core layer to form a gutter along said longitudinal axis within said core layer, the application of which in forming a lintel, for example, has been described above. Additionally and optionally, the fifth cutting station can also be configured to remove at least a portion of one of the outer layers along said longitudinal axis to form a sill, such as might be useful for receiving a window in an assembly of panels used in a building construction.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Life Sciences & Earth Sciences (AREA)
• Wood Science & Technology (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Mechanical Engineering (AREA)
• Laminated Bodies (AREA)

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• 2017
  • 2017-08-22 EP EP17783988.3A patent/EP3723959A1/de not_active Withdrawn
  • 2017-08-22 WO PCT/IB2017/001169 patent/WO2019038574A1/en unknown

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