WO2006088364A1 - Element de construction et procedes de fabrication de celui-ci - Google Patents

Element de construction et procedes de fabrication de celui-ci Download PDF

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Publication number
WO2006088364A1
WO2006088364A1 PCT/NL2006/000091 NL2006000091W WO2006088364A1 WO 2006088364 A1 WO2006088364 A1 WO 2006088364A1 NL 2006000091 W NL2006000091 W NL 2006000091W WO 2006088364 A1 WO2006088364 A1 WO 2006088364A1
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WO
WIPO (PCT)
Prior art keywords
mould
finishing layer
building element
foam
arranging
Prior art date
Application number
PCT/NL2006/000091
Other languages
English (en)
Inventor
Hendrik Johannes Van Dijk
Original Assignee
Sûr-Façe B.V.
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 Sûr-Façe B.V. filed Critical Sûr-Façe B.V.
Publication of WO2006088364A1 publication Critical patent/WO2006088364A1/fr

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Classifications

    • 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
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • E04C2/2885—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material with the insulating material being completely surrounded by, or embedded in, a stone-like material, e.g. the insulating material being discontinuous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/002—Producing shaped prefabricated articles from the material assembled from preformed elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/20—Producing shaped prefabricated articles from the material by centrifugal or rotational casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/30—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon
    • B28B1/32—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon by projecting, e.g. spraying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • B28B11/042—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers with insulating material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1228—Joining preformed parts by the expanding material
    • B29C44/1233—Joining preformed parts by the expanding material the preformed parts being supported during expanding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0006—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects the reinforcement consisting of aligned, non-metal reinforcing elements

Definitions

  • the present invention relates to a building element, and to methods for manufacturing thereof.
  • the building element is suitable for use as a decorative element or construction element for the purpose of constructing and/or finishing buildings.
  • the building element may be applied for the layout of spaces and public areas, as a part of infrastructural applications or applications related to construction, road-building or hydraulic engineering. It is also suitable for other construction-related applications, such as for forming floor and/or wall tiles, outside wall elements, partition walls, roof elements, tabletops, kitchen work surfaces, complete prefabricated outside walls, scenery, furniture, street furniture, shaped parts, works of art, pontoons and the like.
  • US-A-4.229.497 is a building element which comprises a relatively light core of cured foam.
  • the core is encapsulated with cement, to which reinforcement is added.
  • the foam core is pressed into a mould filled with liquid cement, and cement is subsequently poured over the core so as to also cover the remaining side therewith.
  • the known building element is relatively light and thereby provides many advantages, the element is not durable enough for use as outer wall cladding or as construction element.
  • the adhesion of the separate materials is a particular problem. There is no structural connection between the materials apart from the adhesion of the cement to the foam core.
  • US-A-3.536.575 is known a sandwich element comprising a relatively light layer of phenol foam, which is introduced as foaming material into a mould in which plate-like outer layers are already arranged. In this manner a sandwich element is obtained which is relatively light and which is provided with finishing layers on the upper and lower sides. The sandwich element does not however have any finishing on the sides. Creating an almost realistic reproduction of (natural) stone-like materials is moreover impossible with the finishing layers used.
  • the production method as specified in US-A- 3.536.575 does not take into account pressure built up inside the mould by the foaming material. This is demonstrated inter alia by the fact that rubber is mentioned as suitable material for the mould.
  • the production in this way of strong, constructional panels by increasing the quantity or the density of the foam introduced is impossible.
  • the sandwich elements are relatively weak and therefore have a limited number of possible applications.
  • the present invention has for its object to provide a method for manufacturing a stronger light-weight building element.
  • the invention provides for this purpose a method for manufacturing a building element, comprising the steps of: i) arranging a finishing layer in a mould which is provided with a predetermined inner surface; ii) distributing the finishing layer uniformly over the inner surface of the mould; and iii) arranging foaming material inside the finishing layer in order to form a foam core.
  • the building element according to the invention makes a finish of higher aesthetic value possible, particularly as substitute for stone, natural stone or concrete.
  • the element is herein more durable, lighter and easier to produce, and thereby less expensive than the known elements.
  • Structural anchors can here be incorporated in the building element in simple manner without increasing the layer thickness of the cement of the finishing layer.
  • the element has a more favourable mortar to core ratio, whereby the element can be up to 80% or 90% lighter than
  • a good adhesion is also obtained between core and finishing layer in that the core of foaming material is injected afterward into the outer shell formed by the finishing layer, or is injected therein under pressure.
  • finishing layer is cement-bound.
  • Reinforcing layers are optionally arranged in or between the layers from which the building element is constructed.
  • the reinforcement can be arranged in the form of fibre as well as in mat form.
  • the foaming material for forming the foam core is arranged inside the hollow shell, formed by the finishing layer, under a pressure such that the foam core acquires a density between 10 kg/m 3 and 800 kg/m 3 .
  • the pressure which is built up by the material during foaming thereof is in the order of 2 bar to 500 bar.
  • the pressure can optionally rise to 1500 bar.
  • Pressing means arranged round the mould provide for a desired reactive force which ensures that the mould remains intact.
  • the adhesion of the core material being a foaming material such as polyurethane, PIR, phenol or other type of foam, to the continuous outer shell, comprising a cement-like mortar or concrete mortar.
  • the building element comprises one or more reinforcing layers which are incorporated or arranged in the finishing layer. The thus obtained element is stronger and has the above stated advantages to an increased extent.
  • the reinforcing layers extend over substantially the whole surface of the finishing layer, including the sides of the element.
  • the element is thus even stronger, whereby a greater weight- saving can be achieved with a thinner mortar layer, as well as an increased strength.
  • the reinforcing layer comprises a fibre mat or strips of carbon, aramid or glass fibre, although other reinforcing materials such as expanded steel, woven plastic or textile mats or fibre mats of natural materials are also possible options, depending on the application.
  • the reinforcement comprises loose fibres of glass fibre, stainless steel, aramid, carbon and/or natural materials or types of reinforcing textile which are mixed through the material of the finishing layer and/or the foam core.
  • reinforcing fibres as specified above are co-injected into the foam core.
  • the building element hereby has a greater resistance to breakage and pressure, and a higher tensile and compression strength.
  • the finishing layer comprises a cement- bound mortar such as a levelling mortar, concrete mortar, pouring mortar, patching mortar, synthetic resin mortar, insulating mortar, composite cement or high-strength concrete.
  • a cement- bound mortar such as a levelling mortar, concrete mortar, pouring mortar, patching mortar, synthetic resin mortar, insulating mortar, composite cement or high-strength concrete.
  • auxiliary substances such as polymers, plasticizers, super-plasticizers, elastomers, compacting means, fire- retardants, adhesive emulsions, accelerators or decelerators .
  • the applicable mortars combine a thin finishing layer with sufficient strength.
  • the mortar can also be mixed with additional substances such as dyes, fillers or additives in order to obtain a desired quality or finish.
  • the finish can be embodied such that the building element has the external characteristics of a natural stone or stone-like material .
  • the mortars can have a single or multi-component basis.
  • the building element is provided with a magnetic or magnetizable attaching member arranged on the rear side of the elements for attaching thereof to a rear construction by magnetic attraction.
  • the quicker and easier fastening by magnetic action, as well as the possibility of removing the building element more easily, is advantageous for instance when applied in the construction of stands or scenery. Quick and flexible rearrangement or redecoration of houses, business premises and the like also becomes possible.
  • a prefabricated finishing element for house and utility building can be produced.
  • the finishing layer herein comprises a different material on the exterior side of the elements, such as steel, stone, clay, slate, wood, plastic and so on, so that a desired aesthetic exterior finish can be achieved.
  • the opposite interior side of the element is provided with another - aesthetic - finish.
  • the one side can for instance thus be provided with a plaster finish or wood, while the opposite exterior side comprises imitation roof tiles or imitation slate.
  • the method further comprises the steps of:
  • the mould is for instance kept under constant pressure by clamping the mould in a clamping construction or by placing the mould in a press. This is unnecessary when the mould is manufactured from a sufficiently strong material of sufficient thickness, such as aluminium or steel.
  • a structural panel is obtained by introducing sufficient high-density foam. The panel is even stronger when reinforcing fibres are mixed into the foaming core material.
  • the great adhesive power of the foam makes the connection structurally extra-strong.
  • a difference from the method of US-A-3.536.575 is the continuous finishing layer. This forms an outer shell of cement-bound mortar, whereby it is possible to produce an element which is a seamless and realistic reproduction of a stone-like element, panel or form part.
  • the step of distributing the first and second finishing layers over the inner surface of the first and second shaped parts comprises of pressing an inner mould against the first shaped part.
  • the step of distributing the first and second finishing layers over the inner surface of the first and second shaped parts comprises of injecting the finishing layers into the first and second shaped parts in a desired thickness.
  • the step of distributing the first and second finishing layers over the inner surface of the first and second shaped parts comprises of rotating the closed mould for a determined time.
  • the invention provides a building element manufactured according to the above described method.
  • a building or decorative element manufactured according to the method is strong enough to apply a ratio of mortar to core layer of 1:250 in large volumes.
  • the manufactured building element can thus be up to 90% lighter than natural stone, brick or other building materials.
  • Fig. IA-1C show a cross-sectional side view of an embodiment of a building element according to the present invention
  • Fig. 2A-2B show side views of two embodiments of a magnetic building element according to the present invention
  • FIG. 2C-2D show bottom views of embodiments of the magnetic building element of Fig. 2A-2B;
  • Fig. 3 is a perspective view of a wall provided with several magnetic building elements as shown in any of the figures 2A-2D;
  • Fig. 4 is a perspective view of a framework provided with several building elements as shown in any of the figures Fig. 2A-2D;
  • Fig. 5A-5H show cross-sectional side views of production steps of a first production method according to the present invention (casting) ;
  • Fig. 6A-6C show cross-sectional side views of production steps of a second production method according to the present invention (spraying method) ;
  • Fig. 7A-7D show cross-sectional side views of production steps of a third production method according to the present invention (rotation moulding) ;
  • Fig. 8 shows a cross-sectional side view of a building element according to the present invention in an embodiment suitable for use as prefabricated outer wall element; and Fig. 9 shows a cross-sectional side view of a production method for the building element of Fig. 8.
  • a building or decorative element 1 comprises a core layer 2 (fig. 1A-1C) .
  • the density of the core layer is for instance between 10 kg/m 3 and 400 kg/m 3 .
  • the core layer is reinforced throughout with reinforcing fibres 3.
  • building element 1 can also be embodied without reinforcement.
  • the core layer 2 is encapsulated all around by a mortar layer 8.
  • the mortar layer of fig. IB can likewise be reinforced with reinforcing fibres 9 and/or with a reinforcing mat 4. As shown in fig. 1C, this reinforcement can also be omitted, depending on the application for which elements are produced.
  • the reinforcement of the core layer and/or the finishing layer for instance comprises a fibre mat.
  • the fibres comprise for instance glass fibre, aramid, carbon and/or natural material.
  • the building element according to the invention can be manufactured with a cross-section at random. Reference is made in this respect to the production methods described hereinbelow. It is thus possible to imitate in substantially identical manner naturally occurring stones and stone types. This in terms of shape, see fig. 1C, and in appearance, see the production methods.
  • the present invention also provides a tile 20 (Fig. 2A-2D) which comprises a layered structure 22 corresponding to the structure of building elements 1 of fig. lA-lC.
  • Tile 20 is provided with a magnetic layer 24, i.e. magnetic or magnetizable sheet metal or foil, for attaching the tile to a magnetizable or magnetic surface by magnetic attraction. These panels are intended for decorative use.
  • Fig. 2A shows an embodiment wherein the magnetic layer 24 is embedded in building element 20.
  • Layer 24 is glued or, during foaming of the foam of core 2, connected thereto during the production process. It is also possible for the magnetic layer together with a pre-foamed core 2 to be pushed integrally in combination with a mortar layer into a mould and held there under pressure. After curing the mortar layer is adhered to the foam core and the product can be removed from the mould.
  • Magnetic layer 24 is herein embedded in the mortar.
  • the magnetic layer 24 is glued to tile 20 on an outer side of the tile.
  • the magnetic layer 24 as shown in fig. 2A and 2B can cover the whole surface of tile 20 (fig. 2D) or only a part. As shown by the hatched area in fig. 2C, the magnetic layer 24 can for instance be arranged along the edges of tile 20.
  • a wall finishing 30 (fig. 3) with the building elements can be realized by attaching tile 20 from one of the figures 2A-2D by magnetic attraction to a wall 32 which is provided with a magnetizable, for instance iron-containing, or magnetic paint.
  • Tile 20 can be held against wall 32 with the magnetic or magnetizable layer 24 in the direction thereof, and remains attached at that position due to the magnetic attraction. The tile can be easily removed by pulling it loose.
  • a further possibility for forming a wall, floor or ceiling is shown in fig. 4 and comprises a framework, for instance metal-stud 40, which is magnetizable, magnetic or provided with magnets.
  • the framework comprises uprights 42, 44, 46 and beams 48, 50.
  • the tiles are fixed against the frame by being pressed thereagainst .
  • the magnetic force can be overcome by pulling the tile, so that tiles 20 can be removed in simple manner.
  • the elements have a high flexibility through the correct combination of foam, mortar and reinforcement.
  • the building element can hereby follow slopes in a surface without breaking, cracking and the like.
  • the building elements can be glued directly to many surfaces without pre-levelling of the surface.
  • the building elements can be made thermally insulating, acoustically insulating, fire-retardant, resistant to acid, graffiti, heat and/or moisture, as well as wear and impact-resistant .
  • the core layer 2 comprises a polystyrene foam, PIR-foam, resol foam, phenol foam, polyurethane foam or other lightweight foaming material.
  • foams will comprise two or more components. Foaming comprises a process wherein blowing agents are mixed with a thermoplastic or thermoset so that under determined pressure and temperature gas bubbles occur in the mass.
  • the most commonly used type of foam is polyurethane (PUR) .
  • PUR polyurethane
  • Other, less frequently used plastic foams are, among others, extruded polystyrene (XPS) , polyethylene foam (PE) , resol foam, phenol foam and PVC foam.
  • the measure of volume increase which can be obtained by foaming depends on the type of polymer, on the possible presence of softeners and on the technique used.
  • the foam varies in density between roughly 10 kg/m 3 and 800 kg/m 3 .
  • the foam core has for instance a density of 40 kg/m 3 to 200 kg/m 3 .
  • blowing agents physical and chemical blowing agents and inert gases.
  • a gas can be released by the reaction of the raw materials, so that no blowing agent need be added.
  • Physical blowing agents are low-boiling liquids such as pentane.
  • Chemical blowing agents form a gas through reaction, for instance nitrogen or carbon dioxide. Inert gases such as air or nitrogen are used directly as blowing agent.
  • the following table shows an overview of generally used blowing agents per foam type .
  • the polyurethane foam is made by mixing a polyol (polyesters and polyethers) and an isocyanate with a blowing agent, for instance diphenylmethane diisocyanate (MDI) .
  • a blowing agent for instance diphenylmethane diisocyanate (MDI) .
  • the reaction mixture is injected onto the surface or into the cavity of a mould product, whereafter expansion (the blowing agent evaporates due to the exothermic reaction) and curing take place almost simultaneously.
  • the mixture In the first zone the mixture is liquid, in the second zone the mixture becomes cream-like (the cream-zone) without visibly foaming.
  • the blowing agent evaporates due to the exothermic reaction, and the reaction mixture foams.
  • Reinforcing layers 4 for instance comprise fibre mats, loose fibres or strips 3, 9 (fig. IB) of carbon, steel, glass fibre, aramid and/or natural fibres .
  • Finishing layer 8 preferably comprises a mortar, such as a cement- bound mortar which is used as levelling mortar, concrete mortar, epoxy mortar, polyurethane mortar, pouring mortar, patching mortar, synthetic resin mortar, insulating mortar, composite cement or high-strength concrete. It is however also possible for finishing layer 8 to comprise an outer layer or skin formed from plastic.
  • the plastic can for instance comprise synthetic resin, epoxy resin, polyester and the like.
  • a skin can also be formed from natural materials such as clay, plaster, wood or stone veneer.
  • the mould is for instance a reproduction of an original, obtained by casting or by cutting, engraving or laser machining, but can also be a design from the imagination of an architect or designer. In such situations the mould can be produced on the basis of 3D-cutting work on the basis of CAD drawings, by inlaying materials or by forming in a formwork or by for instance etching, acid treatment or machining of the inside of the mould or die with a laser, cutting or engraving machine.
  • the mould or die is made from the materials usual for the purpose such as form board, polyurethane, aluminium, steel, wood or other suitable materials, provided they are suitable for withstanding the pressure built up by the 2-component foam.
  • Almost any colour, texture or size can be produced by adapting the mould to the desired pattern or texture and by mixing dyes and/or other additives through the mortar of the finishing layer until the desired colour is achieved.
  • the desired finish is eventually achieved by giving the building elements a final processing with for instance dyed solutions, oxidation powders, acids or other agents after or, if necessary, during the curing, but after release from the mould.
  • Colour effects can also be realized by sprinkling or spraying on dyes or dye solutions, additives or agents which cause a colour reaction through contact with a mortar layer to be arranged in the mould.
  • Other options for arranging texture are, among others, arranging retarding agents in the mould, post-treating with acids, sand or water- blasting, beating or mechanical ageing in other ways.
  • the building elements can acquire an appearance which resembles natural stone types or otherwise specified patterns, colours or textures. Wood and other imitations are also possibilities.
  • a building or decorative element 1 according to the present invention can be realized in different ways. Examples of different production methods are elucidated with reference to figures 5A-5H, 6A-
  • the respective production methods can be specified as moulding method, spraying method and rotation moulding method.
  • a layer of (optionally fibre-reinforced) mortar 70 is arranged in a first mould part 72.
  • a reinforcing layer is optionally arranged on the first layer of mortar 70.
  • the reinforcement can also be included in the mortar by adding fibres. It is also possible to apply both reinforcements.
  • a second layer of mortar 74 is poured into a second mould part 76 (fig. 5B) . If this is a flat rear plate a thin layer of mortar is arranged within a frame.
  • the second layer of mortar is optionally provided with reinforcement, which can also be included in the mortar. It is also possible to apply both reinforcements.
  • an inner mould or form 78 is pressed into the mortar 70 in first mould part 72 in the direction of the arrows. In this way a thin, uniform mortar layer is obtained. Surplus material flows away sideways over the edges of the first mould part. To enable placing of second mould part 76 as fitting cover on first mould part 72, the edges of mould part 1 and mould part 2 are cleaned by means of for instance skimming.
  • Frame 80 is likewise removed from mould part 76 (fig. 5E) .
  • the mortar layer 74 on second mould part 76 now forms a perfectly fitting cover for the shaped mortar 70 in first mould part 72.
  • mould parts 72, 76 are now placed onto each other and the mould parts are held in the correct position during vibration, jolting or other movements by means of recesses and counter- forms (fixation points) .
  • the resulting hollow mortar tile (fig. 5F) is dried further before injection of (optionally fibre-reinforced) two or more component foam 82 into this mould (fig. 5G) .
  • Several small openings are arranged in the mould.
  • One or several openings 84 are intended to enable the introduction of the two or more component foam 82 into the mould.
  • Several other smaller openings (not shown) are intended for venting, so that the foam can spread uniformly inside the mould.
  • the foam is thus injected under pressure into the mould in order to form a core layer between the first and second mortar layer until a desired hardness is achieved.
  • the strength of the final product can be controlled by introducing more or less foam into the mould.
  • the two or more component foam is for instance phenol, resol, PE, PVC, PIR or PU foam.
  • the foam is optionally provided with reinforcing fibres.
  • the mould 72, 76 During foaming of the core the mould 72, 76 must be held under pressure at all times by pressing means 86. Depending on the quality, quantity and density of the chosen foam type, a choice can be made from different possibilities for fixing mould parts 72, 76 relative to each other, but also for holding all the contours of the mould in position such that the mortar layer arranged inside the mould does not begin to develop any breaks or (hair) cracks under the influence of the pressure which the foam can transmit onto this layer and the mould.
  • the pressing means 86 for holding together a mould consisting of a (wooden) formwork material comprise for instance screws, bolts or simply a weight arranged on the mould.
  • the pressing means comprise clamps with which the mould parts can be pressed together.
  • the pressing means 86 comprise a mechanical, hydraulic or pneumatic press 88, 90 in which mould parts 72, 76 are arranged during foaming (fig. 5G) .
  • Other suitable pressing machines are also possible.
  • the pressure developed during foaming amounts to a minimum of 2 bar and a maximum of 1500 bar. Foaming can optionally take place without pressing means, auxiliary constructions or press if the mould provides sufficient resistance to the forces of the foaming material.
  • the mould parts generally comprise steel or aluminium dies.
  • Another production method is the spraying method.
  • the mortar is not poured into the mould parts but sprayed under pressure against the mould parts.
  • Mortars which are suitable for this method are generally less liquid and have a greater power of adhesion to different surfaces.
  • the advantage relative to the above stated method is the absence of inner mould 78.
  • the layers will also have the correct toughness sooner, so that the mould parts can be placed onto each other sooner, i.e. more quickly.
  • the other steps of the production process are the same as those of the other variants shown in figures 5 and 7.
  • a first layer of mortar 100 is sprayed under pressure against a first mould part 102 of the mould using spraying equipment 104 suitable for the purpose (fig. 6A) .
  • a second layer of mortar 106 is sprayed in the same manner against a second mould part 108 (fig. 6B) .
  • a reinforcing layer (not shown) is optionally arranged on the first and/or second mortar layer, and/or a reinforcement is already included in the mortar by adding fibres.
  • a reinforcement is already included in the mortar by adding fibres.
  • the reinforcement it is also possible to spray on an extra mortar layer after arranging a separate reinforcing mat.
  • the reinforcement it is possible for the reinforcement to have a three-dimensional (3D) form, whereby the reinforcement is incorporated partly in the mortar and protrudes partly from the mortar in order to realize an additional structural connection between the mortar and the foam core described hereinbelow.
  • the surplus mortar is removed, skimmed from the edges of the mould parts so as to enable the mould parts to be placed on each other as tightly as possible later.
  • the mould parts are closed by arranging second mould part 108 against the first mould part (fig. 6C) .
  • Mortar layers 100, 106 merge seamlessly into each other at the edges of the mould parts.
  • a substantially seamless, hollow tile or building element is created in this manner.
  • the production step of fig. 6C is followed by the same production steps as shown in fig. 5G and 5H. This means that, after sufficient curing and drying of the mortar, foaming material (optionally provided with reinforcing fibres) - for instance phenol, resol, PE, PVC, PIR or PU foam etc.
  • a third production method also differs in the manner in which mortar is distributed over the mould parts.
  • this "rotation moulding method” a measured quantity of very liquid mortar 120 is arranged in a first mould part 122 (fig. 7A) .
  • the mortar is optionally provided with a reinforcement as described above.
  • a second mould part 124 is then arranged on first mould part 122 such that a closed mould 126 results.
  • the quantity of mortar 120 is sufficient to cover the entire internal surface area of both mould parts.
  • Mould 126 is secured in a rotation moulding machine suitable for this purpose (not shown) . In this machine the mould 126 makes rotating movements in all directions, i.e. degrees of freedom, during the curing time of mortar 120 (fig. 7C) .
  • the mortar is distributed uniformly in mould 126 by the centrifugal force.
  • the machine is stopped and mould 126 is removed from the machine (fig. 7D) . Venting caps (not shown) present in the mould are opened so that excess moisture can escape.
  • the mould with mortar 120 is then given the time and rest for the mortar to cure sufficiently. A substantially seamless, hollow tile or element is created in this way.
  • the foaming material (optionally provided with reinforcing fibres) is for instance phenol, resol, PE, PVC, PIR or PU foam, etcetera.
  • the foam is injected under pressure into mould 126 to form a core layer inside the mortar skin 120 until a desired hardness is obtained.
  • the foam is injected into the mould through injection apertures in the mould (see fig. 5G) .
  • the venting takes place through small holes in the mould.
  • the strength of the end product can be controlled by introducing more or less foam into the mould.
  • a completely prefabricated (prefab) outer wall element 140 can be realized according to the same technique.
  • the outer wall element comprises a first finishing layer 142 which forms the outer or visual side of the outer wall element.
  • a second, inner finishing layer 144 is arranged on an opposite side.
  • a foam core 146 which is provided with cavity or air channels 148, is arranged between the first and second finishing layers.
  • a reinforcement 150 is arranged in foam core 146 for the purpose of strengthening the foam core .
  • Anchoring members 152 are arranged to enable fixing of the outer wall element to a construction such as the front wall of a building. Anchors 152 extend from foam core 146, through second finishing layer 144 and outside outer wall element 140.
  • the wall element can have a thermally and/or acoustically insulating function in that materials with the desired insulating function are incorporated therein.
  • the insulating function is for instance the result of the air in the cavity channels, or additional insulating layers arranged in or against the first and/or second finishing layer.
  • the first finishing layer 142 is held fixedly on a top side of the mould without being arranged fixedly on the upper mould part 162.
  • the first, upper mould part 162 is provided for this purpose with air channels 164. By extracting air through said channels via a hose 166 connected to a pump, the first finishing layer 142 can be arranged floatingly in the mould by creating a sufficient vacuum.
  • this first finishing layer 142 will of course remain in position and the air extraction can be stopped.
  • the second finishing layer 144 is then arranged on a second, bottom part 170 of mould 160.
  • Inner moulds 168 and optional reinforcement 150 are then arranged.
  • Foam is then injected into mould 160 by injection apparatus 172.
  • the two-component foam is optionally reinforced with fibres.
  • foam core 146 After foaming of foam core 146 a building element results which is for instance suitable for application as outer wall for house and utility building.
  • the moulds must be pressed at all times during the foaming by means of the pressing techniques specified above with reference to fig. 5G and 5H.
  • the press 174 is shown for this purpose. Where two-component foam is referred to in the foregoing, this always signifies a foam comprising two or more components.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Composite Materials (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Finishing Walls (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention concerne un procédé de fabrication d'un élément de construction qui consiste: (i) à agencer une couche de finition dans un moule pourvu d'une surface intérieure prédéterminée, (ii) à répartir la couche de finition uniformément sur la surface intérieure du moule et, (iii) à agencer un matériau moussant à l'intérieur de la couche de finition dans le but de former un noyau de mousse.
PCT/NL2006/000091 2005-02-21 2006-02-21 Element de construction et procedes de fabrication de celui-ci WO2006088364A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NL1028355A NL1028355C2 (nl) 2005-02-21 2005-02-21 Constructie-element en werkwijze voor het vervaardigen daarvan.
NL1028355 2005-02-21

Publications (1)

Publication Number Publication Date
WO2006088364A1 true WO2006088364A1 (fr) 2006-08-24

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Country Link
NL (1) NL1028355C2 (fr)
WO (1) WO2006088364A1 (fr)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ITPD20110020A1 (it) * 2011-01-27 2012-07-28 Millepelli S R L Pannello per rivestimento
WO2012139587A1 (fr) * 2011-04-12 2012-10-18 Connovate Aps Procédé de fabrication de béton et panneau fabriqué par ledit procédé, ledit panneau ayant une densité décroissante en s'éloignant à partir d'une surface dense exposée de béton ou de béton à hautes performances (hpc)
WO2013010545A1 (fr) * 2011-07-19 2013-01-24 Connovate Aps Procédé de fabrication d'un élément en béton de haute résistance isolé complet ayant une excellente surface, et élément en béton de haute résistance fabriqué par ledit procédé
ITBO20130286A1 (it) * 2013-06-07 2014-12-08 Gianluca Casadio Elemento per l'edilizia ed arredo urbano con conformazione irregolare
GB2552446A (en) * 2016-03-24 2018-01-31 Waring Stephen Improvements in and relating to building materials
CN108274875A (zh) * 2018-01-05 2018-07-13 东南大学 一种磁性水泥玻毡面聚氨酯复合板及其制备方法

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US4084362A (en) * 1975-12-31 1978-04-18 Maso-Therm Corporation Anchored composite building module
US4229497A (en) * 1977-11-03 1980-10-21 Maso-Therm Corporation Composite module with reinforced shell
NL8801991A (nl) * 1988-08-09 1990-03-01 Willem Frederik Jense Wandsysteem met magnetische bevestiging en onderdelen daarvoor.
WO2004005020A1 (fr) * 2002-07-02 2004-01-15 Woodbridge Foam Corporation Structure composite a surface decorative

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NO123078B (fr) * 1966-04-13 1971-09-20 Anfi As
FR1517757A (fr) * 1966-09-05 1968-03-22 élément de construction en résine phénolique et son procédé de fabrication
NL6710335A (fr) * 1967-07-26 1969-01-28
US3512327A (en) 1968-06-20 1970-05-19 Natale P La Padura Decorative and/or structural material
GB8811033D0 (en) * 1988-05-10 1988-06-15 A Foam Co Ltd Foam composite & method of forming same
DE3937432C2 (de) * 1989-11-10 1997-02-13 Knauf Westdeutsche Gips Bindemittel und seine Verwendung

Patent Citations (4)

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Publication number Priority date Publication date Assignee Title
US4084362A (en) * 1975-12-31 1978-04-18 Maso-Therm Corporation Anchored composite building module
US4229497A (en) * 1977-11-03 1980-10-21 Maso-Therm Corporation Composite module with reinforced shell
NL8801991A (nl) * 1988-08-09 1990-03-01 Willem Frederik Jense Wandsysteem met magnetische bevestiging en onderdelen daarvoor.
WO2004005020A1 (fr) * 2002-07-02 2004-01-15 Woodbridge Foam Corporation Structure composite a surface decorative

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ITPD20110020A1 (it) * 2011-01-27 2012-07-28 Millepelli S R L Pannello per rivestimento
WO2012139587A1 (fr) * 2011-04-12 2012-10-18 Connovate Aps Procédé de fabrication de béton et panneau fabriqué par ledit procédé, ledit panneau ayant une densité décroissante en s'éloignant à partir d'une surface dense exposée de béton ou de béton à hautes performances (hpc)
WO2013010545A1 (fr) * 2011-07-19 2013-01-24 Connovate Aps Procédé de fabrication d'un élément en béton de haute résistance isolé complet ayant une excellente surface, et élément en béton de haute résistance fabriqué par ledit procédé
ITBO20130286A1 (it) * 2013-06-07 2014-12-08 Gianluca Casadio Elemento per l'edilizia ed arredo urbano con conformazione irregolare
GB2552446A (en) * 2016-03-24 2018-01-31 Waring Stephen Improvements in and relating to building materials
GB2552446B (en) * 2016-03-24 2020-11-25 Waring Stephen Method for forming a coated building element and mould therefor
CN108274875A (zh) * 2018-01-05 2018-07-13 东南大学 一种磁性水泥玻毡面聚氨酯复合板及其制备方法
CN108274875B (zh) * 2018-01-05 2019-10-29 东南大学 一种磁性水泥玻毡面聚氨酯复合板及其制备方法

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