ES2606167T3 - Composite construction element, in particular for manufacturing wall structures for buildings and manufacturing process - Google Patents

Abstract

Composite construction element (1) comprising: a) a body (2) made of expanded plastic material provided with opposite faces (8, 9); b) at least one reinforcement profile (10, 11), which extends transversely in said body (2) between said faces (8, 9) and incorporated in said expanded plastic material, said at least one reinforcing profile ( 10, 11) a central portion (12) having at least one fin (13, 14) which extends in a cantilever from said central portion (12) and which forms a longitudinal edge (15a, 15b) therewith; said at least one reinforcement profile (10, 11) comprises a plurality of openings (16, 17) formed in the central portion (12) of the profile (10, 11) at a predetermined distance from said longitudinal edge (15a, 15b) , characterized in that said distance is between about 1% and about 4% of the width of the central portion (12) of the profile (10, 11).

Description

5

10

fifteen

twenty

25

30

35

40

Four. Five

fifty

55

60

65

DESCRIPTION

Composite construction element, in particular for manufacturing wall structures for buildings and manufacturing process

Background of the invention

In a general aspect thereof, the present invention relates to a composite construction element, which has a preferred, but not exclusive, use for manufacturing vertical or horizontal wall structures or cladding structures for housing units, industrial warehouses and buildings in general, as well as to manufacture exterior walls or dividing bodies for trucks or similar contention structures.

The present invention relates, more specifically, to a composite construction element comprising:

a) a body made of expanded plastic material provided with opposite faces;

b) at least one reinforcement profile, which extends transversely in said body between said faces and incorporated in said expanded plastic material, said at least one reinforcing profile comprising a central portion having at least one flap extending overhang from said central portion and forming a longitudinal edge therewith.

Prior art

In the field of construction elements for manufacturing walls or containment structures in general and in particular in the field of building constructions, construction elements made of expanded plastic material, preferably expanded polystyrene, have been used for some time. in the form of sheets or sections of suitable shape and size, which have the function of thermal and acoustic insulating elements.

In several applications in the construction sector and, in order to confer appropriate self-supporting characteristics to the construction elements of this type, it has become common practice to incorporate one or more reinforcement profiles with adequate shape in the mass of expanded plastic material.

In the following description and in the subsequent claims, the term "self-supporting" is used to indicate the ability of the construction element to resist without structural plastic deformations or permanent deformations, the stresses experienced during transport and / or installation.

Therefore, for example, in European patent EP 0 459 924 a self-supporting construction element made of expanded plastic material is described, in particular a floor element, comprising a substantially parallelepiped central body in which a profile is integrated reinforcement, made of a thin metal sheet with an I-beam shape, during molding operations.

The applicant has observed, however, that although the construction elements of this class have, on the one hand, characteristics of lightness, relative ease of use and low cost, they could present, on the other hand, characteristics of self-support not always adequate and , more specifically, an insufficient resistance against bending loads near the reinforcement profile.

The applicant has observed, in fact, that when the areas of the construction element located externally with respect to its reinforcement profile (s) extending transversely in the body of the construction element are bent, cracks or fissures may form which can be propagated to such a degree that they can cause, in the worst case, the separation of entire portions of expanded plastic material.

In addition, the international patent application WO 98/16703, in the name of the same applicant, discloses a composite construction element according to the preamble of revindication 1 comprising a body made of expanded plastic material provided with opposite faces and at least a reinforcement profile that extends transversely in the body between said faces and incorporated in said expanded plastic material, the reinforcement profile comprising:

- a central portion that has at least one flap that extends in a cantilever from said central portion and that forms a longitudinal edge therewith; Y

- a plurality of openings formed in the central portion of the profile at said longitudinal edge.

Summary of the invention

The present invention therefore has the objective of providing a composite construction element made

5

10

fifteen

twenty

25

30

35

40

Four. Five

fifty

55

60

65

of expanded plastic material that is provided with improved self-supporting characteristics and, more specifically, an improved resistance to bending loads applied to the construction element during transport and / or installation.

In accordance with the invention, this problem is solved by a construction element of the type indicated above, wherein said at least one reinforcement profile comprises a plurality of openings formed in the central portion of the profile at a predetermined distance from said longitudinal edge. between about 1% and about 4% and, more preferably, between about 2% and about 3%, of the width of the central portion of the profile.

In the following description and in the subsequent claims, it is understood that the distance between the openings formed in the central portion of the profile and the longitudinal edge mentioned above, is measured from the peripheral edge of the openings and along a direction substantially perpendicular to the own longitudinal edge.

The applicant has perceived in particular that the desired improved self-support characteristics and the improved flexural strength characteristics of a composite construction element of the type indicated above can be achieved by improving the integration of the reinforcement profile in the mass of material of expanded plastic in areas that can trigger possible cracks or fissures, that is, on the longitudinal edge formed by the fin with respect to the central portion of the profile.

According to the invention, this improved integration of the reinforcement profile in the mass of expanded plastic material can be advantageously and effectively achieved by forming a plurality of openings in the central portion of the profile immediately adjacent to the longitudinal edge mentioned above.

The applicant has observed, in particular, that openings of this type can significantly increase the strength of the construction element against the flexural loads applied in the areas of the body located on the outer sides of the reinforcement profiles.

Within the framework of the invention, in which the openings are formed in the central portion of the profile near the aforementioned longitudinal edge, it is preferred and advantageous that the distance between such openings and the longitudinal edge is between about 2 mm and about 5 mm and preferably between about 3 mm and about 4 mm.

Within the framework of the invention, the shape of the openings formed near the longitudinal edge mentioned above is not critical.

The openings, in fact, can have any suitable geometric shape such as, for example, circular, polygonal (for example triangular, rectangular, square), elliptical, etc. For reasons of practicality and ease of realization, the preferred form is circular.

Preferably, in addition, the aforementioned openings have a transverse size, measured along a direction substantially perpendicular to the longitudinal axis of the central portion of the profile, between about 10 mm and about 60 mm and, even more preferably, between about 20 mm and approximately 50 mm.

In this way, it has been found that it is possible to optimize the desired improved integration of the reinforcement profile in the mass of expanded plastic material of the construction element.

Preferably, in addition, the aforementioned openings are longitudinally separated progressively and can be arranged in accordance with one or more fixed parallel to the longitudinal edge formed by the at least one fin mentioned above of the reinforcing profile.

Preferably, the reinforcement profile is made of any material having suitable structural characteristics compatible with the expanded plastic material, for example cold rolled sheet, rigid plastic materials, preferably galvanized, such as for example PVC, polyester polymers, polycarbonates , acrylonitrile-butadiene-styrene copolymers (ABS) and the like.

According to a preferred embodiment of the invention, the reinforcement profile extends transversely in the central body of the construction element along its entire thickness.

Preferably, the reinforcement profile also extends longitudinally in the central body of the construction element along substantially the entire length thereof.

According to a preferred embodiment of the invention, the reinforcement profile is provided with a pair of fins that extend perpendicularly from axially opposite sides with respect to the central portion of the profile.

5

10

fifteen

twenty

25

30

35

40

Four. Five

fifty

55

60

65

For clear reasons of simplicity of execution and to limit manufacturing costs, the reinforcement profile is preferably C-shaped, Z-shaped, Q-shaped or I-shaped, for example joining two C-shaped elements together, making fit the respective central portions with each other so that the openings formed in or in the immediate vicinity of the longitudinal edge are preferably coaxial with each other, so that they have the desired optimum structural continuity of the expanded plastic material on opposite sides of the reinforcing element.

In the latter case, the construction element is also provided with optimal support characteristics.

According to a preferred embodiment of the invention, the fin (s) of the reinforcement profile extends flush with and substantially parallel to at least one face of the body made of expanded plastic material of the construction element.

In accordance with an alternative preferred embodiment of the invention, the fin (s) of the reinforcement profile are / are fully incorporated in the expanded plastic material of the body made of expanded plastic material of the construction element.

In such a case, the fin that extends flush with the construction element performs the function of providing a suitable support surface to which possible exterior finishing elements can be fixed, while the fin (s) completely incorporated into the expanded plastic material, they perform the advantageous function of increasing the compressive strength of the reinforcement profile, increasing the self-supporting characteristics of the construction element.

Preferably, the fin (s) comprises (n) at least a first rectilinear portion, substantially perpendicular to the central portion of the reinforcement profile and possibly a second inclined end portion forming an angle of predetermined value with the first rectilinear portion. .

Preferably, this second end portion forms an angle between about 40 ° and about 120 ° and, even more preferably, equal to about 90 ° with respect to the first portion of the fin.

In the course of some tests carried out by the applicant it has been observed that such a configuration of the fin contributes to further increase the stiffness of the reinforcement profile, further increasing the characteristics of self-support and compressive strength of the element of building:

Preferably, the reinforcement profile has a thickness between about 0.4 mm and about 1.2 mm and, even more preferably, between about 0.6 mm and about 1.0 mm.

Preferably, the central portion of the reinforcement profile has, after the formation of the fins, a width between about 50 mm and about 180 mm and, even more preferably, between about 60 mm and about 120 mm, while the (s) opposite fin (s) of the profile have a width between about 15 mm and about 60 mm and, even more preferably, between about 30 mm and about 50 mm.

If the fin (s) comprise a first rectilinear portion, substantially perpendicular to the central portion of the reinforcement profile and a second inclined end portion, a first portion of this type has a width between about 15 mm and about 60 mm and, even more preferably, between about 30 mm and about 50 mm, while the second portion has a width between about 4 mm and about 10 mm and, even more preferably, between about 4 mm and about 6 mm.

In a particularly preferred embodiment, the reinforcement profile is advantageously provided with a second plurality of openings formed in the central portion thereof.

Such openings carry out the double advantageous function of lightening the reinforcement profile by improving the self-supporting characteristics of the construction element, and allowing an even more intimate integration of the reinforcement profile in the mass of expanded plastic material.

Thanks to the presence of additional openings of this type, in fact, the mass of expanded plastic material can interpenetrate with the reinforcement profile during molding, stably integrate and securely position the reinforcement profile in the central body of the element. of construction.

This intimate integration of the reinforcement profile in the mass of expanded plastic material, furthermore, helps prevent unwanted deformations or bends along the transverse direction of the reinforcement profile even if the latter essentially consists, as indicated above, in a somewhat thin metal strip.

5

10

fifteen

twenty

25

30

35

40

Four. Five

fifty

55

60

65

Preferably and in order to further increase the stiffness of the body of the construction element, these additional openings formed in the central portion of the reinforcement profile can be advantageously equipped, along the peripheral edge thereof, with a protruding lip or, as alternatively, with one or more projections distributed along the peripheral edge and angularly displaced with respect to each other, adapted to constitute an additional means of joining the reinforcement profile to the mass of expanded plastic material.

Such projections can extend either from a single side of the reinforcement profile or from opposite sides thereof.

Preferably, these additional openings are astride the longitudinal axis of the central portion of the reinforcement profile.

Preferably, the total area of all openings formed in the reinforcement profile is comprised between approximately 10% and approximately 60% of the total area of the profile, the term of the global lateral surface area of the profile being expressed with this term including that of its fin (s) (ie the area of the overall lateral surface before the fins and openings are formed).

Even more preferably, the total area of all openings formed in the reinforcement profile is comprised between about 30% and about 40% of the total area thereof.

According to the invention, also the shape of the openings of this second plurality - which can be obtained in a manner known per se, such as for example by perforation, is not critical; however, it is preferably circular for clear reasons of simplicity of realization.

Preferably, in addition, the additional openings mentioned above have a transverse size, measured along a direction substantially perpendicular to the longitudinal axis of the central portion of the profile, between about 15 mm and about 100 mm and, even more preferably, between approximately 30 mm and approximately 80 mm.

In a preferred embodiment, the openings are formed in the reinforcement profile according to three parallel rows: a first central row of circular openings, having a predominant diameter, arranged progressively along the longitudinal axis of the central portion of the reinforcement profile and two lateral rows of circular openings of smaller diameter, arranged progressively on opposite sides of the central row mentioned above and formed near the longitudinal edge formed by the fins with the central portion of the profile.

Preferably, the circular openings of the lateral rows have parallel axes and are located between two consecutive openings of the central row, as will be clearer in the following description.

Advantageously, it is thus possible to distribute in a particularly effective manner the hollow areas mentioned above in the various portions of the reinforcement profile, lightening their structure without damaging their mechanical resistance characteristics and, at the same time, obtaining an optimal integration of the reinforcement profile. in expanded plastic material.

Preferably, the passage of the openings of the central row is proportional to its size and is equal to that of the lateral rows and is between approximately 80 mm and approximately 100 mm and, even more preferably, is equal to approximately 90 mm.

Within the framework of this preferred embodiment, the openings formed at a predetermined distance from the aforementioned longitudinal edge have a global area comprised between about 15% and about 40% of the total area of all openings formed in the reinforcement profile.

According to a further preferred embodiment of the invention, the construction element may additionally comprise at least one rigid cover element associated with the reinforcement profile.

Preferably, such a covering element is a panel of plasterboard, wood, rigid plastic material or other suitable material having a decorative and / or structural function and optionally coated with ceramic tiles.

The construction elements of the invention can also achieve advantageous support characteristics, that is to say they can autonomously support possible static loads applied thereon, depending on the predetermined cover element chosen, which has structural characteristics or not.

In accordance with the invention, the construction elements described above comprising a plurality of openings formed in the central portion of the profile near the longitudinal edge formed between the at least one fin mentioned above and said central portion, can be obtained by means of a process as defined in the attached revindication 18.

5

10

fifteen

twenty

25

30

35

40

Four. Five

fifty

55

60

Advantageously, such a process can be carried out by means of shearing, profiling and molding apparatus that are conventional in themselves and known in the art.

Preferred features of this process are disclosed in dependent claims 19-27.

According to a third aspect thereof, the invention also relates to a wall structure for buildings comprising at least one construction element composed of the type described above and, preferably, comprising a plurality of construction elements of this type. arranged next to each other.

In accordance with a fourth aspect thereof, the invention finally relates to a building cladding structure comprising a plurality of composite construction elements of the type described above arranged side by side on a support structure.

Brief description of the drawings

Additional features and advantages of the invention will become more readily apparent from the description of some preferred embodiments of a construction element in accordance with the invention, given hereinafter, for illustrative and non-limiting purposes, with reference to The attached drawings.

In the drawings:

- Figure 1 shows a perspective view, in partial cross-section, a construction element that is not part of the invention;

- Figure 2 shows an enlarged perspective view of some details of the reinforcement profile incorporated in the construction element of Figure 1;

- Figures 3 and 4 show perspective views, in partial cross-section, of additional construction elements that are not part of the invention;

- Figure 5 shows a perspective on a respective enlarged scale of some details of an embodiment of the reinforcement profile incorporated in a construction element according to the invention;

- Figure 6 shows a perspective view, in partial cross-section, of an additional construction element that is not part of the invention;

- Figure 7 shows a cross-sectional view of a further embodiment of a construction element according to the invention;

- Figure 8 shows a plan view of a strip of structural material that can be used to make a construction element according to the invention;

- Figure 9 shows an enlarged plan view of a detail of the strip of Figure 8.

Detailed description of preferred embodiments

With reference to Figures 1 and 2, a composite construction element made of expanded plastic material, for example expanded polystyrene, which is not part of the present invention is generally indicated by 1.

The construction element 1 can advantageously be used to manufacture support and partition walls for buildings and comprises a body 2, in which a plurality of parallel recesses 3 are longitudinally defined.

Alternatively, the construction element 1 can also be used advantageously to manufacture bodies for trucks or similar structures.

In a manner known per se, the body 2 is also laterally equipped with opposite sides 4, 5 respectively provided with a groove 6 and, respectively, with a rib 7, which have a concordant shape, which extend longitudinally along the entire length. the length of the building element 1.

5

10

fifteen

twenty

25

30

35

40

Four. Five

fifty

55

60

65

Thus, a plurality of construction elements 1 can be stably connected to each other by means of a substantially concordant joint.

The construction element 1 is also provided with opposite, upper and respectively lower faces 8, 9, and incorporates two structurally identical reinforcement profiles 10, 11, arranged specularly with respect to a longitudinal symmetry plane YY of the construction element 1 .

Although in the illustrated example the faces 8, 9 are substantially flat, it goes without saying that their shape is not critical for the purposes of the invention; The shape of the faces, in fact, can take on any other geometric configuration useful for the intended purposes.

The reinforcement profiles 10, 11 extend longitudinally in the body 2 of the construction element 1 along substantially the entire length thereof between the lower and upper faces 8, 9 mentioned above.

Preferably, the reinforcement profiles 10 and 11 are substantially C-shaped and each comprise a central portion 12 and a pair of upper and, respectively, lower fins 13, 14, which extend in cantilever from the central portion 12 and which form axially opposite longitudinal edges 15a, 15b therewith.

Preferably, the fins 13, 14 extend from the ends of the central portion 10 substantially perpendicularly thereto.

Preferably, the reinforcement profiles 10 and 11 are obtained by suitably forming a cold-rolled galvanized steel sheet having a thickness of approximately 0.8 mm, by means of known apparatuses and as will be more apparent below.

Preferably, the reinforcement profiles 10, 11 extend transversely in the body 2 of the construction element 1 substantially along the entire thickness thereof, so that - as illustrated in Figure 1 - the fins 13, 14 they extend substantially flush with faces 8, 9 of body 2.

Preferably, the opposing fins 13, 14 comprise a first portion 13a, 14a substantially perpendicular to the central portion 12 of the reinforcing profiles 10, 11 and a second inclined end portion 13b, 14b forming an angle having a predetermined value with the First portion 13a, 14a.

Preferably, in addition, the central portion 12 of the reinforcement profiles 10, 11 has a width equal to approximately 80 mm, while the first portion 13a, 14a of the fins 13, 14 has a width equal to approximately 45 mm, while the end portion 13b, 14b has a width equal to about 5 mm and forms an angle equal to about 90 ° with respect to the first portion 13a, 14a.

Some tests carried out by the applicant, showed that a construction element reinforced with profiles shaped in this way has characteristics of self-support and compressive strength totally comparable to those of a similar construction element, reinforced with profiles that have a thickness of approximately 1.2 mm but which have no bent fins 13,14.

In this preferred embodiment, the reinforcement profiles 10, 11 comprise two rows of openings respectively indicated with reference numbers 16 and 17, substantially parallel to each other and to the longitudinal axis X-X of the central portion 12.

Preferably, the openings 16 and 17 are circular holes obtained by perforation and are longitudinally separated progressively.

In the construction element 1, the openings 16 and 17 are at least partially formed in the central portion 12 of the reinforcement profiles 10, 11 at the longitudinal edges 15a, 15b.

Such openings carry out the advantageous function of providing the expanded plastic material constituting the body 2 of the construction element 1 with a structural continuity that substantially eliminates the problems of insufficient resistance to bending loads that affect the elements of construction composed of the prior art.

More specifically, the openings 16 and 17 maximize the resistance of the construction element to bending loads applied in zones 2a, 2b of the body 2 that are located on the outer sides of the reinforcement profiles 10, 11.

The openings 16 and 17 also carry out the additional advantageous functions of lightening the reinforcing profiles 10, 11 and fixing them as firmly as possible to the mass of expanded plastic material.

5

10

fifteen

twenty

25

30

35

40

Four. Five

fifty

55

60

65

In the construction element 1 illustrated in Figures 1 and 2, the openings 16 and 17 are astride the respective longitudinal edges 15a, 15b and comprise a first portion 16a, 17a extending in the fins 13, 14 and a second portion 16b, 17b extending in the central portion 12 of the reinforcement profiles 10, 11.

Preferably, the first portion 16a, 17a of the openings 16, 17 in this case has an area smaller than the area of the second portion 16b, 17b.

More specifically, the area of the first portion 16a, 17a mentioned above of the openings 16, 17 is equal to about 30% of the total area of the openings themselves.

In the construction element 1 illustrated in Figures 1 and 2, the reinforcement profiles 10, 11 are advantageously provided with an additional plurality of openings 18, preferably circular holes obtained by perforation, formed in the central portion 12.

The additional openings 18 perform both the doubly advantageous function of lightening the reinforcing profiles 10, 11 and fixing them as firmly as possible to the mass of expanded plastic material as well as the advantageous function of contributing to increase the strength of the element of construction 1 to bending loads.

In the construction element 1 illustrated in Figures 1 and 2, therefore, the reinforcement profiles 10, 11 are provided with three parallel rows of openings: a first central row that includes the circular openings 18, which has a predominant diameter , progressively arranged astride the longitudinal axis XX of the central portion 12 of the profiles, and two lateral rows that include the circular openings 16, 17 having a smaller diameter, located on opposite sides of the central row mentioned above.

Preferably, the circular openings 16, 17 of the lateral rows have parallel axes and are located between two consecutive openings 18 of the central row, as illustrated in Figure 1.

Preferably, the openings 18 have a diameter equal to approximately 60 mm, while the openings 16 and 17 have a diameter equal to approximately 30 mm, while the passage of all the rows of holes 1618 is equal to approximately 90 mm.

The aforementioned openings 16-18, therefore, define a perforated area or a hollow area equal to approximately 30% of the total area of the reinforcement profiles 10 and 11, with the expression "total area" expressing the area of the overall lateral surface of the profiles (central portion 12 and fins 13, 14).

Preferably, in addition, the openings 16, 17 have a global area equal to about 30% of the total area of all openings 16-18 formed in the reinforcement profiles 10.11.

Advantageously, the construction element 1 described above can achieve the desired improved self-supporting characteristics conferred thereto by the reinforcement profiles 10, 11 properly integrated without any substantial interruption in the structural continuity of the mass of expanded plastic material guaranteed by the openings 16.17.

In a further preferred embodiment, the construction element 1 may further comprise a rigid cover element, such as for example a plasterboard panel, indicated with reference number 19 and illustrated with dotted lines and dashed lines in the figures, associated with one or both fins 13, 14 of the reinforcement profiles 10, 11.

Preferably, the construction element 1 comprises a pair of panels 19 associated with the fins 13, 14 of the reinforcement profiles 10, 11 on the faces 8, 9 of the construction element 1 in a manner known per se, for example by means of a series of screws or nails that are not shown.

In this case, the construction element 1 can achieve advantageous support characteristics, that is, it can autonomously support possible static loads applied thereon.

Additional embodiments of the construction element 1 are schematically illustrated in Figures 3-7.

In the following description and in such figures, the components of the construction element 1 structurally and functionally equivalent to those illustrated with reference to the previous embodiment will be indicated with the same reference numbers and will not be described further.

In accordance with the embodiment illustrated in Figure 3 which is not part of the present invention, the reinforcement profiles 10, 11 of the construction element 1, fins included, are fully incorporated in the expanded plastic material of the body 2.

5

10

fifteen

twenty

25

30

35

40

Four. Five

fifty

55

60

65

Advantageously, the fins 16, 17 carry out in this case the additional advantageous function of increasing the compressive strength of the reinforcement profiles 10, 11, increasing the self-supporting characteristics of the construction element 1.

In accordance with the embodiment of the invention illustrated in Figure 4 which is not part of the present invention, the openings 16, 17 formed in the central portion 12 of the reinforcement profiles 10, 11 - showing only the upper part thereof in such a figure for clear reasons of symmetry - they are substantially tangent to the longitudinal edges 15a, 15b.

The applicant, in fact, has observed that also with this construction the desired improvement in the flexural strength characteristics of the construction element 1 can be advantageously achieved.

According to the embodiment of the invention illustrated in Figure 5, the openings 16, 17 are formed in the central portion 12 of the reinforcement profiles 10, 11 - only showing the upper part thereof in this case as well as in a figure of this type for clear reasons of symmetry - at a predetermined distance d from the longitudinal edges 15a, 15b between about 1% and about 4% of the width of the central portion 12 of the profiles themselves.

Preferably, such a distance d is equal to about 3 mm.

The applicant has observed that with this construction the desired improvement in the flexural load resistance characteristics of the construction element 1 can be advantageously achieved.

According to the embodiment of the construction element 1 which is not part of the invention illustrated in Figure 6, the reinforcement profiles 10, 11 of the construction element 1 are substantially Z-shaped and each comprise a pair of lower fins and , respectively, upper 16, 17 extending perpendicularly from the ends of the central portion 12 from opposite sides thereof.

Preferably, the reinforcement profiles 10, 11 extend transversely in the body 2 of the construction element 1 substantially throughout its thickness, such that, - as illustrated in Figure 6 - the fins 13, 14 extend substantially to flush with opposite faces 8, 9 of body 2.

In the same way as the embodiments illustrated hereinbefore, the fins 13, 14 also comprise in this case a first rectilinear portion 13a, 14a substantially perpendicular to the central portion 12 of the reinforcing profiles 10, 11 and a second portion of inclined end 13b, 14b forming an angle of predetermined value with the first portion 13a, 14a.

Preferably, the first portion 13a, 14a of the fins 13, 14 has a width equal to approximately 45 mm, while the end portion 13b, 14b has a width equal to approximately 5 mm and forms an angle equal to approximately 90 ° with Regarding the first portion.

Advantageously, the characteristics of resistance to bending loads of the construction element 1 are further improved.

In accordance with the embodiment of the invention illustrated in Figure 7, the substantially Z-shaped reinforcing profiles 10, 11 of the construction element 1 are fully incorporated into the expanded plastic material of the body 2.

Advantageously, the fins 13, 14 also carry out in this case the additional advantageous function of increasing the compressive strength of the reinforcement profiles 10, 11, increasing the self-supporting characteristics of the construction element 1.

With reference to the embodiments of the construction element 1 described above and to Figures 8 and 9, a preferred embodiment of a process for example for manufacturing the construction element 1 illustrated in Figures 1 and 2 will not be described.

In a preliminary stage, carried out in a manner known per se, a strip 20 of rigid structural material, for example galvanized steel, provided to form the reinforcement profiles 10, 11 is provided.

Advantageously, the strip 20 has a predetermined thickness and width for example equal to about 0.8 mm and about 180 mm.

The strip 20 comprises a central portion 21 and a pair of lateral portions 22, 23 extending from axially opposite sides with respect to the central portion 21, portions that are provided to constitute the central portion 12 and, respectively, the fins 13, 14 of the reinforcement profiles 10, 11 that are manufactured, as will be clearer later in this document.

5

10

fifteen

twenty

25

30

35

40

Four. Five

fifty

55

60

65

At a later stage, the process comprises the formation in the strip 20 of the openings 16 and 17 which extend at least partially in the central portion 21 on the opposite side portions 22 and 23.

Preferably, the openings 16 and 17 are circular and form a pair of parallel rows that extend in the longitudinal direction along the strip 20.

Preferably, in addition, the additional row including the openings 18, also preferably circular, is also formed simultaneously astride the longitudinal axis X-X of the strip 20.

An operation of this type of openings 16-18 can be carried out in a conventional manner known per se, for example by drilling.

In an alternative embodiment of the process, it is also possible to manufacture the construction element 1 from a previously perforated strip wound on a reel and located upstream of the bending station.

At a later stage, the strip 20 bends in a manner known per se - for example by means of a profiler - along a pair of longitudinal bending lines 24, 25 substantially parallel to each other and intersecting the openings 16 and 17.

In this way, the reinforcement profiles 10, 11 are formed comprising the central portion 12 mentioned above and the fins 13, 14 which extend in cantilever therefrom the plane of arrangement of the strip 20 below or above and forming the opposite longitudinal edges 15a and 15b.

Preferably, the bending step is carried out in such a way that the fins 16 and 17 form an angle of approximately 90 ° with respect to the layout plane of the central portion 21 of the strip 20.

Preferably, the bending lines 24, 25 extend parallel to the row of openings 16, 17 at a distance d 'from the longitudinal axis ZZ of the row between about 15% and about 50% of the maximum transverse size D of the aforementioned openings (in this case equal to the diameter of the circular openings) measured along a direction substantially perpendicular to the longitudinal axis XX of the central portion 21 of the strip 20.

In the case of the construction element 1 illustrated in Figures 1 and 2, the distance d 'is preferably equal to approximately 5 mm.

It goes without saying that alternative embodiments of the construction element 1, in which the openings 16 and 17 are substantially tangent to the longitudinal edges 15a and 15b or, according to the invention are located in their immediate vicinity, can be produced by bending the strip 20 along bending lines 24, 25 that are properly positioned with respect to the aforementioned openings.

In the case where it is desired to place the openings 16 and 17 in the immediate vicinity of the longitudinal edges 15a and 15b of the reinforcement profiles 10, 11, it is preferable and advantageous that the distance between the longitudinal bending lines 24 and 25 and the openings 16, 17 are between about 1% and about 4% of the width of the central portion 12 of the resulting profile, in this case coinciding with the width of the central portion 21 of the strip 20.

In the case of the reinforcement profile illustrated in Figure 5, the distance d is preferably equal to about 3 mm.

Preferably, in addition, the bending step of the strip 20 can be carried out, even using known apparatus itself, so that the fins 13, 14 are further bent at approximately 90 ° to obtain the first portion 13a, 14a mentioned above substantially perpendicular to the central portion 21 of the strip 20 and the second inclined end portion 13b, 14b forming an angle of predetermined value with respect to the first portion 13a, 14a.

In an alternative preferred embodiment, the stage of bending of the strip 20 can be carried out, using even known devices, so that the fins 13, 14 respectively are bent further above and below the plane of arrangement of the strip 20 itself, to obtain the construction element structures 1 illustrated in Figures 6 and 7.

At a later stage, the reinforcement profiles 10, 11 thus obtained are placed on a molding surface of an apparatus suitable for molding plastic material that is conventional in itself and is not shown.

Once the placement of the reinforcement profiles 10, 11 on the molding surface has taken place, the steps of feeding granules of expandable plastic material into said space and submitting the granules of plastic material are then carried out on the surface of expansion molding and subsequent welding, in order

of forming the body 2 of the construction element 1 incorporating reinforcement profiles 10, 11.

In a preferred embodiment, the step of forming the body 2 made of expanded plastic material is carried out in such a way that the fins 13, 14 of the reinforcement profiles 10, 11 extend flush with and substantially 5 parallel to the faces 8, 9 of the body 2 itself, to obtain the construction element structures 1 illustrated in figures 1,2 and 6.

In an alternative preferred embodiment, the step of forming the body 2 made of expanded plastic material can be carried out so that the fins 13, 14 of the reinforcement profiles 10, 11 are fully incorporated in the body 2 itself, to obtain the construction element structures 1 illustrated in figures 3 and 7.

If the construction of the construction element 1 is carried out continuously, the process finally comprises a final stage, also carried out with known devices, in which the body 2 is cut to a size so that Obtain a construction element that has the desired length.

Obviously, one skilled in the art can introduce changes and variants in the invention described above in order to meet specific and eventual application requirements, changes and variants that in any case fall within the scope of protection as defined by the following claims. .

twenty

Claims (29)

5 10 fifteen twenty 25 30 35 40 Four. Five fifty 55 60 65 1. Composite construction element (1) comprising: a) a body (2) made of expanded plastic material provided with opposite faces (8, 9); b) at least one reinforcement profile (10, 11), which extends transversely in said body (2) between said faces (8, 9) and incorporated in said expanded plastic material, said at least one reinforcing profile ( 10, 11) a central portion (12) having at least one fin (13, 14) which extends in a cantilever from said central portion (12) and which forms a longitudinal edge (15a, 15b) therewith; said at least one reinforcement profile (10, 11) comprises a plurality of openings (16, 17) formed in the central portion (12) of the profile (10, 11) at a predetermined distance from said longitudinal edge (15a, 15b) , characterized in that said distance is between about 1% and about 4% of the width of the central portion (12) of the profile (10, 11). 2. Composite construction element (1) according to claim 1, wherein said openings (16, 17) have a transverse size, measured along a direction substantially perpendicular to the longitudinal axis (XX) of the central portion (12) of the profile (10, 11), between approximately 10 mm and approximately 60 mm. 3. Composite construction element (1) according to claim 1, wherein said openings (16, 17) are longitudinally separated progressively. 4. Composite construction element (1) according to claim 1, wherein said reinforcement profile (10, 11) extends transversely in the body (2) of the construction element (1) along the entire thickness of it. 5. Composite construction element (1) according to claims 1 or 4, wherein said reinforcing profile (10, 11) extends longitudinally in said body (2) along substantially the entire length thereof. 6. Composite construction element (1) according to claims 1, 4 or 5, wherein said reinforcement profile (10, 11) comprises a pair of fins (13, 14) extending from opposite sides of the central portion (12) of the reinforcement profile (10, 11). 7. Composite construction element (1) according to claim 6, wherein said reinforcing profile (10, 11) is substantially C-shaped or Z-shaped. 8. Composite construction element (1) according to claims 1, 5 or 6, wherein said at least one fin (13, 14) of the reinforcing profile (10, 11) extends flush with and substantially in parallel to at least one face (8, 9) of said body (2) made of expanded plastic material. 9. Composite construction element (1) according to claims 1, 5 or 6, wherein said at least one fin (13, 14) of the reinforcement profile (10, 11) is completely incorporated in the material of expanded plastic of the body (2) of the construction element (1). 10. Composite construction element (1) according to claim 1, wherein said at least one fin (13, 14) comprises at least a first rectilinear portion (13a, 14a) substantially perpendicular to the central portion (12) of the reinforcement profile (10, 11). 11. Composite construction element (1) according to claim 1, wherein said reinforcement profile (10, 11) has a thickness between about 0.4 mm and about 1.2 mm. 12. Composite construction element (1) according to claim 1, wherein said reinforcing profile (10, 11) further comprises a second plurality of openings (18) formed in said central portion (12) of the profile (10) , eleven). 13. Composite construction element (1) according to claim 12, wherein the total area of all openings (16, 17, 18) formed in the reinforcement profile (10, 11) is between approximately 10 % and approximately 60% of the total area of the reinforcement profile (10, 11). 14. Composite construction element (1) according to claim 12, wherein the openings (18) of said second plurality have a transverse size, measured along a direction substantially perpendicular to the longitudinal axis (XX) of the central portion (12) of the profile (10.11), between approximately 15 mm and approximately 100 mm. 5 10 fifteen twenty 25 30 35 40 Four. Five fifty 55 60 65 15. Composite construction element (1) according to claim 12, wherein the openings (16, 17) formed in the central portion (12) of the profile (10, 11) on said longitudinal edge (15a, 15b) or at a predetermined distance from said longitudinal edge (15a, 15b), they have a global area comprised between approximately 15% and approximately 40% of the total area of all openings (16, 17, 18) formed in the reinforcement profile ( 10.11). 16. Composite construction element (1) according to claim 1, further comprising at least one rigid cover element (19) associated with said reinforcement profile (10, 11). 17. Composite construction element (1) according to claim 16, wherein said rigid cover element (19) is a panel of plasterboard, wood, rigid plastic material or other suitable material, optionally coated with ceramic tiles . 18. Process for the manufacture of a composite construction element (1) according to claim 1, comprising the steps of: a) providing a strip (20) of a rigid material having a predetermined thickness and width, said strip (20) having a central portion (21) and extending a pair of opposite side portions (22, 23) from opposite sides of said central portion (21); b) forming in said strip (20) a plurality of openings (16, 17) extending in said central portion (21) near at least one of said opposite side portion (22, 23); c) folding said strip (20) along at least one longitudinal bending line (24, 25) that extends a predetermined distance from said plurality of openings (16, 17), in such a way that a reinforcement profile (10, 11) comprising a central portion (12) having at least one fin (13, 14) extending overhang from said central portion (12) and forming a longitudinal edge (15a, 15b) therewith, the distance between said bending line (24, 25) and said plurality of openings (16, 17) between about 1% and about 4% of the width of the central portion (12) of the resulting profile (10, 11); d) placing the reinforcement profile (10, 11) thus obtained on a molding surface of an apparatus suitable for molding plastic material; e) feeding granules of expandable plastic material to said molding surface; f) expanding and then joining the plastic granules on said molding surface, in order to form a body (2) made of expanded plastic material provided with opposite faces (8, 9) incorporating said reinforcement profile (10, 11 ). 19. Process according to claim 18, wherein said openings (16, 17) form at least one row extending in the longitudinal direction along said strip (20). 20. Process according to claim 19, wherein said bending line (24, 25) extends parallel to the row of openings (16, 17) at a distance from the longitudinal axis (ZZ) of the row comprised between about 15% and about 50% of the maximum transverse size of said openings (16, 17) measured along a direction substantially perpendicular to said longitudinal axis (ZZ). 21. Process according to claim 18, wherein said bending stage c) is carried out in such a way that said at least one fin (13, 14) forms an angle of approximately 90 ° with respect to the layout plane of the central portion (21) of said strip (20). 22. Process according to claim 18, wherein said bending stage c) is carried out by bending said strip (20) along two longitudinal bending lines (24, 25) substantially parallel to each other with the in order to form a pair of fins (13, 14) that extend in cantilever from axially opposite sides with respect to the central portion (21) of the strip (20). 23. Process according to claim 22, wherein said fins (13, 14) are cantilevered both above or both below the plane of arrangement of the strip (20). 24. Process according to claim 22, wherein said fins (13, 14) extend in cantilever respectively above and below the plane of arrangement of the strip (20). 25. Process according to claim 18, further comprising the step of forming a second plurality of openings (18) in the central portion (21) of the strip (20). 26. Process according to claim 18, wherein said step f) is carried out in such a way that said at least one fin (13, 14) of the reinforcement profile (10, 11) extends flush with and substantially parallel to at least one face (8, 9) of said body (2) made of expanded plastic material. 27. Process according to claim 18, wherein said step f) is carried out in such a way that said at less a fin (13, 14) of the reinforcement profile (10, 11) is completely incorporated in said body (2) made of expanded plastic material. 28. Wall structure comprising at least one composite building element (1) according to any one of claims 1-17. 29. A building lining structure comprising a plurality of composite construction elements (1) according to any one of claims 1-17 arranged side by side on a support structure. 10