WO2016062697A1

WO2016062697A1 - Method for producing panels, prefabricated products and frames for the furnishing industry and products obtained with such method

Info

Publication number: WO2016062697A1
Application number: PCT/EP2015/074225
Authority: WO
Inventors: Angelo Candiracci
Original assignee: Angelo Candiracci
Priority date: 2014-10-24
Filing date: 2015-10-20
Publication date: 2016-04-28
Also published as: ITPS20140014A1

Abstract

The application relates to a method for producing panels, prefabricated products and frames for the furnishing industry, characterised in that it comprises forming shaped products made of sintered expanded polystyrene (EPS, expanded polystyrene) with high density comprised between 30 (thirty) and 60 (sixty) kg/m³ in an expanded mould and vapour sintering granules or incoherent beads obtained from the polymerisation of styrene and ensuing obtainment of a monolithic mass with solid geometry obtained from the mould and embedding in the mould at least one reinforcement element constituted by a steel grid before the moulding of the sintered expanded polystyrene for attaining composite products with reinforcement armour means as well as to a panel produced by said method.

Description

TITLE

METHOD FOR PRODUCING PANELS, PREFABRICATED PRODUCTS AND FRAMES FOR THE FURNISHING INDUSTRY AND PRODUCTS OBTAINED

WITH SUCH METHOD

DETAILED DESCRIPTION

State of the art

In the furnishing industry, there is known the ever-decreasing utilisation of natural wood with simultaneous ever-increasing use of wood surrogates such as medium density fibreboard panels, hollow cored wood (i.e. honeycomb structure or the like made of melamine cardboard or plastic or aluminium material arranged in a sandwich-like manner between two sheets or beneath strips made of various materials) composite panels, and even composite panels made of expanded polystyrene, but always in sandwich-like structures between sheets or strips, boards, laminas or thin layers made of other materials; see for example, as regards the expanded polystyrene products which are particularly related to the present invention, prior art patent applications numbers WO2014/111711A1, ES386695A1, FR2835470A1, GB1408592A, WO2013110930A1.

All these panels and elements made of wood surrogate for the furnishing industry require, for use, rather complex finishing operations such as covering with laminated finishing or simply covering sheets of various types, and edging; as well as surface finishing or application of decoration layers on the surface, with the aim of creating a bas-relief effect, usually made of moulded expanded polyurethane.

Drawbacks of the prior art

It is imaginable and known that such wood surrogates are heavy and/or expensive, same case applying to the required finishing and covering, not to mention the additional costs for obtaining bas relief decorations, milling for geometric decorations and application of superimposed products, usually moulded polyurethane embellishment, sinuous decorations, moulded polyurethane products which are also extremely heavy given that they are loaded with wood powders or even marble powder or other heavy materials.

Objects of the invention

The main object of the present invention is to provide a method for producing products suitable to obtain succedaneous wood elements, alternative to wood surrogates, for making furniture adapted to obtain furnishing elements and/or relative complex portions and/or the entire piece of furniture; as well as designing such products.

Another object of the present invention is to attain the previous object through a method for producing products capable of bearing stresses deriving from their applications, or suitable to be appropriately reinforced to bear said stresses without jeopardising the attainment of the other objects; as well as designing such products.

Still another object of the present invention is to obtain any one of the preceding objects through a method for producing products suitable to receive both the common metalware for assembling elements forming the furniture and the common metalware for producing furniture for performing their intended purposes; as well as designing such products.

Still another object of the present invention is to obtain any one of the preceding objects through a method for producing products suitable to obtain furniture and/or relative complex portions and/or the entire piece of furniture with surface characteristics not requiring structural finishing interventions but maybe just varnishing; as well designing such products.

Another object of the present invention is to obtain any one of the preceding objects through a method for producing products suitable to obtain furniture and/or relative complex portions and/or the entire piece of furniture with lightness parameters substantially greater any other obtained according to the prior art and simultaneously having robustness, resistance to humidity and fireproof characteristics; as well designing such products.

A further object of the present invention is to attain any one of the aforementioned objects and products made in a simple and functional manner, safe to use and relatively inexpensive considering the actual results attained therewith.

Summary of the solution concept

Method for producing panels, prefabricated products and frames for the furnishing industry and products obtained with such method, comprising: moulding or extruding shaped products made of high density [30 (thirty) to 60 (sixty) kg/m³] sintered expanded polystyrene (EPS); embedding at least one reinforcement element, preferably wire mesh and preferably made of steel, in the mould, before moulding the sintered expanded polystyrene, to obtain composite products with reinforcement armour; shaping the moulds with recesses and projections to obtain shaped bas-relief products with seats and reliefs for application of metalware and/or decorations; positioning plates, strips and support means in the moulds before moulding the sintered expanded polystyrene to obtain products with elements for coupling metalware and/or decorations incorporated initially; localised co-injection of polystyrene with differentiated volume mass parameters in the same mould to attain products made of sintered expanded polystyrene with locally differentiated density for reinforcing portions most subjected to stress during use; embedding at least one element made of low density sintered expanded polystyrene in the mould before moulding the high density sintered expanded polystyrene to obtain lightened products made of stratifically differentiated density.

Static description of preferred embodiments

Sintered expanded polystyrene, also commonly referred to as expanded polystyrene, is a thermoplastic resin derived from benzene, with lightness, isothermy, impermeability, dimensional stability, rigidity and resistance to knocks, self-extinguishing and non-toxic characteristics.

As regards lightness, EPS has low volume mass or density [10 (ten) to 60 (sixty) kg/m³].

As regards isothermy, it is one of the main characteristics of EPS and it is facilitated by the fact that it is 90% formed by air. This air is enclosed in cells so small to prevent the convective motions. Thus, heat transmission may occur solely by conduction, very low in the air, and by radiation, which rapidly reduces upon the multiplication of the screens made up by the walls of the cells. Remaining balanced with respect to the external air, the internal air stabilises heat conductivity over time.

As regards waterproof features and, on the contrary, permeability to water vapour, EPS is not a hygroscopic material, thus products made of EPS do not reveal inhibition phenomena by capillarity. Thus, EPS' right value of permeability to vapour allows the transpiration of the products obtained therewith, thus not vulnerable to mould and the like.

As regards dimensional stability, EPS is isotropic, given that the products obtained therewith are not subjected to tensioning, with ensuing deformation and breakage, regardless of the time of utilisation thereof; actually, there is a physical-mechanical state of balance with homogeneity of characteristics reproduced in all points of the product. Such characteristic is mainly influenced by the type of expansion the cells of the material have. As a matter of fact, the cell structures that expand within the space of a few millimetres of diameter are extremely regular, with almost identical micro-spheres. As regards rigidity and reaction to mechanical stresses, the relation between stresses and deformations is linear up to 3% of deformation. Beyond this limit there is a permanent deformation of the cell structure without breakage.

As regards self-extinguishing characteristics, EPS has delayed flame propagation characteristics. The products tested as regards reaction to fire have resistance values solely exceeded by those made of incombustible material.

As concerns non-toxicity and biological tolerance, EPS is not toxic, it is not a source of nutrition for any living being, micro-organisms included; EPS does not rot, it is not attacked by mould and it is completely recyclable, biologically neutral, neutral to odour and neutral to contact with skin.

As regards production technology, expanded polystyrene should be subjected to a series of transformation processes directly related to the intended use thereof before being used.

At the beginning, the material is in form of fine beads, from one to three millimetres of diameter, added with an expanding agent; the production of semi-finished products and polystyrene - expanded polystyrene - products occurs in three main stages.

Pre-expansion: the expandable polystyrene beads are pre-expanded, generally by means of vapour at a temperature exceeding 90 degrees centigrade, in the so-called pre- expander. In the pre-expansion treated with vapour, the raw material softens and the expanding agent evaporates, causing the swelling of the beads. Following the evaporation of the expanding agent, the beads amplify up to sixty times their initial volume. The duration and intensity of this first operation determine the volume mass of the finished product. A closed cell structure, fundamental for the subsequent use as heat insulator, is formed in this process in the expanded polystyrene beads. The degree of expansion, which essentially depends on the duration of heat treatment in the pre-expander, determines the apparent volume mass of the products made of expanded polystyrene and thus all their physical characteristics.

Maturation of the pre-expanded product: at this stage, the polystyrene beads are stationed for a given period of time in aerated silos. Upon cooling, the expanding material and water vapour residues condensate in the single cells. The vacuum thus formed is nullified by the air which spreads in the cells; thus, the polystyrene or expanded polystyrene pre-expanded beads reach the stability required for the subsequent steps.

Modelling the product: pre-expanded and stabilised polystyrene beads may thus be transformed into products or semi- finished products in various ways. Through moulding of blocks and cutting of polystyrene or sintered expanded polystyrene slabs: it is the most used system. The block-making device, constituted by a parallelepiped-shaped element provided with micro-holes for the inlet of vapour on all sides, is filled with polystyrene or expanded polystyrene and subjected to a new injection of the saturated vapour; temperatures between 110 - 120 degrees centigrade are attained at this stage; the beads swell further and join to each other due to their internal pressure, i.e. they are sintered. The more the EPS has high density, the more the block is subjected to pressure such to facilitate a better sintering. After a brief cooling period, the blocks are extracted and preferably stored for a variable period of time ranging from a few days to two months, a period during which they reach the stability required for the various applications. From here, the expanded polystyrene blocks are picked up for cutting into panels, which occurs with hot wire cutting lines and other possible mechanical operations, such as shaping using numeric control pantographs or by milling.

Through moulding of panels or other expanded polystyrene products: the production process is the same described for the production of blocks but the EPS panels are moulded singularly in special numeric control automatic machines. This leads to the advantage of directly obtaining the desired shape, without further mechanical machining processes. Beads are sintered even in this case. In the EPS, good sintering, i.e. the "bonding" of the beads to each other is very important, actually crucial. The more the EPS has high density, the more the block is subjected to pressure such to facilitate a better sintering.

Through extrusion-drawings: subsequently to polymerisation, polystyrene or expanded polystyrene is joined to the expanding agent and other possible additives in a drawing process, which mixes the ingredients in molten state and extrudes the mixture from a die, usually in form of a flat panel, which are immediately sintered and expanded and, cooling, stiffen in the expanded form.

According to the prior art, the sintered expanded polystyrene, also referred to as EPS or expanded polystyrene, products are mainly if not exclusively utilised in filling sealed chambers for floating, in the packaging and building industry, for obtaining heat and sound insulations as well as usually composite prefabricated building elements with lightness, heat and sound insulation, fireproof and seismic resistance characteristics.

According to the present invention, the characteristics of the sintered expanded polystyrene, also referred to as EPS or expanded polystyrene are used in furniture industry, implementing the method and products implemented therewith, as described and claimed hereinafter. Polystyrene or high density expanded polystyrene [30 (thirty) to 60 (sixty) kg/m³] has an appearance and consistency, even superficial, adapted to constitute the structure and surface of furniture, contingently also being suitable to be varnished, without requiring panels or sheets or films, or protection membranes as well as without requiring edges on the thicknesses.

In addition, there are varnishes, in particular polyurethane varnish, which contribute to providing surface consistency to the sintered expanded polystyrene material.

Implementing the method according to the present invention, the simplest of the obtained products is constituted by a moulded panel singularly in a special dedicated mould, wherein the single moulds may obviously be any plurality, grouped in the entirety of the moulding machinery (preferably of the latest numeric control generation), the beads in said mould being subjected to sintering directly obtaining the desired shape and overall dimension of the product, as well as the relative density, established by the mould and incoherent spherule supply, characteristics thereof, vapour injection and ensuing qualified sintering.

As a function of the conformation of the mould, the panel product may also be shaped, as regards surface decoration, configuration, both in terms of perimeter and in terms of curvature, as well as articulated formation of portions adjacent to the mere panel structure, to create complex products not limited to the simple sheet, but integrating a true semi-finished and advanced pre- fabricated product, which - in a single piece - attains portions as developed as possible with respect to the final complex, in terms of implementation advancement, of the piece of furniture meant to be created.

In this context, alternative embodiments in which the furniture may be obtained in a single moulding process also in its structure entirety are provided for; same case also applies to structures intended to be padded and upholstered such as couches, armchairs and the like.

A first embodiment of the process according to the present invention, simultaneously actuatable with the others described hereinafter, provides for moulding the composite complex, by aggregating an armour preferably made of steel to the sintered expanded polymeric mass, still preferably of the high density type [30 (thirty) to 60 (sixty) kg/m³], by embedding rod-like steel elements therein, preferably preassembled to constitute a mesh or cage of electro welded elements, still dimensioned and shaped as a function of the shape of the product and/or assembly needs and/or assembly and joining means application needs; arranging such steel rod-like elements in the polystyrene expansion mould; pouring - into the mould - incoherent granules or beads obtained from the polymerisation of styrene, with suitable grain size and volume to attain a high density finished product [30 (thirty) to 60 (sixty) kg/m³]; expansion and sintering, namely incorporating incoherent polystyrene through contact with water vapour and temperature exceeding ninety degrees injected into the mould and the ensuing entrapment of the armour in the monolithic mass thus obtained so as to form a solid geometry, defined by the mould, of polystyrene or reinforced sintered expanded polystyrene.

A second embodiment of the method according to the present invention, simultaneously actuatable with the others described hereinafter, provides for shaping the moulds with interface for defining the surface portions of the finished product processed so that there are bas relief decorations, such as wood-like ribs or decoration drawings of any type.

A third embodiment of the method according to the present invention, simultaneously actuatable with the others described hereinafter, provides for shaping the moulds with recesses and projections to obtain shaped bas-relief products, for example channels, guides, reliefs, teeth, bas relief in general, for application of metalware and/or decoration during the assembly of the pieced moulded in the process aimed at attaining the finished product.

A fourth embodiment of the method according to the present invention, simultaneously actuatable with the others described above and hereinafter, provides for moulding the composite complex by aggregating metalware to the sintered expanded polymeric mass, still preferably of the high density type [30 (thirty) to 60 (sixty) kg/m3], by positioning - in the moulds - plates, strips, sections or means for supporting further metalware intended to support the finished product; suitable positioning of the elements through retentions for maintaining the elements on site during the subsequent filling, injection and moulding steps: pouring - into the mould - granules or incoherent beads obtained from the polymerisation of styrene, with grain size and volume suitable for attaining a high density finished product [30 (thirty) to 60 (sixty) kg/m³]; expansion and sintering, namely incorporating the incoherent polystyrene through contact with water vapour injected into the mould at a temperature greater than ninety degrees centigrade and ensuing entrapment of the support means in the monolithic mass thus obtained, so as to form a solid geometry, defined by the mould, of polystyrene or sintered expanded polystyrene, incorporating, where required in the appropriate arrangement on the surface or under the surface, metal portions or materialised portions, suitable to receive the anchoring means or the functional means to assemble and/or use the finished product.

A fifth embodiment of the method according to the present invention, simultaneously actuatable with the others described above and hereinafter, has actuation characteristics similar to the previous one and provides for moulding the composite complex by aggregating sheets or panels to the sintered expanded polymeric mass, still preferably of the high density type [30 (thirty) to 60 (sixty) kg/m³] , by positioning - in the moulds - sheets or panels or means constituting or supporting decoration to support the finished product, on whose surface they project lodged; means for stopping the rest of the actuation steps of the method above for the embedment of metalware.

A sixth embodiment of the method according to the present invention, simultaneously actuatable with the others described above and hereinafter, provides for the localised co- injection of polystyrene with differentiated parameters of volume mass in the same mould, pouring - in the mould - granules or incoherent beads obtained from the polymerisation of styrene, with differentiated grain size and volume mass in the various areas of the mould according to a predetermined distribution, and adjustment of the automatic pouring and injection means for attaining a localised high density finished product [30 (thirty) to 60 (sixty) kg/m³]; expansion and sintering namely incorporating the incoherent polystyrene through contact with water vapour injected into the mould at a temperature greater than ninety degrees centigrade and ensuing sintering of a monolithic mass thus obtained, so as to form a solid geometry, defined by the mould, of polystyrene or sintered expanded polystyrene constituting the product made of the locally differentiated density sintered expanded polystyrene, for reinforcing the portions most stressed in the use of the finished product that the product contingently contributes to forming.

A seventh embodiment of the method according to the present invention, simultaneously actuatable to the others described above and hereinafter, provides for moulding the composite complex by aggregating the low density sintered expanded polymeric mass to the high density sintered polymeric mass [from 30 (thirty to 60 (sixty) kg/m³], by positioning - in the moulds - polystyrene structures previously sintered at low density, suitable positioning of the structures through retentions for maintaining the structures on site during the subsequent filling, injection and moulding steps; pouring - in the mould - granules or incoherent beads obtained from the polymerisation of styrene, with grain size and volume suitable to attain a high density finished product [30 (thirty) to 60 (sixty) kg/m³]; expansion and sintering namely incorporating the incoherent polystyrene through contact with water vapour injected into the mould at a temperature greater than ninety degrees and ensuing entrapment of the polystyrene in the monolithic mass thus obtained so as to form a solid geometry, defined by the mould, of polystyrene or sintered expanded polystyrene incorporating at least one element made of low density sintered expanded polystyrene, before moulding the high density sintered expanded polystyrene, to attain light products with stratifically differentiated density.

The method for producing panels, pre- fabricated products and frames for the furnishing industry or products obtained through this method according to the present invention, at least in its basic application, may also be implemented with other methods for producing sintered expanded polystyrene made of blocks extracted from a block making device and extrusion/drawing operations subsequently to polymerisation; through these systems, the method is also limited in some of the implementations thereof. Thus, the single piece moulding method is preferable for the implementation of the method according to the present invention for the functions to be outlined hereinafter.

Dynamic description of the preferred embodiment

Thus, having completed the static description of preferred embodiments of the method for producing panels, pre- fabricated products and frames for the furniture industry and producing with such method obtained according to the present invention, below is the dynamic description, i.e. the relative operation, application and use of the panels, prefabricated products and frames for the furniture industry, obtained with the method according to the present invention:

The panels and products obtained by implementing the method according to the present invention, with a density comprised between 30 (thirty) and 60 (sixty) kg/m³ reveal aesthetic and surface characteristics, appropriately suitable to constitute furniture surfaces of any kind, without requiring further surface finishing treatment, protection or reinforcement; unless when dealing with a work surface, for example a kitchen surface, which also requires protection sheets made of suitable material, different from wood or wood surrogates, even in the embodiments according to the prior art.

For an appropriate aesthetic valence of the furniture made of panels and products obtained by implementing the method according to the present invention, it is sufficient to varnish, preferably with polyurethane varnishes, or painting the product to attain a finished product of any kind; possibly, with bas-relief surface decoration, for producing wood-like grains of any kind and pattern, attainable during moulding, according to one of the aforementioned implementation applications.

The panels and products obtained to implement the method, according to the present invention, have mechanical characteristics similar, where not positively increased or improved, to homologous structures made of wood surrogates and composite material according to the prior art, for obtaining furniture substantially of any kind; this being due to the fact that sintered expanded polystyrene, with a density comprised between 30 (thirty) and 60 (sixty) kg/m³, is suitable to support compression stresses comparable to those of the best wooden essences and the relative surrogates; whereas, as regards the traction, such synthesis material reveals greater resistance to cracking, i.e. greater elasticity, of the best wood essences, and relative surrogates, where suitably supported with a reinforcement armour, especially metal steel wires assembled in meshes or cages embedded therein, according to one of the relative implementation applications.

As a matter of fact, in the products according to the present invention thus implemented, the traction stresses are countered by the supplementary synergic supporting action of the steel mesh or cage, thus obtaining products comparable - in terms of structural and mechanical characteristics - to similar wood surrogate products, but with lower weight, often much lower.

These products may be obtained in any shape and dimension according to the contingent implementation and project requirements, through suitable conformation of the moulds for sintering the expanded polystyrene.

Applying one or more of the implementation applications of the method, the specific implementation and project needs of any kind may also be met by suiting the product thereto, without useless solutions, heritage or waste of other uses when not required, though implementing the present invention in its method implementation applications.

For example, in the simplest and usual implementation application, or the one that provides for a metal reinforcement, preferably made of electrowelded wire mesh or cage, the joining between the panels/products and application of metalware, to attain the finished product, i.e. the piece of furniture may be attained using the usual fixing means, such as screws and the like, which penetrate into the expanded body and are constrained to the internal meshes, contingently conceived with a mesh dimensioned to suit the purpose, as well as shaped to maximise the anchoring function of the assembly means, besides reinforcement.

Alternatively and/or by way of supplementation, implementing other implementation applications according to the method, the mould may be shaped with receptacles complementary to the shape of any metalware and accessories needed for assembly and use; as regards assembling the metalware to the product subsequently to forming the latter, in reception seats and recesses specifically conceived during moulding and derived from the conformation of the mould.

Still alternatively and by way of supplementation, implementing other applications according to the method, any metalware and accessory required for the assembly may be associated to the polymeric mass during moulding, selectively positioning the accessory in the mould before moulding the product, so that this houses the accessory from the beginning in any position contingently to the conceived design, both on the relative surface and, entirely or partly, embedded therein.

This embedding of accessories in the polymeric mass is advantageously combined with the embedding - in the same mass - of reinforcement armours, by welding or however constraining the reinforcement accessories and structuring the accessories even as a function of such assembly approach; for example a rectangular U-shaped section, with base meant to remain on the surface of the finished product to constitute a metal strip coplanar thereto, with prongs welded apically to the internal reinforcement armour; wherein the prongs bear holes or interruptions of any kind so that the polymeric mass penetrates into the relative internal and expands therein and sinters incorporating the entirety.

The product has the same original incorporation result in the sintered mass as regards an alternative and/or supplementary incorporation of decoration elements, inserted in the polystyrene mass from a decoration and non- functional point of view.

Still alternatively and/or by way of supplementation, implementing other implementation applications according to the method, the density and sintering of the expanded polystyrene mass may be diversified in the finished product, with the aim of attaining greater density and thus resistance in possible uses subject to intense wear; for example on under-hand surfaces, or in the feet of the frames of armchairs, couches and the like, or implementing design options.

Alternative embodiments

It is obvious that in further alternative embodiments of the method for producing panels, pre- fabricated products and frames for the furniture industry and products obtained with the method according to the present invention, may also be implemented and obtained differently, through equivalent technical and mechanical solutions still falling within the scope of protection illustrated and claimed below;

In particular:

the product or panel may also vary in terms of dimensions and shape depending on the mould or technical and design requirements of the furnishing object it should contribute to make;

the steel cage, or internal reinforcement armour, may be variously dimensioned and shaped, mutually constrained and joined in the respective composition elements; any plurality of elements forming the internal reinforcement or associated to the internal reinforcement may be left on the surface or projecting, protruding, on the surface of the product to join to other products in the assembly.

Advantages of the invention

As evincible from the detailed description above of preferred but non-exclusive embodiments, the method for producing panels and frames for the furniture industry and products using such method, according to the present invention, offer advantages corresponding to the preset and other objects:

it introduces a radical innovation in the furniture industry, where the prior art provides for sintered expanded polystyrene substantially solely as a filler, upgrading it to an exposed and bearing structure, thus preferably reinforced but without requiring surface finishing interventions for covering or edging, still possible, though tendentially superfluous in the economy of the method according to the present invention and products attained therewith.

Such radical innovation is introduced simultaneously obtaining results and advantages from the mouldable characteristics for moulding and sintering expanded polystyrene as regards the shaping required to assembly and associate to the assembly means both after and before moulding, the attainment of differentiated solidity as well as maximum lightness.

The method for producing panels, pre- fabricated products and frames for the furniture industry and the products obtained using such method, according to the present invention, integrate a simple, practical, modular and polyvalent solution concept to obtain a product suitable to constitute a valid and practical alternative embodiment with respect to the wooden or wood surrogate elements, and an element constituting panels or shaped for the furnishing industry with similar characteristics of robustness combined with lightness, with immense advantages in terms of reducing weight, even as regards transporting and storing, and simultaneously comparable to other structural and mechanical characteristics.

Claims

1) Method for producing panels, prefabricated products and frames for the furnishing industry, characterised in that it comprises forming shaped products made of sintered expanded polystyrene (EPS, expanded polystyrene) with high density comprised between 30 (thirty) and 60 (sixty) kg/m³ in an expanded mould and vapour sintering granules or incoherent beads obtained from the polymerisation of styrene and ensuing obtainment of a monolithic mass with solid geometry obtained from the mould and embedding in the mould at least one reinforcement element constituted by a steel grid before the moulding of the sintered expanded polystyrene for attaining composite products with reinforcement armour means.

2) Method according to the preceding claim, characterised in that it comprises a shape of the moulds with recesses and projections for attaining products with bas reliefs shaped with seats and reliefs suitable to be joined with metalware and accessories for mounting and/or using the finished product.

3) Method according to any one of the preceding claims, characterised in that it comprises positioning - in the moulds - plates, strips, sections and means for supporting the metalware before the moulding of the sintered expanded polystyrene for attaining products with coupling elements for metalware and accessories for mounting and/or using the finished product incorporated initially since from moulding.

4) Method according the preceding claims, characterised in that said reinforcement armouring means and said means for supporting the metalware are arranged mutually welded and joined in the mould so that they remain embedded mutually bound and constrained in the polymeric mass of sintered expanded polystyrene forming the finished product.

5) Method according to any one of the preceding claims, characterised in that it comprises positioning - in the moulds - decorative panels or tables or decorative elements before the moulding of the sintered expanded polystyrene for attaining products with decorative elements incorporated initially.

6) Method according to any one of the preceding claims, characterised in that it comprises localised co-injection of polystyrene with differentiated parameters of volume mass in the same mould for attaining products made of sintered expanded polystyrene with locally differentiated density for reinforcement of the portions subjected to more stress in use in the finished product. 7) Method according to any one of the preceding claims, characterised in that it comprises embedding - in the mould - at least one element in a low density sintered expanded polystyrene before the moulding of the high density sintered expanded polystyrene for attaining lightened products with a stratifically differentiated overall density.

8) Method according to any one of the preceding claims, characterised in that it comprises forming sintered expanded polymeric mass namely prefabricated products and frames for the furnishing industry with high density comprised between 30 (thirty) and 60 (sixty) kg/m³, in an expanded polystyrene mould of any size and shape, by pouring - into the mould - the granules or incoherent beads obtained from the polymerisation of styrene, with grain size and volume suitable for attaining a finished product with high density comprised between 30 (thirty) and 60 (sixty) kg/m³; expansion and sintering namely incorporating the incoherent polystyrene through contact with water vapour injected into the mould at a temperature greater than ninety degrees centigrade and ensuing obtainment of a monolithic mass with solid geometry obtained from the mould.

9) Method according to any one of the preceding claims, characterised in that it comprises any plurality of moulds grouped in the overall of the moulding machinery, with numeric control, in the moulds the beads sinter directly attaining the desired shape and overall shape of the product as well as the relative density, obtained by the mould and the parameters for the supply of the incoherent beads, typical of the latter, injection of the water vapour and ensuing suitable sintering.

10) Method according to any one of the preceding claims, characterised in that said mould is formed so that a product is shaped which is curved in at least one direction and/or which comprises at least one insert so to attain a product shaped, decoratively at the surface, as regards the configuration, at the perimeter and in terms of curvature, as well as in terms of formation of neighbouring portions, to create more complex and articulated products with respect to a simple sheet or panel, integrating a semi- finished product and advanced prefabricated element which - in a single piece - attains a portion developed from a processing point of view as much as possible with respect to the final overall product - in terms of implementation advancement - of the furniture the piece is intended to compose.

11) Method according to any one of the preceding claims, characterised in that said armour has appendages intended to remain outside the moulded product. 12) Method according to any one of the preceding claims, characterised in that it comprises a shape of the mould with recesses and projections, for attaining finished products with shaped bas reliefs, for example channels, guides, reliefs, notches, bas reliefs in general, suitable to be joined with accessories and metalware during the assembly of the finished products in the process aimed at attaining the finished product.

13) Method according to any one of the preceding claims, characterised in that it is alternatively implemented with the systems for producing sintered expanded polyethylene obtained from blocks extracted from a block element or for extrusion- drawing after polymerisation.

14) Method according to any one of the preceding claims, characterised in that it comprises a shape of the mould with interfaces for defining the surface portions of the finished product processed so that there are bas relief decorations, such as for example decorative lines or drawings of any kind and type in the finished product.

15) Panel products, prefabricated products and frames obtainable with the method according to any one of the preceding claims, characterised in that they comprise structure made of sintered expanded polystyrene with a density comprised between 30 (thirty) and 60 (sixty) kg/m³ incorporating a metal armour made of a grid or cages of meshes.

16) Products according to the preceding claim, characterised in that said metal armour incorporated embedded in the products is electrowelded and has size and shape such to interact with fixing means, such as screws and the like, which penetrate into the expanded body and are constrained into the internal meshes, contingently conceived with grid dimensioned suitably for the purpose, as well as shaped for maximising the function of anchoring as well as armouring the assembly means.

17) Panel products, prefabricated products and frames for the furnishing industry according to claim 15, characterised in that they comprise a structure made of sintered expanded polystyrene with a density comprised between 30 (thirty) and 60 (sixty) kg/m³ shaped with grids complementary to the shape of any metalware and accessory suitable for assembly and use, for assembling the metalware to the product subsequently to the constitution thereof, in seats and reception recesses specifically conceived during moulding and deriving from the configuration of the mould.

18) Panel products, prefabricated products and frames for the furnishing industry according to claim 15, characterised in that they comprise structure made of sintered expanded polystyrene with a density comprised between 30 (thirty) and 60 (sixty) kg/m³ incorporating any metalware and accessory suitable for the assembly and use associated to the polymeric mass in moulding constancy, for selectively arranging the accessory in the mould before moulding the product, so that the product remains incorporating - from the origin - the accessory in any position suitably designed, both on the relative surface and, fully or partly, embedded therein.

19) Panel products, prefabricated products and frames for the furnishing industry according to claim 15, characterised in that they comprise a structure made of sintered expanded polystyrene with a density comprised between 30 (thirty) and 60 (sixty) kg/m³, incorporating a metal armour, made of a grid or cages made of electrowelded mesh, to which there is constrained, welded, any metalware and accessory suitable for the assembly and use associated to the polymeric mass in moulding constancy, for selectively arranging the accessory in the mould before moulding the product, so that the product remains incorporating - from the origin - the accessory in any position designed contingently, both on the relative surface and, fully or partly, embedded therein and stably constrained to armour means.

20) Panel products, prefabricated products and frames for the furnishing industry according to claim 15, characterised in that they comprise a structure made of sintered expanded polystyrene with a density comprised between 30 (thirty) and 60 (sixty) kg/m³ incorporating decorative elements, remaining embedded in the polystyrene mass for decorative purposes.

21) Panel products, prefabricated products and frames for the furnishing industry according to claim 15, characterised in that they comprise a structure made of sintered expanded polystyrene with a density comprised between 30 (thirty) and 60 (sixty) kg/m³ with polystyrene mass density and sintering diversified so as to attain greater density and thus resistance in the arrangements subject to more intense wear in the finished product; for example on the worktops, or in the feet of the frames for armchairs, settees, and the like, or according to the design requirements.

22) Panel products, prefabricated products and frames for the furnishing industry according to claim 15, characterised in that they comprise a structure made of sintered expanded polystyrene with a density comprised between 30 (thirty) and 60 (sixty) kg/m³ incorporating any plurality of elements constituting the internal armour or associated to the internal armour projecting in the surface or projecting on the surface of the product for the incorporated joining to other products in assembly.