IL37990A - Manufacture of sandwich-like building elements - Google Patents

Description

Manufacture of building elements W CORPORATION A method of manufacturing sandwich elements The present invention relates to an improved method of sandwich elements which can be used as wall or floor panels in is known to the art a method for manufacturing sandwich elements according to which a mixture of solid ticles and liquid resinous binder is spread on a the quantity of said binder exceeding the volume of the spaces between the solid whereafter the solid particles are allowed to settle so that a settled layer of particles and an outer layer of excess binder is This outer layer is then broken by inserting therein one side of a core element distance and then the binder is allowed to core element The other opposite side of the diGtanco material may also be inserted in an outer layer of excess binder of a similar ternal unit consisting of a settled layer of solid particles and an outer layer of excess It has been found when manufacturing such sandwich core element elements that the distance is liable to penetrate to different depths in the external unit or thereby causing the pattern of the i a 1 to be visible in 2 patches on the external unit or unite of the sandwich the of adhesion between the external unit or units and the corelelement vary with the depth to which the core element penetrates into the external unit or Another disadvantage is that the thickness of a number of sandwich elements as well as the thickness of one sandwich element owing to the fact that the oore element penetrates into the external unit or units to different The main object of the present invention is therefore to eliminate these With the improved method of the a support member intended to regulate the depth to which the corelelement penetrates into the external unit or units of the sandwich element applied in said external unit or units when each of said units is spread out on a at a predetermined level from the method comprises the steps of spreading out a first layer of a mixture of solid particles and liquid resinous binder on a applying a support member on the surface o said first spreading out a second layer of a mixture of solid particles and liquid resinous binder on said first layer and said support the quantity of the binder in at least said mixture forming said second laye exceeding the volume of spaces between the solid particles in said mixture forming second subsequently allowing the solid particles and to form a of particles with binder forming from the exeess binder an outer Inserting one side portion of a core of 5 core element spaced said thereby causing the binder of said outer layer to enter the cells of said core element to thereby at least partially pick up said excess binder by the core and finally allowing said binder to The method of the present invention may be used to produce both flat and curved sandwich in which one or both sides of the core element is or are united with a layer of binder and solid pari in accordance with the improved The invention will now be described in detail with referenoe to the accompanying in which figure 1 illustrates by wa of example a system for spreading out an external unit of a sandwich and 2 strates a cross section of a part of a sanfiwich element manufactured in accordance with the A first layer of a mixture of liquid resinous binder and solid particles is spread out by means of a doctor device 2 on a flat base which is arranged to move in the direction indicated by the arrow the mixture being supplied from a first supply At the same time as the first layer is spread out on the base by the doctor device a support member is fed from a supply reel between the supply 4 and the doctor device 2 in a manner whereby the support member 6 lies substantially in the surface of the first layer located behind the doctor device when seen in the direction of movement of the base is a further doctor device this latter mixture being supplied from a secp i supply The quantity of binder in the latter mixture ceeds the volume of the spaces between the solid The solid particles in second layer 8 spread out by the doctor device 7 are allowed to settle that an outer layer 10 consisting substantially of the excess binder and a settled layer of particles with binder therebetween is formed progressively as the layer 8 is The combined layer or external unit 12 of binder and solid particles and the support member 6 enclosed thereip is then united with a core or by means of which the outer layer of excess binder is core The material 13 is inserted into the outer layer 10 and into engagement with the support member which is located at a predetermined distance from the outer surface core element of the sandwich The 13 absorbs picks up the outer layer 10 of excess The quantity of excess binder forming the outer layer 10 is adjusted so that the excess provides for sufficient contact element with or adhesion to the located distance thereby core element providing an effective connection between the tori a and the external unit 12 of the sandwich The excess binder also serves to f aci i tate the distribution of the mixture of binder and particles by means of the doctor device It is therefore to advantage to include an excess of binder in the mixture distributed from the supply This latter excess may be collected at the outer layer owing to the fact that the particles in the second ί layer 8 settle down to the first layer the particles of which also although the latter excess of binder may also be absorbed entirely or partially by the inserted support member which may consist of an absorbent The quantity of excess binder in the two mixtures need not necessarily be the As illustrated in Figure the other opposite side core element of the distance material may also be united with a combined layer or external unit of binder and settled particles produced on a base in a manner similar to that described in the The support member intended to fix the position of element stance m may consist of a material which pletely or partially absorbs a possible excess of binder present in the first layer The support member may also consist of an absorptive or a material which is permeable to the binder and the solid particles thereby permitting a possible excess of binder present in the first layer 3 to collect at the owing to the fact that solid particles the second layer are able to pass through the permeable support member when net tures of or gauze ribbon and fabric of glass fibre are examples of suitable material for the support The liquid resinous binder for be an bisphenolic or other polyester taining a curing agent in the form for methylenetetrami ne Further examples of a binder which may be with the present invention are polyvinyl polyvinyl polymers of polyurethanes polyethy lenes combinations of phenol formal dehydes and synthetic resins of epoxy The solid particles present in the mixtures may having an average grain size of The solid particles may also for stone stone granular slag or metal powder or table mixtures of these materials The ri i s i ntended to break or trate the outer layer of excess binder collected at the and may therefore consist of a material which tirely or partially absorbs the excess or may be in the form of a material which picks up the excess binder in spaces in the distance material without absorbing the as shown in Figure Examples of suitable distance for the core element corrugated board and honeycomb board and simi material having a eel core element As an absorbent di at possible to use a mixture of sand with a deficiency of The base onto which the first layer is spread out may be for of glass or stainless metal base is treated with suitable release agent to litate removal of the base from the finished sandwich The binder may also be spread out on a base which is to be included in the finished sandwich For a fireproof sandwich element can be j produced by spreading out the binder or the particles on gypsum The term used in the aforegoing and in the following claims refers to a layer which may be either continuous or the second layer may also be applied in c 8 insufficientOCRQuality

Claims (1)

1. CLAIMS A method of manufacturing sandwich comprisin the steps of spreading out a first layer of a mixture of solid particles and liquid resinous binder on a applying a like support member on the surface of said first spreading out a second layer of a mixture of solid particles and liquid resinous binder on said first layer and said support the quantity of the binder in at least said mixture forming said second layer exceeding the volume of spaces between the solid particles in said mixture forming said second subsequently allowing the solid particles to settle and to form a settled layer of particles with binder forming from the excess binder an outer inserting one side portion of a core element of structure into and through said outer into engagement with said support member and thereby keeping said core element spaced from said thereby causing the binder of said outer layer to enter the cells of core element to thereby at least partially pick up said excess binder by the core and finally allowing said binder to Λ method opposite portion of said core element is also inserted into another composite layer formed according to claim after which the is allowed to harden on both of For Applicants D insufficientOCRQuality