MANUFACTURING"

FIELD OF APPLICATION

The present invention relates to a construction module and to the related method of manufacturing said construction module.

In particular, according to the present invention a construction module, called also grating, is manufactured with a composite material comprising reinforcing fibres such as, merely by way of example, glass, carbon, boron, basalt or aramid fibres, immersed in a polymerized binding resin.

The present invention is applied, even though not exclusively, for the creation of waikable surfaces such as walkways, stairs, window well covers, fences or gates, or for the creation of structural elements such as formworks, floodgates, floors.

STATE OF THE ART

Construction modules made of composite material, called also pultruded gratings, reinforced with fibres and obtained through composition of pultruded profiles, are known.

Molded gratings obtained through specific molds, to obtain construction modules, also of great dimensions, with different types of meshes, different height or thickness of the bars, and different height of the manufactured product, are also known and more widespread.

In the field of gratings made with polymer resins, it is known to increase their resistance to stresses through the embedding of fibres, for instance glass, carbon or aramid fibres, commercially also known as evlar® fibres.

Known gratings are usually composed of a series of first oblong elements and of a series of second oblong elements formed in a single body in relation to one another so as to define a plane reticular body.

The first oblong elements are placed parallel to each other along a first direction, while the second oblong elements are placed parallel to each other along a second direction, orthogonal to the first direction. In this way, the reticular plane body that is achieved is provided with a plurality of openings or cavities and defines a first surface, waikable in use, and a second surface, opposite said first surface.

Said plane reticular body can have a height, that is the dimension evaluated in a direction orthogonal to the plane development of the plane reticular body, set depending on the mechanical resistance desired for the specific application of the construction module. The height of the plane reticular body can be comprised, for instance, between 15 mm and 60 mm.

It is also known, however, that the bigger the height of plane reticular body, the bigger the weight and the amount of material used to manufacture the construction module. This determines a consequent increase of the overall cost of the construction module.

To try to limit said drawback, it is also known to make the above-mentioned plane reticular body having a reduced thickness, for instance comprised between 6 mm and 12 mm, and to form, in a single piece with said plane body, a plurality of oblong portions projecting orthogonally with respect to the second surface of the plane body. In particular, the oblong portions usually comprise first oblong portions, placed parallel to one another, and second oblong portions, placed parallel to one another and transverse to the first oblong portions.

In addition to that, the first oblong portions and the second oblong portions are generally distanced from one another by a distance that is greater than the distance provided between the first oblong elements or between the second oblong elements of the plane body.

Each first oblong portion usually projects in continuation of one of the first oblong elements, while each second oblong portion projects in continuation of one of the second oblong elements.

The first oblong portions and the second oblong portions together define a grid with a reticular mesh of bigger dimensions, generally a whole multiple, with respect to those of the grid of the plane body.

However, even though that solution of embodiment reduces the weight and the overall cost of the construction module manufactured, it has problems of structural resistance.

It is noticed, in fact, that when this construction module is subjected to stresses, for example to the weight of a person treading on the walkable surface, the first oblong portions and the second oblong portions are subjected to quite considerable bends and deformations.

It is, therefore, an object of the present invention to achieve a construction module with a structural resistance that is higher than that of the construction modules of the known prior art.

It is also an object of the present invention to achieve a construction module that has a reduced weight, i.e. a weight lower than that of similar molded gratings that are able to withstand the same stresses.

It is likewise an object of the present invention to achieve a construction module that is economical.

It is also an object of the present invention to provide a method for manufacturing a construction module that is simple and rapid.

To overcome the shortcomings of the prior art and to achieve these as well as other objects and advantages, the Applicant studied, experimented and realized the present invention.

EXPOSITION OF THE INVENTION

The present invention is set forth and characterized in the independent claims.

The dependent claims describe other characteristics of the invention or variants to the main idea of solution.

In accordance with the above-mentioned objects, a construction module according to the present invention is manufactured in a fibre-reinforced composite material and comprises a first component defined by:

- a first plane reticular body defined by oblong elements crossing each other, and having a first surface, walkable in use, and a second surface opposite said first surface, and

- a plurality of projecting portions integrally associated with the first body and projecting orthogonally with respect to the second surface.

In accordance with an aspect of the present invention, the construction module comprises a second plane component, parallel to the first component and integrally associated with the projecting portions.

The second plane component, in fact, provides the first component with a structural reinforcement and prevents the projecting portions from spreading apart from one another because of the stresses acting on the first surface of the first plane reticular body. Here and in the following description, except for the cases expressly indicated, the expression first component and second component shall not be restricted to a solution where the first component and the second component shall be meant as separate bodies and subsequently joined together, but said first component and second component shall be meant as parts, or portions that, on their whole, define the entire construction module.

So, for instance, a part or portion of the first component can be formed in a single body with a part or portion of the second component, or vice versa.

Additionally, the particular conformation of the construction module as defined above is particularly light as compared to similar construction modules, of the known prior art, having the same mechanical resistance.

Forms of embodiment of the present invention refer also to the process for manufacturing a construction module as defined above.

ILLUSTRATION OF THE DRAWINGS

These and other features of the present invention will be clear from the following description of forms of embodiment, provided by way of a non- limiting example, with reference to the annexed drawings, in which:

- figure 1 is an exploded top view of a construction module in accordance with a possible form of embodiment of the present invention;

- figure 2 is an exploded view of the construction module of figure 1 in an upside-down position;

- figure 3 is a lateral sectional view of the construction module of figure 1 ;

- figures 4 - 8 illustrate variants of embodiment of figure 3.

To facilitate understanding, identical reference numbers have been used, where possible, to identify identical common elements in the figures. It shall be understood that elements and features of a form of embodiment can be suitably incorporated in other forms of embodiment without further clarifications.

DESCRIPTION OF FORMS OF EMBODIMENT

Reference will be now made in detail to the various forms of embodiment of the invention, of which one or more examples are illustrated in the appended drawings. Each example is provided as an illustration of the invention and is not meant as a limitation of the same. For example, the features illustrated or described as being part of a form of embodiment can be adopted on, or in conjunction with, other forms of embodiment to produce a further form of embodiment. It is understood that the present invention comprises said modifications and variants.

Before describing the forms of embodiment, it is further clarified that the present description is not limited, in its application, to the details of construction and arrangement of the components as described in the following description using the appended figures. The present description can provide other forms of embodiment and be realized or put into practice in other different manners. Furthermore, it is made clear that the phraseology and terminology used here have descriptive purposes and shall not be considered as limitative.

With reference to the appended drawings, forms of embodiment of the present invention refer to a construction module designated in its entirety by the reference number 10.

The construction module 10, in accordance with the present invention, is manufactured in a fibre-reinforced composite material.

Here, as well as in the following description and in the claims, with the expression fibre-reinforced polymer material, or composite material, a material having a mainly polymer base with integrated fibres is meant.

The fibres can be selected from a group comprising at least one among glass fibres, boron fibres, carbon fibres, aramid fibres, basalt fibres.

The polymer base used can be selected from a group comprising at least one among polyester resins, phenolic resins, epoxy resins, vinyl esters, or the like.

The construction module 10 in accordance with the present invention comprises at least a first structural component 21 that is defined by a first plane reticular body 1 1 and by a plurality of portions 17, 18 projecting from the first body 1 1 , and as defined below.

The first body 1 1 , in turn, is defined by oblong elements 12, 13 crossing each other and has a first surface 14, walkable in use, and a second surface 15 opposite the first surface 14.

In accordance with a possible solution of embodiment, the oblong elements can comprise first oblong elements 12, placed parallel to one another, and second oblong elements 13, placed parallel to one another and transverse to the first oblong elements 12. Additionally, the first oblong elements 12 and the second oblong elements 13 are made in a single body in relation to one another.

The crossed arrangement of the first oblong elements 12 and of the second oblong elements 13 allows to define openings 16 that give the first body 1 1 a reticular structure.

The openings 16 can have a rectangular or square shape if the first oblong elements 12 and the second oblong elements 13 are substantially orthogonal to each other.

Simply by way of an example, it can be provided that the reticular mesh defined by the first oblong elements 12 and by the second oblong elements 13 has a square shape with a side of the square comprised between 8 mm and 50 mm, preferably between 19 mm and 50 mm.

According to a variant, the first oblong elements 12 and the second oblong elements 13 can have a rhomboid shape, or of a parallelogram, if they cross each other at an angle other than 90°.

In accordance with possible solutions of embodiment, the first oblong elements 12 and the second oblong elements 13 can have a shape of the cross section that is trapezoid, or substantially rectangular.

In accordance with possible solutions of embodiment, the first oblong elements 12 and the second oblong elements 13 can have, on the side directed towards the first surface 14, a concave surface, of the meniscus type, having a non-slip or non-skid function.

In accordance with possible variants of embodiment, the first surface 14 of the first body 11 is provided with a plurality of surface irregularities to provide the construction module 10 with non-slip and/or non-skid properties.

The surface irregularities can be defined by knurls or by particles, such as quartz, or sand, integrated in the first surface 14.

The projecting portions 17, 18 of the first component 21 are integrally associated with the first body 1 1 and project orthogonally from the second surface 15 of the first body 1 1.

The projecting portions 17, 18 can be formed in a single piece with the first body 1 1 as illustrated for example in the forms of embodiment of the figures 1 -4 and 6 and 7. Simply by way of example, it can be provided that the projecting portions 17, 18 are made during the step of manufacturing the first body 1 1, for example in the same manufacturing mold.

In accordance with possible variants of embodiment, it can be provided that the projecting portions 17, 18 are integrally connected to the first body 11 "freshly", i.e. before the polymer resin of the latter has cross-linked for instance as illustrated in figure 8. For example, it can be provided that the projecting portions 17, 18 were manufactured previously, possibly associated with a further component as described below, and that during the operations of manufacturing the first body 1 1 said projecting portions 17, 18 are integrally associated during the cross-linking of the resin of the first body 1 1 , directly in the manufacturing mold of the latter.

In particular, it can be provided that for the manufacturing of the first body 1 1, the fibers and the resin are deposited in a mold according to a predefined pattern and that, before the resin is polymerized, at least the projecting portions 17, 18 are associated.

According to possible variants of embodiment, the projecting portions 17, 18 can be connected with the first body 1 1 by means of gluing (figure 5).

Gluing can be effected by means of the use for example of polyurethane or silicone glues, or for example of epoxy resins, polyesters, or vinyl esters, etc.

Said solution of embodiment allows to manufacture in a separate manner the first body 1 1 and the projecting portions 17, 18, and subsequently to integrally connect said components to one another.

In accordance with a possible variant of embodiment, not illustrated, the projecting portions are placed parallel to one another.

In accordance with possible solutions of embodiment of the present invention, the above-mentioned projecting portions can comprise first oblong portions 17, placed parallel to one another, and second oblong portions 18, placed parallel to one another and transverse to the first oblong portions 17.

In particular, with the term oblong portions it is meant that they have a dimension of their length that is much greater than the dimensions of the cross section.

In accordance with a possible aspect of the present invention, the first oblong portions 17 and the second oblong portions 18 are formed in a single body in relation to one another to define a grid having a mesh of bigger dimensions with respect to those of the grid defined by the first body 11.

Merely by way of example, it can be provided that the grid defined by the first oblong portions 17 and by the second oblong portions 18 has dimensions that amount at least to the double, or in general to a multiple, of the dimensions of the grid defined by the first body 1 1.

According to a possible solution of embodiment, the first oblong elements 12 or the second oblong elements 13 are reciprocally distanced from one another by a first distance Dl . The first oblong portions 17 or the second oblong portions 18 are reciprocally distanced from one another by a second distance D2 that is greater than the first distance Dl .

Only by way of example, the above-mentioned second distance D2 can be a multiple, for example 2, 3 or 4 times greater than the above-mentioned first distance Dl.

In accordance with possible formulations of the invention, it can be provided that between a couple of first oblong portions 17, or of second oblong portions 18, at least three, preferably four first oblong elements 12 or second oblong elements 13, respectively, are positioned.

In accordance with a possible solution of embodiment, for example illustrated in figure 5, the first oblong portions 17 and the second oblong portions 18 are formed in a single body in relation to one another and as a separate component with respect to the first body 1 1. Subsequently, said separate component is integrally connected to the first body 1 1 for instance by means of bonding agents, or embedded in a part of the first body 1 1 for example during the steps of manufacturing the latter.

In accordance with possible forms of embodiment, each of the above- mentioned first oblong portions 17 is parallel to and overlapping a respective first oblong element 12 and each of the above-mentioned second oblong portions 18 is parallel to and overlapping a respective second oblong element 13. In accordance with this form of embodiment, the first oblong portions 17 and the second oblong portions 18 are overlapping, over their entire length, the respective first oblong elements 12 and the second oblong elements 13, respectively.

According to a possible variant of embodiment, illustrated for instance in figure 7, the first oblong elements 12 and the first oblong portions 17 define a shape of the cross section resembling a "T" or an "L", and the second oblong elements 13 and the second oblong portions 18 define a shape of the cross section resembling a "T" or an "L".

With "T"- or "L"-shaped cross section a section is meant that is defined by a first segment and by a second segment, both with an elongate quadrangular shape, and in which the first segment is placed incident against the second segment.

Said configuration of embodiment allows to give the first component 21 a high mechanical resistance.

In accordance with a further variant of embodiment, illustrated for example in figure 8, the first body 1 1 can be provided with reticular meshes 19 arranged in the openings 16 provided between the first oblong elements 12 and the second oblong elements 13.

It can be provided that the above-mentioned reticular meshes 19 are formed in an inner position of the openings 16, or in bas-relief with respect to the above- mentioned first surface 14 of the first body 1 1. In this manner, also when treading over the construction module 10, a damage to the reticular meshes 19 is avoided.

Said solution of embodiment can be particularly effective if it is desirable to give the construction module 10 also a function of ball-proof containment, that is to give the construction module 10 a function of holding bodies.

In accordance with further forms of embodiment, the first body 1 1 can have a first height HI, which, merely by way of example, is comprised between 4 mm and 10 mm.

In particular, the height H 1 identifies the dimension of the first body 11 in a direction orthogonal to its plane development.

The projecting portions 17, 18 can have a second height H2, which is comprised between 1 and 10 times the first height HI .

In accordance with an aspect of the present invention, the construction module 10 comprises a second structural component 22, plane, parallel to the first component 21 and integrally associated with the projecting portions 17, 18.

With the term integrally associated it is meant that the two components considered are connected to each other unremovably. In accordance with possible solutions of embodiment, it can be provided that the second component 22 is glued to the projecting portions 17, 18.

According to a possible alternative of embodiment, the projecting portions 17, 18 are integrally associated with the second component 22 for example before the latter has completely cross-linked. Namely, in other words, it can be provided that for the manufacturing of the second component 22, fibers and resin are deposited in a mold and, before the resin is cross-linked, it is provided to position said projecting portions 17, 18 in contact with the second component 22. The further cross-linkage of the resin determines the solid connection between the projecting portions 17, 18 and the second component 22.

In accordance with a possible solution of embodiment (figure 8) the projecting portions 17, 18 are formed in a single body with the second component 22, for example during the steps of manufacturing the latter, and subsequently the projecting portions 17, 18 are integrally coupled to the first body 1 1.

According to a further variant of embodiment, not illustrated, it can be provided that the projecting portions 17, 18 are integrally connected to the second component 22 by means of mechanical connection elements, or by means of generation of geometrical connections, for instance fitting connections.

Advantageously, the integral connection of the second component 22 with the projecting portions 17, 18 of the first component 21 allows to increase the structural resistance of the construction module 10, and in particular to reduce the tendency to bending and/or to deformation of the projecting portions 17, 18 in the presence of the normal stresses acting on walkways.

The second component 22 is also manufactured in a fibre-reinforced composite material.

In accordance with possible solutions of embodiment, illustrated for example in the figures 1-3 and 5, the second component 22 has a reticular structure defined by a plurality of oblong segments 23, 24 crossing each other to define a reticular mesh.

The second component 22 is defined by first oblong segments 23 and by second oblong segments 24, placed transverse to the first oblong segments 23.

Additionally, the first oblong segments 23 and the second oblong segments 24 are formed in a single body in relation to one another. The reticular mesh defined by the oblong segments 23, 24 can be substantially similar to the one defined by the first body 1 1 defined above. In particular, it can be provided that the dimensions of the meshes defined by the oblong segments 23, 24 are similar to those defined by the oblong elements 12 and 13. This solution of embodiment allows to obtain a construction module 10 that is structurally balanced with respect to the plane passing through the centre-line of the same.

In accordance with a further form of embodiment (figure 4), the second component 22 has a conformation that is the same as that of the first component 21. In particular, the first projecting portions 17 are integrally associated with some of the first segments 23, while the second projecting portions 18 are integrally associated with the second segments 24.

The projecting portions 17, 18 of the first component 21 are integrally associated with those of the second component 22.

Said configuration of embodiment of figure 4 allows to define a construction module 10 that behaves structurally like a rank of double-T beams placed side by side and crossing each other, in which the central core of the double-T beam is defined by the connection of the projecting portions 17, 18 of the first component 21 with those of the second component 22, while the flanges of the double-T beam are defined by the oblong segments 23, 24 and by the oblong elements 12, 13.

In accordance with possible solutions of embodiment (figures 6 and 7), the second component 22 is defined by a plurality of first bars 25, placed parallel to one another, and by a plurality of second bars 26, placed parallel to one another and transverse to the first bars 25.

The first bars 25 and the second bars 26 have a shape of the cross section resembling a "T" or an "L", in which the free ends of the "T" or "L" connect, by overlapping over the entire length, with the first projecting portions 17 and with the second projecting portions 18.

The first bars 25 and the second bars 26 can be substantially orthogonal to one another.

The shape of the cross section resembling a "T" or an "L" gives each first bar 25 and second bar 26 a greater bearing capacity, in the two orthogonal directions, of resistance to stresses, and in particular to bending stresses as compared with the known solutions for molded gratings in which transverse elements have a substantially rectangular or trapezoid shape.

In this way, it is possible to obtain, with the same weight, a construction module 10 with a resistance, in the two orthogonal directions, that is much greater than composite structures of the known prior art. Additionally, thanks to this, with the same performances of mechanical resistance, it is possible to reduce the total weight of the construction module 10, as well as the quantity of material used for its manufacturing to the benefit also of the manufacturing costs.

Forms of embodiment of the present invention refer also to a method for manufacturing the construction module 10 described above, which provides to manufacture a first component 21 made with a first plane reticular body 1 1 defined by oblong elements 12, 13 crossing each other, and having a first surface 14, walkable in use, and a second surface 15 opposite the first surface 14, and in which the method provides to integrally associate with the first body 1 1 a plurality of projecting portions 17, 18 projecting orthogonally with respect to the second surface 15.

In accordance with an aspect of the method according to the present invention, it is provided to integrally associate with the projecting portions 17, 18 a second plane component 22, arranging it parallel to the first component 21.

According to a possible variant of embodiment, the projecting portions 17, 18 can be made in a single body, for example in the same mold, with the first body 1 1.

In accordance with possible implementations of the method, it can be provided that the projecting portions 17, 18 are integrally associated with the first body 1 1 by gluing.

According to a variant of embodiment of the method, during the step of manufacturing the first body 1 1 or the projecting portions 17, 18, respectively, before the resin has cross-linked, it is provided to position, resting on the first body 1 1 or on the projecting portions 17, 18, respectively, the projecting portions 17, 18 or the first body 1 1 manufactured previously, respectively.

In other words, it can be provided that during the manufacturing of the projecting portions 17, 18, fibers and resin are deposited, for example in a mold, according to a predefined pattern, and before the resin of the projecting portions 17, 18 has cross-linked, the first body 1 1 manufactured previously is positioned resting on the projecting portions 17, 18. In this way, the resins, not yet cross- linked, of the projecting portions 17, 18 incorporate in the inside the interface surfaces of the first body 1 1 to define a single body. In the same manner, during the step of manufacturing of the first body 1 1, the fibers and resin are deposited in a mold according to a predefined pattern and it can be provided to position, resting on the latter, the projecting portions 17, 18 manufactured previously, so that the resin of the first body 1 1 incorporates, namely solidly connects, the projecting portions 17, 18, once the resin is cross-linked. This solution of embodiment is particularly advantageous, since the resistance of the connection is particularly high, and glues or auxiliary bonding resins are not necessary.

According to a further variant of embodiment, it can be provided that the projecting portions 17, 18 are integrally associated with the first body 1 1 by means of fits or by means of mechanical connection elements.

In accordance with a possible implementation of the method, the projecting portions 17, 18 are integrally associated with the second component 22 by gluing.

According to a variant of embodiment, during the operations of manufacturing the second component 22, or the projecting portions 17, 18, respectively, before the resin has cross-linked, it is provided to position, resting on the second component 22 or on the projecting portions 17, 18, respectively, the projecting portions 17, 18 or the second component 22 manufactured previously, respectively. The cross-linking of the resin, in fact, determines the integral connection between the projecting portions 17, 18 and the second component 22.

In other words, it can be provided that, during the operations of manufacturing the second component 22, the projecting portions 17, 18 of the first component 21, manufactured previously, are integrally associated, during cross-linking of the resin of the second component 22, in the manufacturing mold of the latter.

The fibers and the resin, are deposited in a mold according to a predefined pattern and, before the resin is cross-linked, the projecting portions 17, 18 are positioned in contact with the second component 22. Said method of manufacturing can be used, for instance, to make the construction module illustrated in figures 3 and 5. In the same way, it can be provided that during the operations of manufacturing the projecting portions 17, 18, the second component 22, manufactured previously, is integrally associated with the latter, during cross- linking of the resin of the projecting portions 17, 18, in the manufacturing mold of the latter.

According to a further variant of embodiment (figure 8), the projecting portions 17, 18 can be formed in a single body with the second component 22, for example in the same mold.

According to variants of embodiment, not illustrated, the projecting portions 17, 18 can be connected with the second component 22 for instance by means of mechanical connections or fits.

According to another embodiment of the present invention, not illustrated, the method according to the present invention provides to manufacture said projecting portions 17, 18 as a solid body with oblong segments 23, 24 of the second component 22 to define longitudinal bars, possibly crossing each other, having a shape of the cross section resembling a "T" or an "L". Moreover, the method can provide the manufacturing of said first body 1 1 in a mold, by depositing said fibers and resin in the mold, and that before the resin of the first body is polymerized, it is provided to position said projecting portion 17, 18 in contact with the first body, said projecting portions being previously manufactured as a solid body with the oblong segments 23, 24. The cross-linkage of the resin defines the solid coupling between the projecting portions 17, 18 and the oblong elements 12, 13 of the first body 1 1.

It is evident that modifications and/or additions of parts and/or steps can be made to the construction module in a composite material and to the related method of manufacturing described heretofore, without, for this, departing from the scope of the present invention.

Merely by way of example, the second plane component 22 can be defined by a plane plate having a uniform height and without openings.

It is also evident that, even though the present invention has been described with reference to some specific examples, a person of skill in the art will be readily able to achieve other equivalent forms of the construction module and related method of manufacturing having the features as set forth in the claims and hence all coming within the field of protection defined thereby.