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WO2010106558A1 - Élément de structure à plusieurs couches et en forme de planche - Google Patents

Élément de structure à plusieurs couches et en forme de planche Download PDF

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Publication number
WO2010106558A1
WO2010106558A1 PCT/IT2009/000101 IT2009000101W WO2010106558A1 WO 2010106558 A1 WO2010106558 A1 WO 2010106558A1 IT 2009000101 W IT2009000101 W IT 2009000101W WO 2010106558 A1 WO2010106558 A1 WO 2010106558A1
Authority
WO
WIPO (PCT)
Prior art keywords
core
board
structural element
confining layers
layer
Prior art date
Application number
PCT/IT2009/000101
Other languages
English (en)
Inventor
Giuseppe Liati
Original Assignee
Dipiemme Dies And Plastic Machinery S.R.L.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Dipiemme Dies And Plastic Machinery S.R.L. filed Critical Dipiemme Dies And Plastic Machinery S.R.L.
Priority to PCT/IT2009/000101 priority Critical patent/WO2010106558A1/fr
Publication of WO2010106558A1 publication Critical patent/WO2010106558A1/fr

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
    • E04C2002/3411—Dimpled spacer sheets
    • E04C2002/3416—Dimpled spacer sheets with cylindrical dimples

Definitions

  • the present invention relates to a "board-shaped structural element", i.e. a structural element capable of receiving and bearing even strong mechanical stresses (in comparison with its general sizes and the features of the materials composing it) , provided with a structure having several layers variously connected to each other.
  • a "board-shaped structural element" i.e. a structural element capable of receiving and bearing even strong mechanical stresses (in comparison with its general sizes and the features of the materials composing it) , provided with a structure having several layers variously connected to each other.
  • boars are for instance used for making particular types of outer covers for buildings which therefore do not possess a mere aesthetic value but succeed in defining self-supporting structures (or, more generally, are capable of bearing important stresses such as big weights or aerodynamic actions resulting from the effect of the wind on the building walls) .
  • the structural boards of known type have a great specific weight exactly due to their structure (that generally contemplates important thicknesses and also has high density values, above all in the central layer of polymeric material) ; this gives rise to difficulties in handling the boards during the assembly and/or transport works, and involves a corresponding and necessary increase in the sturdiness of the frameworks that have to receive said structural boards.
  • the "solid" structure of the structural boards of known type could for some applications involve a non-negligible thermal and/or acoustic conductivity, so that it is not possible (or convenient) to provide structures consisting of these boards adapted to offer satisfactory capabilities of thermal and/or acoustic environmental insulation.
  • packaging interspaces or inserts consist of two thin layers (films) of metal inside which a polymeric core is included which has a porous structure (usually consisting of a polymeric foam) ; these articles of manufacture are exactly used in sectors where shock resistant properties are required to be given to particular packages .
  • thermal and/or acoustic insulation structures consisting of outer metal films inside which there is a cellular plastic structure which is of very reduced thickness as well, so that it can offer a very low weight per square meter and excellent insulating properties.
  • the present invention aims at devising a board-shaped multi-layer structural element that can have high mechanical capacities of resistance to stresses, also of great intensity, both in its plane and out of the plane itself, with an important reduction in the specific weight of the board-shaped element itself.
  • the present invention further aims at devising a board- shaped multi-layer structural element also having important additional properties of thermal and/or acoustic insulation.
  • FIG. 1 is a diagrammatic view of a first embodiment of a production plant for manufacturing a composite board according to the present invention
  • FIG. 2 is a diagrammatic view of a second embodiment of a production plant for manufacturing a composite board according to the present invention
  • FIG. 3 is a diagrammatic view of a third embodiment of a production plant for manufacturing a composite panel in accordance with the present invention.
  • the multi-layered board according to the present invention has been identified by reference numeral 1 and usually comprises at least one, and preferably two, confining layers 2, which in turn have a face that can be exposed to an external environment and an opposite face that, on the contrary, can be defined as the "inner face” (i.e. the face directed towards the inside of the structural element itself) .
  • a core 3 which is interposed between the just mentioned confining layers 2 and therefore takes part in defining the mechanical/structural resistance capability of the structural element according to the present invention, both from the geometric/topologic point of view and from the constructional point of view.
  • this core 3 comprises a predetermined number of three- dimensional hollow structures 4 extending at least partly between the two confining layers 2.
  • the present invention is based on a structure offering high mechanical capabilities due to a more efficient exploitation of the inner volume of the board-shaped structural element; essentially this is made possible by the three-dimensional hollow structures, the arrangement and conformation of which is such selected as to give the article of manufacture the necessary performance and to simultaneously ensure an important weight saving (obtained by virtue of the lack of material in the core 3 itself) .
  • core 3 is made (also only partly, based on current requirements) of thermoplastic polymeric material; selection of the thermoplastic polymeric material may depend on a great number of factors and by way of example, the substances that can be considered as the most appropriate for this use are polyolefins (PE, PP), styrenes (PS, ABS, SAN, etc.), PET, PC, PMMA, PVC, etc. It should be noted that the polymeric materials used for making said core can be new or recycled materials or mixtures thereof.
  • the above mentioned three-dimensional hollow structures are continuously formed in core 3 (that in turn can be conveniently defined starting from a continuous laminar element) , and the volume of same can be delimited both by suitable portions of core 3 and by suitable portions of the confining layers 2; in other words, according to the present invention, it is possible for the three-dimensional hollow structures to be defined in co-operation with inner faces 2b of the confining layers 2 facing core 3 (and in particular, the substantially cylindrical structures shown by way of example in the figures have a base formed in core 3, a side surface belonging to core 3 as well and an opposite base that on the contrary is defined by a corresponding portion of an inner face 2b of one of the two confining layers 2) .
  • the geometric conformation of the three- dimensional hollow structures can be of a different nature and geometry depending on the intended applications and generally said hollow structures are provided to comprise cellular or spongy structures, bent and/or bulged portions, and/or elevations and/or depressions formed without a break in a laminar body of polymeric material; for instance, in addition to the just mentioned cylindrical structures, spherical-sector structures or prismatic structures having polygonal or mixtilinear bases and so on, can be taken into account
  • core 3 can be made of a polymeric material
  • at least one (and preferably both) of the confining layers 2 can advantageously be made of a metal material; typically, for achieving the best compromise between mechanical performance, weight control and technical-aesthetic features of the inner and outer faces of element 1, this metal material can be aluminium and/or an aluminium alloy.
  • At least one and preferably both, of the confining layers 2 have been submitted to treatments or painting operations on the respective outer faces 2a (that conveniently are opposite to the already mentioned inner faces 2b) ; in particular, these treatments and/or painting operations can comprise one or more layers of paint resisting to UV, acids and ozone, passivation-proof paints and/or coloured or transparent enamels, lacquers and others, depending on current requirements.
  • a confining layer 2 can have a thickness included between 0.25 mm and 1.5 mm, while core 3 can have a thickness included between 2 and 15 mm, preferably between 3 mm and 5 mm; generally it will be noted that the overall thickness of the board-shaped structural element 1 in accordance with the invention, in its preferred form, can vary between 3 and 8 mm.
  • the composite-board mass will generally vary between 300 g/m 2 and 3000 g/m 2 and the average mass will be of 1500 g/m 2 .
  • It is a further aim of the present invention to provide an innovatory and original method of manufacturing a board-shaped multi-layer structural element comprising the following steps: - first of all, providing at least one and preferably two semi-finished metal products, typically in the form of flat elements (to be unwound from suitable reels, for example) ; these semi-finished metal products being adapted to define the so-called "confining layers"; - co-ordinately providing a semi-finished product (through unwinding from a roller/reel or extrusion "in real time", for example) adapted to define a core 3 (this semi-finished product will be conveniently made of polymeric material) ; and - mutually coupling the confining layers 2 and core 3, in such a manner that core 3 is included between the confining layers 2.
  • the present method further comprises a step of forming a predetermined number of three- dimensional hollow structures (i.e. with suitable pits or cells) in the semi-finished product adapted to define core 3.
  • the last-mentioned operating step can be implemented shortly before the step of associating, through suitable operating tools, the confining layers with the core, or irrespective of said associating operation
  • a three-dimensional semi-finished product can be produced in advance, which product can be stored in a warehouse for a later use, for instance in the form of a pre-packaged roller or reel 400, as shown in Fig. 1) .
  • the step of forming the three-dimensional hollow, structures in core 3 can be advantageously coordinated and implemented in a machinery carrying out both formation of the three-dimensional hollow structures and association of layers 2 with core 3; for instance, with reference to the accompanying figures, it is possible to see a plant capable of carrying out the following operating sub-steps (Figs. 2 and 3) : - providing by extrusion, a thin plate or lamination in the state of plastic aggregation (this lamination will have a substantially flat surface, i.e. devoid of three-dimensional structures) ;
  • a forming surface that in the accompanying figures belongs to a roller having a plurality of recesses or cavities and in an alternative embodiment could be defined by a shaped belt or belts;
  • rollers and counter-rollers which receive the polymeric semifinished product laying thereon in its plastic- aggregation state and shape it in the most appropriate manner; in particular, shown in the figures is a main forming roller 10 disposed immediately downstream of an extrusion head 20 and provided with said recesses (as well as of suitable penetration means or suction means acting on the semifinished product in the plastic state so that it conforms in shape to said recesses), a pair of gauging counter-rollers 30 placed downstream of the forming roller 10 and finally traction means 40, preferably of the roller type, disposed downstream of the gauging counter-rollers 30.
  • a step which consists in associating at least one adhesive layer 5 between a confining layer 2 and core 3; for instance, this associating step is carried out by interposition of an adhesive film between mutually adjacent faces of a confining layer 2 and core 3 (and with reference to the figures it is possible to see the presence of rollers 50 for distributing adhesive films which through a suitable idler and coupling roller 60 move ah adhesive film close to a confining layer, after unwinding from the distributing roller 50 itself; after approaching between the confining layer and the adhesive film, a pair of convergence or coupling rollers 70 join all the above mentioned components to core 3) .
  • the adhesive film can be co-extruded with the polymeric semi-finished product in the plastic state, as shown in the drawings (where the presence of a co-extruder 100 is shown that in turn is adapted to produce a multi-layer core 300 in turn consisting of a central layer 300a of polymeric material and two outer layers 300b of adhesive material) .
  • Said heating step is carried out by suitable heating elements 80 to be operatively activated, at different points of the machinery, on the confining layers 2 and/or core 3 and/or adhesive films 5.
  • suitable heating elements 80 to be operatively activated, at different points of the machinery, on the confining layers 2 and/or core 3 and/or adhesive films 5.
  • This material designed to define core 3 of the composite board is pulled along and guided through a traction roller 40, passes through two opposite heating elements and is then coupled to the confining outer metal layers 2.
  • said layers 2 are unrolled from respective reels 90 coupled through idler rollers 60 to the suitable adhesive material 5 in the form of an adhesive film unrolled from respective reels 50.
  • two counter-rollers associate said metal layers internally provided with the layer of adhesive film 5 with the cellular polymeric material 3.
  • the adhesive material 5 too is heated by suitable means 80 also diagrammatically shown in Fig. 1.
  • the embodiment in Fig. 1 shows a discontinuous system for producing the composite board starting from a cellular plastic lamination in rolls previously produced (extruded and formed, for example) and from an adhesive film.
  • FIG. 2 shows a continuous system for producing the composite board starting from a single extruder with extrusion head 20 supplying a thermoplastic resin in the form of a lamination which is suitably formed by means of roller 10 and the shaping counter-rollers 30 so as to define said cellular structure 3.
  • This structure is pulled along by rollers 40, passes through opposite heating means and receives the outer metal layers 2 in engagement to which the respective adhesive film 5 is coupled.
  • the metal films 2 are unrolled from respective reels 90 and coupled to the adhesive film 5 by means of rollers 60.
  • the last-mentioned structures are suitably heated by heating means 80 disposed close to the coupling rollers 70 so as to define said AL-PE- AL composite board once again.
  • Fig. 3 it is therein diagrammatically shown a continuous production system starting from a pair of extruders and extrusion head 20 supplying thermoplastic resin co-extruded with the appropriate adhesive material.
  • Traction rollers 40 guide the material through a UV heating system and two counter-rollers 70 allow engagement of the metal laminations 2 unwound from the respective reels 90 with the cellular structure 3 provided with said adhesive material on the respective opposite surfaces.
  • the invention achieves many advantages.
  • the conformation of the central layer of the present structural element allows the "hollow" cells too to be utilised as insulating element from a thermal and/or acoustic point of view; in this manner the present structural element enables exploitation of functional qualities that are not present in the solid structural elements of known type.
  • the present invention allows low costs to be maintained for the structural element and does not involve particular complications or modifications and adaptations even on production machinery of known type, which is advantageous from the point of view of the overall production costs and the final price of the product.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un élément composite de structure à plusieurs couches et en forme de planche comportant deux couches encaissantes de matériau métallique et une âme en matière plastique intercalée entre les couches encaissantes ; l'âme comportant un nombre prédéterminé de structures creuses tridimensionnelles s'étendant entre les deux couches encaissantes de manière à définir une structure composite entièrement alvéolaire.
PCT/IT2009/000101 2009-03-17 2009-03-17 Élément de structure à plusieurs couches et en forme de planche WO2010106558A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/IT2009/000101 WO2010106558A1 (fr) 2009-03-17 2009-03-17 Élément de structure à plusieurs couches et en forme de planche

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/IT2009/000101 WO2010106558A1 (fr) 2009-03-17 2009-03-17 Élément de structure à plusieurs couches et en forme de planche

Publications (1)

Publication Number Publication Date
WO2010106558A1 true WO2010106558A1 (fr) 2010-09-23

Family

ID=42470579

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IT2009/000101 WO2010106558A1 (fr) 2009-03-17 2009-03-17 Élément de structure à plusieurs couches et en forme de planche

Country Status (1)

Country Link
WO (1) WO2010106558A1 (fr)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3876492A (en) * 1973-05-21 1975-04-08 Lawrence A Schott Reinforced cellular panel construction
EP1023955A1 (fr) * 1999-01-27 2000-08-02 Van der Meulen, Alfred Procédé et dispositif de fabrication d'un panneau composite
US20020028318A1 (en) * 1996-09-13 2002-03-07 Clark Brian Hall Structural dimple panel
EP1215037A1 (fr) * 2000-12-14 2002-06-19 Interplast Kunststoffe GmbH Panneau composite avec couche centrale comportant des protubérance; de préférence en matière plastique; méthode de fabrication
EP1223032A2 (fr) * 2001-01-11 2002-07-17 Bayer Aktiengesellschaft Eléments de construction allégés en forme de plaque

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3876492A (en) * 1973-05-21 1975-04-08 Lawrence A Schott Reinforced cellular panel construction
US20020028318A1 (en) * 1996-09-13 2002-03-07 Clark Brian Hall Structural dimple panel
EP1023955A1 (fr) * 1999-01-27 2000-08-02 Van der Meulen, Alfred Procédé et dispositif de fabrication d'un panneau composite
EP1215037A1 (fr) * 2000-12-14 2002-06-19 Interplast Kunststoffe GmbH Panneau composite avec couche centrale comportant des protubérance; de préférence en matière plastique; méthode de fabrication
EP1223032A2 (fr) * 2001-01-11 2002-07-17 Bayer Aktiengesellschaft Eléments de construction allégés en forme de plaque

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