EP2678490A1

EP2678490A1 - Lightweight construction element which is capable of bearing or is bearing

Info

Publication number: EP2678490A1
Application number: EP11794641.8A
Authority: EP
Inventors: Peter Meyer; Harry Klein
Original assignee: Meyer Yvonne
Current assignee: MEYER YVONNE; WOLF, THOMAS; WOLTER, ANTJE
Priority date: 2011-02-25
Filing date: 2011-11-28
Publication date: 2014-01-01
Anticipated expiration: 2031-11-28
Also published as: WO2012113423A1; DK2678490T3; HRP20190636T1; EP2678490B1

Abstract

The invention relates to a lightweight construction element (2) which is capable of bearing or is bearing and has one or more rows of parallel chambers (6) which are each surrounded by tubular boundary walls (12, 42), wherein the boundary walls (12, 42) are at least partially composed of paper. In order to increase the bearing capacity of the lightweight construction elements (2) and to reduce the weight thereof per unit area, it is proposed according to the invention that the boundary walls (12, 42) are connected to one another and form a multi-chamber hollow profile (4) which has a uniform cross section in the direction of the longitudinal centre axes (8) of the chambers (6), and that the inner surfaces (16, 52) of the boundary walls (12, 42), which surfaces face the chambers (6), and the outer surfaces (14, 54) of the boundary walls (12, 42), which surfaces face away from the chambers, are provided with a water-repelling coating (10) and/or impregnation increasing the bending and/or compressive strength of the paper.

Description

Carrying or supporting lightweight component

The invention relates to a load bearing or carrying

Lightweight element with one or more rows of parallel chambers, each surrounded by tubular boundary walls, wherein the boundary walls are at least partially made of paper. From DE 100 18 710 AI already designed as a wall element lightweight element of the type mentioned is known with a support structure consisting of juxtaposed and / or superimposed tubular hollow bodies and carries a coating to form the wall surfaces. The elongated tubular hollow bodies are made of paper, cardboard,

Made of plastics or the like. Recycled paper is particularly preferred as a low-cost starting material for producing the hollow body, since the rough surface in this case the adhesion of the preferably formed as a plaster layer

Improved coating. However, the plaster layer increases the weight of the lightweight elements without them

Load capacity of the support structure is improved. In addition, untreated tubular hollow bodies of paper or paperboard have only a limited carrying capacity in their longitudinal direction, unless they have very thick boundary walls, which in turn increases the weight of the lightweight components. Another disadvantage of the known lightweight components is that made of paper tubular hollow body easily from the environment or from the plaster layer of water

absorb, whereby their load capacity decreases sharply.

Proceeding from this, the present invention seeks to provide a sustainable or lightweight structural element of the type mentioned with a very high load capacity and a very low weight or weight per unit area.

CONFIRMATION COPY This object is achieved in that the boundary walls are interconnected and form a multi-chamber hollow profile, which has a constant cross section in the direction of the longitudinal center axes of the chambers, and that the chambers facing the inner surfaces and facing away from the chambers outer surfaces of the Boundary walls with a water repellent and the bending and / or

Compressive strength of the paper-enhancing coating and / or impregnation are provided.

It has been found by experiments that the load-bearing capacity of the multi-chamber hollow profile is higher than that of the side-by-side tubular hollow body made of untreated paper according to DE 100 18, which is provided with a plaster layer and increases the bending and / or compressive strength of the paper 710 AI can be increased many times over with corresponding cross-sectional dimensions and wall thicknesses, and thus also the load-bearing capacity of the entire lightweight component. At the same time prevents the water-repellent coating after assembly of the lightweight element that moisture penetrates into the paper over the life of the lightweight element, which could affect the strength of the hollow section and thus the carrying capacity of the lightweight element.

A preferred embodiment of the invention provides that at least one outside of the chambers facing away from the

Multi-chamber hollow sections hard foam is applied. By using a hard foam as a topcoat or

alternatively as an intermediate layer between the outside of the

Hollow sections and an additional cover layer can be in comparison to the known lightweight element further reduce the weight and on the other hand increase the strength, since hard foam despite a very low specific weight has a higher strength than plaster or plaster. Also by the mutual connection of the boundary walls of the chambers can the carrying capacity can be increased, since in this way buckling of individual boundary walls or wall sections is difficult. For flat lightweight elements with a

Variety of short juxtaposed hollow bodies, which together form a honeycomb, can also be dispensed with the hard foam, since the buckling of individual boundary walls or wall sections is prevented by the small length of the hollow body. In this case, the boundary walls of the adjacent

Chambers expediently connected to each other by the applied to the outer surfaces of the boundary walls water-repellent coating, which adheres the abutting boundary walls together. Where a hard foam is applied to the outside of the multi-chamber hollow profile, the boundary walls of the adjacent chambers are suitably interconnected by the hard foam, which also acts as an adhesive or binder and the boundary walls

holds together.

With the combination of features according to the invention can be plate-shaped lightweight elements with a basis weight of less than 2 kg / m ^{2 produced} at a thickness of about 50 mm, which are capable of a width of 1000 mm, parallel to the direction of the longitudinal center axes of the chambers loads of more than To carry 10 tons.

In order to prevent the penetration of moisture to the paper, the boundary walls of the chambers are provided both at its inner and outer periphery with the coating and / or impregnation so that neither from inside nor from the outside moisture penetrate to the paper and thereby the bending and /or

Pressure resistance of the boundary walls of the chambers and thus may affect the lightweight element. In addition, by a double-sided inner and outer coating and / or

Impregnation a greater increase in bending and / or Compressive strength than in the case of a one-sided coating and / or impregnation and thus a further increase in the carrying capacity of the lightweight components can be achieved. Preferably, the coating and / or impregnation consists of a resin which is applied to the inner and outer peripheral surfaces of the tubular hollow bodies either after or during the manufacture of the tubular hollow body of paper in the liquid state and then cured. Conveniently, a resin is used which cures rapidly with or without the application of heat, preferably a thermosetting reaction resin in the form of a two-component system comprising, in addition to the reaction resin, an accelerator or catalyst for accelerating the curing. A preferred embodiment of the invention provides for the use of a polyisocyanuric or Epoxyisocyanuratharzes, for example a P.oly- or Epoxyisocyanuratharzes, the company Bayer MaterialScience under the name

Blendur is available. Alternatively, however, other resins can be used, such as epoxy resins or

Phenolic resins which are also water repellent when cured and increase the flexural and / or compressive strength of the tubular hollow body made of paper.

According to a first alternative of the invention, the hollow profile consists of one or more rows of tubular bodies arranged side by side, which abut with their outer periphery against the outer periphery of adjacent tubular hollow body and are glued to the adjacent hollow bodies, each hollow body defining one of the parallel chambers. However, in order to facilitate the introduction of rigid foam in the interstices or gusset between adjacent hollow bodies, the hollow profile may alternatively be made of one or more

Rows of spaced apart tubular hollow bodies are made, so that the flowable rigid foam from one side into a previously equipped with the hollow bodies

Form can be introduced where he passes through the gaps between penetrates through the adjacent hollow bodies and so fills the entire shape. This alternative is particularly suitable for wall elements containing only one or two rows of elongated, embedded in hard foam hollow bodies. In particular, such wall element can be used well for the production of walls of freight containers, railway cars or other means of transport, where a low basis weight is particularly advantageous. To the production of such tubular hollow body

To facilitate paper, these advantageously have cylindrical outer and inner peripheral surfaces or a circular cross section, so that they can be used on existing machines

can be used, for example, in the manufacture of paper or cardboard wrapping cores from kitchen rolls or toilet paper rolls. These hubs are made by two or more strip-shaped

Layers of paper are wound helically and overlapping each other onto a mandrel with an adhesive applied to one or both strips of paper in the areas of overlap. Alternatively, the tubular

However, hollow bodies are also produced by wrapping wider sheets or webs of paper in the circumferential direction of the tubular hollow bodies in several layers one above the other. This invention alternative has a particularly high

Load capacity.

According to this alternative, when the tubular hollow bodies abut with their outer circumferential surfaces against the outer peripheral surfaces of adjacent tubular hollow bodies and are glued together by the coating and / or rigid foam, the lightweight supporting structural element can be further stiffened and, in the case of an insert as a plate-shaped wall element or as a columnar supporting element its compressive strength in the vertical direction can be further increased as the adjacent

tubular hollow body support each other and themselves hold each other in their position, which counteracts kinking of individual tubular hollow body under load. By the mutual investment of adjacent tubular

Hollow body can also reduce the volume of the chambers inside the tubular hollow body compared to the total volume of the

Leichbauelements increased and thus the weight of the latter without affecting the carrying capacity are further reduced, since the latter to a large extent by the

tubular hollow bodies is delivered.

According to a second alternative of the invention, the hollow profile of two or more plates is formed with preferably wave-shaped profile having alternating parallel projections and depressions and are placed on each other so that the projections of adjacent plates abut each other and can be glued together. In this way, in each case between the recesses of the adjacent plates, the parallel chambers are created, which are arranged in a row next to each other and as well as the chambers in the tubular hollow bodies of adjacent chambers are separated. These

Invention alternative is easier to produce.

Similar as described above, the bonding between the adjacent panels ensures that they support each other and prevent buckling of individual panels. For bonding the adjacent plates, the water-repellent coating applied to the surfaces of the boundary walls is expediently used. The paper used is preferably

Paper of low quality, expedient to a recycled paper, which must have only a low bending and / or compressive strength without the coating and / or impregnation, however, should preferably have a rough surface and a certain absorbency to ensure that a sufficient amount of liquid applied coating and / or impregnation adheres to the surface of the paper and advantageously at least partially penetrates the paper. Through experiments it has been found that even a relatively small wall thickness of the boundary walls of the chambers is sufficient to give the lightweight component a very high load capacity

so that the boundary walls according to a further advantageous embodiment of the invention from less than eight superimposed layers or layers, preferably from less than five layers or layers and best of only two to three layers or layers of paper, so that the wall thickness the boundary walls is less than 4 mm, preferably less than 2 mm and most preferably less than 1 mm. With this wall thickness of the boundary walls, the chambers may conveniently have cross-sectional dimensions of about 50 mm so that the ratio between the wall thickness of the tubular hollow bodies and the cross-sectional dimensions is desirably less than 1:25, preferably less than 1:50 and most preferably about 1: 100 , With such dimensions can be load-bearing

Lightweight wall elements are produced during construction

single-storey houses with roof no supporting structure

make necessary. If the lightweight element is to be used as a plate-shaped wall element or as a columnar support element, the hollow profile is aligned so that the longitudinal axes of the parallel chambers have a vertical orientation. As a result, the boundary walls in the direction in which the

Weight of components placed over it on the load-bearing component

Wall or support element acts, their greatest compressive strength, so that the wall or support member receives a maximum load capacity. The hollow profile extends advantageous

continuously from an upper to a lower end of the lightweight construction element. If the wall or support member is to be given a relatively small thickness, the hollow profile expediently encloses only a single row of juxtaposed chambers whose longitudinal central axes in the cross section expediently lie on a line.

In contrast, two or more rows of chambers can be arranged side by side for larger wall thicknesses, wherein the chambers of adjacent rows expediently offset from each other longitudinal central axes, in order to ensure the most dense packing of the chambers and a low basis weight. When the hollow section of parallel cylindrical

Hollow bodies, the hard foam fills the gusset between the tubular hollow bodies, wherein it connects adjacent hollow body together and prevents mutual displacement or displacement of adjacent hollow body under load.

An additional stiffening of the lightweight element can be achieved by one or more layers of a fiber-reinforced resin, such as

For example, polyurethane with a fiber fabric or fiber fabric embedded therein may be applied, preferably directly onto the flat surface of the rigid foam. Over the fiber-reinforced resin layer, a surface cover layer may be applied as a termination.

At the upper and lower ends of each wall or support member, end members are preferably attached which close the open upper and lower ends of the chambers. The end elements of lightweight wall elements are preferably elongated and extend along the top and bottom ends, being on one side with projections

are provided, which can be inserted into the open ends of the parallel chambers. The closing elements ensure that the upper and lower end of the chambers

is closed and the wall or support elements to the upper and lower ends have no openings, and on the other hand also improve the cohesion of wall or support elements when they consist of tubular hollow bodies. The

End elements are suitably connected by the rigid foam with the rest of the lightweight element, for example by being attached prior to curing of the rigid foam.

When the lightweight element as a plate-shaped bottom or

Ceiling element is to be used, the parallel chambers also have vertical longitudinal central axes, in which case, however, a plurality of short tubular hollow bodies or short plates with wavy profile in rows offset from each other are arranged so that they are aligned perpendicular to the broad side surfaces of the floor or ceiling element and together form a honeycomb structure. In this case, the upper and lower ends of the chambers or the honeycomb structure can be closed by plates which abut against the aligned upper and lower end faces of the hollow profile.

Alternatively, the upper and lower ends of the chambers or honeycomb structure may also be closed by one or more layers of fiber reinforced resin or resin, for example by fiber reinforcement as a nonwoven, woven fabric or scrim of fibers on the respective upwardly turned or facing broadsides the honeycomb structure is placed so that the fleece, fabric or scrim the open ends of the

Chambers completely covered, and then by soaking with the resin and the resin is cured. The resin may preferably be a thermosetting synthetic resin which cross-links upon application of heat or UV radiation and thereby harden, or a two-component resin. Depending on the strength requirement, the fiber reinforcement can consist of glass, carbon, aramid or synthetic fibers. If required, one or more further layers of fiber-reinforced resin and optionally an additional surface covering layer may be applied as a finish. Alternatively, the honeycomb structure can also be placed with its broadside turned downwards on a resin impregnated layer of the nonwoven fabric, fabric or -gelege to close the ends of the chambers. In both cases, the ends of the boundary walls of the chambers connect with the curing of the resin with the latter, so that they are then firmly bonded to the layers of fiber reinforced resin and form a floor or ceiling element with high bending stiffness. This type of lightweight element can be used with advantage as a floor or ceiling element for a cargo or living container, such as a sea or transport container, since the floors and ceilings of the latter are currently made of so-called multiplex panels from a tropical wood, not more is available for a long time.

As a hard foam, a hard foam is preferably used, which has a large total pore volume and thus a low specific gravity, but in which the individual pores are very small and preferably have cross-sectional dimensions of less than 1 mm, more preferably less than 0.5 mm. The rigid foam can be a curing reaction foam, for example a higher crosslinked rigid polyurethane foam, which is also referred to as PIR foam. When using such a rigid foam, two or more components of the starting material may be introduced into a mold containing the tubular hollow body and crosslinked or cured in the mold. Alternatively, a rigid foam may be used, which consists of a plurality of microcavities in a surrounding matrix, for example, so-called microballs, that is, microscopic hollow bodies of glass, which are embedded in the matrix.

If the lightweight structural elements are used in the construction of buildings or the like, they must have sufficient fire resistance, in Germany at least Fire protection class B1S-D0 required, but fire protection class A is preferred. In order to increase the fire resistance of the lightweight components, a material with a relatively high temperature resistance is advantageously used for a coating or impregnation of the tubular hollow body, such as the aforementioned poly- or Epoxyisocyanuratharz, and on the other a temperature-resistant, dimensionally stable foam at higher temperatures, such as For example, the already mentioned PIR foam of fire protection class B1S-D0 or AI. This

Hard foam has a specific weight of 40 kg / m ³ and is thus very light, but on the other hand has such a hardness that it can be drilled or otherwise processed. This makes it possible to hard foam on the opposite narrow sides of the adjacent lightweight components in their

Manufacture to form a groove or spring, so that the adjacent lightweight components mate and thus can be easily connected together. In principle, it is also possible to mill the grooves and springs after the production of lightweight components on the narrow sides of the hard foam. Alternatively, the grooves and springs on the opposite narrow sides of adjacent lightweight components can also be formed by profiles made of metal or plastic, which are glued by the rigid foam with the hollow profile.

Fire protection class AI can also be achieved in that the hard foam consists of microscopic hollow spheres of glass, which are embedded in a non-combustible matrix, such as a waterglass adhesive.

The transport weight of the lightweight components according to the invention is the lowest when the parallel chambers are filled with air. However, it is also possible for sound and / or

Thermal insulation already in the manufacture of lightweight construction a suitable material with a low specific weight to introduce into the chambers, such as a polystyrene granules, paper flakes or a fibrous insulating material. Heavier soundproofing materials and especially sand, which has a very good sound-insulating effect, are preferably filled only in the course of assembly of the lightweight components in the chambers. As sound insulation materials preferably flowable materials, such as sand or polystyrene granules are used, because these materials can be easily filled from above into the open-topped chambers, where they then fall by gravity down. Alternatively, however, the chambers can also be filled with a fibrous or flake-shaped sound and / or heat-insulating material which can be blown into the chambers, for example, or with an open-cell foam with which the chambers are foamed for sound and / or thermal insulation become. A filling of the chambers with the hard foam is also a preferred embodiment of the invention.

Since a lightweight component having a hollow profile of cylindrical tubular hollow bodies arranged next to one another or of plates with a wave or zigzag profile has an uneven surface structure unsuitable as a wall surface, a further advantageous embodiment of the invention provides that the rigid foam has at least one and preferably above all wall elements forms two flat broadside surfaces. However, the lightweight component may also be provided with one or two additional cover layers, which are formed by a voltage applied to a broad side against the hard foam and / or the hollow profile plate.

Preferably, in the latter case to increase the refractory plates of a mineral material used, preferably mineral plates of magnesium oxide and magnesium chloride with a glass fiber reinforcement, which are commercially available under the name Megapan and in a thickness of a few millimeters as a topcoat on the Lightweight element can be attached so that they form the visible outer surfaces. The plates are preferably connected by the rigid foam with the hollow profile or glued to this.

In the following the invention will be explained in more detail with reference to an embodiment shown in the drawing. Show it:

Figure 1 is a partially cut away perspective view of parts of two lightweight wall elements.

FIG. 2 is an enlarged cross-sectional view of a portion of one of the lightweight wall elements of FIG. 1; FIG. Fig. 3 is a partially cut away perspective view of parts of two modified lightweight wall elements;

FIG. 4 is an enlarged cross-sectional view of a portion of one of the lightweight wall elements of FIG. 3; FIG.

Fig. 5 is a partially cut away perspective view of parts of two further modified lightweight wall elements; Fig. 6 is an enlarged cross-sectional view of a part of one of the lightweight wall elements of Fig. 5;

Fig. 7 is a partially cut away perspective view of a portion of yet another modified lightweight wall element;

Fig. 8 is an enlarged cross-sectional view of a portion of the lightweight wall elements of Fig. 7; 9 is an enlarged side view of a portion of a top bar for the upper or lower end of the

Lightweight wall element of Fig. 1; Fig. 10 is an enlarged bottom view of the portion of the end strip of Fig. 4;

11 is an enlarged cross-sectional view of a portion of another lightweight wall element;

Fig. 12 is an enlarged cross-sectional view of a part of still another lightweight wall element;

Figure 13 is an enlarged cross-sectional view corresponding to Figure 10, but with a heat-insulating granules in a part of the chambers ..;

Fig. 14 is a cross-sectional view of a columnar

Lightweight element;

Fig. 15 is a sectional view of a formed as a floor or ceiling plate lightweight construction element;

Fig. 16 is a partially cut away enlarged

perspective cutaway view of the lightweight element

Fig. 15.

Fig. 17 is a partially cut away enlarged

perspective cutaway view of another designed as a floor or ceiling slab lightweight construction element.

The structural or supporting lightweight components 2 shown in the drawing each contain a multi-chamber hollow section 4, the one or more rows of chambers 6 with parallel longitudinal central axes 8 and one in the direction of the longitudinal central axes

8 constant opening cross-section surrounds. In the lightweight elements 2 in Figures 1 to 10 and 14 to 17, the multi-chamber hollow section 4 of a plurality of interconnected cylindrical hollow bodies 12 made of paper whose outer and inner peripheral surfaces 14, 16 are coated with a resin 10 and together with the Coating of the resin 10, the boundary walls of the chambers 6 form. In the lightweight components 2 in Figures 1 to 10 and 14 to 16, the hollow body 12 are embedded in a hard foam 18, which the gusset 20 between the adjacent tubular

Hollow bodies 12 fills and the hollow body 12 also

connects with each other.

If the lightweight element 2 is a wall element, as shown in FIGS. 1-8, or a support element, e.g. a column, as shown in Fig. 14 in cross-section, the tubular hollow bodies 12 are arranged inside the lightweight member 2 in a parallel and vertical alignment side by side. The hollow body 12 of the lightweight components 2 in Figures 1 to 8 and 14 to 17 lie with their outer peripheral surfaces 14 against the outer peripheral surfaces 14 of adjacent hollow body 12, so that the hollow body 12 are mutually supported. In the lightweight wall elements 2 in Figures 1 to 8, depending on the thickness of the wall member 10 and the

Diameter of the tubular hollow body 12 used

be provided between two opposite broad sides 22, a single row of tubular bodies 12 arranged side by side, the longitudinal central axes 8 a vertical

Span as in Figures 1 to 4, 7 and 8, or more rows, as shown in Figures 5 and 6. If the lightweight wall element 2 includes a plurality of rows of tubular hollow bodies 12, the longitudinal center axes 8 are the

Hollow body 12 in adjacent rows of hollow bodies 12 offset by the diameter of the hollow body 12 against each other, so that the rows are meshed with each other and the hollow body 12 not only parallel and perpendicular to the broad sides 22 of the lightweight element 2 are supported against each other, but also at an acute angle of 45 degrees to these directions. In addition, this is the volume of filled with foam 18

Spaces or gussets 20 between the adjacent ones

Hollow bodies 12 minimized.

The tubular hollow bodies 12 consist of several completely or partially glued together wound layers or layers of recycled paper. Each of the layers or layers may consist of helical paper strips that are continuously wound on a mandrel so that they overlap with adjacent coils or strips, adhering to one another at the points of overlap. However, the layers may also consist of wider sheets or webs wound in the circumferential direction of the hollow body 12. The recycled paper has no special quality requirements.

In lightweight construction elements 2 in the form of wall or support elements, the tubular hollow bodies 12 have a length corresponding to the height of the wall or support element 2 and are open at their opposite ends. The ratio between the outer diameter and the wall thickness of the tubular

Hollow body 12 is greater than 25: 1, preferably greater than 50: 1 and is best between about 50: 1 and about 100: 1. In the latter case, the wall thickness of

Hollow body 12 at a diameter of about 50 mm about 0.5 mm. The weight of the hollow body 12 coated with resin 10 prior to its embedding in the hard foam 18 is less than 100 g per meter length, preferably less than 50 g and most preferably less than 25 g. Resin 10 used for coating is an MDI based epoxy or polyisocyanurate reactive resin or a modified epoxy or polyisocyanurate reaction resin, both commercially available under the name

Blendur are available from Bayer MaterialScience. Depending on the composition, these resins either trimerize after addition of a catalyst by the addition of heat or without the need for a catalyst by heat alone to form a highly crosslinked thermosetting resin or plastic having excellent thermal stability. The crosslinking or curing of the resin occurs subsequent to the application of the resin 10 to the outer and inner peripheral surfaces

14, 16 of the hollow body 12, which preferably takes place immediately after the winding of the hollow body 12 made of paper.

After the trimerization or curing of the resin 10, the finished tubular hollow body 12 are introduced in the desired number and arrangement in a closable mold with a shape corresponding to the shape and dimensions of the lightweight elements 2 mold cavity, so that the open ends of the chambers 6 to the opposite Front ends of the hollow body 12 are closed by mold walls of the mold. Subsequently, the gaps or gussets 20 are foamed between the adjacent hollow bodies 12 with the hard foam 18, which consists of a PIR foam and is cured in the mold. To the introduction of the flowable foam in the mold a

Enclosing air between the foam and the hollow bodies 12, it is preferable if adjacent hollow bodies 12 are spaced from each other, as shown in Fig. 7 and 8, so that the flowable foam on one side of the lightweight elements 2 in the mold can be supplied and from there through the gaps between the adjacent hollow bodies 12 can fill the entire mold cavity. After curing, the hard foam 18 ensures a firm connection between the hollow bodies 12 embedded therein. The lightweight wall elements 2 in Figures 1, 2, 5, 6, 7 and 8 are not provided at its two opposite broad sides 22 with one or two additional cover layers, so that they essentially only from the tubular hollow bodies 12 and the hard foam 18th exist, which fills the gaps or gusset 20 between the outer periphery 14 of the adjacent hollow body 12 and in this case, the surfaces of the two broad sides 22 of the lightweight elements 2 forms. Here can be used as rigid foam with advantage a so-called integral foam, in which the hardness of the cured foam in the direction of the surfaces of the broadsides 22 increases.

The lightweight components 2 in Figures 1 and 2 and 7 and 8, each with a single row of cylindrical

tubular hollow bodies 12 having an outer diameter of 50 mm have a weight per unit area of less than 3 kg / m ² and preferably less than 2 kg / m ² . The weight per unit area of these lightweight components 2 is approximately 1.5 to 2 kg / cm ² , the weight per unit area of the untreated

Paper 0.45 to 0.55 kg / m ² , the basis weight of the

Coating used resin 10 0.55 to 0.60 kg / m ² and the basis weight of the rigid foam 18 is 0.55 to 0.65 kg / m ² , so that these three components thus deliver about one-third of the basis weight.

In contrast, the surfaces of the opposite

Broad sides 22 of the lightweight wall elements 12 in Fig. 3 and 4 and the outer periphery 26 of the lightweight support member 2 in Fig. 3 formed by a parallel to the broad sides cover layer 28 made of a fiber-reinforced resin, which serves to stiffen the

Wall elements 12 is applied. The resin may, for example, be polyurethane, in which a woven or scrim of glass fibers, synthetic fibers or carbon fibers is embedded. Alternatively or additionally, however, it is also possible to use cover layers of other materials, such as, for example, mineral fiber cover plates, which consist of one with glass fibers reinforced mixture of magnesium oxide and magnesium chloride, abut with their inner surfaces against the adjacent row of hollow bodies 12 and are bonded by the hard foam 18 with the tubular hollow bodies 12. Possibly.

can the cover layer or cover layers by screws with the from the hollow body 12 and the rigid foam 18th

existing core of the lightweight elements 2 are connected.

The rigid foam 18 is a PIR foam, ie polyurethane foam, which is crosslinked higher than the conventional polyurethane foam and is thus dimensionally stable even at higher temperatures. Due to the dimensional stability and the relatively small pore dimensions of less than 1 mm, the hard foam 18 in the production of the lightweight wall elements 2 in Figures 1 to 8 on the two opposite vertical narrow sides of each wall element 2 to a groove 30 and to a spring 32nd be formed so that adjacent wall elements 2 by means of a tongue and groove joint 30, 32 are interconnected.

In order to shoot the openings of the tubular hollow body 12 at the upper and lower ends of the lightweight wall elements 2 and to provide a flat finish, the lightweight wall elements 2 are each provided at its upper and lower ends with a closure strip 34. As best illustrated in FIGS. 9 and 10, the end strip 34 has a planar broad side 36 facing away from the ends of the hollow bodies 12. About the opposite, the ends of the hollow body 12 facing

Broadside 38 is a series of cylindrical projections 40 whose outer diameter is slightly smaller than that

Inner diameter of the tubular hollow body 12 so that they can be inserted into the open ends of the chambers 6 at the front ends of the hollow body 12 and thus improve the cohesion of the hollow body 12 at the top and bottom. In order to facilitate the insertion of the projections 40 into the opposite openings, the free ends of the projections 40 are tapered or chamfered. The end strips 34 have a length and width of the lightweight wall elements 2 corresponding length and width and can at the

Manufacture of the lightweight wall elements 2 or mounted in the same. In the latter case, the strips 34 can each be offset from the tongue and groove joints 30, 32 are attached to the joints of adjacent lightweight wall elements 2, so that they the shocks

bridge over.

It has been found by experimentation that lightweight wall elements 2 having a height of 980 mm, a width of 250 mm and a thickness of 56 mm, consisting of a series of cylindrical tubular hollow bodies 12, which at their outer and inner peripheral surfaces 14, 16 with an epoxy or polyisocyanurate

Reaction resin 10 are coated, and two cover layers 28 of mineral fiber cover plates with a thickness of 3 mm on both broad sides and a filling of rigid PIR foam 18 in the interstices or gussets 20 between the tubular hollow bodies 12 and the cover layers 28 of FIG

Direction of the longitudinal central axes 8 of the hollow body 12 a

Pressure load of more than 2.5 t can take before it comes to a fracture of the wall elements 10. In bending tests with the same lightweight wall elements 2, but with a rigid polyurethane foam 18 in the spaces 20 between the hollow bodies

12, it has been found that the wall elements 2 introduced at a distance at two points in one of the broad sides 22

Withstand lateral pressure load of 0.4 t, before it comes to a bending of the lightweight components 2.

The high carrying capacity of the lightweight elements 2 in the direction of the longitudinal center axes 8 of the tubular hollow body 12 is achieved by the coating of the outer and inner peripheral surfaces 14 and 16 of the hollow body 12 with the resin 10, after its crosslinking and curing the compressive strength of the hollow body 12 in the direction of their Longitudinal central axes 8 increased by a multiple. In the light construction elements 2 shown in cross section in FIGS. 11 to 13, the multi-chamber hollow profile 4 does not consist of one or more rows of individual interconnected hollow bodies 12, but of two or more

abutting and interconnected plates 42, each having a cross section in the form of a sine wave with alternating projections in the form of wave crests 44 and

Wells in the form of troughs 46 have. The

Wave crests 44 and the wave troughs 46 of adjacent plates 42 are offset from each other by one half-wave, so that in each case the wave crests 44 and the wave troughs 46 of the two plates 42 are opposite, with respective opposite wave crests 44 abut with their crests 50 against each other and the crests 50 together are glued. As a result, a row of juxtaposed chambers 6, which have the same cross sections, which remain the same in the direction of the longitudinal axes of the chambers 6, is formed between two adjacent plates 42. The adjacent chambers 6 are separated from each other by the adhesive 50 at the apexes 50. The

Panels 42, like the hollow profiles 6, consist of one or more paper layers and are on their chambers 6

facing inner surfaces 52 and on their side facing away from the chambers 6 outer surfaces 54 with a

Coating of the resin 10 provided as before for the

Hollow body 12 described. The resin 10 used for coating is the same as previously described. The wall thicknesses of the plates 42 and the ratio of the cross-sectional dimensions of the chambers 6 to the wall thickness of the plates 42, which the

Form the boundary walls of the chambers 6 are similar, as previously described for the hollow body 12.

The lightweight construction elements 2 in FIGS. 11 to 13 are wall elements. The wall element 2 in Fig. 11 is like the wall element 2 in Fig. 3 and 4 with two flat cover layers 28 in the form of thin mineral fiber plates or from a Provided fiber-reinforced resin, which abut against the apex 56 of the troughs 46 and are glued between them with hard foam 18 to the multi-chamber hollow section 4, wherein the hard foam 18, the gusset 20 between the chambers 6 facing away from the outer surfaces 54 of the plates 42 and the

Cover layers 28 fills.

While the multi-chamber hollow section 4 of the wall element 2 in Fig. 11 consists of two superimposed plates 4, consists of the multi-chamber hollow section 4 of the wall element 2 in Fig. 12 and 13 of a total of four superimposed plates 42 with wave-shaped cross-section, which between them limit three rows of chambers 6. The chambers 6 of adjacent rows are each in the lateral direction by half the chamber width

offset from each other, so that between the plates 42 only chambers 6, but not filled with foam 18 gusset 20 are formed. The inner plates 42 are each with the crests 50 of their peaks 44 against one of the two

adjacent plates 42 and with the vertices 56 of the

Wave troughs 46 against the other adjacent plate 42 and are glued there to the adjacent plates 42. Of the

Hard foam 18 fills the gusset 20 between the outer surfaces facing away from the chambers 6 54 of the outermost plates 42 and forms the surfaces of the two broad sides 22 of the

Wall element 2.

The lightweight construction element 2 shown in FIGS. 15 and 16 in the form of a plate-shaped ceiling or floor element consists of a plurality of short tubular hollow bodies 12 embedded in the hard foam 18 (shown only in FIG. 15). The hollow body 12 are vertically aligned and are each with its outer periphery 14 against the outer periphery 14 of adjacent hollow body 12, with which they are glued back through the hard foam 18 in the interstices or gussets 20. However, it is also possible here, the hard foam 18th

omit and the adjacent hollow body 18 with the help of Resin coating 10 on the outer peripheral surface 16 of the hollow body 12 to connect with each other. The hollow body 12th

each have the same length and are based with their opposite aligned ends against parallel flat plate-shaped cover layers 28, which close the openings of the hollow body 12 at the top and bottom of the plate-shaped ceiling or floor element 2 and also increase its flexural rigidity, especially if the Front ends of the hollow body 12 are bonded by the rigid foam 18 with the inside of the adjacent cover layers 28. The cover layers 28 may be made of any suitable material. Grooves (not shown) and springs 32 are again provided on the narrow sides of the lightweight components 2, so that adjacent elements 2 can be connected to each other by tongue and groove joints 30, 32.

Fig. 17 shows a cross section through a part of another lightweight element 2 in the form of a plate-shaped ceiling or floor element, in which the open ends of the chambers 6 are closed instead of by plate-shaped cover layers 28 by layers 60 of a fiber-reinforced synthetic resin 62. For this purpose, the hollow body 12 as in the ceiling or

Floor element 2 in Fig. 15 in a dense array

arranged staggered rows in which each

Hollow body 12 rests with its outer peripheral surface 14 against the outer peripheral surfaces 14 of six adjacent hollow bodies 12. Subsequently, the mutually adjacent hollow body 12 by means of the resin 10 existing

Coating on the outer peripheral surfaces 14 bonded together to form a rigid honeycomb structure, for example by

Heat input in an oven. Thereafter, the upper and lower ends of the chambers 6 on the broad sides of

Honeycomb structure by one or more layers 60 of the

fiber reinforced resin 62 closed by a fleece 64, fabric or scrim made of synthetic resin, glass or carbon fibers on each upturned broadside of the honeycomb structure is placed so that it completely covers the open ends of the chambers 6. Subsequently, the nonwoven fabric 64, fabric or scrim is impregnated with the curable synthetic resin 62, which is cast in a thin layer on the upper side of the nonwoven fabric 64, fabric or scrim, and through the nonwoven fabric 64, fabric or scrim to the ends of the hollow bodies 12 penetrates where it adheres during curing. After curing of the resin 62, the two ends of all the hollow body 12, which form the boundary walls of the chambers 6 of the multi-chamber hollow section 4, firmly bonded to the fiber-reinforced resin 60 and form a lightweight component 2 with high bending stiffness.

In all cases, the tubular chambers 6 enclosed by the multi-chambered hollow profile 4 can either be empty or contain a heat- or sound-insulating material, for example

Polystyrene granules 56, paper flakes or sand, as exemplified in a part of the chambers 6 in FIG. 11

shown. In the lightweight component in Fig. 9 are the

Chambers filled with hard foam 18.

Claims

claims

1. A load bearing or lightweight structural member having one or more rows of parallel chambers, each of

are surrounded tubular boundary walls, wherein the

Border walls at least partially made of paper, characterized in that the boundary walls (12, 42) of adjacent chambers (6) are interconnected and form a multi-chamber hollow profile (4) in the direction of

Longitudinal central axes (8) of the chambers (6) has a constant cross section and that the chambers (6) facing the inner surfaces (52) and the of the chambers (6)

remote outer surfaces of the boundary walls (12, 42) with a water repellent and the bending and / or

Compressive Strength of Paper Increasing Coating (10)

and / or impregnation are provided.

2. Lightweight construction element according to claim 1, characterized in that a hard foam (18) on at least one of the chambers

(6) opposite outer side of the multi-chamber hollow profile (4)

is applied.

3. Lightweight construction element according to claim 1 or 2, characterized

in that the boundary walls (12, 42) consist of less than four paper layers glued together and have a wall thickness of less than 2 mm.

4. Lightweight construction element according to one of the preceding claims, characterized in that the coating and / or

Impregnation of one in a flowable state on the

Surfaces applied and then crosslinked

thermosetting resin (10) or synthetic resin.

5. Lightweight construction element according to claim 4, characterized in that the coating and / or impregnation consists of a polyisocyanurate or epoxyisocyanurate.

6. Lightweight construction element according to one of the preceding claims, characterized in that the multi-chamber hollow profile (4) one or more rows of juxtaposed

tubular hollow bodies (12), with their outer periphery (14) against the outer periphery (14) of adjacent

tubular hollow body (12) abut and with the

adjacent hollow bodies (12) are glued by the coating and / or the hard foam (18).

7. Lightweight construction element according to one of claims 2 to 6 in the form of a wall element, characterized in that the

Multi-chamber hollow section (4) one or more rows of

elongated tubular hollow bodies (12), wherein gaps are present between adjacent hollow bodies (12), and wherein the gaps are filled with the hard foam (18), which connects the boundary walls (12, 42) of the adjacent chambers (6).

8. Lightweight construction element according to one of the preceding claims, characterized in that the multi-chamber hollow profile (4) comprises at least two plates (42) with wave or zigzag cross-section, the alternating parallel projections (44) and recesses (46), wherein the mutually facing projections (44) and / or the mutually facing recesses (46) of adjacent plates (42) are opposite, and wherein the opposite projections (44) bear against each other and are glued together.

9. Lightweight construction element according to one of the preceding claims, characterized in that the multi-chamber hollow profile (4) extends continuously over the entire height of the lightweight component (10).

10. Lightweight construction element according to one of the preceding claims, characterized in that the ratio between the

Cross-sectional dimensions of the chambers (6) and the wall thickness of the boundary walls (12, 42) is greater than 25: 1 and preferably greater than 50: 1, and is best about 100: 1.

11. Lightweight construction element according to one of claims 2 to 10,

characterized in that the hard foam (18) forms at least one surface (22) of the lightweight component (10).

12. Lightweight construction element according to one of claims 2 to 10,

characterized by an additional cover layer (28).

13. Lightweight construction element according to one of claims 2 to 12,

characterized in that at two opposite

Narrow sides a groove (30) and a spring (32) are arranged, which are molded into the hard foam (18) or milled out of the hard foam (18).

14. Lightweight construction element according to one of the preceding claims, characterized in that at least a part of the chambers (6) contains a sound and / or heat-insulating material (56) and / or is foamed with rigid foam.

15. Lightweight construction element according to one of the preceding claims in the form of a floor or ceiling plate, characterized in that the multi-chamber hollow profile (4) consists of a plurality of short tubular hollow bodies (12) whose

opposite open ends each have a flat surface

span and by at least one layer (60) of a at the ends of the hollow body (12) adhering fiber reinforced resin

(62, 64) are closed.

16. Freight or residential container with a floor, side walls and a ceiling, characterized in that the floor and / or at least part of the side walls and / or the ceiling of lightweight construction elements (2) according to one of the preceding

Claims exist.

17 railway or truck construction with a bottom, side walls and a ceiling, characterized in that the bottom and / or at least a part of the side walls and / or the ceiling of lightweight elements (2) according to one of the preceding claims.