Process for producing a composite structural element

Abstract

A process for producing a composite structural element, which includes the steps of providing a thin-section wall part, placing the thin-section wall part into a mold, applying reinforcing elements to the thin-section wall part, placing a counter-mold onto the mold for forming a mold cavity, and introducing a binder having a foaming agent into said mold cavity via one of injection cannulas and nozzles, after a set time delay a foaming of the binder occurring for encapsulating the reinforcing elements on all sides.

I claim:  
     
         1 . A process for producing a composite structural element, which comprises: 
 providing a thin-section wall part;    placing the thin-section wall part into a mold;    applying reinforcing elements to the thin-section wall part;    placing a counter-mold onto the mold for forming a mold cavity;    introducing a binder having a foaming agent into said mold cavity via one of injection cannulas and nozzles, after a set time delay a foaming of the binder occurring for encapsulating the reinforcing elements on all sides.    
     
     
         2 . The process according to    claim 1   , which comprises introducing the binder having the foaming agent into an open mold.  
     
     
         3 . The process according to    claim 1   , which comprises using the binder having the foaming agent with a set time delay of less than 5 seconds for foaming the binder.  
     
     
         4 . The process according to    claim 1   , which comprises priming the thin-section wall part on a foam application side to improve adhesion before applying the binder.  
     
     
         5 . The process according to    claim 1   , which comprises backing the thin-section wall part with a hard shell formed with reinforcing elements by one of compression molding and injection molding before a formation of the mold cavity, and applying a second hard shell subsequently to the free side of the molding.  
     
     
         6 . The process according to    claim 5   , which comprises molding on transverse cross-pieces to the hard shell during the application of the hard shell.  
     
     
         7 . The process according to    claim 5   , which comprises forming a recycled core from one of a foam and a comparable light weight material and placing the recycled core in the reinforcing elements before the binder is injected.  
     
     
         8 . A process for producing a composite structural element, which comprises: 
 producing moldings formed with reinforcing elements and a binder by foaming of the binder for encapsulating the reinforcing elements;    producing hard shells formed with the reinforcing elements and the binder by foaming of the binder for encapsulating the reinforcing elements; and    providing a thin-section wall part, and bonding adhesively the moldings and the hard shells to the thin-section wall part for forming a composite element.    
     
     
         9 . The process according to    claim 8   , which comprises producing the moldings with recycled cores.  
     
     
         10 . The process according to    claim 8   , which comprises producing the hard shells with transverse cross-pieces.