DK142377B

DK142377B - Method and form for making a building element with a foamed plastic core and a metal plate consisting of a surface coating.

Info

Publication number: DK142377B
Application number: DK159575A
Authority: DK
Inventors: Karl Aage Pederson
Original assignee: Karl Aage Pederson
Priority date: 1975-04-14
Filing date: 1975-04-14
Publication date: 1980-10-20
Also published as: DK159575A; DK142377C

Description

(11) FREMLÆGGELSESSKRIFT 142377 DANMARK <»> im. ci* e o* c 2/26 «(21) Ansøgning nr. 1595/75 (22) Indleveret den l4. apr. 1975 (24) Løbedag 14. apr. 1975 (44) Ansøgningen fremlagt og fremlæggelsesskriftet offentliggjort den 20. okt. 1 9$^(11) PUBLICATION MANUAL 142377 DENMARK <»> im. ci * e o * c 2/26 '(21) Application No 1595/75 (22) Filed on l4. April 1975 (24) Running day 14 Apr 1975 (44) The application presented and the petition published on 20 October. 1 9 $ ^

DIREKTORATET FORDIRECTORATE OF

PATENT-OG VAREMÆRKEVÆSENET <30) Prioritet begæret fra den (71) KARL AAGE PEDERSEN, Godthåbsvej 23, 4800 Nykøbing F, DK.PATENT AND TRADEMARKETENETEN <30) Priority requested from (71) KARL AAGE PEDERSEN, Godthåbsvej 23, 4800 Nykøbing F, DK.

(72) Opfinder: Samme.(72) Inventor: Same.

(74) Fuldmægtig under sagens behandling:(74) Plenipotentiary in the proceedings:

Internationalt Patent-Bureau.International Patent Office.

(54) Fremgangsmåde og form til fremstilling af et byggeelement med en ker« ne af opskummet plast og en af metalplade bestående overfladebeklæd= ning.(54) Method and form for the manufacture of a building element with foamed plastic cores and a sheet metal coating.

Opfindelsen angår en fremgangsmåde til fremstilling af et byggeelement med en kerne af opskummet plast og en af metalplade bestående overfladebeklædning, som lokalt er afbrudt af en not og/eller feder udformet i skumplast med højere rumvægt end skumplasten i det indre af kernen. Fremgangsmåden er af den art, hvor mindst to metalplader anbringes over for hinanden med indbyrdes afstand i en form, hvorefter mellemrummet mellem pladerne udfyldes med den opskummede plast.BACKGROUND OF THE INVENTION 1. Field of the Invention The invention relates to a method of manufacturing a building element with a foamed plastic core and a metal plate surface coating which is locally cut off by a groove and / or spring formed in foam with higher room weight than the foam of the interior of the core. The method is of the kind in which at least two metal sheets are placed opposite each other in a mold, after which the space between the sheets is filled with the foamed plastic.

Den forøgede rumvægt af skumplasten i not- og federoraråderne giver disse områder af byggeelementerne en tilsvarende større mekanisk styrke, som muliggør overføring af betydelige mekaniske kraftpåvirkninger mellem de sammenføjede elementer og mellem det 2 142377 enkelte elements dækplader og skumplasten i noten og federen.The increased bulk weight of the foam plastic in the groove and feather areas provides these areas of the building elements with a correspondingly greater mechanical strength, enabling the transfer of significant mechanical force effects between the joined elements and between the cover elements of the groove and the foam of the groove and the spring.

Som følge heraf kan elementerne også anvendes til ydervægge, stolper og tagplader til fremstilling af lette og højisolerede bygninger, eksempelvis fritidshuse, gæstehuse og nødbebyggelser i katastroferamte områder.As a result, the elements can also be used for exterior walls, posts and roof panels for the manufacture of lightweight and highly insulated buildings, for example holiday homes, guesthouses and emergency buildings in disaster areas.

Fra svensk fremlæggelsesskrift nr. 318 089 kendes et byggeelement af den angivne art, hvis not og feder er udformet i særskilt fremstillede indsatser i form af lister, som består af et andet materiale end skumplasten i det indre af kernen, og som klæbes til metalpladerne og skumkernen efter dennes hærdning eller indlægges mellem metalpladerne før indfyldningen af skumplasten.From Swedish Publication No. 318 089 there is known a building element of the specified kind, whose groove and spring are formed in separately manufactured inserts in the form of moldings, which consist of a material other than the foamed plastic in the interior of the core, and which are adhered to the metal sheets and the foam core after curing or inserting it between the metal sheets before filling the foam.

Fremgangsmåden ifølge opfindelsen er ejendommelig ved, at skumplasten bringes til at størkne ved opretholdelse af temperaturer, der er højere i de områder af formvæggen, som er i berøring med metalpladerne, end i de mellemliggende områder, hvor skumplasten ligger op ad formvæggen.The process according to the invention is characterized in that the foam plastic is solidified by maintaining temperatures higher in the areas of the mold wall which are in contact with the metal plates than in the intermediate areas where the foam plastic lies up against the mold wall.

Opretholdelsen af en lavere temperatur af de formflader, mod hvilke skummet størkner direkte, bevirker på disse steder dannelse af et yderlag eller skind af skum, som i overfladen har flere gange højere rumvægt end skummet i elementets indre, inklusive de flader af kernen, som ved størkningen bindes til metalpladerne, og hvis rumvægt gradvis aftager til en forudbestemt dybde fra formfladen. De ønskede forskelle mellem strukturen og dermed materialeegenskaberne i henholdsvis det indre af elementkernen og i kantzonerne opnås således på væsentlig enklere måde, nemlig i et enkelt fremstillingstrin og med kun ét udgangsmateriale uden anvendelse af præfabrikerede indsatser.Maintaining a lower temperature of the mold surfaces against which the foam directly solidifies causes the formation of an outer layer or skin of foam having in the surface several times higher room weight than the foam in the interior of the element, including the surfaces of the core which at the solidification binds to the metal plates and whose bulk weight gradually decreases to a predetermined depth from the mold surface. Thus, the desired differences between the structure and thus the material properties in the interior of the element core and in the edge zones, respectively, are obtained in a significantly simpler way, namely in a single manufacturing step and with only one starting material without the use of prefabricated inserts.

Ved anvendelse af polyurethanskum som kernemateriale er det ifølge opfindelsen hensigtsmæssigt, at metalpladerne holdes på en temperatur i intervallet 20-40°C, og de mellemliggende områder af formvæggen holdes ved en temperatur i intervallet 10-20°C. Der kan 3 herved med en rumvægt af kernens indre på 30-40 kg/m opnås en rum- 3 vægt i overfladen af not- og federområderne på 100-500 kg/m .Using polyurethane foam as a core material, it is preferred that the sheet metal be kept at a temperature in the range of 20-40 ° C and the intermediate regions of the mold wall be maintained at a temperature in the range of 10-20 ° C. Hereby 3 with a space weight of the core interior of 30-40 kg / m can be obtained a space 3 weight in the surface of the groove and feather areas of 100-500 kg / m.

Opfindelsen angår også en form til udøvelse af fremgangsmåden, og formen er ejendommelig ved, at den har midler til opretholdelse af en styret temperaturforskel mellem områder af formvæggen, mod hvilke metalpladerne skal ligge an, og de mellemliggende vægområder.The invention also relates to a mold for carrying out the method, and the mold is peculiar in that it has means for maintaining a controlled temperature difference between areas of the mold wall against which the metal plates are to abut and the intermediate wall areas.

Den foreskrevne temperaturforskel mellem formvæggens områder kan ifølge opfindelsen opnås ved, at de nævnte mellemliggende områder af formvæggen er hule og indrettet til at gennemstrømmes af 3 142377 et kølemedium.According to the invention, the prescribed temperature difference between the regions of the mold wall can be obtained by the said intermediate regions of the mold wall being hollow and arranged to flow through a cooling medium.

Opfindelsen forklares i det følgende nærmere under henvisning til den skematiske tegning, på hvilken fig. 1 i perspektiv anskueliggør en bygning samlet af ele-menter, som er fremstillet ved en fremgangsmåde ifølge opfindelsen, fig. 2 et lodret snit gennem et vægelement til den i fig. 1 viste bygning, fig. 3 et tilsvarende snit gennem et af bygningens tagelementer, fig. 4 et vandret snit gennem en hjørne- eller midterstolpe i bygningen og tilgrænsende vægelementer, fig. 5 et snit visende forbindelsen mellem et tagelement og et sternelement, og fig. 6 et snit gennem en form ifølge opfindelsen til fremstilling af det i fig. 3 viste tagelement.The invention will now be explained in more detail with reference to the schematic drawing, in which FIG. 1 is a perspective view of a building made up of elements made by a method according to the invention; 2 is a vertical section through a wall element to the one shown in FIG. 1; FIG. 3 shows a corresponding section through one of the building's roof elements; FIG. 4 is a horizontal section through a corner or center post in the building and adjacent wall elements; FIG. 5 shows a section showing the connection between a roof element and a star element, and FIG. 6 is a section through a mold according to the invention for the preparation of the embodiment of FIG. 3.

Det i fig. 1 viste hus er opbygget af bjælkelignende vægelementer 1, hjørne- og dørstolper 2, tagelementer 3 og sternele-menter 4. Alle de nævnte elementer indeholder en indvendig kerne af opskummet plast med lav rumvægt og høj isolationsevne, og de er sammenføjet med not og feder på den i det følgende nærmere beskrevne måde. Huset er opstillet på et fundament 5.The FIG. 1 housing is constructed of beam-like wall elements 1, corner and door pillars 2, roof elements 3 and star elements 4. All of the above-mentioned elements contain an inner core of foamed plastic with low space weight and high insulating capacity, and are joined with groove and spring in the manner described below. The house is erected on a foundation 5.

Hvert vægelement 1, som ses mere detaljeret i fig. 2, består af to parallelle dækplader 6 af tynd metalplade, f.eks. stål eller aluminium, som er formgivet ved kendt valseteknik og i givet fald har en ønsket overfladebeklædning på deres yderside. I det færdige vægelement er de to modstående dækplader 6 bundet til en kerne 7 af plastskum, f.eks. polyurethanskum med en rumvægt på 3 ca. 30-40 kg/m . Som det ses i fig. 2, ligger de ombertlede nedre kanter 8 af pladerne 6 i vandret afstand fra hinanden, og tilsvarende ligger de øvre kanter 9 af pladerne i stort set samme afstand. Langs vægelementets underkant er skumkernen 7 trukket tilbage i forhold til underkanterne af pladerne 6, således at der dannes en langsgående not 10. Foroven i vægelementet ligger kernen 7's overkant i flugt med pladekanterne 9 eller eventuelt lidt højere end kanterne, således at der dannes en langsgående feder 11, som passer ind i noten 10 på et overliggende vægelement i det færdige hus.Each wall element 1, which is seen in more detail in FIG. 2, consists of two parallel thin plates 6 of thin metal plate, e.g. steel or aluminum, which is shaped by known rolling technique and, if applicable, has a desired surface coating on their exterior. In the finished wall element, the two opposing cover plates 6 are bonded to a core 7 of plastic foam, e.g. polyurethane foam with a room weight of 3 approx. 30-40 kg / m. As seen in FIG. 2, the recessed lower edges 8 of the plates 6 are at a horizontal distance from one another, and correspondingly the upper edges 9 of the plates are at substantially the same distance. Along the lower edge of the wall element, the foam core 7 is retracted relative to the lower edges of the plates 6, so that a longitudinal groove 10 is formed. At the top of the wall element, the upper edge of the core 7 aligns with the plate edges 9 or possibly slightly higher than the edges, thus forming a longitudinal groove. spring 11, which fits into the groove 10 on an overlying wall element of the finished housing.

142377 4142377 4

Ved den nedenfor beskrevne fremstillingsproces er skummaterialet i kernen 1 bragt til at størkne under sådanne betingelser, at materialet i federen 11 og i det i tværsnit U-formede område 12, som omgiver noten 10, har væsentlig større rumvægt end skummaterialet i kernens indre. Herved får materialet i de to nævnte områder, uden at dets isolationsevne forringes væsentligt, en betydelig større mekanisk styrke end kernen i øvrigt, således at mekaniske belastninger med sikkerhed kan overføres mellem husets enkelte elementer ved hjælp af not- og federsamlingerne.In the manufacturing process described below, the foam material in the core 1 is solidified under conditions such that the material in the spring 11 and in the cross-sectional U-shaped region 12 surrounding the groove 10 has substantially greater space weight than the foam material in the core interior. In this way, the material in the two mentioned areas, without significantly impairing its insulation capacity, gains a considerably greater mechanical strength than the core, so that mechanical loads can be safely transferred between the individual elements of the housing by means of the groove and feather joints.

Det i fig. 3 viste tagelement svarer i sin opbygning til vægelementet ifølge fig. 2. Det er sammensat af to modstående, ved valsning formede dækplader 13 og 14 og en kerne 15 af opskummet materiale. Som ved vægelementet 1 ligger de to dækpladers nedre og øvre kanter 16, 17, 18 og 19 i vandret afstand fra hinanden, således at der ikke er nogen direkte varmeledende kontakt mellem de to metalplader. Langs tagelementets øvre kant danner kernens skummateriale en langsgående feder 20, der ligesom federen 11 har højere rumvægt end skummet i kernen 15's indre. Ved tagelementets nedre kant er skummaterialets rumvægt tilsvarende forøget ikke blot i det område 21, der omgiver den langsgående not 22, men også i det tilgrænsende, i tværsnit L-formede område 23, der strækker sig fra noten 22 ned til pladen 13's underkant 16, og som i det færdige tag overlapper en kantzone af det underliggende tagelements ydre dækplade 13.The FIG. 3, the roof element shown in its structure corresponds to the wall element according to FIG. 2. It is composed of two opposing, roll-formed cover plates 13 and 14 and a core 15 of foamed material. As with the wall element 1, the lower and upper edges of the two cover plates 16, 17, 18 and 19 are at a horizontal distance from one another, so that there is no direct heat conducting contact between the two metal plates. Along the upper edge of the roof element, the foam material of the core forms a longitudinal spring 20 which, like the spring 11, has higher room weight than the foam in the interior of the core 15. At the lower edge of the roof element, the foam weight of the foam material is correspondingly increased not only in the region 21 surrounding the longitudinal groove 22, but also in the adjacent, cross-section L-shaped region 23 extending from the groove 22 down to the lower edge 16 of the plate 13. and which in the finished roof overlaps an edge zone of the outer cover plate 13 of the underlying roof element.

I fig. 4 ses to vægelementer 1, som er sammenføjet med en stolpe 24. Stolpen 24 har en kerne 25 af skumplast og tre .dækplader 26 og 27 fremstillet ved valsning af metalplade. Dækpladernes kantzoner er valset med et indadgående U-profil, hvis frie kanter 28 i den færdige stolpe ligger indfældet i kernen 25's materiale som vist. I området omkring og mellem pladekanterne 28 er kernen 25 formet således, at der dannes tre lodrette T-noter 29, og vægelementerne 1 er formgivet med en modsvarende, i tværsnit T-formet kantzone 30, som danner en lodret feder til sammenføjning af vægelementerne og stolpen. Det område af hvert vægelements kerne 7 og de tilsvarende områder af stolpens kerne 25, som grænser op til henholdsvis fedrene og noterne, har på samme måde som de tilsvarende områder af vægelementernes over- og underkant forøget rumvægt, og som vist i fig. 4 er metalkanterne 28 samt de lodrette kanter 31 af vægelementernes dækplader helt indfældet i det fortættede skummateriale.In FIG. 4 shows two wall elements 1 which are joined together with a post 24. The post 24 has a foam 25 core 25 and three cover plates 26 and 27 made by rolling sheet metal. The edge zones of the cover plates are rolled with an inward U-profile whose free edges 28 of the finished post lie in the material of the core 25 as shown. In the region around and between the plate edges 28, the core 25 is formed such that three vertical T-grooves 29 are formed and the wall elements 1 are shaped with a corresponding, cross-sectional T-shaped edge zone 30, which forms a vertical spring for joining the wall elements and post. The area of the core element 7 of each wall element and the corresponding areas of the column core 25, which adjoin the fathers and grooves respectively, have the same weight as the corresponding areas of the upper and lower edge of the wall elements, and as shown in FIG. 4, the metal edges 28 as well as the vertical edges 31 of the cover elements of the wall elements are completely enclosed in the densified foam material.

5 142377 Søjlens kerne 25 indeholder en gennemgående lodret udsparing 32, der f.eks. kan dannes af et plastrør, der indsættes i den form, hvori søjlen fremstilles. Udsparingen tjener til optagelse af en bolt, hvormed søjlen kan fastspændes til husets fundament 5.The core 25 of the column contains a continuous vertical recess 32, e.g. may be formed of a plastic tube inserted into the mold in which the column is made. The recess serves to receive a bolt by which the column can be fastened to the housing foundation 5.

Det vil forstås, at dersom der ikke, som antydet med punkterede linier i fig. 4, skal indsættes en indvendig tværvæg i søjlen 24, vil dennes inderside være dannet af en enkelt dækplade identisk med den viste udvendige dækplade 26. Hvis stolpen er en hjørnestolpe, vil dens udvendige dækplade tilsvarende strække sig ubrudt hen over to af stolpens lodrette sideflader.It will be understood that if not, as indicated by dashed lines in FIG. 4, an inner transverse wall is to be inserted into the column 24, its inside will be formed of a single cover plate identical to the outer cover plate 26 shown. If the post is a corner post, its outer cover plate will extend continuously across two of the post's vertical side surfaces.

Den i fig. 5 anskueliggjorte sammenføjning mellem tagelementerne 31 s endekanter og sternelementerne 4 er analog med den i fig. 4 viste. Sternelementet 4 har en kerne 33 af skumplast samt tre dækplader 34 og 35 med U-formet ombøjede kantzoner, der er indfældet i kernens materiale. De to dækplader 35 danner tilsammen en T-formet not, hvori en T-formet feder 36 på tagelementet er fastholdt. Endekanterne af tagelementets plader 13 og 14 ligger helt indfældet i skummaterialet i federen 36, og dette materiale samt det modstående skummateriale i sternelementets not er fremstillet med forøget rumvægt.The FIG. 5 illustrates joining between the end edges of the roof elements 31 and the star elements 4 is analogous to that of FIG. 4. The star element 4 has a foam 33 core 33 and three cover plates 34 and 35 with U-shaped curved edge zones incorporated into the core material. The two cover plates 35 together form a T-shaped groove in which a T-shaped spring 36 is retained on the roof element. The end edges of the roof elements 13 and 14 of the roof element are completely enclosed in the foam material of the spring 36, and this material as well as the opposite foam material in the groove of the star element is made with increased room weight.

Den i fig. 6 helt skematisk anskueliggjorte form til fremstilling af et tagelement som vist i fig. 3 har en bærende underramme 37, hvortil der er fastgjort en plade 38 af isolerende materiale.The FIG. 6 is a fully schematic illustration of a roof element as shown in FIG. 3 has a supporting subframe 37 to which a plate 38 of insulating material is attached.

En overramme 39 er ved hjælp af et hængsel 46 hængslet forbundet med underrammen 37, og en plade 40 af isolerende materiale er fastgjort til overrammen. En hul formpart 41 strækker sig parallelt med hængselaksen mellem de to formrammer langs den ene side af formhulrummet mellem pladerne 38 og 40, og en anden hul forrapart 42 ligger i formens lukkede stilling, som er vist i fig. 6, mellem de to plader ved den modstående længdekant af formhulrummet. Som markeret med en pil er formparten 42 forskydelig i vandret retning, således at den efter formens åbning kan trækkes ud for at frigøre det færdige tagelement. De to formparter 41 og 42 har ikke viste tilslutninger for tilgang og afgang af et kølemedium, og gennem formparten 41 er endvidere ført ét eller flere rør 43, gennem hvilke det materiale, som skal danne elementets kerne, kan indsprøjtes efter formens lukning.An upper frame 39 is hingedly connected to the lower frame 37 by means of a hinge 46, and a plate 40 of insulating material is attached to the upper frame. A hollow mold part 41 extends parallel to the hinge axis between the two mold frames along one side of the mold cavity between plates 38 and 40, and another hollow mold part 42 lies in the closed position of the mold shown in FIG. 6, between the two plates at the opposite longitudinal edge of the mold cavity. As indicated by an arrow, the mold portion 42 is slidable in the horizontal direction so that after the mold opening it can be pulled out to release the finished roof member. The two mold portions 41 and 42 have no shown connections for supply and discharge of a refrigerant, and through the mold portion 41 are also passed one or more pipes 43 through which the material which is to form the core of the element can be injected after the mold closure.

Før lukningen af formen placeres den ene dækplade 14 på denPrior to closing the mold, one cover plate 14 is placed on it

Claims

6, insulating lower plate 38 with its edges in contact with the mold portions 41 and 42, and the second cover plate 13 is mounted on the mold surface plate 40, which for this purpose may be provided with recessed magnets 44 for holding the plate 13 if it consists of magnetizable material. Then, the upper part of the mold is pivoted about the hinge 46 to the closed position shown, and plastic material is injected through the tubes 43 while conducting refrigerant through the hollow mold portions 41 and 42. When erecting the housing, the posts 2 are first placed on the foundation and secured by means of the bolts mentioned above through the internal recesses of the posts. Then, the wall elements are mounted successively from above in the vertical grooves of the posts, and when all the wall and end elements are mounted, the roof elements 3 are mounted successively, whereby the lower roof element can be fixed by means of screws to the posts. Finally, the star elements 4, which lock the roof elements to one another, are mounted and the one shown in FIG. 1 smoking element 45.

A method of manufacturing a building element having a foamed plastic core (7, 15, 25, 33) and a sheet metal surface coating (6, 13, 14, 26, 27, 34, 35) which is locally interrupted by a groove (10, 22, 29) and / or a spring (11, 20, 30, 36) formed in foam having a higher weight than the foam in the interior of the core, the method of which is at least two metal sheets (13 14) are spaced apart in a mold, after which the space between the sheets is filled with the foamed plastic, characterized in that the foam plastic is solidified by maintaining temperatures higher in the regions (38, 40) of the mold wall, which is in contact with the metal plates, than in the intermediate areas (41, 42) where the foam rests up against the mold wall.

Process according to claim 1, and using polyurethane foam as a core material, characterized in that the metal sheets are kept at a temperature in the range 20-40 ° C and that the intermediate regions of the mold wall are kept at a temperature in the range 10-20. ° C.

Form for carrying out the method according to claim 1 or 2, characterized in that it has means for maintaining