WO1990000474A1 - Composite construction elements with tridimensional armatures - Google Patents

Composite construction elements with tridimensional armatures Download PDF

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Publication number
WO1990000474A1
WO1990000474A1 PCT/FR1989/000371 FR8900371W WO9000474A1 WO 1990000474 A1 WO1990000474 A1 WO 1990000474A1 FR 8900371 W FR8900371 W FR 8900371W WO 9000474 A1 WO9000474 A1 WO 9000474A1
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WO
WIPO (PCT)
Prior art keywords
matrix
plywood
approximately
composite
rigid foam
Prior art date
Application number
PCT/FR1989/000371
Other languages
French (fr)
Inventor
Willem Arnold Van Willigen
Jean-Yves Soria
Original Assignee
Willem Arnold Van Willigen
Soria Jean Yves
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Willem Arnold Van Willigen, Soria Jean Yves filed Critical Willem Arnold Van Willigen
Publication of WO1990000474A1 publication Critical patent/WO1990000474A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • E04C2/243—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 one at least of the material being insulating
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0221—Vinyl resin
    • B32B2266/0228—Aromatic vinyl resin, e.g. styrenic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/022—Foam

Definitions

  • the present invention relates to composite construction elements of the type comprising at least one matrix of cellular material, in particular expanded polystyrene foam and at least one layer of internal and / or external reinforcement in plywood.
  • Composite elements of this type are for example described in European patent application EP-A-016 280 by the applicants. This patent application also describes methods for producing multidimensional structures by forming and / or assembling such composite elements.
  • the present invention proposes to produce composite elements having improved mechanical properties compared to the composite elements of the prior art as well as a method of manufacturing such composite elements making it possible to directly obtain complex structures, in particular three-dimensional structures, without having to implement the cutting and assembly operations provided for in the process described in the previous patent application.
  • the composite elements according to the invention are essentially characterized by the fact that the matrix (s) are made of a rigid foam having a compressive strength greater than 1 kg / cm 2 and that they comprise between the matrix (s) of rigid foam and or each of the plywood reinforcements, a transition layer of rigid foam / polyurethane composite material with a thickness greater than that of the associated plywood reinforcement and preferably between 10 and 20 mm.
  • the transition layers of composite material are obtained by applying all the main surfaces of a matrix of rigid foam, in particular of expanded polystyrene intended to form the core of the composite element and having to receive a plywood frame.
  • an appropriate amount of a polyurethane resin preferably of the pre-crosslinked single-component type, the polyurethane resin penetrating a significant depth in the interstitial network formed in the gaps of the rigid foam and constituting the transition layer.
  • this transition layer is therefore formed of polystyrene balls fully coated and connected together by the polyurethane resin once the latter has hardened.
  • an amount of polyurethane resin of between about 25 and about 120% by weight of the rigid foam matrix is applied according to the invention.
  • the particularly remarkable mechanical properties of the composite elements according to the invention come from the fact that the composite transition layer achieves between the matrix in rigid foam, in particular in expanded polystyrene and the or each of the plywood reinforcements, a gradient transition coupling, the amount of polyurethane in the transition composite material decreasing in effect progressively between the or each of the plywood reinforcements and the matrix.
  • the use of the polyurethane according to the invention is not only intended to provide a bonding function between the matrix and the or each of the plywood reinforcements, as for example, in the prior document mentioned. above, but aims to achieve between the matrix and the or each of the plywood reinforcements an interface zone of composite material achieving the mentioned coupling gradient and surprisingly increasing the mechanical properties of the assembly.
  • the matrix forming the core of the composite element according to the invention is preferably made of an expanded polystyrene having a specific weight of between approximately 15 and approximately 25 kg / m 3 , and preferably of the order of 20 kg / m 3 .
  • the or each of the plywood frames preferably has a thickness of between about 4 and about 10 mm, the plywood frame (s) being present in the element composite according to the invention so as to represent 50 to 75% of the total weight of the element produced.
  • the present invention also relates to a method for manufacturing such composite elements, characterized in that the or each of the dies is produced by cutting a block of rigid foam, which is applied to all the main faces of the or matrices to be covered with a plywood reinforcement, the appropriate quantity of polyurethane resin to obtain a transition layer having the specified thickness, which one places the reinforcement (s), which one replaces the set of matrices and reinforcements in a mold consisting of the remaining parts of the starting rigid foam block, which is put into compression the mold for a period of between approximately 5 minutes and approximately 3 hours depending on the curing time of the polyurethane resin used, after which the finished composite element is removed from the mold.
  • a composite element is directly produced which can form a three-dimensional structure and the shape of which is determined by the configuration of the matrix or matrices obtained by cutting out the starting rigid foam block, the latter constituting during from the hardening phase of the polyurethane a counter-form which achieves, due to its conformation complementary to that of the matrix (s), a perfect distribution of the pressure exerted during the hardening phase of the polyurethane, as well as a perfect maintenance in place of the reinforcement (s).
  • FIG. 1 illustrates a first embodiment of a composite element according to the invention
  • FIG. 2 illustrates two phases of implementing the method for producing a plurality of elements as illustrated in FIG. 1,
  • FIG. 1 Illustrated in Figure 1 a composite element according to the invention in the form of a curved profile panel.
  • the composite element 1 illustrated comprises a core 2 consisting of a polystyrene matrix and two external reinforcements in 5 plywood constituting external skins 3.
  • an interface layer is made of an expanded polystyrene / polyurethane composite material 4.
  • FIGS. 2 and 3 illustrate two steps of a method for the simultaneous manufacturing, according to the invention, of several composite elements of the type of that illustrated in FIG. 1.
  • a parallelepipedic block 5 of expanded polystyrene in which a plurality of cuts are made, in particular by the hot wire technique, so as to constitute a plurality of dies, four in number in the illustrated example, 2a, 2b, 2c and 2d each having the desired shape and final dimension (actual matrix and zone (s) of expanded polystyrene / polyurethane composite material).
  • Two additional cutouts 6 are also made in block 5 so as to remove two zones of material on either side of the dies 2a and 2d respectively, the total thickness of these zones corresponding to the total thickness of the reinforcements to be placed on the dies. It is thus possible to set up as illustrated in FIG. 3 in the remaining parts 5a and 5b of the starting block 5, after cutting, four assemblies consisting of the dies 2a, 2b, 2c, 2d each coated on each of their main faces of the reinforcements 3 necessary so as to constitute four composite elements la, ib, le, ld which are produced simultaneously by applying, as illustrated in the - "- arrows of FIG.
  • FIG. 4 illustrates a reinforced planar panel constituting a second embodiment of a composite element according to the invention. -5-
  • the element designated as a whole by 10 comprises a plurality " of expanded polystyrene matrices 11 of parallelepiped shape and of substantially square section between which reinforcements 12 are arranged in plywood, layers of composite material 13 expanded polystyrene / polyurethane being produced between each matrix 11 and the corresponding plywood reinforcements.
  • the composite element further comprises on its main faces and if appropriate on its edges, external plywood reinforcements with the interposition of a layer of transition composite material. transition layers have not been shown for clarity of the drawing.
  • FIG. 5 illustrates another embodiment of a composite element according to the invention generally designated by 20, this composite element having the shape of a cylindrical assembly and consisting of a plurality of dies 21 in the form of cylinder sectors on which are fixed plywood reinforcements 22, layers of expanded polystyrene / polyurethane composite material 23 being produced between each of the reinforcements and the corresponding matrix.
  • FIG. 5 also shows the block of expanded polystyrene which, according to the invention, serves as a counterform during the manufacture of the composite element.
  • the element 20 illustrated comprises a peripheral plywood reinforcement forming an external skin (not shown), this being produced during the same molding step as that illustrated in FIG. 5, by means, as in the embodiment of the Figures 2 and 3, the removal in the starting block of an area corresponding to the thickness of the frame to form the outer skin.
  • the element 30 illustrated in Figure 6 has a left triangular shape formed by cutting from a block of expanded polystyrene (not shown) to the desired final shape of a matrix of expanded polystyrene 31 on all sides of which are placed external reinforcements, only some of which are shown at 32, layers of expanded polystyrene / polyurethane composite material 33 being produced as in previous embodiments between the frames 32 and the matrix 30.
  • rigid foam expanded polystyrene other rigid foams having the specified mechanical properties can be used according to the invention, in particular extruded polystyrene or polyurethane foams.

Abstract

The invention relates to a composite construction element of the type having at least one matrix made of cellular material and at least one internal and/or external armature layer consisting of plywood. The matrix or matrices are made of rigid foam having a compression resistance higher than 1 kg/cm?2. There is provided between the matrix or matrices (2) and the armature or each of the armatures of plywood (3) a transition layer consisting of a composite material of rigid foam/polyurethane (4) having a thickness higher than that of the associated plywood armature and preferably comprised between 10 and 20 mm.

Description

Eléments composites de construction à armatures tridimensionelles Composite building elements with three-dimensional reinforcement
La présente invention est relative à des éléments composites de construction du type comportant au moins une matrice en matériau cellulaire, notamment mousse de polystyrène expansé et au moins une couche d'armature interne et/ou externe en contreplaque.The present invention relates to composite construction elements of the type comprising at least one matrix of cellular material, in particular expanded polystyrene foam and at least one layer of internal and / or external reinforcement in plywood.
Des éléments composites de ce type sont par exemple décrits dans la demande de brevet européen EP-A-016 280 des déposants. Cette demande de brevet décrit également des procédés pour la réalisation de structures multidimensionnelles par formage et/ou par assemblage de tels éléments composites.Composite elements of this type are for example described in European patent application EP-A-016 280 by the applicants. This patent application also describes methods for producing multidimensional structures by forming and / or assembling such composite elements.
La présente invention se propose de réaliser des éléments composites présentant des propriétés mécaniques améliorées par rapport aux éléments composites de l'art antérieur ainsi qu'un procédé de fabrication de tels éléments composites permettant d'obtenir directement des structures complexes, notamment tridimensionnelles, sans avoir à mettre en oeuvre les opérations de découpe et d'assemblage prévues dans le procédé décrit dans la demande de brevet antérieure.The present invention proposes to produce composite elements having improved mechanical properties compared to the composite elements of the prior art as well as a method of manufacturing such composite elements making it possible to directly obtain complex structures, in particular three-dimensional structures, without having to implement the cutting and assembly operations provided for in the process described in the previous patent application.
Les éléments composites selon l'invention se caractérisent essentiellement par le fait que la ou les matrices sont réalisées en une mousse rigide présentant une résistance à la compression supérieure à 1 Kg/cm2 et qu'ils comportent entre la ou les matrices en mousse rigide et la ou chacune des armatures en contreplaque, une couche de transition en matériau composite mousse rigide/polyuréthane d'une épaisseur supérieure à celle de l'armature en contreplaque associée et de préférence comprise entre 10 et 20 mm. Selon l'invention, les couches de transition en matériau composite sont obtenues en appliquant toutes les surfaces principales d'une matrice en mousse rigide, notamment en polystyrène expansé destinée à former l'âme de l'élément composite et devant recevoir une armature en contreplaque, une quantité appropriée d'une résine polyurethane, de préférence du type monocomposant préréticulé, la résine polyurethane pénétrant sur une profondeur importante dans le réseau interstitiel formé dans les lacunes de la mousse rigide et constituant la couche de transition. Dans le cas où la mousse rigide est formée de polystyrène expansé, cette couche de transition est donc formée de billes de polystyrène entièrement revêtues et reliées entre elles par la résine polyurethane une fois le durcissement de cette dernière réalisé.The composite elements according to the invention are essentially characterized by the fact that the matrix (s) are made of a rigid foam having a compressive strength greater than 1 kg / cm 2 and that they comprise between the matrix (s) of rigid foam and or each of the plywood reinforcements, a transition layer of rigid foam / polyurethane composite material with a thickness greater than that of the associated plywood reinforcement and preferably between 10 and 20 mm. According to the invention, the transition layers of composite material are obtained by applying all the main surfaces of a matrix of rigid foam, in particular of expanded polystyrene intended to form the core of the composite element and having to receive a plywood frame. , an appropriate amount of a polyurethane resin, preferably of the pre-crosslinked single-component type, the polyurethane resin penetrating a significant depth in the interstitial network formed in the gaps of the rigid foam and constituting the transition layer. In the case where the rigid foam is formed of expanded polystyrene, this transition layer is therefore formed of polystyrene balls fully coated and connected together by the polyurethane resin once the latter has hardened.
Pour obtenir l'épaisseur spécifiée ci-dessus de la couche de transition, on applique selon l'invention une quantité de résine polyurethane comprise entre environ 25 et environ 120 % en poids de la matrice de mousse rigide.To obtain the thickness specified above of the transition layer, an amount of polyurethane resin of between about 25 and about 120% by weight of the rigid foam matrix is applied according to the invention.
La ou les couches de transition, du fait des propriétés d'adhésion du polyurethane, réalisent la liaison entre la matrice et la ou les armatures en contreplaque.The transition layer (s), due to the adhesion properties of the polyurethane, provide the connection between the matrix and the plywood reinforcement (s).
Les propriétés mécaniques particulièrement remarquables des éléments composites selon l'invention ainsi obtenus, proviennent du fait que la couche de transition composite réalise entre la matrice en mousse rigide, notamment en polystyrène expansé et la ou chacune des armatures en contreplaque, une transition à gradient de couplage, la quantité de polyurethane dans le matériau composite de transition décroissant en effet progressivement entre la ou chacune des armatures en contreplaque et la matrice.The particularly remarkable mechanical properties of the composite elements according to the invention thus obtained, come from the fact that the composite transition layer achieves between the matrix in rigid foam, in particular in expanded polystyrene and the or each of the plywood reinforcements, a gradient transition coupling, the amount of polyurethane in the transition composite material decreasing in effect progressively between the or each of the plywood reinforcements and the matrix.
On doit donc bien comprendre que l'utilisation du polyurethane selon l'invention n'a pas uniquement pour but d'assurer une fonction de collage entre la matrice et la ou chacune des armatures en contreplaque, comme par exemple, dans le document antérieur mentionné précédemment, mais a pour but de réaliser entre la matrice et la ou chacune des armatures en contreplaque une zone d'interface en matériau composite réalisant le gradient de couplage mentionné et accroissant de façon surprenante les propriétés mécaniques de l'ensemble.It should therefore be understood that the use of the polyurethane according to the invention is not only intended to provide a bonding function between the matrix and the or each of the plywood reinforcements, as for example, in the prior document mentioned. above, but aims to achieve between the matrix and the or each of the plywood reinforcements an interface zone of composite material achieving the mentioned coupling gradient and surprisingly increasing the mechanical properties of the assembly.
La matrice formant l'âme de l'élément composite selon l'invention, est de préférence réalisée en un polystyrène expansé présentant un poids spécifique compris entre environ 15 et environ 25 kg/m3, et de préférence de l'ordre de 20 kg/m3. La ou chacune des armatures en contreplaque présente de préférence une épaisseur comprise entre environ 4 et environ 10 mm, la ou les armatures en contreplaque étant présentes dans l'élément composite selon l'invention de manière à représenter 50 à 75 % du poids total de l'élément fabriqué.The matrix forming the core of the composite element according to the invention is preferably made of an expanded polystyrene having a specific weight of between approximately 15 and approximately 25 kg / m 3 , and preferably of the order of 20 kg / m 3 . The or each of the plywood frames preferably has a thickness of between about 4 and about 10 mm, the plywood frame (s) being present in the element composite according to the invention so as to represent 50 to 75% of the total weight of the element produced.
La présente invention a également pour objet un procédé pour fabriquer de tels éléments composites, caractérisé par le fait que la ou chacune des matrices est réalisée par découpe d'un bloc de mousse rigide,que l'on applique sur toutes les faces principales de la ou des matrices devant être recouvertes d'une armature de contreplaque, la quantité appropriée de résine polyurethane pour obtenir une couche de transition ayant l'épaisseur spécifiée, que l'on met en place la ou les armatures, que l'on replace l'ensemble des matrices et des armatures dans un moule constitué par les parties restantes du bloc de mousse rigide de départ, que l'on met en compression le moule pendant une durée comprise entre environ 5 minutes et environ 3 heures en fonction du temps de durcissement de la résine polyurethane utilisée, après quoi l'on retire l'élément composite terminé du moule.The present invention also relates to a method for manufacturing such composite elements, characterized in that the or each of the dies is produced by cutting a block of rigid foam, which is applied to all the main faces of the or matrices to be covered with a plywood reinforcement, the appropriate quantity of polyurethane resin to obtain a transition layer having the specified thickness, which one places the reinforcement (s), which one replaces the set of matrices and reinforcements in a mold consisting of the remaining parts of the starting rigid foam block, which is put into compression the mold for a period of between approximately 5 minutes and approximately 3 hours depending on the curing time of the polyurethane resin used, after which the finished composite element is removed from the mold.
On comprend que, selon l'invention, on réalise directement un élément composite qui peut former une structure tridimensionnelle et dont la forme est déterminée par la configuration de la ou des matrices obtenues par découpage du bloc de mousse rigide de départ, ce dernier constituant lors de la phase de durcissement du polyurethane une contre-forme qui réalise, du fait de sa conformation complémentaire à celle de la ou des matrices, une parfaite répartition de la pression exercée pendant la phase de durcissement du polyurethane, ainsi qu'un parfait maintien en place de la ou des armatures.It is understood that, according to the invention, a composite element is directly produced which can form a three-dimensional structure and the shape of which is determined by the configuration of the matrix or matrices obtained by cutting out the starting rigid foam block, the latter constituting during from the hardening phase of the polyurethane a counter-form which achieves, due to its conformation complementary to that of the matrix (s), a perfect distribution of the pressure exerted during the hardening phase of the polyurethane, as well as a perfect maintenance in place of the reinforcement (s).
D'autres avantages et caractéristiques de l'invention apparaîtront à la lecture de la description suivante d'exemples de réalisation nullement limitatifs en se référant au dessin annexé dans lequel :Other advantages and characteristics of the invention will appear on reading the following description of nonlimiting exemplary embodiments with reference to the appended drawing in which:
- la figure 1 illustre un premier exemple de réalisation d'un élément composite selon l'invention,FIG. 1 illustrates a first embodiment of a composite element according to the invention,
- la figure 2 illustre deux phases de mise en oeuvre du procédé pour la réalisation d'une pluralité d'éléments tels qu'illustrés à la figure 1,FIG. 2 illustrates two phases of implementing the method for producing a plurality of elements as illustrated in FIG. 1,
- les figures 4 à 6 illustrent trois autres exemples de réalisation d'éléments composites selon l'invention. On a illustré à la figure 1 un élément composite selon l'invention sous la forme d'un panneau de profil cintré.- Figures 4 to 6 illustrate three other embodiments of composite elements according to the invention. Illustrated in Figure 1 a composite element according to the invention in the form of a curved profile panel.
L'élément composite 1 illustré comporte une âme 2 constituée d'une matrice de polystyrène et deux armatures externes en 5 contreplaque constituant des peaux externes 3.The composite element 1 illustrated comprises a core 2 consisting of a polystyrene matrix and two external reinforcements in 5 plywood constituting external skins 3.
Entre la matrice en polystyrène 2 et chacune des armatures 3 est réalisée une couche d'interface en un matériau composite polystyrène expansé/polyuréthane 4.Between the polystyrene matrix 2 and each of the reinforcements 3, an interface layer is made of an expanded polystyrene / polyurethane composite material 4.
Les figures 2 et 3 illustrent deux étapes d'un procédé de 10 fabrication simultanée, selon l'invention, de plusieurs éléments composites du type de celui illustré sur la figure 1.FIGS. 2 and 3 illustrate two steps of a method for the simultaneous manufacturing, according to the invention, of several composite elements of the type of that illustrated in FIG. 1.
On part à cet effet d'un bloc parallélépipédique 5 en polystyrène expansé dans lequel l'on réalise une pluralité de découpes, notamment par la technique du fil chaud, de manière à 15 constituer une pluralité de matrices, au nombre de quatre dans l'exemple illustré, 2a, 2b, 2c et 2d ayant chacune la forme et la dimension finale désirée (matrice proprement dite et zone (s) de matériau composite polystyrène expansé/polyuréthane) .To this end, we start from a parallelepipedic block 5 of expanded polystyrene in which a plurality of cuts are made, in particular by the hot wire technique, so as to constitute a plurality of dies, four in number in the illustrated example, 2a, 2b, 2c and 2d each having the desired shape and final dimension (actual matrix and zone (s) of expanded polystyrene / polyurethane composite material).
On réalise également dans le bloc 5 deux découpes 20 supplémentaires 6 de manière à retirer deux zones de matière de part et d'autre respectivement des matrices 2a et 2d, l'épaisseur totale de ces zones correspondant à l'épaisseur totale des armatures devant être mises en place sur les matrices. On peut ainsi mettre en place comme illustré à la figure 3 dans les parties 25 restantes 5a et 5b du bloc 5 de départ, après découpe, quatre ensembles constitués des matrices 2a, 2b, 2c, 2d revêtues chacune sur chacune de leurs faces principales des armatures 3 nécessaires de manière à constituer quatre éléments composites la, ib, le, ld que l'on réalise simultanément en appliquant comme illustré sur les -"- flèches de la figure 3, une pression de 0,3 Kg/cm2 pendant un temps de 1 heure pour réaliser l'adhérisation des armatures sur les matrices en polystyrène après mise en place de la quantité appropriée de résine polyurethane pour former les zones de transition en matériau composite polystyrène expansé/polyuréthane 35 3, sur une profondeur de 10 mm environ.Two additional cutouts 6 are also made in block 5 so as to remove two zones of material on either side of the dies 2a and 2d respectively, the total thickness of these zones corresponding to the total thickness of the reinforcements to be placed on the dies. It is thus possible to set up as illustrated in FIG. 3 in the remaining parts 5a and 5b of the starting block 5, after cutting, four assemblies consisting of the dies 2a, 2b, 2c, 2d each coated on each of their main faces of the reinforcements 3 necessary so as to constitute four composite elements la, ib, le, ld which are produced simultaneously by applying, as illustrated in the - "- arrows of FIG. 3, a pressure of 0.3 Kg / cm 2 during a 1 hour time to adhere the reinforcements to the polystyrene matrices after placing the appropriate quantity of polyurethane resin to form the transition zones made of expanded polystyrene / polyurethane composite material 35 3, to a depth of approximately 10 mm .
La figure 4 illustre un panneau plan armé constituant un second exemple de réalisation d'élément composite selon l'invention. -5-FIG. 4 illustrates a reinforced planar panel constituting a second embodiment of a composite element according to the invention. -5-
L'élément désigné dans son ensemble par 10 comporte une pluralité" de matrices en polystyrène expansé 11 de forme parallélépipédique et de section sensiblement carrée entre lesquelles sont disposées des armatures 12 en contreplaque, des couches de matériau composite 13 polystyrène expansé/polyuréthane étant réalisées entre chaque matrice 11 et les armatures en contreplaque correspondantes. L'élément composite comporte en outre sur ses faces principales et le cas échéant sur ses chants, des armatures externes en contreplaque avec interposition d'une couche de matériau composite de transition. Ces armatures et ces couches de transition n'ont pas été représentées pour une plus grande clarté du dessin.The element designated as a whole by 10 comprises a plurality " of expanded polystyrene matrices 11 of parallelepiped shape and of substantially square section between which reinforcements 12 are arranged in plywood, layers of composite material 13 expanded polystyrene / polyurethane being produced between each matrix 11 and the corresponding plywood reinforcements. The composite element further comprises on its main faces and if appropriate on its edges, external plywood reinforcements with the interposition of a layer of transition composite material. transition layers have not been shown for clarity of the drawing.
La figure 5 illustre un autre exemple de réalisation d'un élément composite selon l'invention désigné globalement par 20, cet élément composite présentant une forme d'ensemble cylindrique et étant constitué d'une pluralité de matrices 21 en forme de secteurs de cylindre sur lesquelles sont fixées des armatures en contreplaque 22, des couches de matériau composite polj'styrène expansé/polyuréthane 23 étant réalisées entre chacune des armatures et la matrice correspondante.FIG. 5 illustrates another embodiment of a composite element according to the invention generally designated by 20, this composite element having the shape of a cylindrical assembly and consisting of a plurality of dies 21 in the form of cylinder sectors on which are fixed plywood reinforcements 22, layers of expanded polystyrene / polyurethane composite material 23 being produced between each of the reinforcements and the corresponding matrix.
On a également illustré sur la figure 5 le bloc de polystyrène expansé qui sert selon l'invention de contre-forme lors de la fabrication de l'élément composite.FIG. 5 also shows the block of expanded polystyrene which, according to the invention, serves as a counterform during the manufacture of the composite element.
L'élément 20 illustré comporte une armature périphérique en contreplaque formant une peau externe (non représentée) , celle-ci étant réalisée au cours de la même étape de moulage que celle illustrée à la figure 5, moyennant, comme dans le mode de réalisation des figures 2 et 3, l'enlèvement dans le bloc de départ d'une zone correspondant à l'épaisseur de l'armature devant former la peau externe.The element 20 illustrated comprises a peripheral plywood reinforcement forming an external skin (not shown), this being produced during the same molding step as that illustrated in FIG. 5, by means, as in the embodiment of the Figures 2 and 3, the removal in the starting block of an area corresponding to the thickness of the frame to form the outer skin.
L'élément 30 illustré à la figure 6 présente une forme triangulaire gauche formée par découpe dans un bloc de polystyrène expansé (non représenté) à la forme finale voulue d'une matrice de polystyrène expansé 31 sur toutes les faces de laquelle sont mises en place des armatures externes dont certaines seulement sont représentées en 32, des couches de matériau composite 33 polystyrène expansé/polyuréthane étant réalisées comme dans les modes de réalisation précédents entre les armatures 32 et la matrice 30.The element 30 illustrated in Figure 6 has a left triangular shape formed by cutting from a block of expanded polystyrene (not shown) to the desired final shape of a matrix of expanded polystyrene 31 on all sides of which are placed external reinforcements, only some of which are shown at 32, layers of expanded polystyrene / polyurethane composite material 33 being produced as in previous embodiments between the frames 32 and the matrix 30.
Bien que l'invention ait été décrite en liaison avec des modes de réalisation particuliers, il est bien évident qu'elle n'y est nullement limitée et qu'on peut lui apporter de nombreuses variantes et modifications sans pour autant sortir ni de son cadre, ni de son esprit.Although the invention has been described in connection with particular embodiments, it is obvious that it is in no way limited thereto and that it can be brought to many variations and modifications without departing from its scope or , nor of his spirit.
En particulier, bien que les différents exemples utilisent comme mousse rigide du polystyrène expansé, on peut utiliser selon l'invention d'autres mousses rigides présentant les propriétés mécaniques spécifiées, notamment des mousses de polystyrène ou de polyurethane extrudées. In particular, although the different examples use as rigid foam expanded polystyrene, other rigid foams having the specified mechanical properties can be used according to the invention, in particular extruded polystyrene or polyurethane foams.

Claims

REVENDICATIONS
1 - Elément composite de construction du type comportant au moins une matrice en matériau cellulaire et au moins une couche d'armature interne et/ou externe en contreplaque, caractérisé par le fait que la ou les matrices sont réalisées en une mousse rigide présentant une résistance à la compression supérieure à 1 Kg/cm2 et qu'il comporte entre la ou les matrices (2, 11, 21, 31) et la ou chacune des armatures en contreplaque (3, 12, 22, 32), une couche de transition en un matériau composite mousse rigide/ polyurethane (4, 13, 23, 33) d'une épaisseur supérieure à celle de l'armature en contreplaque associée, et de préférence comprise entre 10 et 20 mm.1 - Composite construction element of the type comprising at least one matrix of cellular material and at least one layer of internal and / or external reinforcement in plywood, characterized in that the matrix or matrices are made of a rigid foam having a resistance at compression greater than 1 Kg / cm 2 and that it comprises between the matrix (s) (2, 11, 21, 31) and the or each of the plywood reinforcements (3, 12, 22, 32), a layer of transition into a rigid foam / polyurethane composite material (4, 13, 23, 33) with a thickness greater than that of the associated plywood frame, and preferably between 10 and 20 mm.
2 - Elément composite selon la revendication 1, caractérisé par le fait que la ou lesdites couches de transition sont obtenues par application d'une quantité de résine polyurethane compris entre environ 25 et environ 120 % en poids de la ou des matrices. 3 - Elément composite selon l'une quelconque des revendications 1 et 2, caractérisé par le fait que la ou les armatures en contreplaque représentent 50 à 75 % du poids total de l'élément.2 - composite element according to claim 1, characterized in that the said transition layer (s) are obtained by application of an amount of polyurethane resin of between approximately 25 and approximately 120% by weight of the matrix (s). 3 - composite element according to any one of claims 1 and 2, characterized in that the plywood frame (s) represent 50 to 75% of the total weight of the element.
4 - Elément composite selon l'une quelconque des revendications 1 à 3, caractérisé par le fait que la ou les matrices sont en polystyrène expansé d'un poids spécifique compris entre environ 15 et environ 25 Kg/m3.4 - composite element according to any one of claims 1 to 3, characterized in that the matrix or matrices are made of expanded polystyrene with a specific weight of between approximately 15 and approximately 25 kg / m 3 .
5 - Procédé pour fabriquer un élément composite selon l'une quelconque des revendications précédentes, caractérisé par le fait que l'on réalise la ou chacune des matrices par découpe d'un bloc de mousse rigide (5) que l'on applique toutes les faces principales de la ou des matrices devant recevoir une armature de contreplaque, une résine polyurethane en une quantité comprise entre environ 25 et environ 120 % en poids de la ou des matrices, que l'on met en place la ou les armatures, que l'on replace l'ensemble des matrices et des armatures dans un moule constitué par les parties restantes (5a, 5b) du bloc de mousse rigide de départ, que l'on met en compression le moule pendant une durée comprise entre environ 5 minutes et environ 3 heures en fonction du temps de durcissement de la résine polyurethane, après quoi l'on retire l'élément composite terminé du moule. 5 - Process for manufacturing a composite element according to any one of the preceding claims, characterized in that the or each of the dies is produced by cutting out a block of rigid foam (5) which is applied every main faces of the matrix (s) to receive a plywood reinforcement, a polyurethane resin in an amount of between approximately 25 and approximately 120% by weight of the matrix (s), which one places the reinforcement (s), that the '' we replace all the matrices and reinforcements in a mold consisting of the remaining parts (5a, 5b) of the starting rigid foam block, which we put in compression the mold for a period of between approximately 5 minutes and approximately 3 hours depending on the curing time of the polyurethane resin, after which the finished composite element is removed from the mold.
PCT/FR1989/000371 1988-07-12 1989-07-12 Composite construction elements with tridimensional armatures WO1990000474A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR88/09472 1988-07-12
FR8809472A FR2634160B1 (en) 1988-07-12 1988-07-12 COMPOSITE CONSTRUCTION ELEMENTS WITH THREE-DIMENSIONAL FRAMEWORK COMPRISING AT LEAST ONE MATRIX OF CELLULAR MATERIAL AND METHOD FOR THE PRODUCTION THEREOF

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WO1990000474A1 true WO1990000474A1 (en) 1990-01-25

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EP (1) EP0383877A1 (en)
JP (1) JPH03501592A (en)
AU (1) AU623674B2 (en)
ES (1) ES2014895A6 (en)
FR (1) FR2634160B1 (en)
WO (1) WO1990000474A1 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105402910A (en) * 2015-12-29 2016-03-16 山东小鸭新能源科技有限公司 WIFI (Wireless Fidelity) long-distance intelligent controlled home solar split-type water heater and control method
WO2018046819A1 (en) 2016-09-06 2018-03-15 Willem Arnold Van Willigen Method for assembling building elements and building thus produced

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1187291A (en) * 1957-11-27 1959-09-09 Prefabricated panels for construction and decoration
FR2294826A1 (en) * 1974-12-16 1976-07-16 Normac Rigid lightweight polyurethane foam panels - and mouldings with foamed polystyrene particles as filler
EP0044286A2 (en) * 1980-07-04 1982-01-20 KemaNord AB A method of securing adhesion
EP0164280A2 (en) * 1984-04-16 1985-12-11 Jonathan Christopher Mc Intosh Enveloping composite comstruction elements and process for making multidimensional structures from these elements

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1187291A (en) * 1957-11-27 1959-09-09 Prefabricated panels for construction and decoration
FR2294826A1 (en) * 1974-12-16 1976-07-16 Normac Rigid lightweight polyurethane foam panels - and mouldings with foamed polystyrene particles as filler
EP0044286A2 (en) * 1980-07-04 1982-01-20 KemaNord AB A method of securing adhesion
EP0164280A2 (en) * 1984-04-16 1985-12-11 Jonathan Christopher Mc Intosh Enveloping composite comstruction elements and process for making multidimensional structures from these elements

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105402910A (en) * 2015-12-29 2016-03-16 山东小鸭新能源科技有限公司 WIFI (Wireless Fidelity) long-distance intelligent controlled home solar split-type water heater and control method
WO2018046819A1 (en) 2016-09-06 2018-03-15 Willem Arnold Van Willigen Method for assembling building elements and building thus produced

Also Published As

Publication number Publication date
JPH03501592A (en) 1991-04-11
AU4039489A (en) 1990-02-05
FR2634160B1 (en) 1991-02-15
ES2014895A6 (en) 1990-07-16
EP0383877A1 (en) 1990-08-29
AU623674B2 (en) 1992-05-21
FR2634160A1 (en) 1990-01-19

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