NL8005343A - METHOD FOR MANUFACTURING STRUCTURAL ELEMENTS. - Google Patents

Description

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Method for manufacturing construction elements.

The invention relates to a method for the manufacture of construction elements, and construction elements obtained with this method.

The usual construction, ie that consisting of erecting a building with classical materials on site, has hardly changed during the last 50 years. Only the handling, lifting and transportation means have been improved.

In this type of construction, the large number of operations to be carried out consecutively is a major drawback: the multiple preparation of masonry mortar; a frequent back and forth for placing small elements in place: stones, blocks, bricks, etc.

15 using a trowel; waiting for drying, the need for plastering, and too much time and movement before the great work is completed.

Sometimes the result of this is that cracks and breaking cracks occur on the walls and the terraces.

When the major work is completed, the lack of coordination between different state bodies, plastering workers, carpenters, plumbers, electricians will prevent or make it difficult to install the insulation, which is thus susceptible to numerous thermal bridges.

It is known that heat and sound insulation problems are always important in the field of building structures.

The importance of the insulation is further emphasized by the recent measurements taken for energy savings. 8 0 0 5 34 3 * 2 savings.

The placement of the insulation and the choice of the insulation materials often take place without technical and scientific knowledge of the materials used, the users are for the most part guided by publications, which do not all have the desired clarity with regard to the characteristics. of the products used.

In the event of a fire, the plastics largely cause the development of flames and toxic smoke.

This danger can increase at the moment when, due to the energy savings, the insulation problems become very important.

Presently, to obtain lower costs and quick construction, more and more use is made of prefabricated elements.

Usually these are pre-fabricated heavy elements that are factory-made (prestressed cement).

These elements often have an excessively large weight, which weight is poorly suited to actual needs. In order to be handled and transported on the construction site, a significant amount of material for handling and lifting is required.

25 This material requires very large investments that are difficult to reduce.

Moreover, the connection of the outer part and of the inner part covering the insulation is established by a braid extending transversely thereto, with numerous heat bridges being present.

The object of the invention is to eliminate the above-mentioned drawbacks.

The object of the invention is to provide a new construction element, in the form of panels which are particularly useful for the formation of floors, partition walls, ceilings, roofs, 3 installations for solar heating.

This construction element usually has the shape of a panel, the body of which is formed by a plate of a non-flammable expanded resin.

5 The panel, optionally reinforced by a layer of cement or plaster on its surfaces, is transported on the build plate where the panel is completed in its final build position.

It is a light element that can be easily handled and transported without the aid of operating tools or lifting tools.

The invention relates to a new method for the production of building elements, which method consists of continuously forming a panel of expanded resin and of the desired thickness, bringing the panel to the desired dimensions, transporting these light panels of large dimensions on the construction site; and coating the surfaces of the expanded panels with a sprayed product such as cement, plaster, resin, etc.

The expanded resin panels are advantageously formed by phenolic resin foam, which has the advantage over certain synthetic foams that it is fire resistant and does not release toxic flue gases.

Preferably, the light panel, of which at least one surface is provided with protrusions, in particular notches with counter-undercuts, is continuously formed in a corridor, which is bounded by two movable walls without an end.

These projections provide excellent anchoring of sprayed products such as cement, plaster, resin, etc.

For the continuous manufacture of light panels, advantageously use is made of the device described in French patent application 77.18360, filed in France on June 15, 1977, which patent application is entitled 35 "Method and machine for improving capacity of 80 05 34 3 r 4 production of panels of molded materials ".

In order to improve the mechanical resistance of the panels according to the invention, it may be advantageous to provide their surfaces with a first coating in a continuous manner, in the factory by a little spraying of cement or plaster on the latter surfaces.

By this method, a panel having a life greater than that of the foam without a coating can be obtained, without the weight per se being significantly increased.

According to an embodiment of the invention, after the initial spraying of cement or plaster on the surfaces of the panel has taken place in the factory, the latter can be laid flat on a fixed or movable support on which continuous cement is poured in advance to a certain thickness. .

After the cement has adhered to the tops of the protrusions and after releasing the support, a flat-walled plate behind which passages have been reserved between said protrusions is obtained. This method can be carried out on any of the surfaces of the panel of expanded resin.

In connection with this it is noted that it is also possible to cast on the support a plaster material, a synthetic reinforced resin, or any other binder, and to obtain, as with the cement, a flat wall formed from one of these materials.

In another embodiment of the invention, the light panel, the surfaces of which are provided with protuberances, is longitudinally centered in its full part - intersected - to form two half panels which are placed together with the vanes. protrusions on opposite surfaces.

It is thus possible to obtain a formwork in the longitudinal and transverse directions and to install in the corridors formed between the opposite projections the amount of cement necessary to obtain the 80 0 5 34 3 5 • 4. of a central supporting wall, which is covered on both sides with a foam.

The light panels, which have been placed on the building board, are combined in their final construction position. They are held, for example, by a mesh designed to arm the cement, plaster material, etc., which are sprayed on site or introduced by casting or molding; the latter operations serving to provide the desired thickness and strength to the partition walls and to the bearing walls.

One of the advantages of notched panels with projections according to the invention is that each side of the parts,

that serve as amplification is maintained without the emergency daV

15 business / net braids are joined to hold them across the insulation portion. All heat bridges are thus switched off.

The invention will now be further elucidated with reference to the drawing.

Figure 1 schematically shows the method for manufacturing building elements according to the invention, in which the panels are manufactured continuously with a machine with lateral movement.

Figure 2 schematically shows the method for manufacturing building elements according to the invention, in which the panels are manufactured continuously with a down-moving machine.

Figure 3 shows a partial vertical section of a support on which cement has been poured and on which a panel has been laid flat, the surfaces of which are provided with protrusions.

Figure 4 shows a perspective view of a panel of expanded resin, the faces of which have protrusions in the form of a truncated pyramid.

Figure 5 shows a perspective view of a 5 x 1% f * 6 panel of an expanded resin panel, the surfaces of which are provided with notches with notches.

Figure 6 shows a vertical section of a panel provided with protrusions in the form of a truncated pyramid.

Figure 7 shows a vertical cross-section of a panel obtained after cutting the panel shown in Figure 6 in longitudinal center, the two half panels being joined using the surfaces with protrusions.

Figures 8, 10 and 12 show cross sections of some modified embodiments of panels, the surfaces of which are provided with notches with notches.

Figures 9, 11 and 13 show cross sections of panels obtained after the panels shown in Figures 8, 10 and 12 have been cut in their longitudinal center, and the two half panels are joined with their protuberance surfaces.

Figure 14 shows a schematic view of the interior of a house, showing the manner in which the light panels are assembled in the final construction position 20 and completed on site by spraying cement or plaster material.

Figure 15 shows a detailed view of Figure 14 showing how a panel serving as a wall is completed in place.

Figure 16 shows a cross-section of a wall obtained by joining two panels according to the invention.

Figure 17 shows the mode of use of the panels according to the invention for creating an assembly consisting of a ceiling-floor.

Figure 18 shows a partial cross-section of a ceiling and floor assembly and of an intermediate wall formed with the panels of the invention.

Figure 19 shows the system for continuously deforming panels provided with protrusions 80 05 343 *! 7 with notches according to the invention.

As shown in Figure 1, a continuous molding panel of expanded resin and manufactured to the desired thickness in a continuous manufacturing machine is shown schematically in Figure 1.

This machine consists of an endless corridor, the width of which is variable. The walls 2 of the machine advance continuously.

The expanded resin panel 3, which leaves the machine 10 in the direction indicated by the arrow, is cut to the desired length by a saw 4 carried along at the same speed as the panel 3.

The panels cut to the desired dimensions are stored at 5 and are ready for use.

In order to increase the stiffness of the panels to facilitate handling, the surfaces can be sprayed with cement, plaster material or any other binder, which is shown at 6.

This spraying of cement or plaster material can be accomplished using seals available on the market and known to those skilled in the art.

After spraying, the panels are stored at 7.

The expanded resin panels are lightweight and very easy to handle.

They are easily transported and handled on the build plate without the need for heavy operating equipment.

The panels placed on the building board are stored at 8, then assembled at 9 where they are completed on site.

In figure 2 a machine is indicated schematically with 1 for the continuous manufacture of panels and with a downward movement.

35 This machine includes a forming corridor, 80 05 343 δ, which opening is vertically open at its top and bottom ends and is bounded by movable walls formed by endless chains of interchangeable shapes, of various designs. which forms serve to produce protrusions on the surfaces of the panels, as will be explained in more detail below. The panels, manufactured by means of the machine, have surfaces which are provided with projections which form corridors in the longitudinal and transverse directions.

In this figure, the spraying of the cement onto the surfaces of the panels is schematically shown.

In an embodiment of the invention shown in this figure, continuous liquid cement 51 is poured onto a support 50, which may be fixed or movable, to a small thickness of, for example, 5 to 10 mm, and the panel 3 is laid which leaves the production machine and the surfaces of which are provided with projections, flat down.

After the cement has adhered to the tops of the protrusions 38 and after releasing the panel 3 (Figure 20 3), a plate is obtained which contains a flat cast wall or with the / desired protrusions / behind which passages between said protrusions are reserved.

Obviously, the same operation can be performed on the other face of the panel.

A panel is then obtained and with two pure surfaces which form a complete partition wall with empty inner spaces which provide all possibilities for the passage of profiles, pipes, jackets, etc .; of a braid for reinforced cement or other material, for ventilation, circulation of cold or warm air, or for covering with cement on the work site for bearing walls.

In another embodiment of the invention, the panel exiting the machine is cut in the longitudinal center of its full part to form two half panels 10 and 11 35, which are joined together with projections 80 05 34 3 9 ( figure 7).

The passages 12 are thus located between the protrusions of which the opposite surfaces are provided.

It is also possible to take two panels which have projections only on one of their surfaces and to place the panels against each other with the projected surfaces.

When such panels are erected vertically on the construction site, cement can be poured into the corridors after a reinforcement has been fitted in the latter, if necessary.

In this way, support structures are obtained which are recessed into the panel, whereby a formwork is formed.

In order to improve the mechanical resistance of the panels and to obtain an economical use of the resin, fillings can be included, such as glass balls, clay balls, etc.

Figures 6, 8, 10 and 12 show cross-sections of expanded resin panels, the surfaces of which are provided with notched projections, all of which allow excellent anchoring of sprayed products such as cement, plaster, reinforced resins , etc.

Figures 14 to 18 show some uses of panels according to the invention for the formation of walls, partition walls, floors, ceilings.

As shown in Figure 14, the panels placed on the construction site are joined together with the ends to form, for example, an intermediate wall or a wall. The joining of the panels can be accomplished by a simple joining together (figure 16): a receiving notch 39 in the plane of an element 40 corresponds to an insertion projection applied to or adhered to the adjacent plane of the adjacent element 41. The finishing of these panels thus assembled is then carried out, and 80 05 343 10 by spraying with a plaster material or with cement.

Figure 14, which shows a schematic view of the interior of a house under construction, shows a wall 13 and a floor 14, which have been obtained using notched panels.

Concrete is poured at 15 to form wall 13, cement is sprayed at 16 on the notched panels forming floor 14.

This same figure shows an inner wall 18 and 10 intermediate walls 17 obtained by joining together a number of panels onto which a plaster material is sprayed at 19.

Figure 15 shows the course of the construction of a wall with the aid of panels according to the invention, wherein the plate of expanded resin, which carries projections on its surfaces, is surrounded by a formwork 20. each side of the insulating material 21 by 22 cement.

In the case where the panels according to the invention are used to realize a ceiling and floor assembly, these panels are advantageously placed in a metal frame 23, as shown in figure 17. The sides of these frames obtain a configuration formed by brass 24 and groove 25, allowing their joining together during mounting.

It is possible to spray the floor with cement 25, which floor is formed by joining together a number of panels placed in their frame, after which a concrete slab 26 is poured on this floor (figure 18).

On the other face 27, which forms the ceiling of the bottom floor, a plaster material is sprayed to form the visible surface of the ceiling. This spraying of plaster material is not always necessary because the protrusions applied to the surfaces of the panels can have a decorative effect that is sought.

As can be seen in Figure 18, which is a vertical cross-section of an angle formed by an intermediate wall and forming a ceiling / floor assembly formed with the panels of the invention the insulating material has a continuous tape in the wall 29 and the ceiling and floor assembly 30, avoiding any heat bridge. Also figure 18 shows the plate 26, which has been poured on the floor, and the metal reinforcements 31 which can be inserted for reinforcing the panel.

It should be noted that the corridors surrounding the protrusions provided with the surfaces of the panels allow passage of the reinforcements and of the cement which are reinforced by a connecting grid and connected throughout the structure, with main beams and floor beams to replace.

This system allows a resistor 15 to be evenly distributed throughout the structure, which can be useful in earthquakes or landslides.

Figure 19 shows continuous removal of a panel from the mold, the surfaces of which are provided with notches with notches.

The movable walls of the continuous panel making machine are formed by endless chains, which bear the interchangeable shapes, which allow the manufacture of notched and counter-cut protrusions on the faces of the panels.

The molds are rotatably carried by two whorls 32 in the direction indicated by arrows. The screen with sat shapes forming the movable walls is formed by a succession of contiguous shapes 35 and 36 hinged together at 34 to form a continuous belt.

It is also possible to fix these shapes on the movable walls of the currently used continuous panel manufacturing machines, both for a machine with lateral movement (the case of figure 1) and for the machine with downward movement ( the case of figure 2).

These shapes are particularly designed for allowing continuous molding and continuous de-molding of panels provided with notched and counter-undercut protrusions, according to the invention.

Figure 19 shows only, among the numerous embodiments of the possible shapes, an example of a shape profile by means of which it is possible to obtain panels which are provided with projections with notches and which are especially suitable for continuous removal from the mold.

The figure shows how the molds 35 divert at the exit of the device and how a panel 37 with notches is continuously obtained.

Fig. 19 shows how the panel is continuously removed from the mold, which is provided on its surfaces 15 with projections with notches and with counter-undercuts, shown in Fig. 5. Since the shapes 35, which are arranged on the endless chains mounted, interchangeable, it is sufficient to proceed to a simple change of the shapes to obtain panels whose faces are provided with notches with notches, such as those shown in Figures 8, 10 and 12.

This continuous demoulding system makes it easy to achieve the rate at which it is possible to continuously manufacture panels having notched projections with notches according to the invention, thereby substantially reducing the manufacturing costs by this method .

Briefly summarized, the invention relates to a method of manufacturing building elements 30 which are in the form of panels. A panel 3 of expanded resin is continuously cast in a continuously operating machine, the surfaces of the panels are provided with protrusions, in particular with notches. The panel is brought to the desired dimensions and the large-sized light panels are transported to construction site 9. The surfaces of the panels are covered with a sprayed product such as cement; a plaster material, resin, etc. The panels are especially useful for the formation of floors, walls, partitions, ceilings, roofs and installations for solar heating.

80 05 34 3

Claims (15)

1. Method for the manufacture of building elements, which have the form of panels, in which a body of an insulating material is provided and in which the surfaces of this body are coated with a resistive material characterized by continuously forming a panel of expanded resin of the desired thickness, bringing this panel to the desired dimensions, transporting these light panels to the construction site, and coating the surfaces of the panels of expanded resin with a sprayed product. Method according to claim 1, characterized in that the panel of expanded resin is continuously formed in a corridor, bounded by two movable walls, at least one of the surfaces of the panel being provided with projections, in particular of notches with counter-undercuts provide such that excellent anchoring of the sprayed product is obtained. 3. A method according to any one of claims 1 and 2, characterized in that before the said panel is transported to the construction site, the surfaces of the resin panel are coated with a sprayed product, in particular cement, so that a panel is obtained with a service life greater than that of uncovered foam and easier handling and assembly. h. A method according to any one of claims 1 to 3, characterized in that the panel, the surfaces of which are provided with protrusions, is laid flat on a support on which, in particular cement, is poured in advance to a certain thickness, such that after adhering the cement to the tops of the protrusions and after releasing the support, the plate has a smooth wall behind which passages are formed between said protrusions. Method according to claim 4, characterized in that this treatment takes place on each of the surfaces of the expanded plate body, so that a smooth panel is obtained through which passages run. 35 80 05 34 3 6. Method according to any one of claims 1 to 4, characterized in that two panels with protrusions, optionally cut in the longitudinal direction, are placed against each other and with the surfaces with protrusions opposite each other, so that passages between the protrusions of the opposing faces are formed. Method according to any one of claims U to 6, characterized in that when the panels are placed on the construction site, cement is poured into the corridors, in particular after the reinforcements have been installed in the latter, such that sunken structures formed in the panel forming the formwork. Method according to any one of claims 1 to 7, characterized in that the passages surrounding the projections 15 provided with the surfaces of the panels are used for the passage of reinforcements and of the cement which reinforces networked, providing connections and connections across the entire structure so that the resistance is evenly distributed. Apparatus for applying the method according to claims 1 and 2, consisting of means for pouring a material between two walls, means for displacing the walls in the same direction, and means for truncating the panels characterized by means for continuously forming on the surfaces of the panels, protrusions, in particular provided with notches. 10. Device according to claim 9, characterized in that the means for providing the protrusions are a number of interchangeable shapes, which form said movable walls. 11. Device as claimed in claim 10, characterized in that the shapes have a profile which permits continuous demoulding of the panel. Panel according to claims 1 and 2, 35, characterized in that it consists of a web plate of expanded 80 05 34 3 resin, the surfaces of which are provided with projections with notches and with counter-undercuts, and coated with a resistance material. 13. Panel obtained by applying the method according to claims 6 and 7, characterized in that it comprises a body of guaranteed resin which has longitudinal and transverse passages forming a formwork over its thickness. 14. Panel according to claims 12 and 13, characterized in that the expanded resin body is formed by phenolic resin foam. 15. Method substantially as described in the description and / or examples. 16. Device for the application of the method substantially as indicated in the description and / or shown in the drawing. ♦ 80 05 34 3