WO2007099452A2 - Composite structural panel and relative method of production - Google Patents

Composite structural panel and relative method of production Download PDF

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Publication number
WO2007099452A2
WO2007099452A2 PCT/IB2007/000593 IB2007000593W WO2007099452A2 WO 2007099452 A2 WO2007099452 A2 WO 2007099452A2 IB 2007000593 W IB2007000593 W IB 2007000593W WO 2007099452 A2 WO2007099452 A2 WO 2007099452A2
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WO
WIPO (PCT)
Prior art keywords
panel
cells
panel according
filling material
stratiform element
Prior art date
Application number
PCT/IB2007/000593
Other languages
French (fr)
Other versions
WO2007099452A3 (en
Inventor
Luigi Papa
Original Assignee
Luigi Papa
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 Luigi Papa filed Critical Luigi Papa
Priority to EP07705688A priority Critical patent/EP1989043A2/en
Publication of WO2007099452A2 publication Critical patent/WO2007099452A2/en
Publication of WO2007099452A3 publication Critical patent/WO2007099452A3/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D3/00—Making articles of cellular structure, e.g. insulating board
    • B31D3/02—Making articles of cellular structure, e.g. insulating board honeycombed structures, i.e. the cells having an essentially hexagonal section
    • B31D3/0284—Laminating honeycomb cores; applying cover sheets to core edges; working core edges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D3/00—Making articles of cellular structure, e.g. insulating board
    • B31D3/02—Making articles of cellular structure, e.g. insulating board honeycombed structures, i.e. the cells having an essentially hexagonal section
    • B31D3/0292—Making articles of cellular structure, e.g. insulating board honeycombed structures, i.e. the cells having an essentially hexagonal section involving auxiliary operations, e.g. expanding, moistening, glue-applying, joining, controlling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/002—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising natural stone or artificial stone
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/005—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile
    • 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
    • E04C2/36—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 transversely-placed strip material, e.g. honeycomb panels
    • E04C2/365—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 transversely-placed strip material, e.g. honeycomb panels by honeycomb structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0242—Acrylic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0264—Polyester
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0285—Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/04—Inorganic
    • B32B2266/053—Mineral element, e.g. asbestos or mica
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B32B2419/04—Tiles for floors or walls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Definitions

  • the present invention relates to a composite structural panel, with a honeycomb cellular structure, containing a filling material designed to give at least thermal resistance, acoustic resistance and fire resistance properties.
  • the invention also relates to a method for production of the panel .
  • the technology for construction of composite structural panels already includes light panels for structural and covering purposes, produced with an aluminium inner honeycomb structure; panels designed for specific uses in the aviation and space sector, but more recently also used in sectors other than the sector of origin.
  • Such panels basically comprise a thin aluminium honeycomb central core, on the opposite faces of which plastic resins are used to glue thin aluminium sheets, or layers of fabric or even plastic laminates.
  • Such panels have very high levels of stiffness and planarity relative to their mass.
  • the density of such panels - due to the presence of a central core with empty cell structure - is very low, being between 30 and 80 kg/m 3 .
  • the panels also have very disadvantageous thermal insulation, acoustic insulation and fire resistance properties, which greatly limit their possibilities for use in application sectors other than those for which said panels were originally designed.
  • the above-mentioned negative properties are further aggravated by the reduced thermic inertia and acoustic mass possessed by such panels, to which one must also add a high capacity for emitting black smoke in the event of a fire.
  • Further application limits for said panels are also represented by some poor mechanical and structural properties, which may be attributed for example to: their relatively low load- bearing capacity; a limited capacity for withstanding pressure and/or vacuum loads,- a limited resistance to peeling or, more generally, abrasive actions on their surfaces.
  • the aim of the present invention is therefore to overcome the above-mentioned disadvantages with a composite structural panel which, although maintaining a basic structure that can be traced back to a prior art type, is able to extend the spectrum of intrinsic features of such a basic type, to combine them in various ways and to modulate them quantitatively depending on the specific requirements of the possible and different intended application sectors .
  • the invention also has for an aim to provide a method for production of the above-mentioned panel.
  • Figure 2 is an exploded perspective view of the panel of Figure 1;
  • Figure 3 is a side view of a possible alternative embodiment of the panel illustrated in the previous figures;
  • Figures 4a - 4f are diagrams of the steps of a first method for production of the panel of Figure 1;
  • Figure 5 is an exploded view of the panel of Figure 1 illustrated in a characteristic forming step belonging to an alternative method of production;
  • Figure 6 is a cross-section of a detail of the panel obtained using the alternative method illustrated in Figure 5.
  • the numeral 1 denotes as a whole a composite structural panel, basically comprising a three-dimensional stratiform element 2 with a honeycomb structure, having a plurality of open cells 3 arranged in an orderly fashion, containing a filling material 4.
  • the panel 1 also includes two covering sheets 5, glued to the three-dimensional stratiform element 2, substantially forming two opposite faces of the panel 1.
  • the panel 1 generally has a density which may substantially vary between 30 and 1500 kg/m 3 , depending on the materials used and the performance properties required of the panel 1 by the applications for which it is intended; properties which by way of example, but without limiting the scope of the invention, include: thermal resistance; acoustic resistance; and fire resistance, considered both individually and in various combinations and if necessary also with other additional performance properties.
  • the filling material 4 may be obtained in various structural forms, in particular concerning the state of aggregation of the material, and the physical/chemical compositions.
  • the filling material 4 may include: mineral aggregates expanded, agglomerated, or in the loose state; vegetable fibres; and/or amorphous silicate resins mixed with expanding agents, which are inserted in the cells
  • the filling material 4 may also be obtained using thermally expanded insulators, chosen from the families of phenolic resins, polyurethane resins, acrylic resins or polyester resins.
  • the filling material may also include expanded mineral mixtures .
  • Said covering layer 6, which can be applied to the outside of the panel 1 is designed to give the panel 1 a specific surface finish, or is even designed to give it structural and mass properties particularly useful in allowing the panel 1, for example, to have a specific inertia to some physical phenomena involved in construction or in the architectural field.
  • the panel 1 may advantageously include in its structure such a covering layer 6 which may consist of a layer of plaster; a stone material, such a marble or granite; a ceramic material; a vitreous material; a metal laminate; or even a plastic material (for example phenolic) .
  • a covering layer 6 which may consist of a layer of plaster; a stone material, such a marble or granite; a ceramic material; a vitreous material; a metal laminate; or even a plastic material (for example phenolic) .
  • the panel 1 may have technical features which allow additional advantages in terms of the capacity to withstand weather, the abrasive effects of dusts carried by the wind and/or even a chemical attack ascribable for example to the acidity of meteoric water.
  • the materials used to make the three-dimensional stratiform element 2 may be metals, such as aluminium and/or steel alloys; or even fibreglass and/or carbon fibre materials. However, it should be noticed that the three-dimensional stratiform element 2 may also be made from a chequered plate or even a net whose mesh forms the above-mentioned cells 3.
  • Figures 4a - 4f may be used to describe a method for production of a panel 1, as described above, in which the material 4 which will be used to fill the cells 3 is in a loose solid state. Said method basically comprises the steps of :
  • Figures 5 and 6 may be used to describe an alternative method of production for a panel 1 as described above, an alternative particularly advantageous in cases in which a preformed panel of filling material 4 is to be used, for example a panel of relatively friable solid material.
  • the method basically comprises the steps of:
  • This step may comprise simple cleaning to remove even the smallest particles, which could prevent effective gluing of the second sheet 5 which must cover the entire outline of the edges 8 of the cells

Landscapes

  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Architecture (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Laminated Bodies (AREA)
  • Building Environments (AREA)

Abstract

A composite structural panel (1) comprises a three- dimensional stratiform element (2) with a plurality of open cells (3) having an orderly structure; and a filling material (4) positioned in the cells (3) , and at least one covering sheet (5) glued to the three-dimensional stratiform element (2) . The panel (1) has a density which may vary from 30 to 1500 kg/m3 and has thermal resistance, acoustic resistance and fire resistance properties . The invention also relates to a method for production of the panel .

Description

Description
Composite structural panel and relative method, of production
Technical Field
The present invention relates to a composite structural panel, with a honeycomb cellular structure, containing a filling material designed to give at least thermal resistance, acoustic resistance and fire resistance properties. The invention also relates to a method for production of the panel .
Background Art
The technology for construction of composite structural panels already includes light panels for structural and covering purposes, produced with an aluminium inner honeycomb structure; panels designed for specific uses in the aviation and space sector, but more recently also used in sectors other than the sector of origin.
Such panels basically comprise a thin aluminium honeycomb central core, on the opposite faces of which plastic resins are used to glue thin aluminium sheets, or layers of fabric or even plastic laminates.
Such panels have very high levels of stiffness and planarity relative to their mass. The density of such panels - due to the presence of a central core with empty cell structure - is very low, being between 30 and 80 kg/m3.
However, despite such advantageous properties, the panels also have very disadvantageous thermal insulation, acoustic insulation and fire resistance properties, which greatly limit their possibilities for use in application sectors other than those for which said panels were originally designed.
Moreover, the above-mentioned negative properties are further aggravated by the reduced thermic inertia and acoustic mass possessed by such panels, to which one must also add a high capacity for emitting black smoke in the event of a fire. Further application limits for said panels are also represented by some poor mechanical and structural properties, which may be attributed for example to: their relatively low load- bearing capacity; a limited capacity for withstanding pressure and/or vacuum loads,- a limited resistance to peeling or, more generally, abrasive actions on their surfaces.
Other application limits are represented by their limited resistance to bad weather and chemical attacks, even of the atmospheric type.
Disclosure of the Invention
The aim of the present invention is therefore to overcome the above-mentioned disadvantages with a composite structural panel which, although maintaining a basic structure that can be traced back to a prior art type, is able to extend the spectrum of intrinsic features of such a basic type, to combine them in various ways and to modulate them quantitatively depending on the specific requirements of the possible and different intended application sectors . The invention also has for an aim to provide a method for production of the above-mentioned panel.
The technical features of the present invention, in accordance with the above aim and concerning the panel, are clear from the content of the claims herein, in particular claim 1, and from any of the claims directly or indirectly dependent on claim 1.
The technical features concerning the method of production are clear from the content of claim 19 and any of the claims directly or indirectly dependent on claim 19.
Brief Description of the Drawings
The advantages of the present invention are more apparent in the detailed description which follows, with reference to the accompanying drawings which illustrate preferred, non-limiting embodiments of the invention, in which: Figure 1 illustrates a composite structural panel as a whole;
Figure 2 is an exploded perspective view of the panel of Figure 1; Figure 3 is a side view of a possible alternative embodiment of the panel illustrated in the previous figures;
Figures 4a - 4f are diagrams of the steps of a first method for production of the panel of Figure 1; Figure 5 is an exploded view of the panel of Figure 1 illustrated in a characteristic forming step belonging to an alternative method of production;
Figure 6 is a cross-section of a detail of the panel obtained using the alternative method illustrated in Figure 5.
Detailed description of the Preferred Embodiments of the Invention
With reference to Figures 1 and 2 of the accompanying drawings, the numeral 1 denotes as a whole a composite structural panel, basically comprising a three-dimensional stratiform element 2 with a honeycomb structure, having a plurality of open cells 3 arranged in an orderly fashion, containing a filling material 4.
The panel 1 also includes two covering sheets 5, glued to the three-dimensional stratiform element 2, substantially forming two opposite faces of the panel 1. The panel 1 generally has a density which may substantially vary between 30 and 1500 kg/m3, depending on the materials used and the performance properties required of the panel 1 by the applications for which it is intended; properties which by way of example, but without limiting the scope of the invention, include: thermal resistance; acoustic resistance; and fire resistance, considered both individually and in various combinations and if necessary also with other additional performance properties.
The filling material 4 may be obtained in various structural forms, in particular concerning the state of aggregation of the material, and the physical/chemical compositions. The filling material 4 may include: mineral aggregates expanded, agglomerated, or in the loose state; vegetable fibres; and/or amorphous silicate resins mixed with expanding agents, which are inserted in the cells
3 then expanded directly in position using suitable treatments at suitable temperatures and if necessary pressures.
The filling material 4 may also be obtained using thermally expanded insulators, chosen from the families of phenolic resins, polyurethane resins, acrylic resins or polyester resins.
When insulating properties are also to be combined with suitable fire resistance properties, the filling material may also include expanded mineral mixtures . Various choices are possible for the materials used for the covering sheets 5, including thin sheets of glass cloth; metal foils, for example aluminium, steel, copper; loose-woven synthetic cloths, all of these being materials which can form both panel 1 aesthetic surface finishing elements and elements for supporting another covering layer 6 (Figure 3) . Said covering layer 6, which can be applied to the outside of the panel 1 is designed to give the panel 1 a specific surface finish, or is even designed to give it structural and mass properties particularly useful in allowing the panel 1, for example, to have a specific inertia to some physical phenomena involved in construction or in the architectural field.
It is known that, irrespective of the greater or lesser resistance to conducting heat or transmitting sound, some construction structures must have a suitable delay in the response to thermal and acoustic transients, or even total non-flammability, or in any case deferred lighting in case of fire. Therefore, with respect both to purely aesthetic aspects and to the above-mentioned functional aspects, the panel 1 may advantageously include in its structure such a covering layer 6 which may consist of a layer of plaster; a stone material, such a marble or granite; a ceramic material; a vitreous material; a metal laminate; or even a plastic material (for example phenolic) .
It should be noticed that, depending on the material used for the covering layer 6, the panel 1 may have technical features which allow additional advantages in terms of the capacity to withstand weather, the abrasive effects of dusts carried by the wind and/or even a chemical attack ascribable for example to the acidity of meteoric water.
The materials used to make the three-dimensional stratiform element 2 may be metals, such as aluminium and/or steel alloys; or even fibreglass and/or carbon fibre materials. However, it should be noticed that the three-dimensional stratiform element 2 may also be made from a chequered plate or even a net whose mesh forms the above-mentioned cells 3.
Figures 4a - 4f may be used to describe a method for production of a panel 1, as described above, in which the material 4 which will be used to fill the cells 3 is in a loose solid state. Said method basically comprises the steps of :
- [Figure 4a] gluing the three-dimensional stratiform element 2 with open cells 3 above a first covering sheet 5 for the panel 1;
- [Figure 4b] inserting the filling material 4 in the cells 3 of the three-dimensional stratiform element 2. Said step may be performed for example using a suitable filling material dispensing apparatus 10, under which the stratiform element 2 is fed, as indicated with the arrow 11;
- [Figure 4b] settling the filling material 4 in the cells 3 by supporting the stratiform element 2 on a vibrating table 12;
- [Figure 4c] mechanically compressing the material 4 in the cells 3;
- [Figure 4d] subjecting the material 4 contained in the cells to heat treatment, for example to activate the expanding agents, if it contains any; or to remove the liquids if the material 4 is in the mortar state, as happens in the case of water-based amorphous silicate resins; or to remove, in general, the moisture content; and/or to subject the material 4 to a temperature of between 250 and 4000C for example to bake it. Said heat treatment may be carried out in many different ways. In the diagram in 4d it is assumed that said treatment is carried out in a discontinuous or continuous tunnel furnace 13 , through which the panel 1 being produced passes in the semi-finished state;
- [Figure 4e] gluing a second covering sheet 5 to, and above, the three-dimensional stratiform element 2 with open cells 3, to obtain an assembly in a single body forming the panel 1 [Figure 4f] .
Figures 5 and 6 may be used to describe an alternative method of production for a panel 1 as described above, an alternative particularly advantageous in cases in which a preformed panel of filling material 4 is to be used, for example a panel of relatively friable solid material. In said case, the method basically comprises the steps of:
- gluing the three-dimensional stratiform element 2 with open cells 3 above a first covering sheet 5 for the panel 1;
- positioning the filling material 4, in the form of a preformed panel, above the cells 3 of the three-dimensional stratiform element 2; pressing the filling material 4, in the form of the preformed panel, against the three-dimensional stratiform element 2 (arrow 14) so that it is inserted in the cells 3 and cut by walls 7 delimiting the outline of the cells 3 ;
- removing the residues of filling material 4 outside the cells 3 ; and
- gluing a second covering sheet 5 to, and above, the three- dimensional stratiform element 2 with open cells 3, thus making the whole assembly a single body.
Before gluing the second covering sheet 5 it is advisable to proceed to a step of preparing the edges 8 of the cells 3. This step may comprise simple cleaning to remove even the smallest particles, which could prevent effective gluing of the second sheet 5 which must cover the entire outline of the edges 8 of the cells
3. But it may also comprise a step of mechanically upsetting the edges 8 of the cell 3 walls (Figure 6) . This would have the advantage of not only increasing the extent of the glued surface, but also gripping the filling material 4, preventing it from moving any more relative to the cell 3 walls 7, after definitive panel 1 forming.
The invention described has evident industrial applications and may be modified and adapted in several ways without thereby departing from the scope of the inventive concept. Moreover, all details of the invention may be "substituted by technically equivalent elements .

Claims

Claims
1. A composite structural panel, comprising a three-dimensional stratiform element (2) with a plurality of open cells (3) arranged in an orderly fashion; and a filling material (4) positioned in the cells (3), at least one covering sheet (5) glued to the three- dimensional stratiform element (2) ; the panel being characterised in that it has a density which may vary from 30 to 1500 kg/m3 and has thermal resistance, acoustic resistance and fire resistance properties.
2. The panel according to claim 1, characterised in that the filling material (4) includes expanded mineral aggregates.
3. The panel according to claim 1, characterised in that the filling material (4) includes vegetable fibres.
4. The panel according to claim 3 , characterised in that the filling material (4) includes amorphous silicate resins and expanding agents.
5. The panel according to any of the foregoing claims, characterised in that the filling material (4) includes thermally expanded insulators, chosen from the families of phenolic resins, polyurethane resins, acrylic resins or polyester resins.
6. The panel according to claim 1 or 2 , characterised in that the filling material (4) includes expanded mineral mixtures.
7. The panel according to any of the foregoing claims, characterised in that the one or each covering sheet (5) includes a thin sheet of glass cloth.
8. The panel according to any of the foregoing claims, characterised in that the one or each covering sheet (5) includes a metal foil .
9. The panel according to claim 8, characterised in that the foil is made of aluminium.
10. The panel according to any of the foregoing claims, characterised in that it comprises another covering layer (6) designed to give the panel (1) a specific surface finish.
11. The panel according to claim 10, characterised in that the covering layer (6) is a layer of plaster.
12. The panel according to claim 10, characterised in that the covering layer (6) consists of a stone material.
13. The panel according to claim 10, characterised in that the covering layer (6) consists of a ceramic material.
14. The panel according to claim 10, characterised in that the covering layer (6) consists of a vitreous material.
15. The panel according to claim 10, characterised in that the covering layer (6) consists of a metal laminate.
16. The panel according to claim 1, characterised in that the covering layer (6) consists of a fibreglass material.
17. The panel according to claim 1, characterised in that the covering layer (6) consists of a carbon fibre material.
18. The panel according to any of the foregoing claims, characterised in that the stratiform element (2) consists of a net with mesh forming the cells (3) .
19. A method for production of a panel, according to the foregoing claims, characterised in that it comprises the steps of: - gluing a three-dimensional stratiform element (2) with open cells (3) above a first covering sheet (5) for the panel (1); inserting the filling material (4) in the cells (3) of the three-dimensional stratiform element (2); compressing the filling material (4) contained in the cells (3); - subjecting the filling material (4) contained in the cells (3) to heat treatment; and gluing a second covering sheet (5) to, and above, the three- dimensional stratiform element (2) with open cells (3) .
20. The method according to claim 19, characterised in that the heat treatment consists of a material (4) baking treatment.
21. A method for production of a panel, according to the foregoing claims, characterised in that it comprises the steps of: - gluing a three-dimensional stratiform element (2) with open cells (3) above a first covering sheet (5) for the panel (1); positioning the filling material (4) , in the form of a preformed panel, above the cells (3) of the three-dimensional stratiform element (2) ; - pressing the filling material (4) , in the form of the preformed panel, against the three-dimensional stratiform element (2) so that it is inserted in the cells (3) and cut by walls (7) delimiting the outline of the cells (3) ; removing the residues of filling material (4) outside the cells (3); and gluing a second covering sheet (5) to, and above, the three- dimensional stratiform element (2) with open cells (3) .
22. The method according to claim 21, characterised in that it comprises, before gluing the second covering sheet (5) , a step of preparing the edges (8) of the cells (3) .
23. The method according to claim 22, characterised in that said preparation step includes cleaning to remove any particles which could prevent effective gluing of the second sheet which must cover the entire outline of the edges (8) of the cells (3) .
24. The method according to claim 21 or 22, characterised in that the preparation step comprises a step of mechanically upsetting the edges (8) of the cell (3) walls, to increase the extent of the glued surface and/or to grip the filling material (4) , preventing the latter from moving relative to the cells (3) in which it is contained.
PCT/IB2007/000593 2006-02-28 2007-02-21 Composite structural panel and relative method of production WO2007099452A2 (en)

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IT000144A ITBO20060144A1 (en) 2006-02-28 2006-02-28 COMPOSITE STRUCTURAL PANEL AND ITS MANUFACTURING METHOD.
ITBO2006A000144 2006-02-28

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WO2012046127A1 (en) 2010-10-08 2012-04-12 Iplast Holding Nv Composite plate and method for manufacturing such a composite plate
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CN106739175A (en) * 2016-12-15 2017-05-31 中航复合材料有限责任公司 A kind of aramid fiber paper honeycomb impregnation purifies tunnel equipment
CN107877936A (en) * 2017-11-07 2018-04-06 安徽星瑞包装材料有限公司 A kind of cardboard processing technology for being used to pack
CN109291518B (en) * 2018-10-25 2020-05-12 北京卫星制造厂有限公司 Curing forming tool and method for honeycomb sandwich structure
US20220203665A1 (en) * 2019-07-30 2022-06-30 Airbus Operations Gmbh Method for producing a composite component

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CN109291518B (en) * 2018-10-25 2020-05-12 北京卫星制造厂有限公司 Curing forming tool and method for honeycomb sandwich structure
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WO2007099452A3 (en) 2007-12-21
ITBO20060144A1 (en) 2007-09-01

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