FR2680336A1 - Manufacture of alveolate pallets made of agglomerates of wood and of cement using a press - Google Patents

Abstract

The present invention relates to the manufacture of alveolate pallets made of agglomerates of wood and of cement using a press. This invention constitutes an extension of the invention filed on 21 February 1991 with the number 91 02313, the title of which was: "Manufacture of alveolate panels made of agglomerates of wood and of cement for pallets and multiple uses, using a press". A conversion of the mould allows longitudinal members (girders) (3) to be incorporated into the alveolate panel (1) in order to convert it into a true pallet, whereas in the aforementioned invention it was necessary to add legs. The mould makes it possible to manufacture panels with alveoli (cells) (2) with or without longitudinal members. The alveolate panels with longitudinal members may have other uses: curtain wall and floor with built-in insulation, formwork (shuttering), etc.

Description

 The present invention relates to the manufacture on press of honeycombed pallets in agglomerated wood and cement.

This invention is an improvement of the invention filed on February 21, 1991 under the number 91 02313, whose title was: "Manufacture in press of honeycomb panels in wood chips and cement for pallets and multi-purpose"
A modification of the mold allows to integrate the honeycomb panel longitudinal members to transform it into a true palette, while in the aforementioned invention, it was necessary to add feet.

The advantage of the present invention is that it is possible to manufacture with a single mold
Either a honeycomb panel of uniform thickness having the same level pressers (with the possibility of obtaining different thicknesses of panel).

 Either a honeycomb panel with longitudinal members (the height of the side members and the thickness of the panel may vary).

 The design of the honeycomb pallet is similar to that of the honeycomb panel of the aforementioned invention The rows of cells can be alternately staggered, or simply aligned.

The thickness is locally increased to form longitudinal members. These longitudinal members have a part of their contour which marries the alveoli which allows to obtain forms both light and having a very great stiffness. Integrating cavities into the longitudinal members allows them to be expanded without increasing their weight. This has three advantages
The distribution of the loads supported by the pallet is best done especially when the pallets are stacked, for example pallet supporting bags of cement.

 With wide side members the pallet can circulate on a roller mat, the side members can be indifferently perpendicular or parallel to the rollers.

 The width of the feet reduces the free span of the tray, which minimizes its thickness. On the other hand it is formed with the palletized materials a vault effect that greatly restricts the efforts supported by the plateau.

 The cells whose side walls are slightly conical may have either a curved bottom or be open holes and have different sections.

The mold design has some similarities
The mold consists of a rectangular frame whose thickness is equal to the height of the pallet to the right of the side members. On this frame, resting on the boards of manufacture, is fixed a perforated plate consisting of a set of surfaces having the same contour as the base of the cells. These surfaces are interconnected by connecting tabs that secure them and connect them to the frame. This perforated plate has in the upper part notches which allow sliding plates to close, during certain manufacturing phases, the areas between longitudinal members. The height of this perforated plate is also a function of compaction of the material to the right of the longitudinal members.

 This perforated plate is used to suspend and position the cores realizing the shape of the cells (convex bottom, or open).

 To form the edges of the side members it will be implanted between the cores, plates of the same width as the corresponding junction legs and height equal to the height of the side members.

 The battery of pressers will be at two different levels depending on whether they will be located at the right of the side members or between the side members.

We will now describe the different phases of manufacturing
The mold rests on the board of manufacture.

 The drawer of the hopper will pass several times on the mold to fill through the openings of the perforated plate.

The product height to implement to form the tray (upper part of the pallet) will be adjusted by the filling time or the number of passage of the hopper on the mold.

 A vibration will intervene to distribute the material evenly.

 Then the battery of pressers will drop to compress the surface between spars. The squeezers at the right of the side members being located at a higher height will have no action in this phase.

 The battery of pressers will rise.

 The two sliding plates, described above, will come close the surface between longitudinal members, actuated by two jacks integral with the frame.

 The drawer of the hopper will again pass over the mold to complete the filling right of the side members. The filling height being adjusted in the same manner as before.

 The two sliding plates will then withdraw from the grip of the mold to allow the battery of pressers to go down again to compress and vibrate the concrete sintered wood.

 The battery of pressers plating the product on the board of manufacture, the mold is raised, then all the pressers.

 The demolded product leaves to dry, then to be palletized by simple stacking.

 The honeycomb panel can have an infinity of shapes and dimensions depending on its use.

 The cells can be arranged in rows alternately staggered or simply aligned.

 The cells may be through holes or bottom convex shape and have different sections.

 The panels may be of uniform thickness or comprise longitudinal members.

 The spars can be implanted in different ways and take many forms.

 We will now analyze some examples of use of honeycomb panels with longitudinal members.

 For example, let us design a 1200 * 1000 mm panel with rows of aligned cells with a curved bottom.

This panel has three longitudinal spars, one in the axis conforming the shape of two rows of cells and two others near the banks. The latter have a side that marries a row of cells, the other right side being located 500 mm from the axis of symmetry. These panels have regularly spaced holes located near the side members.

 Figures 8, 9 & 10 will further clarify, below, the shape and uses of these panels.

 These panels can also be dimensioned in 1200 * 500 mm or 1000 * 600 mm to be more manageable. This dividing the base panel respectively along the axis of symmetry perpendicular to the longitudinal members or along the axis of symmetry of the central spar.

 These panels can be used to build walls with integrated insulation, by mounting the honeycomb sides of the side members against each other. The panels will be secured to the assembly by elements such as threaded rods, for example, passing through the holes described above.

 Flat insulating plates of 1000 * 400 mm embedded between the panels clog the cells. This will have a very important side effect: the air contained in the cells will be static and contribute to the insulation of the wall.

 If we want to obtain a lower insulation wall, we can simply increase the height of the cells between spars to give them the same height as the side members. Wood concrete is itself a thermal insulating material.

 At the junction of two contiguous elements, after incorporation of flat insulating plates (1000 * 200 mm) on the outside and reinforcement elements, concrete may be poured to form stiffeners every 1.2 meters between axes. .

 These panels will be made with wood concretes having a good vacuum index, to allow a bonding of the cement coating on the outside and plaster inside.

 At the lower level of the floor, the interior panel will be sawn to accommodate a chaining. It should be remembered that these panels can be very easily sawn and nailed.

 These panels can also be used as cladding elements with a similar assembly, the poles, for example, metal replacing the stiffeners.

 With these same panels can be built slab walls, using them as simple formwork elements. The holes indicated above allow the passage of threaded rods resistant to the thrust of the concrete. These threaded rods or other devices pass through the concrete wall in conventional spacer tubes.

 It will be interesting to create building structures with shuttering walls and façade walls with integrated insulation.

 We can also make solid walls with the same assembly described above, without of course putting the insulation elements and filling the whole with concrete. We will use this solution when we want to have a wall for good adhesion of the plaster, for example.

 With the same type of panels we can also achieve floors with integrated insulation.

 For this purpose, panels placed face downwards (dimensions: 1200 * 1000 mm or 600 * 1000 mm) should be laid transversely on the struts lines arranged every meter.

 This will be a very rigid decking due to the presence of the side members. It will then be necessary to use insulating plates of 1000 * 400 mm in the areas between longitudinal members and loose insulation to the right of the ribs in the cells.

 Another series of panels of 1000 * 1000 mm or 500 * 1000 mm will be put in place on the previous panels with honeycomb faces down.

 It should be noted that these panels will be manufactured with the same mold as the lower panels by simply obscuring the edges of the mold to remove the two rows of extreme cells.

 A reinforcement element will be placed in each rib, as well as a welded mesh on the entire floor surface. The ribs and the floor screed will be poured.

 In such a structural system, the ribs of the floor will preferably be in line with the stiffeners of the walls to create a good bond especially in anti-seismic structures.

 A frame of 1.2 meters is very wide, which makes it very easy to pass the hoppers. It is understood that the dimensions mentioned are only indicative to clearly specify the example of panels.

 Other dimensions may be provided. The number, distribution and section of cells and spars may be different.

 FIG. 1 represents, in bottom view, the cellular pallet (1), according to the invention, which comprises several rows of cells (2). The hatched portions correspond to the base surfaces of the longitudinal members (3).

 Figure 2 shows the cross section of the pallet.

 The upper part of the pallet constitutes the plate (4).

 This cut on the cells (2) shows the side walls (5) which have a slight taper allowing good demolding.

 Figures 1 and 2 relate to an example of pallet with through holes.

 FIG. 3 represents the bottom view of an example of a pallet with cavities with a convex bottom. The hatched portions correspond to the base surfaces of the longitudinal members (3).

 Holes (6) may optionally be reserved in the curved bottom.

Figure 4 shows the cross-section of the pallet
This cut on the cells shows the side walls (5) which also have a slight taper, the bottom (7) curved shape, and the holes (6).

 Figure 5 shows the top view of an example of a mold.

 FIG. 6 represents the cross-section AA of the mold, when the cores make it possible to produce a domed pallet.

Figure 7 shows the BB cross-section of the same mold
The mold (8) rests on the manufacturing boards (9) serving as a mold bottom. The mold comprises a rectangular peripheral frame (10) on which is fixed a perforated plate (11)
The perforated plate (11) consists of a set of surfaces (12) having the same contour as the base of the cells.

 These surfaces are interconnected by junction tabs (13) & (14) which allow them to be joined and connected to the peripheral frame.

 The connecting lugs (14) are located at the edges of the side members.

 The perforated plate is used to suspend and position the cores (15) forming the cells.

 The filling of the mold takes place through the hatched surfaces (16).

 Under the junction tabs (14) of the perforated plate and between the cores are plates (17) of height equal to the height of the longitudinal members. These plates are used to form the edges of the side members.

 The upper part of the perforated plate, between the longitudinal members, has notches (18) where plates (19) slide, actuated by two jacks integral with the frame. The sliding plates (19) are only partially represented, and the cylinders are not indicated.

 Nipples (20) will eventually be reserved under some cores (15) to form the holes (6).

 In Figures 6 & 7 we can see the batteries of pressers (21) & (22) mounted on a frame (23). The pressers (21) are in line with the side members, while the pressers (22) are in line with the plate.

 If with this mold we want to manufacture flat honeycomb panels, ie without longitudinal members, it will be sufficient to put the pressers (21) at the pressers (22). The height of the panel will be adjusted by the filling time.

 FIG. 8 shows another example of honeycomb panels (1) with longitudinal members. The beams (3) have a different section narrower. Note the location of the holes (6). This type of panel can be a palette, but also suitable for other uses that we will analyze in Figures 9 & 10.

 Figure 9 shows in horizontal section a wall element made with the honeycomb panel shown in Figure 8 with the mark (24). Indeed with the panels (24), put alveolate sides of the rails against each other, we can build walls with an integrated insulation. The panels (24) can be secured by possibly threaded rods passing through the holes (6). Insulating boards (25) & (26) will be put in place.

The cells plugged by the plates (25) & (26) will contain air, which will be a complementary factor of insulation.

After incorporating reinforcing elements (27), concrete (28) will be cast to form stiffeners.

 Figure 10 shows in section a floor with integrated insulation. we can see the lower panel (24) on which is placed the bulk insulation (30) to the right of the ribs, and the insulating plates (31) between the ribs.

The upper panel (29) positioned on the panel (24), will be put in place the reinforcement elements (32) and the welded mesh (33). The concrete (34) will be poured afterwards.

The constructive possibilities of these panels are very important: pallet, wall, cladding, floor, formwork, etc.
We could not expose everything in detail. What is important is the manufacturing principle described in this patent application.

Claims (11)

RZVENDICATIONS  1) Honeycomb panels (1), manufactured on the press with agglomerates of wood and cement, consisting of a plate comprising rows of cells (2) alternately arranged in staggered rows, characterized by longitudinal members (3) which transform the said honeycomb panels in honeycomb pallet.  2) honeycomb panels (1) with or without longitudinal members, according to claim 1, characterized by rows of cells (2) simply aligned.  3) corrugated panels (1) with longitudinal members, according to claims 1 & 2, characterized by cavities with through holes.  4) honeycomb panels (1) with longitudinal members, according to claims 1 & 2, characterized by cavities with curved bottom (7).  5) honeycomb panels (1) according to claims 1 to 4, characterized by the shape of the longitudinal members which have a portion of their contour which embraces the cells, which allows to obtain forms both light and having a very large stiffness.  6) honeycomb panels (1), according to the preceding claims, characterized by the manufacturing technique which consists of casting in two phases, on the one hand the plate (4) and on the other hand the longitudinal members (3), thanks to the design of the mold which comprises two sliding plates (19) integrated into notches (18) of the upper part of the perforated plate (11). Sliding plates (19) are actuated by jacks.  7) Mold (8) according to claim 6, characterized by plates (17), located under the junction lugs (14) of the perforated plate (11) and between the cores (15). These plates (17) of height equal to the height of the side members are used to form the edges of the side members.  8) mold (8) according to claims 6 & 7, characterized by batteries of pressers (21) & (22) mounted on a frame (23) at different levels. The pressers (22) are in line with the plate, while the pressers (21) are in line with the side members.  9) mold (8), according to claims 6 to 8, characterized by the possibility of also manufacture honeycomb panels without spar, putting the pressers (21) at the pressers (22). The height will be adjusted by the filling time of the mold.  10) corrugated panels (24) with longitudinal members, according to claims 1 to 5, characterized in that they can become a wall element or cladding with integrated insulation. Said panels (24) placed honeycombed side members against each other, can be secured by threaded rods passing through the holes (6). Insulating plates (25) & BR <(26) will be put in place. After incorporating reinforcing elements (27), concrete (28) will be cast to form stiffeners.  11) Honeycomb panels (24) & (29) with longitudinal members, according to claims 1 to 5, characterized in that it can constitute a floor with integrated insulation. On the lower panels (24), upwardly honeycomb faces, will be placed the loose insulation (30) to the ribs right, and the insulating plates (31) between the ribs. The upper panels (29), honeycomb faces downward, will be positioned on the panels (24). Reinforcing elements (32) and the welded mesh (33) allow the concrete (34) to form the floor.