This object of the invention is solved by the features described in Claim
1. The surprising, unforeseeable advantage of this solution lies in that by the use of a synthetic material between the layer and the covering layer it is possible, even if this layer consists of foamed plastics, in particular of recycling material having a low specific gravity and a higher elasticity, to produce a very hard, load-bearing supporting layer on the layer surface and between this layer and the covering layer. Said supporting layer is, on the one hand. tightly connected both with the covering layer and the layer and forms a supporting cover for the covering layer, whereby it is now possible, in a surprisingly simple manner, to use also covering layers which may have extremely small wall thicknesses, for example only the thickness of foils of a magnitude of 0. 001 mm. Thereby the edge pressure strength and the risk of damage during production, storage and transport of the structural members are considerably reduced both in the region of these thin foils and in the region of covering layers having thicknesses ranging between 0.2 and 0.8 mm. Owing to the fact that this synthetic material can be used simultaneously for the bonding between the layer and the covering layer, it is possible to create a covering layer with high bearing strength in a fastening and forming on process. It is also advantageous to use as plastic a thermoplastic synthetic material, which can be liquefied at a temperature range wherein the foamed plastic layers forming the layer and the shaped body and having a low specific gravity do not lose their strength and wherein the cell structure of such foamed plastics does not break down. A further advantage when using a thermoplastic synthetic material lies in the reprocessin. and reworking of plastic arisings of such structural members, since thereby the separation of the plastic and the foamed plastics of the layer from the coverina layer can be achieved in a simple manner by heating the covering layer to an appropriately high temperature and by re-liquefying the thermoplastic synthetic material.
But in particular by this type of construction and by the reinforcement of the structural members directly below the covering layer it is possible to create very rigid, cantilever or self-supporting structural members provided with a shaped body. for example also a foamed plastic having a low specific gravity, which comprises a correspondingly great number of cells filled with air, the cells again having a high insulating effect. By making separation of the individual layers of the structural member possible, however. the recycling material recovered from such structural members can be utilized a-ain and again and used for the production of new structural members.
without their strength properties and heat insulation properties being impaired by this process.
A further development according to Claim 2 is also advantageous because due to the possibility of constructing the covering layer with the layer so as to be inherently stable, the latter can also be subsequently applied to prefabricated shaped bodies by means of a bonding process. Thereby a damage-safe production and storage of various different covering layers in different colour designs and surface types is possible, and the desired covering layer in each case can then be applied. for example on the site, to the forming body, which may already be attached, if necessary.
A variant of an embodiment according to Claim 3 makes it possible to insert already the layer with the covering layer positioned on it into the foaming mould and, as a result of the adhesive effect of the foamed plastic, to attach the shaped body directly to the layer. A further advantage of this solution lies in the fact that by utilizing this layer the same is impervious to liquids but not airtight and that, consequently, when producing large structural members with a high volume of the shaped body made of foamed plastic, the air displaced during the foaming operation of the foamed plastic can diffuse out in the direction of the layer, thus preventing cavities from being formed in the transition zone between the layer and the shaped body. This permits. on the one hand, a higher strength of the structural member and. on the other hand, it minimizes bulging and denting in the region of the covering layers of such structural members, in particular during exposure to the sun or one- sided heating to high temperatures, thanks to the absence of cavities or voids.
An embodiment according to Claim 4 is also advantageous because depending on the recycling material used during the waste disposal of recycling materials, the specific gravity and the damping behaviour as well as the strength of the structural member can be easily established.
By a further development according to Claim 5, in connection with the application of the covering, layer to the structural member, a processing of recycling plastics provided with hard or semi-hard coatings is made possible since the hard com- e ponents of the coatings are not pushing through the covering layers and consequently. there is no surface deterioration.
An embodiment accordin. to Claim 6 is also advantageous because. denending on the case of use and the recycling material arisinC, the composition of the layer can be easily varied.
A tight connection of the recycling materials and the flocks of foamed plastic is achieved by a variant of an embodiment according to Claim 7, whereby furthermore, in particular when using flocks of recycling material, the portion of the primary material for the production of the core can be held at a minimum.
A further embodiment according to Claim 8 achieves advantageously a tight embedding of the flocks into the core and in spite of it, a slight proportional increase of the specific gravity.
0 An embodiment according to Claim 9 is also advantageous because besides sufficient strength. a satisfactory elastictiy can be achieved for the reduction of vibration and for an elastic bearing between the two covering layers even when exposed to greatly varying temperatures.
0 By adapting the thermoplastic according to Claim 10 a universal matching of the structural members to various different cases of use can be achieved. A further advantage of this solution derives from the fact that the thermoplastics have a high hardness at the temperatures as they usually occur in the field of application of such structural members and, consequently, the edge pressure strength and impact resistance of the covering layer is substantially increased. Furthermore, during reaction and preparation of the connection between the layer and the covering layer, there is no disadvantageous change in the foam structure and the recycling foamed plastics in the layer - in particular, no oozing out of oil -, and enough strength of this layer is maintained, while at the same time any unevenness of the surface between these two structural members, as a result of the liquefaction of the thermoplastic when connecting the covering layer with the layer, can be levelled out, thereby permitting to produce also structural members with higher demands on the surface standard as regards the covering layer. Thereby, the creeD limit is increased and, in particular, the risk of delaminations is minimized.
Other advantages are shown by Claims 11 and 12. because thereby it is possible in a simple manner to permanently connect with cach other. by means of an additionally inserted intermediate layer, very different materials which do not form a stable connection with each other.
Moreover, it is advantageous when using thermoplasts to use those described in Claim 13. Thereby it is possible to take account of any required adhesive forces and hardnesses for the various different conditions of use.
A further development according to Claim 14 makes is possible to minimize disadvantages such as high brittleness in the as-cured condition, which occur in some thermoplastics, since through reinforcement of the thermoplastic its strength properties and, in particular its resistance to deformation, can be considerably increased in a simple manner. By the use of the thermoplastic which is liquefied when connecting the layer with the covering layer also adverse effects on the surface quality of the covering layer can be prevented, since by means of the liquefied thermoplastic the., unevenness between the layer and the covering layer, created by the supporting body, can be levelled out.
The wide variety of configuration possibilities of the covering layer, which permit a universal use of the structural members produced in such a way, in different areas of noice damping, e.g. the inside facing of vehicles, in the constuction industry 0 and the like, are shown by the features in Claim 15.
By a further development acording to Claim 16, such structural members can also be used in highly stressed regions, for example in regions wherein they are subjected to higher impact and frictional stresses, e.g. in tank or boiler lining.
0 A variant of an embodiment according to Claim 17 is also advantageous because thereby the supoorting body can be coated with the required materials, which can be easily handled due to the powder used during the production process, and for example can also be processed without adhering to the roller so that the thermoplastic synthetic material can only be liquefied when it is heated up accordingly, which ensures an even distribution over the supporting body. It is also recommended to arrange a foil of thermoplastic synthetic material, which is softened accordingly and which is plasticized or liquefied. since this way, the production of the structural member in accordance with the invention is -reatly simplified.
0 However, an embodiment according to Claim 18 is also possible wherein 1 the energy costs for the liquefaction of the thermoplastic material are kept lower. and C1 the use of various different raw materials for this thermoplastic synthetic material is possible.
-6 By a further development according to Claim 19 it is possible to use the thermoplastic synthetic material for the shaping or embedding of the supporting body without exceeding the temperatures which would lead to a disadvantageous change and cracking or an oozing out of oil of the cell structure of the core.
Furthermore, by a variant of an embodiment according to Claim 20, a disposal of such structural members is relatively easy, since the structure of the core, even if the latter consists of foamed plastics, is not destroyed during the separation and thereby, it is possible to reuse the foamed plastics as flocks for the production of a new structural element after said plastics have been torn up and reprocessed.
Moreover, an embodiment according to Claim 21 is also advantageous since the thermoplastic synthetic material besides the production of a sufficiently strong covering layer allows also for an all-over connection and application of a top layer without the need of applying an additional adhesive layer.
A variant of an embodiment according to Claim 22 is also advantageous because thereby fastening means are created which allow for greater tearing strengths 0 and an improved introduction of force than the use of the shaped body as fastening. elements.
A further development according to Claim 23 proved also very advantageous, because thereby before covering layers are applied, reinforcement elements can be mounted on the already prefabricated structural members in the different surface regions where they are needed.
An embodiment according to Claim 24 makes it possible to adapt the structural members in a simple manner to different fields of application and different kinds of stressing. Panels and foils of plastics are in particular suited for applications such as masts and poles and for indoor uses, where UV radiation is relatively low.
By a further development according to Claim 25, however, the use of the 1 1 structural elements is also possible for outside use. for example for heat- insulatin C' f c- a ing of tanks, silos, reaction tanks. e... settling tanks in waste water diSDosal and the like.
A variant of an embodiment according to Claim 26 allows for a simple adaptation of the outer covering layer of the structural element to various different applications and for a matching of the properties of the connection to the materials of the flocks used for the layer.
By the selection of the thicknesses of the sheet and the foil in accordance with the Claims 27 or 28 also the stresses to which the layer and the synthetic material are subjected and the corrosion resistances can be simply adapted to varying needs.
By a further development according to Claim 29 a good adhesive effect and c 0 stability for the subsequent connecting operation of the covering layer with the intermediate layer formed as hard layer can be achieved.
A high material strength and a higher total strength of the structural element is achieved by the embodiment according to Claim 30.
An embodiment according to Claim 3 1 is also advantageous because it is possible through the production of the shaped body also to connect at the same time the two covering layers to the latter.
In particular an embodiment according to Claim 32 prevents during the forming on of the shaped body, if this is made of plastic or foamed plastic, the formation of voids, since the air trapped during the foaming operation between the foamed plastic and the covering layer can diffuse out in the direction of the layer.
An optimal utilization of recycling plastics, in particular of structural members made of foamed plastic, can be achieved by a further development according to Claim 33.
A better adhesion between the individual layers can be obtained by a variant of an embodiment according to Claim 314.
A uniform hardness and a high edge pressure strength of the layer and a good backing of the covering layer can be achieved by the -embodiment according to Claim 35.
A variant of an embodiment accordinú! to Claim 36 has the advantage that polyurethane is reacting only under predetermined conditions and. consequently. the operation until the time of reaction can take place with a dry mixture for the layer and the shaped body.
Furthermore, the invention encompasses also a method for the production of a multi-layered structural member as described in the generic term of Claim 37.
0 This method is characterized by the measures according to Claim 37. Due to this type of production, it is now possible to carry out in a simple way a cycle production for large series of such structural members, whereby the handling for the production of the structural members can be greatly simplified for the individual compnents. In addition, some of the materials used can now be processed directly from the roller, and often an application of liquid components, in particular adhesives admixed with solvents and the like, is no longer required. In addition. structural members for various different requirements can be produced according, to the same system with very few changes during the course of production.
By the measures according to Claim 38, it is achieved that also a threedimensional shaping of the member can take place by using the temperature, which is needed to liquefy the thermoplastic synthetic material, whereby it is also possible to ensure a different threedimensional shape by means of a differently strong compression of the core, in particular of foamed plastic elements in the core, without that the cell structure of the core has to be thermally deformed and cracked, since only by pressing the elastic core materials the latter are proverbially frozen in the prestressed state due to the solidification of the thermoplastic covering layer, and thereby their elasticity properties are not destroyed or eliminated in Mite of the higher density and specific gravity. Consequently, the damping properties of such structural members, in particular during noise damping, are very good.
An even greater three-dimensional deformation and, if required, partial strengthening of the cell structure of the core can be achieved by proceeding according c to Claim 39. In individual cases it is thereby also possible to get by with low forces of pressure for the spatial deformation of structural members.
By proceeding according to Claims 40 and 41 a uniform distribution of the intermediate layer provided as hard layer over the entire connection area is achieved. whereby shrinkage is reliably avoided during the heating operation.
Due to the measures according to Claim 42, it is only necessary to reduce the recycling materials used to the appropriate flock size and to loosely feed it in the desired mixing ratio to the processing unit.
Proceeding according to Claim 43 is also advantageous because it does not result in additional increased dust exposure in the work area of the installation.
By proceeding according to Claim 44 one achieves a simpler assembly of the installation and a better control of the process sequence.
The measures according to Claim 45 permit a strengthening of thestructural c L_ C member, for example in fastening regions, so that these members receive almost the 0 structure of a solid material component with the advantages of a sandwich construction.
By using a plastic according to Claim 46 and the appropriate heating, it is possible to use a range of different materials for the layer which do not lose their mechanical or chemical properties.
By the measures according to Claim 47, a separate waste disposal of the individual coatings and layers of the structural member is ensured in a simple manner.
term of Claim 50.
By a variant of an embodiment according to Claim 48, the thermoplastic synthetic material can be almost completely removed from the supporting body.
However, it is also advantageous to proceed according to Claim 49, since in one processing step with a supporting layer required for the mechanical properties of the structural member, the connection can be made simultaneously to the different top layers.
Furthermore, the invention comprises a device as described in the generic This device is characterized by the features described in Claim 50. Thereby. it is advantageous to create an in-line method, which, especially when the same supporting body is used for the two covering, layers, is enough to get by with a 1 1 C manufacturing installation for the supply of the top layers and the introduction of ihe thermoplastic synthetic material for the production of the structural member. Thereby, it is also possible that after the covering layer has been supplied, several form tools can be provided, which can be alternately fed from a continuing feeding installation whereby the output of such a manufacturing device can be greatly increased.
Finally, an embodiment of the device according to Claim 51 is also advantageous, because thereby the individual coverina layers can be held in a precise position 0 0 during the forming and deforming process and during curing, whereby a displacement 1.
of the vacuum slots can be prevented in that after the compression and positioning of the covering layers and the layer in the mould by means of these vacuum slots, if required, air for cooling can be supplied for the rapid solidification of the shaped part.
The invention will now be described by way of example with reference to the accompanying drawings, in which:- Fig. 1 is a side view, in section and a simplified, diagrammatic, exploded representation of the individual layers of a multi-layered structural member constructed in accordance with the invention:
Fig. 2 is a side view, in section and a simplified, diagrammatic. exploded representation of a different structure of a multi-layered structural member in accordance with the invention Fig. 33 is a side view, in section, of another lay-up of a multi-layered structural member in accordance with the invention. and with a spaced representation of the individual layers; Fig. 4 Fia. 5 C is a side view, in section, of another embodiment of the lay-up of a multi-layered structural member in accordance with the invention, likewise with a spaced represenmtion of the individual layers:
is a side view, in section and a simplified. diagrammatic representation of a possible structure of a multi-layered structural member Fig. 6 is a side view. in section and a simplified, diagrammatic representation of anothe.r embodiment of a multi-layered structural member in accordance with the invention:
Fig. 7 Fig. 8 is a simplified, graphic representation of a container lined by means of multilayered structural members constructed in accordance with the invention; is a plan view, in section along the lines VIII-VIH in Fig. 7, of a part of the container with the multi-layered structural members constructed in accordance with the invention, Fig. 9 is a plan view, in section and an enlarged. diagrammatic representation of two multi-layered structural members according to Fig. 8-, Fig. 10 shows the multi-layered structural members at the joint abuttal, in section along the lines X-X in Fig. 7-, shows the multi-layered structural member with the covering layer, the intermediate layer and the layer, after forming the impressions with a tool indicated schematically; Fig. 12 is a side view, partly in section, of a variant of an embodiment of a boiler lining 0 made of multi-layered structural members in accordance with the invention:
Fig. 13 is a front view, in section along the lines XIII-= in Fig. 12, of a part of the boiler lining according to Fig. 12 in the area of the fastening device., Fig. 14 is a side view and a simplified, diagrammatic representation of a device for the production of a multi-layered structural member in accordance with the invention:
Fig. 15 is a side view and a simplified, diagrammatic representation of a different embodiment of a device for the production of a multi-layered structural member in accordance with the invention.
Fig. 1 shows the individual layers of a multi-layered structural element 1 spaced apart, in a simplified, diagrammatic representation.
This multi-layered structural member 1 is composed of a layer 2 consisting of flocks 3 to 5 of recycling and primary synthetic materials, in particular foamed plastie. Thus, the flocks 3 to 5, which are shown schematically in a different representation in Fig. 1, can consist of different materials. The flocks 3, for example, - l-) - can be formed by recycling foamed plastic having a hard and/or semi-hard or soft consistence. The flocks 4 again can consist, for example, of thermoset plastics and thermoplastics or coating materials such as, for example, textiles, leather, plastics or imitation leather. Furthermore, it is also possible, however, to use as material for the flocks 4, for example, waste textiles and/or paper and/or paperboard and/or textile remnants and/or leather andlor metal and/or threads and fibre material of coal, ceramics, glass, graphite, kevIar, metal, textiles, etc. and any combination of any of the above materials. Finally, the flocks 5 can be provided from different synthetic materials, in particular flocks of foamed plastic with coatings of textiles, leather, synthetic materials or imitation leather. The materials of the flocks 3 to 5 can, of course, be used in any mixing ratio required for the development of the layer 2.
The individual flocks 3 to 5, by means of a plastic of primary material, for example foamed plastic of polyurethane or polyethylene or the like, are combined into a coherent layer, for example a plate or the like. This layer 2 can also be produced by combining the flocks 3 to 5 by means of the plastic 6 into a foamed block, which can be divided up into individual plates by means of known cutting devices, and it is also possible to prefabricate the individual flocks 3 to 5 due to their inherent adhesive force into rolled stock, which subsequently can be fed to further production operations.
The foamed plastic forming the synthetic material preferably comprises a large number of open cells 7, which are separated from one another by means of cellular webs 8. In the embodiment presented the layer 2 is already shown in a compacted state, in which the cells 7 and the cellular web 8 are deformed under the action of pressure and temperature and are fixed in this deformed position by cooling. The specific gravity of the layer 2 is therefore in dependence of the free-rising density and dependent on the weight and specific gravity of the flocks 3 to 5 and of the plastic 6 and, in addition, can be adjusted to any desired values by means of a cracking process, so that, for example due to the fusion of open cells in the region of the opposite surfaces 9 and 10 of the layer 2 a structural part is created which is impermeable to fluids. but is permeable to -as.
0 This compaction of the layer 2_ can take place before connecting the laver 2 with a covering layer 11 or at the same time as the connection of the coverinG laver 11 is made. This connection between the covering layer 11 and the layer 1 is effected via an intermediate layer 12. This intermediate layer 12 is,,ormed by a supporting body 1 - 1 z:k 13, for example a net, knitted fabric, lattice or the like of fibres 14 and 15, which is embedded in a synthetic material 16. Here it is possible to apply the synthetic material 16 in a pulverulent or paste-like consistence to the supporting body 13.
If, for example, the covering layer 11 is put into the mould, the supporting body 13 provided with the synthetic material 16 is placed onto it and the layer 2 is positioned onto these and the mould is closed, it is possible to achieve, for example by exerting a pressure on this sandwich structure via individual moulding surfaces and under the action of temperature, a liquefaction of the thermally or chemically bonded synthetic material 16 and at the same time a spatial deformation of the cellular webs 8 and of the cells 7 of the layer 2, wherein this deformation can even be increased by the degree of heating. If, in fact, the layer 2 is exposed to a higher temperature, the synthetic material of the layer 2 is also softened, which causes an even greater deformation of the cell structure of the layer 2 and a greater liquefaction of the synthetic material 16 of the intermediate layer 12. If on sufficient liquefaction of the synthetic material 16 of the intermediate layer 12 the further supply of heat is stopped and the structural member 1 is cooled down to a temperature at which an adequate strengthening of the synthetic material 6 and of the synthetic material 16 of the intermediate layer 12 is achieved, the structural member 1 in this compacted and now spatially stable form can be taken out of the processing mould.
It is of course also possible to loosely insert the individual layers illustrated in Fig. 1, namely the covering layer 11, the intermediate layer 12 and the layer 2_ into a heating device, for example into a heating channel, in which then the deformation of the covering layer 11 of the intermediate layer 12 and of the layer 2 into the desired spatial shape and simultaneously the cooling takes place, so that the above mentioned layers are frozen so to speak in the desired spatial shape. Thereby, on withdrawal of the structural member, the cellular webs 8 and the cells 7 in the layer 2 retain their deformed compacted state just as the liquefied synthetic material 16 of the intermediate layer 12 has been uniformly distributed between the covering layer 11 and the layer 2 or has infiltrated into and penetrated the surface 10 of the layer 22, facing towards the covering layer 12 and, consequently constitutes a permanent, tight and rigid connection between the elastic layer 2 and the covering layer 11.
C Thanks to this hard, intermediate layer 12 reinforced by the supporting body 13 it is now advantageously possible to use very thin covering layers. for example even foils having a thickness of less than 0.2 mm downto a thickness of only 0.001 mm, and structural members produced in this way have a hardness of their covering layer which is substantially higher than for known structural members, where the covering layers 11 are foamed directly with a foamed plastic.
The semi-finished product prefabricated in this way, namely the covering layer 11, the intermediate layer 12 and the layer 2, which now after heating and compression constitute an integrated structural member, can then be put into a foaming mould, in which, for example by introduction of a liquid synthetic material on the surface 9 of the layer 2, a shaped body 17, e.g, of foamed plastic, that is a synthetic material 18, which may be formed by closed or open cells 19, 20, can be formed on.
When producing this shaped body of PU cold-curing foam or of a differently doped foamed plastic having a hard or semi-hard consistence, simultaneously 0 with the connection of the shaped body 17 to the layer 2 a further covering layer 21 may be connected to the shaped body 17, if a further covering layer 21 is positioned correspondingly on a forming element.
Depending on the intended use of the structural member 1 to be produced, this further covering layer 21 can consist of cardboard, panels or foils of synthetic material, metal or textiles, for example jute or knitted fabrics. batts or fabrics of fibres and threads of synthetic material and natural substances.
Fig. 2 shows another possible structure of a structural element 1 in accordance with the invention. Therein the multi-layered structural element consists of a covering layer 11, a layer 2 and the shaped body 17. Whereas the shaped body 17, as re-ards its basic structure, as well as the layer 2 and the covering layer 11 can be constructed in the same way, as this has been described already on the basis of Fig. 1, the connection between the layer 2 and the covering layer 11 is made by means of the synthetic material 6. This is possible, in part. by the fact that. for example flocks 22, '213 of hard or semi-hard polyurethane are mixed with a polyol, whereby this polyol through chemical combination or thermal bonding can be in a pulverulent state at room temperature. Consequently, the mixture of the flocks 22, 23 with the synthetic material 6 would constitute a dry mixture which, after insertion of the covering layer 11 into a mould, is applied in a sufficient coating, thickness. After the mixture has been applied. this synthetic material 6 together with the flocks 2-2. 23 can be activated by the effec.. of heat or by the effect of steam or other processing steps and interconnects the flocks and simultaneously connects these flocks 22, 23 with the c-!Is 24 of the synthetic material 6, located inbetween, and with the covering layer 11.
By this preferred variant of an embodiment it has become possible to use, for example, recycling foamed plastic arisings from damaged or previously produced and dismantled structural members for the production of the layer 2, whereby then the linking of the flocks 22, 213 among themselves and their connection with the covering layer 11 can be effected by means of the synthetic material 6, or more precisely the polyol mixed into the flocks 22, 23.
An appropriate doping of polyol has rendered it also possible that polyol forms a hard, highly shock-resistant supporting layer between the surface 10 of the layer 2 facing towards the covering layer 11 and the covering layer 11, which counteracts a deformation of the covering layer 11 in the direction of the layer 2 when subjected to impact- or edge stresses.
In this case, too, the shaped body 17 can be produced by foaming, after the semi-finished product formed by the covering layer 11 and the layer 2 has been produced. Likewise, it is possible to bond the shaped body 17 by an adhesive to the surface 9 of the layer 2, facing away from the covering layer 11, and individual or further covering layers 21 - as indicated by broken lines - can of course be provided on the surface of the shaped body 17, facing away from the covering layer 11.
In Fig. 3 another variant of an embodiment of a structural member 1 in accordance with the invention is illustrated, with the individual layers shown in a position separated from each other.
In this exemplary embodiment the covering layer 11 is connected with the layer 2, which can be developed according to the embodiments in Fig. 1 or 2, via an intermediate layer 25, which is formed by a batt 26 and a synthetic material 16. The synthetic material 16 can be inserted into the batt 26 in a manner that the batt 26 is impregnated with the synthetic material 16 or that the synthetic material 16 is applied in the form of a paste onto the batt 26 or is placed in solid form on the surface or in the batt. It is of course also possible, however, that individual threads 27 of the batt are made of such a synthetic material 16 as, for example, polypropylene. polerhylene, etc., so that during subsequent heating and. if required. through the action of pressure.
C tP 'D the threads 27 liquefy and impregnate the batt with this synthetic rnaterial 16 and simultaneously make the connection between the layer 2 and the covering layer 11.
Another embodiment is also possible, wherein the entire batt 26 is formed by threads 27 of the synthetic material 16, so that during heating and under the action of pressure the entire batt 26 is liquefied and can be used for connecting the layer 2 to the covering layer 11. The advantage of this embodiment lies in the fact that also recycling plastics, that is arisings, reprocessed by a suitable pretreatment can easily be used for the production of this batt, since also mixed thermoplastics of different primary materials may be processed into threads for the batt with the result that individual threads of the batt of synthetic materials, which have higher softening temperatures, form a net framework which then reinforces the intermediate layer 25 like a supporting body. Furthermore, it is advantageous if additionally, for stiffening and reinforcement, individual threads or fibres of metal and /or kevIar and/or coal and/or graphite andlor glass andlor ceramics andlor textiles and/or synthetic materials and/or natural materials are incorporated in the batt 26 formed by individual threads or fibres of polypropylene, which become embedded in the liquefied synthetic material 16 during the heating process and which additionally stiffen or reinforce the intermediate layer 25 after cooling. Thereby a thermoplastic hard layer is developed.
Such an embodiment likewise can result in a very hard and resistant intermediate layer 25 and simultaneously can make a high-stren-th connection between the layer 2 and the coverin - layer 11.
c According to the exemplary embodiments described hereabove the shaped body 17 and, if required, one or several additional covering layers 21 may then be ap- 0 plied to the layer 2 by adhesive bonding or by foaming or the like, in the way described herabove.
In connection with the shaped body 17 it is furthermore to be stated that its thickness at ri-ht an-les to the covering layer 11 may vary according to the different 0 0 C purposes for which the structural member 1 is employed, and that the shaped body 17 can of course also consist of several different components or panels of identical or different synthetic materials having identical or different specific gravities.
Fi.. 4 shows a structural member 1 which essentialIv has the same structure as the structural member 1 illustrated in Fig. 3. Therefore the same reference numbers are used for the same parts.
In order to obtain even better adhesion of the intermediate layer 1-5 to the covering layer 11, however, an interlayer 228, e.g. a PE-foil or a coating made of such a material or another foil of synthetic material which may be used as a fusible adhesive foil or additional adhesive layer and shows good adhesion, is arranged between the intermediate layer 25 and the covering layer 11. In the present example of embodiment, this interlayer 28 may be used as bonding agent between the synthetic material 16 of the intermediate layer 25 forming the hard layer and a surface 29 of the covering layer 11, which faces towards said intermediate layer. Depending on the material of the intermediate layer 25, it is also possible to produce the interlayer 28, for example from polypropylene, polyamide, PVC or other synthetic materials or adhesives.
If, for example an aluminium panel or foil is used as material for the covering layer 11, it is also possible that this interlayer 128, as shown in one part of Fig. 4, is directly applied to the surface 29 of the covering layer 11. This prevents oxidation. in particular in the case of aluminium sheets or foils, so that a very stable and permanent connection between the intermediate layer 12 or 25 and the covering layer 11 can be obtained. It is also possible, however, to use as material for the covering layer 11 or 21 e.g. paper and/or plastic foils and/or paper film and/or plastic foils with highvacuum metal depositings, such as aluminium and/or knitted fabric andlor fabric and/or nets made of a variety of different materials. Such foils and materials are already obtainable commercially in most varied coatings. such as for example with PEcoatings.
The arrangement of such an interlayer 28 formed by a fusible adhesive foil is of course also possible in the case of structural members according to the examples of an embodiment in the Fi..s 1 to 3.
0 Fig. 5 now shows a structural member 1, with the individual layers connected with each other.
This structural member 1 comprises a covering layer 11 which is corrugated or tufted, such a type of surface of the covering layer 11 being especially advanta-eous where this covering layer 11 is formed by a foil. for example an aluminium foil having a thickness of less than 0.2 mm, c.g. of 0.009 mm. Thereby, wrinkle formation in the production of the strutural member 1. in particular when applying the intermediate layer 25, is avoided in that the appropriately developed foil 30 of the covering layer 11 can be drawn onto the mould wall by vacuum, whereupon the batt 26 with the svnthetic material 16 can be applied to connect the covering laver 11 to the laver 2.
As is shown schematically in this illustration, during liquefaction of the synthetic material 16, when connecting the layer 2 with the covering layer 11, the liquefied synthetic material 16 partly diffuses or flows into cavities of the layer 2 and therein hardens during subsequent cooling. Thereby, a good denticulation between the intermediate layer 25 and the layer 2 is provided.
Likewise, a tight connection between the shaped body 17 and the layer 2 is obtained, if the shaped body 17, as already described in the exemplary embodiment in Fig. 1, is directly formed onto a surface 9 of the layer 2 by a foaming operation.
Accordingly, the dividing line between the layer 2 and the intermediate layer 25 and the shaped body 17 was merely drawn by broken lines, since the individual parts practically merge. This causes at the same time, however, a tight connection of these components, so that the stresses occurring in the covering layers 11, 21 for example due to varying temperature stresses or great temperature variations, can be transferred, even for a long time with long-lasting effect. to the layers situated behind them, without causing delaminations or disbonding between these layers.
Of course it is also possible in this embodiment as well as in the embodiments described by way of the Fig.s 1 to 4 that the shaped body 17 can be mixed by adding recycling materials, for example plastic scraps of different kind, such as thermoset plastics, thermoplastics, prepolymers, monomers and the like, or can be produced solely from such parts by sintering or compression moulding processes.
It is also shown in the case of the structural member 1 illustrated in Fig. 6 that after assembly of the individual layers, as they have been described by way of Fig. 4, the interlayer 28 dissolves under the action of heat and pressure and forms a connecting link or a kind of adhesive layer between the covering layer 11 and the intermediate layer 25. The connection of the remaining layers, namely the intermediate layer 25 to the layer 21 and the layer 2 to the shaped body 17 as well as the shaped body 17 to an additional covering layer 21, if any, is effecied in the way as already explained in detail on the basis of the above exemplary embodiments shown in Fig.s 1 to 5.
Fi.. 7 shows a possible application for the use of structural members 1 for the insulation of a storaú!e container 3 1.
The storage container 31 is produced in approximately cylindrical form and can be utilized as large storage container, for example for fluid substances such as mineral oils, bitumen or liquefied gases such as liquid oxygen and nitrogen or as cornposting tower. A longitudinal axis 32 of the storage container 31 runs approximately at right angles to a supporting surface 33. The storage container 31 may consist of steel plate or concrete or the like. For thermal insulation of the storage container 3 1, its outer side is encircled with the structural members 1, acting as insulating elements.
The structural members 1 are constructed as straight panels 34 and are provided with coupling and/or reinforcing elements in the area of their longer lateral edges 35, 36 and in the area of their shorter lateral edges 37, 38.
As apparent from the detail shown in Fig.s 8 and 10, the coupling and rein- forcing elements in the area of the shorter lateral edges 3)7, 38 are formed by steps 40, which are arranged in mirror symmetry with respect to the panel surfaces 39. The coupling and/or reinforcing members in the area of the longer lateral edges 35, 36 are formed by tongues 41 and grooves 42 which are of complementary mating form. A cross-section of the tongue 41 has a greater arc length than a cross-section of the groove 42. The panels 3)4 may thereby by placed in different angular positions with respect to each other, which means that panels 34 which are identical may be utilized to face storage containers J3 I having different external diameters.
As also apparent from the drawing in Fig. 7, the panels 34 lying one beside c another in peripheral direction are in each case laid in staggered pattern, staggered by c= c half a panel length in each case, in the direction of the longitudinal axis 32. This forms a solidly jointed structure, thereby securing a high degree of inherent rigidity of the facin g.
It is shown moreover in Fig.s 7 and 10 that a coupling and/or reinforcing element of a tensioning device 44 is situated at an approximately identical distance 4321 from the two narrower lateral ed-es 37, 38 of the panels 34. This tensioning device 44 comprises a transverse tensioning element 45 which is integrated in the panel J34 durin- foaming. The transverse tensioning element 45 may be provided with openings which mav be traversed by the plastic material of the panel 34 during the foaming ODeration. The transverse tensioning element 45 is thereby solidly anchored inside the panel 34 and is apt to bear greater tractive forces.
0 The extremities of the transverse tensioning element 45 are joined to coupling members 46, 47 in force-locked manner.
The coupling members 46, 47 of two adjacent transverse tensioning elements 45 may be interconnected and form a coupling device 48. The coupling device 48 may simultaneously also be constructed in the form of tensioning element. It is also possible, however, for a reinforcing element 50 to be provided in the area of webs 49 left beside the said step. It is possible in this case to tension the transverse tensioning elements 45 in each case and to join these in the tensioned condition to the reinforcing element 50, e.g. by means of nails or screws, whereby the connection between the coupling members 46 and 47 of two adjacent transverse tensioning elements 45 can be performed at the same time by means of these nails or screws. A hermetic and solid cohesion between the separate panels 34 is obtained thereby.
The coupling device 48 is shown in section in Fig. 10. The coupling members 46 of adjacent transverse tensioning elements 45 are provided with cross-ribs or a denticulation on the sides facing towards each other. The coupling member 47 is formed by a sleeve which enflanks the two coupling members 46. The coupling members 46, 47 are compressed and immobilised in the tensioned state in their position with respect to each other. by a deformation of the coupling device 48. It is of course also possible for the coupling member 47 organised as a sleeve for example, to be provided with transverse fins of a milled surface or the like at the side facing towards the coupling members 46, so that apart from the frictional immobilisation a shape-locked immobilisation of the position of the transverse tensioning elements 45 in the coupling device 48 is also established. It is also apparent from Fig. 10 that the panels 34 may be made of complementary form in the area of their lateral edges 37 and 38. A projection 51 in the area of the lateral edge 38 thus has allocated to its step 522 of approximately identical thickness, which however extends over a part only of a height 53 of the projection 51. This step 5- 1 is adjoined by an excision 54 which forms an open space for the transverse tensioning element 45 and the coupling device 48. A height 55 of a projection 56 in the area of the lateral edp-e 37 is smaller by the amount 57 of the overlap of the projection 51 and of the step 52 than the height 53 of the projection 51. In a terminal edge of the projection 56 is situated an approximately Vee-shaped roove 58 which has associated with its bearin. web 59 in the area of the lateral ed,-e 3.7 of the panel 34, which has a complementary structure. A lateral surface 60 of this bearing web 59 slopes in the direction of the panel surface 39. whereas a 'lateral surface 6i slopes towards the panel surface 39 in the direction of the lateral edge 38. Thanks to the oblique extension of the lateral surface 60, the panels 34 may be placed one on another, since the oblique lateral surface 60 causes a lateral surface 62 of the step 52 to be thrust against the oppositely situated lateral surface of the projection 51. Any water or humidity which may enter the gap between the mutually opposite lateral surfaces 61 of the groove 58 and of the bearing web 59 may run off outwards and downwards thanks to the oblique shape of the lateral surface 61. The penetration of humidity into the insulation is made even more difficult thereby, without the need for costly sealing means. It is of course possible to install a joint as well in the region of the lateral surface 6 1, which may for example consist of a lip joint which closes off a possible unoccupied space between the groove 58 and the bearing web 59, or this cavity may be filled with foamed plastic, or an adhesive or a sealing composition. may be inserted between the lateral surface 60 of the bearing web 59 and the oppositely situated lateral surface of the projection 56.
Thanks to the utilization of the bearing web 59 the mutually associated lateral edges 37, 38 are prevented from separating or being deflected in the event of a suction effect, and primarily during a wind loading on the storage container 31, and as an extra to the action of the transverse tensioning elements 45, the risk that individual panels 34 may be turned out of the structure by the negative pressure or suction is thereby reduced.
In Fig.s 7 and 8, panels 34 constructed as insulating elements are installed on the outer side of a cylindrical wall of the storage container 3 1 with vertical longitudinal axis, that is to say parallel to the generatrix of this cylindrical wall. Each panel 34, which may be provided with a covering layer, e.g. of aluminium, on its outer side, has a -roove 42 in the one narrow longitudinal side or lateral edge 35, and at the oppositely situated narrow longitudinal side or lateral edges 36 has a coupling projection or a tongue 41 (Fig. 8), the coupling projection, that is the tongue, and the groove 42 being of complementarty fitting form. In plan view, the two elements - tongue 41 and,groove 42. - have an arcuate outline, the arc length of the groove 42 being greater than a semicircular arc and the are length of the coupling projection is even greater than that of the cross-section of the -roove 41 To install an insulation of this nature. the coupling projection or the:ongue 41 of a panel 34 is inserted into the groove 42 of the adjacent panel 34 in its longitudinal direction, and the panels 34 thus joined together are laid around the wall of the storage container 3 1, whereupon the insulation is already half-finished.
- 11) - As also apparent from Fig. 8, each panel 34 is provided transversely to its longitudinal direction, at the stepped contour or step 40, with reinforcements protecting the rigid foam material against deformation, e. g. a reinforcing member 50 of plywood, that is to say at the upper marginal portions only.
0 In order to permit an appropriate overlapping of the tongue 41 and the groove 42, as shown in Fig. 9, the two flanks 63 delimiting the groove 42 project by a height 64 between 2 mm and 15 mm. preferably 7 mm, beyond a diametrical line 67 through the centre 68 of the semicircular crosssection of the groove 42, said line being parallel to the connecting line 66 of the front sides 65 of the flanks. As also apparent from this illustration, the connecting line 66 is at a slope of < 90' towards an outer surface 69. It has become possible thereby to wrap a convex surface through fitting adjacent structural members 1 or the panels 3)4 into each other. If, for example, a concave outer surface is to be faced with the structural members 1 or the panels 34, it is likewise possible to position this connection at an angle towards the outer surface 69, which is greater than 90.
The structural member 1 in accordance with the invention or the panels 34 can be built-up according to the different variants of structure shown in Fig.s 1 to 6.
1 The panel 34 as shown in Fig.s 8 and 9, for example, consists of a covering layer 11 formed by aluminium plate and provided with trapezoidal depressions 70 to obtain a higher degree of rigidity on the outer side. This covering layer 11 is connected with the layer 2 by an intermediate layer 122 and 25 as shown in the examples of the embodiment described above. To this layer'-', for example, the shaped body 17 is attached by a forming-on operation.
0 The procedure followed in the production of the panel 34 is that first of all a semi-finished part. that is a prefabricated semi-finished product. consisting of the covering, layer 11, the intermediate layer 12 and 25 and the layer 2. is produced. In those regions where the covering layer 11 has to be spatially deformed. flor example in the region of the flanks 63 and in the transition zone to the tongue 41, the prefabricated component consisting of the covering layer 11, the intermediate layer 1Z and Z5 and the layer 2, is provided in the corner regions '71, 72-, 73, 774 and 75. as shown in Fie.. 11, with impressions 76. wherein for exampie the intermediate layer 12---2-5 ' and the layer 2 are compressed to a smaller wall thickness 78 as compared zo a hickness 77. Therebv, a "oint in the nature of a film hinge;S dCVC10Ded in the corner reQions -2, J 73 and 74, which makes it possible to perform the trimming of the covering layer 11 with the intermediate layer 12, 25 and the layer 2, to enable this semi-finished component to be inserted into a foaming mould or the mould for the production of the shaped body 17.
This achieves in a simple manner that marginal strips 79, 80 can be swung inwards so that they are situated inside the shaped body 17. This prevents the covering layer 11 from separating from a surface of the shaped body 17 in the region of the C mar-inal strip 79, 80, these marainal strips 79, 80 are firmly anchored inside the 0 0 shaped body 17.
As furthermore shown schematically in Fig. 9, it is also possible for the panel 34 to be furnished on its two mutually opposite surfaces 81, 82 with a corresponding covering layer 11 provided with a layer and/or intermediate layer. If necessary, it is also possible that the covering layer 11 and an additional covering layer 211, as shown in a further panel 34, may consist only of one layer of cardboard, aluminium, steel plate or the like. However, the marginal strips 79, 80 of such covering layers 21 are preferably folded back such that they protrude inside the shaped body 17, thus preventing also delamination of the same.
The covering layers 11, may, if these are connected with the intermediate layer 12, 25 and /or the layer 2 and are arranged on mutually opposite surfaces 81, 82 of a panel 34, be made of different materials, for example, on the outside, of steel plate or an aluminium foil and, on the inside, of a fabric or a thin plastic foil.
The covering layers 11 which show lower stressability in most cases are ar- rancred on the surface 82 of the panel 3)4, facing towards the storage tank 3 1, since they are not directly under the effects of the weather or exposed to other kinds of stresses. The covering layers 11 and 21 arranged on the surfaces 82 can rather be adapted to the in. mediate environment conditions prevailing in the area of the storage tank 31. It is thus advantageous if the storage tank 3 1, in which very hot gases and liquids are stored, is selected so as to have covering layers 11 resistant to elevated temperatures, whereas in the case of liquids and gases, which are stored at very low temperatures in the storage tank 3 1, covering layers 11 and 21 are of advantage whic.11 even at low temperatures show a certain minimum elasticity and will not become brittle or will not crack.
Fig.s I'- and 13 show another variant of an embodiment of structural members 83 to 85 in accordance with the invention.
These structural members 83 to 85, for example, form an insulation cover 86 for a hot-water, electric or gas-heated boiler. In the present case, the structural members 83, 84 form half-shells of the ho 11 o w-cylindershaped insulation cover 86, whereby end wall portions 88, preferably in one piece, are formed onto the cylindrical wall portions 87 in a front end region. In the opposite end region, the structural member 85 constructed as a cover is put onto the assembled half-shell, i.e. the structural members 83, 84. The two structural members 83, 84 are fixed in their position to each other in the region of the end wall portions 88 by means of a ring with L-shap'ed crosssection, in the same way as the structural member 85 forming the cover 89 in the upper end region of the insulation cover 86 is held in the position shown via a securing ring 90.
To obtain an adequate fixing in position of the structural members 83 to 85 with respect to each other. a coupling device 91 having a snap buckle is provided between the structural members 83 and 84. For this purpose. a locking strip 92 is pivoted by means of an excenter lever 93 in peripheral direction of the insulation cover 86 and. for tensioning the two structural members 83, 84, it engages at a specific setting posi- t -1 -C1 tion of the locking stop 94, which corresponds to the required degree of tension. A burred tape arrangement. for example, can also be used as coupling device 91.
In order to achieve a plane outer surface of the insulation cover 86, the coupling device 91, as is more clearly apparent from Fig. 13, may also be arranged in a recess 95 in the surface of the structural members 83, 84.
As also apparent from the drawing in Fig. 12, the structural members 83) to 85 can again be provided at their outer side with a coating, protecting the shaped body 17 of foamed plastic, in particular insulation foam, and consisting of a covering layer 11, a layer 2 and, if necessary, an intermediate layer 12 or 25 arranged between these. The covering layer 11 and the layer 11 and, if necessary, the intermediate layer 12 and 25 may in this case extend in one piece overthe wall portions 87 and the end wallportions 88. The structural member 85, that is the cover. 89, can likewise be provided with an identical protective laver, consisting of the covering laver 'I l. the laver and, if necessarv, an intermediate layer 12 or 25 as a protection against damage from outside, in particular during transport, storage and assembly.
It is of course also possible to arrange a covering layer 21 or an identical, protective layer formed by a covering layer 11, layer 2 and, if necessary, an intermediate layer 12 or 25 on the inner surface of the structural member 83 to 85 facing towards the boiler.
The layer 2 in the above described variants of an embodiment can consist between 70 % and 95 %, preferably 85 %, of flocks 3 to 5 of foamed plastc. Another 10 % to 20 % of the weight of the layer 14. can be formed by a foamed plastic 10, e.... polyurethane and/or a thermoplastic. Both the foamed plastic and the thermoplastic can be formed either by recycling materials produced from plastic scrap or by primary materials.
Recycling foamed plastics, whose specific gravity or free-rising foam weight is 30 kg/M3 and 150 kg/M3 j, are preferably used for the production of flocks 3 to 5 for the layer 2.
A specific gravity of the shaped body 17, in particular formed by a cold curing foam, can be be between 30 kg/M3 and 80 kg/M3. By the arrangement of the intermediate layer 12, 25 and by the consolidation of the layer 2 in the surface area facing towards the covering layer 11, the specific gravity can be reduced to 40 kg/m3 or less. The shaped body 17 of the structural members that are known so far would have to be produced with a higher specific gravity, in order to obtain an adequate stability of the covering layer 11.
By the use of a thermoplastic synthetic material 6 and 16. primarily in the intermediate layer 12 and 25, which may be formed by polyethylene, polyamide, polypropylene, polystyrene, PVC, polyamide, ABS or the like, especially if this intermediate layer 12, 25 is reinforced by a fibreshaped or thread-shaped supporting body 13, a hard skin is created for the structural member, which during subsequent service ensures a high stability under load and, in particular, a lower degree of twist. especially under greatly varying thermal stresses or great temperature variations in the region of the oppositely situated covering. layers 11 and 21. The fibres 14, 15 and the threads from which the supporting body 1-31 can be produced, may consist of alass and/or metal and/or keylar or graphite or textile. These fibres 14, 15 and threads can be worked into a net or knitted fabric or braiding, lattice or batt.
Especially in the production of batt from fibres 14, 1-55 and threads which are produced from recovered thermoplastics, a simple processing of such supporting bodies is achieved, since the thermoplastic is already incorporated in thread- or fibreform in the supporting body 13, and the thermoplastic provided in the batt can only be activated under the action of pressure or temperature. Preferably, the threads or fibres 14, 15 consist of polypropylene. The synthetic material 16 and 6 may, however, also be inserted by introduction of a pulverulent thermoplastic into the batt in particular onto the fibres of polypropylene primarily by polypropylene powder.
The thermoplastic material can be applied to the supporting body 13 or the flocks of the layer 'cl, however, also in the form of a granulate or a foil, that is in a solid state. An application in paste form likewise is possible.
In order to permit dry mixing of the individual components of the layer 2 and the intermediate layer 12, 25, the thermoplastic synthetic material 16 can be chemically or thermally blocked, so that it assumes a viscous or liquid state only at temperatures exceeding 1OWC. It is advantageous that the thermoplastic synthetic material 16 under pressure and a temperature between 2WC and 18WC is at least viscous and between 150C and 2001C is liquid or shows only very slight adhesion between 5 N15 cm and 30 NIS cm.
However, also the covering layers 11. 21 can be formed by a variety of different natural or synthetic materials, for example a knitted fabric, fabric or a batt or a foil. For the covering layers 11, 21, preferably panels, for example having a thickness of greater than 0.2 mm, of metallic materials, e.g. steel sheet or aluminium or of plastics materials or cardboard, are formed.
Thanks to the reinforcement and stiffening of the covering layer 11 and, if required 21, by the layer 2 arranged behind it and the intermediate layer 12. 25, it is advantageously also possible that foils having very small thicknesses between 0.001 mm and 0.2 mm can be used. These foils can be produced from synthetic material, preferably however also from metallic materials. e.g. aluminium.
0 In some cases of application. also the use of cardboard or textiles has proved to be advantageous.
As is further schematically shown in Fi-2.s 12 and 13. a reinforcin. element 96, which may be formed by synthetic material. wood or metal, can be arran-ú!ed be- tween the supporting body 13 of the intermediate layer 12 and the covering layer 11 for securing, for example, the coupling device 91. It is of course also possible to provide this reinforcing element 96 between the intermediate layer 12 and the layer 2.
Preferably, this reinforcing element 96 will be embedded in the synthetic material 6 or 16 of the intermediate layer 12, however.
Such reinforcing elements 96 can, as is further indicated by broken lines in Fig. 13, equally be arranged between the layer 2 and the shaped body 17. If the shaped body 17 consists of several layers or panels, it is also possible to place this reinforcing element 96 between these. Such reinforcing elements can be used to ensure a tearresistant positioning of certain devices, such as the coupling device 9 1, on the structural member 1. It is also possible, however, as shown in Fig. 9, to utilize such reinforcing elements 96 for attaching the structural member 1, for example, to a fagade of a building or the like.
Fig. 14 shows a device 97 for the production of a structural member 1 in a simplified, diagrammatic representation Thereby the production of the structural member 1 takes place in such a way that in a foaming mould 98 either panels 99 for the layer are produced individually or, as is also indicated schematically, a foamed block 100 is produced which is divided up into individual panels 99 by a cutting device 101. The foaming mould 98 is fed, for example from a receptacle 102 and from a tube material tank 103, with flocks 3 to 5 of different types of foams having a different hardness and stiffness such as hard, semi-hard or soft foams, whereby in this case it is a matter of so-called recycling foams or recycling materials which can also be provided with corresponding parts of foils or coatings, and with a primary material which can also be extracted by a recycling process and can be in a liquid state for the production of the cell structure of a mixing device 104 and can be supplied via corresponding dosing, elements 105.
1 In this mixing device 104, the flocks 3) to 5 are mixed with a liquid raw material 106 for the cells 19, 20 and thereafter are filled into a mould cavity 107. By the supply of a reaction agent, for example with a pump 108, perhaps a vapour, in particu- ZP lar a dry vapour of between 12WC and 160'C, the liquid raw material 106 is reacting due to a heat exchanger 109 and is blown up for example by released gases. so that a cell structure, in particular the cells 19, 220 is built up by closed or open or partially _,)8_ closed or open cells.
After a drying phase, which follows the reaction phase and during which only dry air is blown through, the foamed block 100 can be taken out of the foaming mould 98. Furthermore, it would also be possible to use rolled stock or end- less sheeting in appropriate form and composition instead of the individual panels 99.
The production of the structural member 1, for example in an illustrated phase sequence takes place in such a manner that in a first workstation 110 the supporting body 13 is rolled off a ro ller 111 and put onto a rotatin belt c onveyer 112, for example with a Teflon band or a band coated with a lubricant. The supporting body 13 is preferably coated with a paste-like and/or pulverulent thermoplastic synthetic material 16. However. it is also possible that immediately in front of a heating device 113 the thermoplastic synthetic material 16 is applied in liquid or paste-like state by means of a coating device 114. When passing through the heating device 113), the thermoplastic synthetic material 16 can be softened to such an extent that it shows its full adhesive properties and can be displaced at least in an elastoplastic manner, i.e. it shows a plastic or liquid or paste-like consistence.
A front end of the supporting body 13 is gripped by a gripper 115 of a handlina device 116 and is pulled forward to a further conveyer 118 by means of a conveying belt 117. This way, for example it is possible to grip the supporting body 133 with a further gripper 115. In a cutting process the supporting body 13 is separated at a desired length 119 of the panel 99 by means of a cutting device 120 and is put directly onto the conveying belt 117 of the conveyer 118 by means of two griDDers 115.
Thereafter, by means of a further handling device 116, which is not shown in detail, or by using the same grippers 115, a panel 99 is put onto the bearing element and thereafter, as in a manner described hereabove, a supporting body 13 is applied again to the upper side of this panel 99.
Thereafter, the conveyer 118, for example along a guideway 127 1, can be c 0 - transported from a layer positioning station 12-2 to a heating station 1, 23. In this heating, station, the layer 2 and the synthetic material 6 or the synthetic material 116 of the intermediate layer 12 now can be heated to a sufficiently high temperature. so "hat the synthetic material 16 is softened or liquefied.
Then the preheated member consisting of the covering layer 11, the layer 2 and, if required, the intermediate layer 12 or 25, is put into the shaping press 124 positioned downstream.
By closing and by putting a male mould 125 onto a female mould 126 by means of pressure drives 127, the structural member consisting of the covering layer 11, the layer 2 and, if required, the intermediate layer 12, 25 can be deformed into a spatial form drawn schematically by full lines, whereby the structural member 1 is held between the male mould 125 and the female mould 126 until the thermoplastic synthetic material 6 or 16 of the layer 2 and of the intermediate layer 12, 25 in which the supporting body 13 is embedded, is solidified or cooled to the extent that-the dimensional stability is enough to hold or secure the layer 2 and the flocks 31 to 5 contained therein with the cells 19, 20 and their deformed cellular webs pressed into the desired spatial form. Due to the fact that the heating of the individual layers takes place in the heating station 123, the male mould 125 and the female mould 126 can be constantly cooled, so that cooling of the covering layer 11 and of the layer 2 and, if required, of the intermediate layer 12, 25 occurs relatively rapidly, until a sufficient cooling is achieved to reduce the readjusting forces which are inside the individual parts, in particular the layer 2, to the extent that the desired spatial form can also be maintained after the structural member 1 is cooled completely.
Downstream of the shaping press 124 a punching station 1278 can furthermore be arranged, in which for example, as marked in chain lines in Fig. 14, the recesses for forming the film hinges in the corner areas can be produced. At the same time it is possible to construct this punching station 128 in such a way that the prefabricated component, consisting of the covering layer 11, of the layer 2 and, if required, of the intermediate layer 12 and/or 25, is cut at its periphery to the desired final shape and, if required, is brought into the desired modified form by an additional thermal transformation.
The punching station 11-8 may simultaneously also be constructed as a foamin- mould, however, so that after punching of the component the production of the Z structural member can be completed by co-expansion of the shaped body 17 and, if required, by simultaneously applying the further covering layer 21.
Of course, it is a matter of possible embodiment and arrangement variants in the described device 97 and the method described in connection with this device 97 and the device 97 as well as the method can be changed in any way possible by the expert within the scope of knowledge at the state of the art as lon. as the required 0 porperties of the structural member 1 are achieved during production.
Merely for good order's sake it should be finally indicated that for improved understanding of the invention the individual parts of the devices 97 and the structural member 1 and the layers thereof have been presented in a distorted manner, unproportionally and untrue to scale. The same applies for the selected thickness, width and length ratios of the individual layers, in particular of the supporting body 13) and the layers of the thermoplastic synthetic material as well as the shaped body 17.
It is advantageous in this embodiment of the structural member 1 that thanks to the air absorbing power of the layer 2_ during the direct foaming of the shaped body 17, the formation of voids or air bubbles, in particular between the layer 2 and the shaped body 17, is prevented.
By the liquefaction of the primarily thermoplastic synthetic material 6 and 16 also the area immediately adjoining the surface of the covering layer 11 and 21, which latter faces towards the layer 2, can be fully filled, so that the formation of voids or air bubbles is prevented in this region as well.
Thanks to the arrangement of the thermoplastic synthetic material on the surface of the covering layer 11, facing towards the layer 2, it is also easy to restore the finished structural member 1 in case of damage occuring, for example, during storage, transport or assembly, since during heating of the covering layer 11, in particular if it consists of aluminium or another metallic material, the pressing out of the covering layer 11 into its original form during heating is assisted by the expansion of the air in the open space formed behind it. and through the liquefaction of the thermoplastic synthetic material. in particular if polypropylene has been used. the said layer is softened and, after the covering layer 11 has been brought into the originally required form, it is held and stren-thened in this restored proper position. after the thermoplastic synthetic material has cooled and thereby stiffened.
Fig. 15 shows another embodiment of a device 129 for the production of a c 1 structural member 1 in a simplified. diagrammatic representation, in which the same reference numbers have been used for the same parts. as in Fig. 14.
r The device 129 in this embodiment comprises a transfer station 130, a feeding station 131, a processing station 132, a finishing station 133, followed by the shaping press 124 and the punching station 128. The individual stations of the device 129 described hereabove are preferably arranged in tandem, operating in a kind of fixed-cycle operation, intermittent and alternating.
In the transfer station 130, c... the individual coatings or layers are held in c 0 the form of rolled stock, for example the intermediate layer 25 on roller 111, the covering layer 11 on a roller 134 and, if necessary, on a further roller 135 the interlayer 28, which is formed by a PE-foil, for example, and is inserted as an additional adhesive layer between the covering layer 11 and the intermediate layer 25.
It is of course also possible, as already described above, to provide the covering layer 11 which may, for example, be formed by a thin aluminium foil, with a polyethylene coating on one side as an additional adhesive layer. Furthermore, it is also possibe, however, to apply a print- or design layer to the side of the covering layer 11 facing the intermediate layer 1-5, to give the structural member 1 a decorative appearance.
Thus the individual webs of the intermediate layer 25, of the covering layer 11 and. if required, of the interlayer 28 are transferred from the transfer station 130 to the feeding station 13 l by means of the -ripper 115 and are put onto the conveying 1 C.P belt 117 of the conveyer 118 there. In this example of the embodiment, this conveyer 118 extends from the feeding station 131 to the finishing shation 133 and is preferably formed by a continuous Teflon band. Here it proved advantageous to provide this TefIon band in black design to keep a static charge of the same at a minimum.
In the feeding station 13 1, the covering layer 11 supplied from the feeding ty station 130, the interlayer 28, if required, and the intermediate layer 25 are now loosely lying one on top of the other on the conveying belt 11- 1. The flocks to 5 are now loosely applied to these layers described hereabove, by means of a dosing device 136, which is stored in a stora.e container 137, for example. The individual flocks 3 to 5 may consist of the above described materials and may be mixed among themselves in any combination desired.
In order to distribute the flocks 3 to 5 uniformly over the conveyinp, 'Delt 11-, and the layers arranged in between, it is advantageous to position an aligner 1.38 c - - -3 2 after the dosing device 136 to achieve a uniform height 139 of a loose flock layer 140. For the control of the dosing device 136 any control cells and systems known from the prior art may be used.
Following the feeding station 131, the processing station 1332 is arranged, where pressure is exterted on the flock layer 140 and the layers placed underneath, such as the covering layer 11, the intermediate layer 25 and, if necessary, the interlayer 28, by means of a compression device 141.
During the application of the compressive forces the conveying belt 117 of the conveyer 118 is at a standstill. in order to achieve the bonding and compacting of the flock layer 140 to the layer 2 in this processing station 132. The compression device 141, in addition, is associated with an upper and a lower heating device 142. 1433.. which enable the individual layers and flocks 3 to 5 to be heated. The important point in this respect is that different temperatures are selected for the upper and lower heating device 142, 143, depending on the material used for the covering layer 11, intermediate layer 25 and interlayer 28 as well as the flocks 3 to 5, in order to ensure an optimum procedure. The temperature of the lower heating device 143 can be between WC and 160'C, preferably 12WC, and the temperature of the upper heating device 142 between WC and 220'C, preferably between 12WC and 180'C. The station time in the processing station 132 may be between 220 seconds and 3 minutes, depending on the material used.
Furthermore, it is important, if a mat of loose polypropylene threads with the reinforcing threads inserted therein is used as material for the intermediate layer 25, that already before heating, a corresponding surface pressure is applied by means of the compression device 141, in order to clamp and to hold this intermediate layer 25 between the layer 2 and its flocks 3 to 5 and the covering layer 11 and. if existent, the interlayer 28 in its position. This applied pressure is preset according to the materials used. In this way, shrinkage due to residual stresses inherent in the material is avoided during subsequent heating, whereby a hard layer of thermoplastic material is obtained throughout the entire surface of the covering layer 11.
This residual stress is relieved when the material changes to the plastic state, whereby in this state shrinkage is no Ion-er possible. This heating in the processing. station 132 causes on the one hand a compression of the flock layer 1140 with respect to the layer 2 and, as a result of the intermeCiate!aver 25 and the interlayer 28.
a tight connection to the covering layer 11. During this process, additionally also the cell structure of the individual flocks 3 to 5 is compacted accordingly.
After the heating and compression process in the processing station 132, the sheet material thus produced is adequately cooled to obtain a solidification of the individual plastic layers.
The cooling temperature is between 4WC and 70 'C, depending on the materials used. During cooling, the intermediate layer 25 forms a thermoplastic hard layer with the fibres and threads inserted in it, which latter may also be formed by the supporting body 13, whereby thanks to the interlaye.. 28, which may also be called an additional adhesive layer. a tight adherence to the covering layer 11 is achieved.
C C When cooling is finished, the conveying belt 117 of the conveyer 118 carries on the semi-finished product described hereabove to the finishing station 133, where it can be cut to the desired length or cut to size by a separating means 144.
By means of the handling device 116, the prefabricated structural member 1 can be transferred to the shaping press 124 arranged behind said handling device, whereby by closing and putting the male mould 125 onto the female mould 126 by means of the pressure drives 127, and by further heating, the structural member 1 can be deformed into the spatial form drawn schematically by full lines. Thereby the structural member is held between the male mould 125 and the female mould 126 until, subsequent to the deformation process, the thermoplastic synthetic material 6 or 16 of the layer 2 or of the intermediate layer 12, 25, in which e.g. the supporting body 13 can be embedded, is solidified or cooled to the extent that the dimensional stability is enough to hold or secure the individual layers or flocks 3 to 5 in the desired spatial form. When the structural member 1 is cooled appropriately and shows dimensional stability, it can be conveyed to the punching station 128 with handling devices, which are not shown in detail, where the final cutting to size and the punching operation and thus the final forming take place.
After this forming, it is possible to form the shaped body 17 onto the llayer 2 in a separate moulding process or to co-expand it. in order to complete the desired structural member.
It remains to be mentioned that it is of course possible to carry out addi- tional machining and bending operations in the finishing station 133 to ensure an adequate processing of the structural member 1.
c Moreover, each exemplary embodiment can also form its own solution in accordance with the invention, and likewise, individual or any combinations of the claims may form their own solutions in accordance with the invention. and also individual features of the embodiments. if required, in any combination of different exemplary embodiments.
In particular, the individual embodiments shown in Fig.s 1. 21: 3; 4: 5: 6; 7 to 11; 12, 13; 14; 15 can form the object of own solutions in accordance with -the invention. Relating tasks and solutions are apparent from the detailed descriptions of these figures.
CLAIMS 1. Multi-layered structural member comprising a layer of flocks of foamed plastic interconnected by a plastic of primary material and one covering layer arranged on a surface of the layer and connected with the latter in a frictional and formlocking manner, a cell structure of the flocks of foamed plastic being deformed in some areas in the layer, wherein the covering layer is embedded in a synthetic material of the layer, which material is in particular formed by a thermoplastic, and/or in a synthetic material of an intermediate layer arranged between said layer and the covering layer and/or, by means of this synthetic material, is at least formed onto the layer and/or connected thereto in a frictional and/or formlocking manner.
c 2. Multi-layered structural member according to claim 1, wherein a shaped body, in particular of synthetic material, is secured to a surface of the layer facing away from the covering layer.
r= 3. Multi-layered structural member according to claim 2, wherein the shaped body of synthetic material is formed onto the surface of the layer facing away from the covering layer, in particular by a foaming process.
C In 4. Multi-layered structural member according to claims 1 to 3, wherein the layer is formed by flocks of recycling and primary foamed plastic, in particular of hard or semi-hard and/or soft foams.
5. Multi-layered structural member according to claim 4, wherein the flocks of recycling and primary foamed plastic are provided with coatings. in particular of textiles, leather. synthetic material or imitation leather or are backed, herewith.
6. Multi-layered structural member. according to claims 1 to 5 wherein the floc.ks consist of recyclin. textiles and/or paper and/or cardboard and/or textile remnants and/or leather and/or textiles and/or metals.
M -j - 7. Multi-layered structural member according to claims 1 to 6, wherein the layer between 70 % and 95 %, preferably 85 %, consists of flocks of foamed plastic.
8. Multi-layered structural member according to claims 1 to 7, wherein 10 to 20 % of the weiaht of the layer is formed by a foamed plastic andlor a thermoplastic of 0 primary materials, for example polyurethane.
9. Multi-layered structural member according to claims 1 to 8, wherein the specific gravity or the free-rising density of the recycled foamed plastic added to the layer is between 30 and 150 k-lml.
c 10. Multi-layered structural member according to claims 1 to 9, wherein between the 0 layer and the covering layer an intermediate layer of thermoplastic synthetic material is arranged.
11. Multi-layered structural member according to claims 1 to 10. wherein between th covering layer and the intermediate layer an interlayer is arranged.
12.. Multi-layered structural member according to claim 11, wherein the interlayer is produced as adhesive layer and/or layer acting as bonding agent. which preferably consists of polyethylene and/or PVC or other synthetic materials and adhesives having good adhesion.
l-j. Multi-layered structural member according to claim 10, wherein the thermoplastic synthetic material consists of polvethylene. polvamide. polyprODylene, polystyrene, PVC, polvamide, ABS or the like.
er 1 1,1. Multi-layered structural member according to claim 10 or l-3, wherein e a fibre- or thread-shaped supporting body is embedded in the intermediate layer of thermo-plastIc synthetic material.
MW 15. Multi-layered structural member according to claims 1 to 14, wherein the supporting body is formed by a net and/or knitted fabric and/or batt of different fibres or threads of glass and/or metal and/or kevIar and/or graphite and/or textiles.
16. Multi-layered structural member according to claim 15, wherein the fibres and threads of the supporting body are of glass and/or metal and/or kevIar andlor araphite and/or textiles.
0 17. Multi-layered structural member according to claims 1 to 16, wherein the- supporting body and/or the flocks of the foamed plastic are coated or filled with a granulate, for example a powder or a foil of the thermoplastic synthetic material having a hard consistence.
18. Multi-layered structural member according to claims 1 to 17, wherein the supporting body and/or the flocks of the foamed plastic are coated with a paste of the thermoplastic synthetic material, which adheres only slightly at room temperature.
19. Multi-layered structural member according to claims 1 to 18, wherein the thermoplastic synthetic material is at least viscous under pressure and a temperature between 12TC and 18TC.
20. Multi-layered structural member according to claims 1 to 19, wherein the thermoplastic synthetic material is liquid at a temperature between 1500C and 2000C and/or that there is very little adhesion, for example between 5 and 30 N/5 em. 1. Multi-layered structural member according to claims 1 to 20. wherein
the covering layer consists of knitted fabric, fabric. a batt or a foil of natural and/or synthetic materials and wherein it is formed onto or adheres to the supporting 'body and/or the layer by means of the synthetic material formed by the thermopiastic or by means of a layer consisting thereof.
22. Multi-layered structural member according to claims 2 to 21, wherein in the layer which consists preferably of several panels, or between said layer and a surface of the shaped body facing away therefrom, a reinforcing, element is arranged.
23. Multi-layered structural member according to claims 1 to 22, wherein between the supporting body or the layer and a covering layer, a reinforcing, element is ar- 1 ranged or preferably embedded in the layer of the synthetic material, for example in the thermoplastic thereof.
24. Multi-layered structural member according to claims 1 to 1-3j, wherein the covering P layer is formed by a panel or a foil of natural materials or synthetic material.
25. Multi-layered structural member according to claim 24, wherein the panel or a foil is formed by a metallic material, e.g. steel plate or aluminium or by card board.
26. Multi-layered structural member according to claims 1 to 25. wherein the covering layer consists of a foil of paper and/ or synthetic material andlor synthetic material with high vacuum metal depositing andlor textiles.
27. Multi-layered structural member according to claim 24 or 25, wherein a plate thickness of the panel is greater than 0.2 mm.
28. Multi-layered structural member according to claim 21, 24, 25, 26 or 27, wherein a foil thickness is between 0.001 and 0.2mm and is preferably produced from aluminium.
29. Multi-lavered structural member accordina to claims 'L to 28. wherein the covering layer is provided with a coating, in particular of PVC and/or polvethylene andlor polyamide, on the side facing towards the laye. r.
4k :t 1 1 30. Multi-layered structural member according to claims 2 to 29, wherein a further covering layer is arranged on the shaped body on the surface of the same facing the layer.
3 1. Multi-layered structural member according to claim 30, wherein during the production of the shaped body the additional covering layer is formed onto the lat ter.
32. Multi-layered structural member according to claims 1 to 31. wherein the layer on the surface facing away from the covering layer is impermeable to fluids. but permeable to gas.
33. Multi-layered structural member according to claims 1 to 32, wherein the synthetic material is a polyol which is mixed with flocks of hard or semi-hard polyurethane foam, and wherein the flocks are embedded in the synthetic material compacted mechanically as compared with the freerising density.
34. Multi-layered structural member according to claims 1 to 33, wherein between the fibre- or thread-shaped supporting body and the covering layer an interlaver formed by a fusible adhesive foil, in particular PE- foil, is arranged.
35. Multi-layered structural member according to claims 1 to 34, wherein the fibre- or thread-shaped supporting body consists of a batt of polypropylene and. if necessary, is coated with a pulverulent thermoplastic, for example polypropylene powder.
36. Multi-layered structural member according to claims 1 to 35, wherein the flocks of recycling foamed plastic are embedded in a catalytically and/or thermally blocked PU.
1 37. Method for the production of a multi-layered structural member wherein flocks of a foamed plastic are mixed with a liquid primary material of a foamed plastic and are formed into a panel or a block, which under the action of pressure andlor temperature and/or moisture is brought to react, and wherein the flocks of foamed plastic are interconnected by means of the plastic foam of primary material, whereupon at least on one surface of such a panel or block, a covering layer is applied. and under the effect of pressure and/or temperature, if necessary, spatial deformation, the covering layer is connected with the panel or block to a multi-layered structural member. wherein before the covering layer is applied on the layer, e..a. the panel or the block. a granulate and/or a foil and/or a paste of a thermoplastic synthetic material is applied onto said covering layer and/or onto a fibre- or thread-shaped supporting body of an intermediate layer. whereupon thereafter the covering layer with Che layer and/or the intermediate layer and the thermoplastic synthetic material is heated at least to such a degree that it becomes viscous, whereupon the covering layer is pressed onto the layer which forms a core of a multi-layered structural member. and by displacement of the thermoplastic synthetic material the latter is pressed into the surface regions of the layer, whereupon immediately thereafter the covering layer and the layer and/or the intermediate layer are cooled and after a sufficient solidification and/or after falling short of the temperature of the freezing or flow point of the thermoplastic material, the structural member is taken out of the mould.
38. Method according to claim 37, wherein the coverine layer and/or the intermediate layer and/or the layer is Spatially deformed simultaneously when the thermoplastic synthetic material is pressed into the surface regions of the layer.
c 39. Method according to claim 37 or 38. wherein the layer is heated before or during the spatial deformation of the covering layers.
40. Method according to claims 377 to 39, wherein a preset pressure is applied on the layer and/or the intermediate layer andlor the interlayer andlor the coverin'. laver before and/or duriniz heatinz.
9 7 41. Method according to claims 37 to 40, wherein due to the pressure load the intermediate layer between the layer and the covering layer or the interlayer is clamped in its position.
42. Method according to claims 37 to 41, wherein the flocks of the layer are loosely applied to the intermediate layer.
43. Method according to claims ')7 to 421, wherein the layer is supplied to the layer 1 - positioning station in the form of individual plates andlor as rolled stock.
44. Method accordin. to claims 37 to 43, wherein the operation of the device for the production of structural members is intermittent.
45. Method according to claims 37 to 44, wherein simultaneously with the spatial deformation of the covering layer, the cell structure and the cells of the layer are thermally cracked and fixed in the deformed position.
46. Method accordin. to claims 37 to 45, wherein the thermoplastic synthetic material 0 is heated to a temperature between 12WC and 170'C.
47. Method according to claims 37 to 46, wherein the multi-layered structural member at least in the surface regions, is heated to a temperature between 1SO'C and 200'C, whereupon the covering layer is pulled off the core.
48. Method according to claims 37 to 47, wherein the thermoplastic synthetic material in the covering layer is heated to a temperature of above 200'C and is removed, in particular sucked off, in a liquid state from the fibre- or thread-shaped supporting body.
1 49. Method according to claims 37 to 48, wherein before the covering layer is pressed onto the layer, the supporting body is inserted and said supporting body by means of the thermoplastic synthetic material which impregnates the latter, is connected immovably to each other or formed on one another, with the covering layer or the layer.
50. Device for the production of a multi-layered structural member comprising a layer of flocks of foamed plastic interconnected by a foamed plastic of primary material and at least one covering layer arranged on one of the two opposite surfaces of the layer and connected with the latter in a frictional andlor formlocking manner, with a fibre- or threadshaped supporting body with a conveying device for the supporting body which is coated with thermoplastic synthetic material or impregnated therewith, which -ranulates at room temperature, and is present in the form of a foil or slightly adhesive paste, wherein the conveying device is formed by two conveying belts which are parallel to one another and running one above the other spaced apart by an adjustable distance, in particular of Teflon, and wherein a heating device and a compression mould are arranged downstream of this conveying device, and wherein between the conveying device and the compression device, a handling device is arranged for the supporting body which is impregnated with the layer of thermoplastic synthetic material and/or the covering layer and/or the layer which consists of foamed plastic.
51. Device for the production of a multi-layered structural member according to claim 50, wherein at least one of the two mould halves is provided with holding devices. in particular vacuum slots in order to receive and hold a covering layer.
52. Multi-layered structural member substantially as herein described with reference to the accompanying drawings.
53. Method for the production of a multi-layered structural member substantially as herein described with reference to the accompanying drawings.
54. Device for the production of a multi-layered structural member substantially as herein described with reference to the accompanying drawings.
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