Multilayer panel for construction and method for its production

Abstract

The present finding relates to a panel and a method for its production, used for the production of floorings provided with a liquid drain opening ( for example, shower trays ), and whose upper surface comprises at least two sections with different slopes, arranged so as to facilitate the outflow of liquids towards the drain opening.

Description

[0001] MULTILAYER PANEL FOR CONSTRUCTION AND METHOD FOR ITS

[0002] PRODUCTION

[0003] The present finding relates to a multilayer panel for construction and to a method for its production .

[0004] In particular, the finding relates to a panel ( and a method for its production) used for the production of floorings provided with a liquid drain opening ( for example , shower trays ) and whose upper surface has at least two sections with di f ferent slopes , arranged so as to facilitate the outflow o f liquids towards the drain opening .

[0005] Nowadays , it is known to use panels for the production of shower trays which comprise a drain opening and whose upper surface has a plurality of sections with di f ferent slopes , arranged so as to facilitate the outflow of liquids towards such drain opening .

[0006] Such known-type panels are typically positioned on the surface where the shower tray is to be obtained, connecting the drain opening with the drain system of the building, and then covered with dedicated covering resins and / or covering solid elements ( for example , tiles ) , to obtain a shower tray with the desired appearance .

[0007] Such known-type panels generally comprise a layer made of extruded (XPS ) or expanded ( EPS ) polystyrene , a few centimetres thick, in which the drain opening i s formed, provided with a flat lower face , adapted to be positioned on a surface where the shower tray is to be obtained, and an upper face which has a plurality o f flat portions , of which at least two , contiguous and communicating with each other through a connection line , have di f ferent inclinations with respect to the lower face , and are oriented so as to promote the outflow of liquids towards the drain opening .

[0008] In order to ensure the waterproofing of the panel , the upper face of the polystyrene layer is covered with a layer made of waterproof material .

[0009] In some known embodiments , the waterproof layer is a thin layer made of cement , or cement and resin, which is placed, in the liquid state , on the upper face o f the polystyrene layer, so as to leave only the drain opening uncovered . The cement or cement-resin layer perfectly fits to the shape of the upper face of the polystyrene panel and once solidi fied, forms a barrier to water penetration .

[0010] Furthermore , due to the density and surface hardness of the cement or cement-resin layer, a relatively low- density, and therefore relatively inexpensive , polystyrene ( for example , 30 kg / m3) can be used for the polystyrene layer, since the cement or cement-resin layer reinforces the polystyrene layer and protects it from possible crushing by the installer during the installation of the shower tray .

[0011] However, such known solution has several drawbacks .

[0012] First of all , drying the cement or cement-resin layer requires relatively long times and / or the use o f dedicated ovens , which involve high energy consumption and an increase in both the manufacturing times and costs of the panel .

[0013] Furthermore , such known solutions typically use chemical accelerators and hardeners , which are generally relatively expensive and present handling challenges from the point of view of health and safety of the operators.

[0014] Furthermore, if form and / or dimension modifications of the panel are required when placing it, for example, in order to fit to a not perfectly regular or non-project- compliant configuration of a recess where the panel is to be installed, such modifications would be very difficult and, in some cases, unmakeable, since the cement or cement-resin layer is not well-suited for cutting, particularly during the installation of the panel; indeed, due to its high density and surface hardness, cutting the cement or cement-resin layer requires tools which create a lot of dust, and there is also a significant risk of irreversible damage to the panel in the case of an error by the operator.

[0015] In addition, the cement or cement-resin layer has a relatively high weight, which makes its transportation and installation relatively difficult.

[0016] In order to overcome such drawbacks, panels are also being used in which the waterproof layer covering the upper face of the polystyrene layer consists of a multilayer membrane comprising at least one layer made of low-density polyethylene, or ethylene-vinyl acetate, or low-density polyethylene and ethylene-vinyl acetate, and at least one layer of non-woven fabric of alkali- resistant treated polyester or polypropylene.

[0017] Such known-type multilayer membrane ensures sufficient waterproofing and is also sufficiently flexible and elastic to fit to the differently sloped sections of the upper face of the polystyrene layer; however, such known solution has the drawback that, in order to fix the membrane to the different flat portions of the polystyrene layer, which have inclinations different to each other, using a f lat press or a calender is not suf ficient , but it is required to use a vacuum thermoforming process , which requires indeed a vacuum thermoforming plant , which is very expensive and involves relatively slow times for the production of the panels ( since only one panel can be subj ected to such process at a time ) , which increases the overall manufacturing times and costs of such known-type panels .

[0018] Furthermore , the thermoforming process involves a high risk of air bubble formation being formed between the upper surface of the polystyrene layer and the multilayer membrane ; the presence of such air bubbles in a panel involves the need to discard it , thereby increasing both the overall manufacturing costs and the disposal costs .

[0019] Such known-type multilayer membrane also has the drawback of not providing suf ficient mechanical protection with respect to the compression of the polystyrene layer ; for such reason, in the case where such typology of multilayer membrane is used, in order to prevent accidental de formation by compression of the polystyrene layer, the polystyrene used must necessarily be of the high-density expanded (EPS ) or extruded (XPS ) type ( or with a density between 50- 60 kg / m3) .

[0020] However, such typology of polystyrene is relatively expensive , and its availability on the market i s signi ficantly lower than that of extruded polystyrene with lower density ( e . g . , 25-35 kg / m3) , which increases the manufacturing costs of such known-type panels . Therefore , the main task of the present finding is to overcome the above-mentioned drawbacks , and in particular to obtain a panel for the production of floorings provided with a liquid drain opening, and whose upper surface has at least two sections with di f ferent slopes arranged so as to facilitate the outflow of liquids towards the drain opening, which is waterproof and allows relatively low manufacturing costs and times to be achieved .

[0021] In the scope of such task, an obj ect of the present finding is to obtain a panel for the production of floorings provided with a liquid drain opening, and whose upper surface has at least two sections with di f ferent slopes arranged so as to facilitate the outflow of liquids towards the drain opening, which can have relatively high resistance to crushing, without necessarily requiring the use of high-density expanded or extruded polystyrene .

[0022] Another obj ect of the finding is to obtain a panel for the production of floorings provided with a liquid drain opening, and whose upper surface has at least two sections with di f ferent s lopes arranged so as to facilitate the outflow of liquids towards the drain opening, which has a relatively low weight .

[0023] Still another obj ect is to obtain a panel for the production of floorings provided with a liquid drain opening, and whose upper surface has at least two sections with di f ferent s lopes arranged so as to facilitate the outflow of liquids towards the drain opening, which can be subj ected to small dimens ional modi fications during its installation, without necessarily requiring any particular level of skill or experience of the operator performing them . Still another obj ect is to obtain a panel for the production of floorings provided with a liquid drain opening, and whose upper surface has at least two sections with di f ferent s lopes arranged so as to facilitate the outflow of liquids towards the drain opening, whose manufacturing process does not require the use of a vacuum thermoforming plant .

[0024] The task and obj ects according to the present finding are achieved by a multilayer panel as in claim 1 .

[0025] The task and obj ects indicated above are also achieved by a method for the production of a multilayer panel as in claim 10 .

[0026] Other advantageous features of the finding are indicated in the dependent claims .

[0027] The features and advantages of the present finding wi ll become more apparent from the following exemplary and non-limiting description referred to the attached schematic drawings , in which :

[0028] Figure 1 is a plan view of a first advantageous embodiment of a panel according to the finding;

[0029] - Figure 2 is a bottom plan view of the covering layer of the panel of Figure 1 ;

[0030] - Figure 3 is a top plan view o f the base layer of the panel of Figure 1 ;

[0031] - Figures 4 to 7 schematically illustrate various steps of the production of the panel o f Figure 1 , in views taken according to section plane I-I of Figure 1 ;

[0032] - Figure 8 is a plan view of a second advantageous embodiment of a panel according to the finding;

[0033] - Figure 9 is a bottom plan view of the covering layer of the panel of Figure 8 ;

[0034] - Figure 10 is a top plan view of the base layer of the panel of Figure 8 ;

[0035] Figures 11 to 14 schematically illustrate various steps of the production of the panel of Figure 8 , in views taken according to section plane I I-I I of Figure 8 ;

[0036] - Figure 15 is a lateral sectional view of a third advantageous embodiment of a panel according to the finding;

[0037] - Figure 16 is a lateral sectional view of a fourth advantageous embodiment of a panel according to the finding .

[0038] With reference to the attached figures , the reference number 1 indicates as a whole a multilayer panel for construction according to the finding .

[0039] The panel 1 comprises a base layer 2 , provided with a flat lower face 3 and an upper face 4 which has a plurality of flat portions 5 , o f which at least two , contiguous and communicating with each other through a straight connection line 6 , have , with respect to the lower face 3 , mutually di f ferent inclinations .

[0040] Advantageously, the base layer 2 has a thickness , in its thickest section, between 5 mm and 70 mm, more advantageously between 15 mm and 50 mm .

[0041] Advantageously, the base layer 2 has a thickness , in its thinnest section, between 2 mm and 50 mm, more advantageously between 2 mm and 40 mm .

[0042] Advantageously, the base layer 2 is made of expanded (EPS ) or extruded (XPS ) polystyrene , preferably with an average density equal to or lower than 45 kg / m3, more preferably equal to or lower than 35 kg / m3, even more preferably equal to or lower than 30 kg / m3, even more preferably equal to or lower than 25 kg / m3. In other advantageous embodiments , the base layer 2 can be made of expanded polyurethane , or another polymeric foam .

[0043] Advantageously, the base layer 2 can have a desired conformation in plan; for example, as in the embodiments illustrated in Figures 1 to 7 and Figure 15 , it can have a square conformation in plan, or, as in the embodiments illustrated in Figures 8 to 14 and Figure 16 , it can have a rectangular conformation in plan .

[0044] Other conformations in plan ( e . g . , circular, elliptical , triangular, irregular shape , and / or having a desired geometry, etc . ) are also possible .

[0045] A first through opening 7 is formed in the base layer 2 , advantageously arranged such that the inclination of at least one of the flat portions 5 promotes the outflow of liquids therefrom towards the first through opening 7 .

[0046] The first through opening 7 can have a desired conformation in plan, for example circular, rectangular, square , etc .

[0047] In advantageous embodiments , such as for example that illustrated in Figures 1 to 7 and Figure 15 , the upper face 4 of the base layer 2 has four flat portions 5 , delimited by the diagonals of the square defined in plan by the base layer 2 , and by the first through opening 7 , which in this advantageous embodiment is arranged in the centre o f such square and advantageously has a circular plan; the connection lines 6 delimiting two contiguous flat portions 5 in this case coincide with respective sections of such diagonals . In this advantageous embodiment , the four flat portions 5 have each an inclination di f ferent from the others with respect to the lower face 3 , such that their distance from the lower face 3 progressively decreases as they approach the f irst through opening 7 , so as to define , as a whole , for the upper face 4 o f the base layer 2 , a convex shape similar to an inverted truncated pyramid, whose smaller base corresponds to the edge of the first through opening 7 .

[0048] In other advantageous non-illustrated embodiments , in the case where the base layer 2 has a square plan, the first through opening 7 can also have a di f ferent conformation in plan ( e . g . , square or rectangular ) .

[0049] In other advantageous non-illustrated embodiments , in the case where the base layer 2 has a square plan, the first through opening 7 can also be formed of f-centre with respect to the square defined in plan by the base layer 2 ; in this case , the f lat portions 5 can advantageously be delimited in pairs by connection lines 6 which connect the corners of the upper face 4 with the edge of the first through opening 7 and which, in this advantageous embodiment , do not coincide with the diagonals of the square defined in plan by the base layer 2 .

[0050] In other advantageous embodiments , such as for example those illustrated in Figures 8 to 14 and in Figure 16 , the upper face 4 of the base layer 2 has three flat portions 5 , respectively delimited by two connection lines 6 parallel to the short s ides of the rectangle defined in plan by the base layer 2 and placed closer to one of such short sides than to the other .

[0051] In such advantageous embodiments , a first flat portion 5 , interposed between the other two flat portions 5 , is advantageously parallel to the lower face 3 of the base layer 2 , and on such first f lat portion 5 , the first through hole 7 is advantageously formed, which in this case advantageously has a rectangular plan, with sides preferably parallel in pairs to those of the rectangle defined in plan by the base layer 2 .

[0052] In such advantageous embodiments , the other two flat portions 5 are advantageously inclined such that their distance from the lower face 3 progressively decreases as they approach the first flat portion 5 interposed therebetween .

[0053] Other numbers , conformations , and orientations of the flat portions 5 , and other positions and conformations of the first through hole 7 are also contemplated in the finding .

[0054] For example , in a further advantageous embodiment , not illustrated, the upper face 4 of the base layer 2 , which has a rectangular plan, can have only two flat portions 5 , delimited by a connection line 6 parallel to the short sides of the rectangle defined in plan by the base layer 2 ; in this advantageous case , one of such flat portions 5 is preferably parallel to the lower face 3 of the base layer 2 and has the first through hole 7 , and the other flat portion 5 is inclined with respect to the lower face 3 of the base layer 2 so as to promote the outflow of liquids therefrom towards the first through hole 7 .

[0055] The panel 1 further comprises a covering layer 8 , fixed to the upper face 4 of the base layer 2 .

[0056] In the embodiments illustrated in the attached figures , the covering layer 8 advantageously has an external perimeter shape such as to reproduce , in plan, the external perimeter shape of the base layer 2 , and external perimeter dimensions , in plan, that are equal to or substantially equal to the external perimeter dimensions of the base layer 2 .

[0057] In the present text , the expression " external perimeter shape such as to reproduce , in plan, the external perimeter shape of the base layer 2 , and external perimeter dimensions , in plan, that are equal to or substantially equal to the external perimeter dimensions of the base layer 2" means that , in a plan view, the external perimeter shape of such layers is the same ( e . g . , square , rectangular, circular, triangular, etc . ) , and that the corresponding elements in the two plan views ( for example , in the case of a rectangular plan, a short side of the rectangle defined in plan by the base layer 2 and the corresponding short side of the rectangle defined in plan by the covering layer 8 ) can be equal or, in the case of " substantially equal" , can di f fer from each other by a certain amount which, for the purposes of the present finding, must not exceed 5% , referred to the greater of the two values being compared .

[0058] In other advantageous embodiments , not illustrated, the conformation in plan and / or dimensions of the base layer 2 and of the covering layer 8 can di f fer from each other, as long as the shape and dimensions of the covering layer 8 allow it to cover at least partially the upper face 4 of the base layer 2 ; for example , the shape and dimensions of the covering layer 8 can be such as to allow such covering layer 8 to completely cover the upper face 4 of the base layer 2 and to laterally protrude , in plan, with respect to the base layer 2 .

[0059] The covering layer 8 comprises a surface layer 9 , with a laminar shape , waterproof , and an internal layer 10 , shaped like a slab, fixed to the surface layer 9 and to the upper face 4 of the base layer 2 .

[0060] Advantageously, the surface layer 9 has a thickness between 100 pm and 600 pm, more advantageously between 200 pm and 500 pm .

[0061] Advantageously, the internal layer 10 has a thickness between 2 mm and 20 mm .

[0062] Advantageously, the surface layer 9 is or comprises a multilayer membrane, preferably comprising a core (not illustrated) made of high-density polyethylene (HDPE ) or polypropylene ( PP ) or other relatively rigid plastics , such as for example high-impact polystyrene (HIPS ) , covered with an external layer, not illustrated, made of non-woven fabric .

[0063] In advantageous embodiments , such as for example those illustrated in Figures 1 to 14 , the internal layer 10 is made of expanded or extruded polystyrene , preferably with a density equal to or lower than 40 kg / m3, more preferably equal to or lower than 35 kg / m3, or expanded polyurethane or another polymeric foam, and is glued directly to the surface layer 9 and to the upper face 4 of the base layer 2 .

[0064] In other advantageous embodiments , such as for example those illustrated in Figures 15 and 16 , the internal layer 10 comprises a first layer 10a, made of expanded or extruded polystyrene , with a density preferably equal to or lower than 40 kg / m3, more preferably equal to or lower than 35 kg / m3, or expanded polyurethane or another polymeric foam, glued to the surface layer 9 , and a second layer 10b, glued to the first layer 10a on the side opposite to the surface layer 9 , consisting of or comprising a multilayer membrane , preferably comprising a core (not il lustrated) made of high- density polyethylene (HDPE ) or polypropylene ( PP ) or other relatively rigid plastics , such as for example high-impact polystyrene (HIPS ) , covered with an external layer, not illustrated, made of non-woven fabric .

[0065] In advantageous embodiments , such as for example those illustrated in Figures 15 and 16 , the second layer 10b is glued directly to the upper face 4 of the base layer 2 .

[0066] In other advantageous embodiments , not illustrated, the internal layer 10 can comprise , in addition to the first layer 10a and the second layer 10b, further layers , not illustrated, interposed between the second layer 10b and the upper face 4 of the base layer 2 ; such further layers can comprise , for example , one or more further layers made of expanded or extruded polystyrene , with a density preferably equal to or lower than 40 kg / m3, more preferably equal to or lower than 35 kg / m3, or expanded polyurethane or another polymeric foam, and one or more second layers consisting of or comprising a multilayer membrane , preferably comprising a core (not illustrated) made of high-density polyethylene (HDPE ) or polypropylene ( PP) or other relatively rigid plastics , such as for example high-impact polystyrene (HIPS ) , covered with an external layer of non-woven fabric .

[0067] According to the finding, a second through opening 11 is formed in the covering layer 8 , facing and in fluid communication with the first through opening 7 .

[0068] In advantageous embodiments , such as for example those illustrated in the attached figures , the second through opening 11 advantageously has the same conformation in plan as the first through opening 7 and plan dimensions equal or substantially equal thereto .

[0069] It is emphasi zed that , in the present text , "substantially equal dimensions " means that such dimensions can di ffer from each other by a certain amount which, for the purposes o f the present finding, must not exceed 5% , referred to the greater of the two dimensional values being compared .

[0070] However, it is emphasi zed that the second through opening 11 can have desired shape and dimensions , as long as it is in fluid communication with the first through opening 7 .

[0071] According to the finding, in the internal panel 10 , a respective cut 12 which af fects the entire thicknes s of the internal layer 10 is formed in correspondence to each connection line 6 , and at least one section of which has a conformation in plan equal to the respective connection line 6 , for the entire extension of the latter and faces it .

[0072] In advantageous embodiments , such as for example those illustrated in the attached figures , each cut 12 has a conformation in plan equal , over its entire extension, to the entire respective connection line 6 and faces it over its entire extension; in other advantageous embodiments , not illustrated, one or more of the cuts 12 can have a plan extension greater than that of the respective connection line 6 , in which case only one section of such one or more cuts 12 has a conformation in plan equal to the respective connection line 6 , for the entire extension of the latter and faces it .

[0073] The one or more cuts 12 divide the internal layer 10 in two or more regions 13 , whose conformation in plan preferably at least partially reproduces the shape of respective flat portions 5 o f the upper face 4 o f the base layer 2 which such regions 13 face and are fixed to .

[0074] It is emphasi zed that the one or more cuts 12 do not af fect the surface layer 9 , which therefore keeps the various regions 13 of the internal layer 10 j oined together .

[0075] In advantageous embodiments , such as for example those illustrated in the attached figures , such two or more regions 13 have plan dimensions equal or substantially equal to the dimensions of the respective flat portions 5 of the upper face 4 of the base layer 2 which such regions 13 face and are fixed to .

[0076] In further advantageous embodiments , such as for example those illustrated in Figures 15 and 16 , a further reinforcing layer 14 consisting of or comprising a multilayer membrane , preferably comprising a core (not illustrated) made of high-density polyethylene (HDPE ) or polypropylene ( PP ) or other relatively rigid plastics , such as for example high- impact polystyrene (HIPS ) , covered with an external layer, not illustrated, made of non-woven fabric, can be fixed to the lower face 3 of the base layer 2 .

[0077] Advantageously, such reinforcing layer 14 comprises a third through opening 15 , facing and in fluid communication with the first through opening 7 . Preferably, the third through opening 15 has the same conformation in plan as the first through opening 7 and plan dimensions equal or substantially equal thereto ; in other advantageous embodiments , not illustrated, the third through opening 15 can have shape and / or dimensions di f ferent from the first through opening 7 , as long as it faces and is in f luid communication with it .

[0078] Advantageously, the panel 1 can have a further cut , not illustrated, which af fects the entire thickness of the panel 1 except for the surface layer 9 , adapted to allow the panel 1 to be folded on itsel f in order to reduce its plan footprint and to facilitate its transportation; in this advantageous embodiment , the surface layer 9 keeps the two sections of the panel 1 separated by such further cut j oined together . Preferably, such further cut is formed so as to divide the panel 1 , except for the surface layer 9 thereof , in two equal parts .

[0079] The method according to the f inding for the production of the panel 1 is described below .

[0080] Such method first comprises a step a ) of obtaining the base layer 2 , provided with the flat lower face 3 and the upper face 4 which has a plurality of flat portions 5 , of which at least two , contiguous and communicating with each other through a connection line 6 , have di f ferent inclinations with respect to the lower face 3 .

[0081] The base layer 2 can, for example , be obtained by molding expanded or extruded polystyrene , with a density preferably equal to or lower than 40 kg / m3, more preferably equal to or lower than 35 kg / m3, or expanded polyurethane or another polymeric foam, in a dedicated mold, or, advantageously, by performing dedicated notches on a slab or block made of expanded or extruded polystyrene , with a density preferably equal to or lower than 35 kg / m3, more preferably equal to or lower than 35 kg / m3, or expanded polyurethane or another polymeric foam .

[0082] The method then provides step b ) of forming on the base layer 2 the first through opening 7 , which connects the upper face 4 to the lower face 3 of the base layer 2 .

[0083] Step b ) can be performed after step a ) , or after the base layer 2 has been made , or, for example in the case where the same is obtained by molding, simultaneously with step a ) of obtaining the base layer 2 ( for example , by appropriately shaping the mold used to manufacture the base layer 2 ) .

[0084] The method according to the finding further comprises step c ) of providing the internal layer 10 , shaped l ike a slab .

[0085] Advantageously, though not necessarily, the shape of the internal layer 10 is such as to reproduce , in plan, the conformation in plan o f the base layer 2 , and preferably has plan dimensions equal or substantially equal to those of the base layer 2 .

[0086] The internal layer 10 can be , for example , a single slab made of expanded or extruded polystyrene , with a density preferably equal to or lower than 40 kg / m3, more preferably equal to or lower than 35 kg / m3, or expanded polyurethane or another polymeric foam, obtained by molding in a dedicated mold, or, advantageously, by performing dedicated notches on a slab or block made of expanded or extruded polystyrene , with a density preferably equal to or lower than 40 kg / m3, more preferably equal to or lower than 35 kg / m3, or expanded polyurethane or another polymeric foam .

[0087] In other advantageous embodiments , such as for example those illustrated in Figures 15 and 16 , in which the internal layer 10 comprises a first layer 10a, made of expanded or extruded polystyrene , with a density preferably equal to or lower than 40 kg / m3, more preferably equal to or lower than 35 kg / m3, or expanded polyurethane or another polymeric foam, glued to the surface layer 9 , and a second layer 10b, glued to the first layer 10a on the side opposite to the surface layer 9 , consisting of or comprising a multilayer membrane , preferably comprising a core (not illustrated) made of high-density polyethylene (HDPE ) , polypropylene ( PP ) , or other relatively rigid plastics , such as for example high-impact polystyrene (HIPS ) , covered with an external layer, not illustrated, made of non-woven fabric, the f irst layer 10a can be obtained, for example , by molding or by notching a s lab or block made of expanded or extruded polystyrene , with a density preferably equal to or lower than 40 kg / m3, more preferably equal to or lower than 35 kg / m3, or expanded polyurethane or another polymeric foam, and the second layer 10b can be obtained by appropriately cutting a multilayer membrane of the type described above .

[0088] In other advantageous embodiments , not illustrated, in which the internal layer 10 comprises , in addition to the first layer 10a and the second layer 10b, further layers , not illustrated, interposed between the second layer 10b and the upper face 4 of the base layer 2 , preferably similar to the first layer 10a and / or the second layer 10b, such further layers can be obtained in the same manner as the f irst layer 10a and the second layer 10b, respectively .

[0089] The method according to the finding then provides a step d) in which, after step c ) , the surface layer 9 , with a laminar shape , waterproof , is glued on a first flat face 101 of the internal layer 10 , so as to obtain the covering layer 8 .

[0090] In advantageous embodiments , such as for example those illustrated in the attached figures , the surface layer

[0091] 9 has shape and dimensions such as to reproduce , in plan, the shape and dimensions of the internal layer

[0092] 10 .

[0093] The surface layer 9 can advantageously be obtained by appropriately cutting a multilayer membrane , preferably comprising a core (not il lustrated) made of high- density polyethylene (HDPE ) , polypropylene ( PP ) , or other relatively rigid plastics , such as for example high-impact polystyrene (HIPS ) , covered with an external layer, not illustrated, made of non-woven fabric .

[0094] Gluing the surface layer 9 to the internal layer 10 can be performed by applying glue , not illustrated, on the first flat face 101 of the internal layer 10 , resting the surface layer 9 on such first flat face 101 , and then exerting a pressure on the surface layer 9 towards the internal layer 10 , for example by a simple flat press or roller ( for example , in a calender ) , not illustrated; this is allowed because the first flat face 101 of the internal layer 10 is indeed flat and has a whole single inclination with respect to the second flat face 102 o f the middle layer 10 ( in fact , it is parallel thereto ) .

[0095] The method further provides step e ) of forming on the covering layer 8 the second through opening 11 , which is arranged in such a way as to be facing and in fluid communication with the first through opening 7 of the base layer 2 when the covering layer 8 is fixed to the upper face 4 of the base layer 2 .

[0096] Advantageously, though not necessarily, the second through opening 11 has shape and dimensions such as to substantially reproduce , in plan, the conformation in plan of the first through opening 7 .

[0097] In an advantageous embodiment, the second through opening 11 can be formed, for example by a milling cutter, in the covering layer 8 after it has been made by gluing together the middle layer 10 and the surface layer 9 .

[0098] In a further advantageous embodiment , the second through opening 11 can be obtained by j oining two respective through openings , I la and 11b, formed, for example by a milling cutter, one on the surface layer 9 and the other on the middle layer 8 , before their assembly .

[0099] The method then provides step f ) of making on the internal layer 10 , in correspondence to each connection line 6 of the upper face 4 of the base layer 2 , a respective cut 12 which af fects the entire thicknes s of the internal layer 10 and at least one section of which has a conformation in plan equal to the respective connection line 6 for the entire extension of the latter .

[0100] In advantageous embodiments , such as for example those illustrated in the attached figures , each cut 12 has a conformation in plan equal , over its entire extension, to the entire respective connection line 6 ; in other embodiments , not illustrated, one or more of the cuts 12 can have a plan extension greater than that of the respective connection line 6 , in which case only one section of said one or more cuts 12 has a conformation in plan equal to the respective connection line 6 for the entire extension of the latter .

[0101] It is emphasi zed that the one or more cuts 12 do not af fect the surface layer 9 , which therefore keeps the various regions 13 of the internal layer 10 j oined together .

[0102] Advantageously, steps a ) and b ) can be performed before or after steps c ) , d) , e ) and f ) , or one or more o f steps a ) and b ) can be performed simultaneously with one or more of steps c ) , d) , e ) and f ) .

[0103] The method according to the finding then comprises step g) , which involves , after steps e ) and f ) , gluing the internal layer 10 of the covering layer 8 to the upper face 4 of the base layer 2 , by arranging the sections of the one or more cuts 12 that have a conformation in plan equal to the respective connection line 6 for the entire extension of the latter at the respective connection line 6 , and exerting a pressure on the covering layer 8 towards the base layer 2 .

[0104] Due to the presence o f the internal layer 10 , shaped like a slab, and the one or more cuts 12 formed thereon, such pressure can be also exerted by pressing only on certain points o f the covering layer 8 , without needing to use a pushing element with a specific geometry to fit to the di f ferent slopes of the flat portions 5 of the upper face 2 of the base layer 2 .

[0105] Indeed, during the pressure of the covering layer 8 towards the base layer 2 , the one or more cuts 12 allow the two or more regions 13 of the internal layer 10 , delimited by said one or more cuts 12 and held together by the surface layer 9 , to rotate with respect to each other, so as to adapt to the di f ferent inclinations of the underlying flat portions 5 and to adhere thereto , without the risk of unglued sections or air bubbles being trapped between the second flat face 101 of the internal layer 10 and the upper face 4 of the base layer 2 .

[0106] In the advantageous embodiment in which the further reinforcing layer 14 is f ixed to the lower face 3 of the base layer 2 , the method according to the finding further provides the further step of obtaining such further reinforcing layer 14 , preferably already provided with the respective third through opening 15, and fixing it to the lower face 3 , for example by gluing .

[0107] In a further advantageous embodiment , step b ) , in which the first through opening 7 is obtained, and step e ) , in which the second through opening 11 is obtained, ( and possibly, though not necessarily, also the step in which the third through opening 15 is obtained, in the case where the panel is provided with the reinforcing layer 14 , can be performed simultaneously, after step g) , for example by a single milling or drilling process , which af fects both the base layer 2 and the covering layer 8 ( and possibly, though not necessarily, also the reinforcing layer 14 , i f present ) .

[0108] It has thus been found that the finding achieves the above-stated task and obj ects , since , due to the presence of the cuts in the internal layer of the covering layer, the surface layer can be fixed to the internal layer when they are in a flat condition ( and therefore , for example , by using a simple flat press or a calender ) , and subsequently such covering layer can be fixed to the upper face of the base layer, fitting the shape of such covering layer to that of the upper face ; indeed, the presence of the middle layer, shaped like a slab, provides the covering layer with suf ficient sti f fness to allow it to be fixed to the underlying base layer, without however needing to use a press counter-shaped with respect to the speci fic shape of the external face of the base layer .

[0109] Since not requiring the use of a vacuum thermoforming plant , nor a speci fic press counter-shaped with respect to the speci fic shape o f the external face of the base layer, the manufacturing costs and times of the panel according to the finding are signi ficantly lower than the known solutions described above .

[0110] Furthermore , since the surface layer can be fixed to the internal layer when they are in a flat condition, it is possible to use for the surface layer a high- density multilayer membrane , such as for example a multilayer membrane comprising a core made of high- density polyethylene (HDPE ) , polypropylene ( PP ) , or other rigid plastics such as for example high-impact polystyrene (HIPS ) , covered with an external layer of non-woven fabric, without needing to use a press counter-shaped with respect to the speci fic shape o f the external face of the base layer, and therefore with relatively low manufacturing costs ; therefore , the possibility to use such type of high-density multilayer membrane allows to obtain a panel with relatively high resistance to crushing, without necessarily requiring the use of high-density extruded or expanded polystyrene .

[0111] Furthermore , since not requiring a cement or cementresin cover, the panel according to the finding has a relatively low weight and is further suitable for small dimensional modi fications during its installation, since both the base layer and the internal layer can be cut during installation, for example by a dedicated cutter .

[0112] Finally, it is clear that the panel and the method according to the finding are susceptible to numerous modi fications and variants , all falling within the finding; furthermore , all details are replaceable by technically equivalent elements . In practice , the materials used, as well as the dimensions , can be any, depending on the technical requirements .

Claims

CLAIMS1) Multilayer panel (1) for construction, which is characterized in that it comprises:- a base layer (2) in which a first through opening (7) is formed, said base layer (2) comprising a flat lower face (3) and an upper face (4) which has a plurality of flat portions (5) , of which at least two, contiguous and communicating with each other through a connection line (6) , have, with respect to said lower face (3) , mutually different inclinations;- a covering layer (8) , fixed to said upper face (4) , in which a second through opening (11) is formed, facing and in fluid communication with said first through opening (7) , in which said covering layer (8) comprises a surface layer (9) , with a laminar shape, waterproof, and an internal layer (10) , shaped like a slab, fixed to said surface layer (9) and to said upper face (4) of said base layer (2) , wherein in said internal layer (10) , in correspondence of each said connection lines (6) of said upper face (4) , a respective cut (12) is formed which affects the entire thickness of said internal layer (10) , wherein at least one section of said cut (12) has a conformation in plan equal to said respective connection line (6) for the entire extension of the latter and faces it.2) Panel (1) , as in claim 1, wherein said base layer (2) is made of expanded or extruded polystyrene or expanded polyurethane or another polymeric foam.3) Panel (1) , as in claim 2, wherein said base layer (2) is made of expanded or extruded polystyrene with a density equal to or lower than 40 kg / m3or equal to or lower than 35 kg / m3.4) Panel (1) , as in claim 1 or 2 or 3, wherein said surface layer (9) is or comprises a multilayer membrane .5) Panel (1) , as in claim 4, wherein said multilayer membrane comprising a core, made of high-density polyethylene (HDPE) or polypropylene (PP) or high- impact polystyrene (HIPS) or of other plastic or set of plastics, covered with an external layer of non-woven fabric .6) Panel (1) , as in a previous claim, wherein said internal layer (10) is made of expanded or extruded polystyrene or expanded polyurethane or another polymeric foam, and is glued to said surface layer (9) and to said upper face (4) of said base layer (2) .7) Panel (1) , as in claim 6, wherein said internal layer (10) is made of expanded or extruded polystyrene with a density equal to or lower than 40 kg / m3or equal to or lower than 35 kg / m3.8) Panel (1) , as in one of claims 1 to 6, wherein said internal layer (10) comprises a first layer (10a) , made of expanded or extruded polystyrene or expanded polyurethane or another polymeric foam, glued to said surface layer (9) , and a second layer (10b) , glued to said first layer (10a) on the side opposite to said surface layer (9) , consisting of or comprising a multilayer membrane.9) Panel (1) , as in claim 8, wherein said first layer (10a) is made of expanded or extruded polystyrene with a density equal to or lower than 40 kg / m3or equal to or lower than 35 kg / m3.10) Method for the production of a multilayer panel (1) for construction, characterized by comprising thefollowing steps: a) obtaining a base layer (2) , shaped like a slab, comprising a flat lower face (3) and an upper face (4) which has a plurality of flat portions (5) , of which at least two, contiguous and communicating with each other through a straight connection line (6) , present, with respect to said lower face (3) , mutually different inclinations; b) forming a first through opening (7) on said base layer (2) , which connects said upper face (4) to said lower face (3) ; c) providing an internal layer (10) , shaped like a flat slab; d) following said step c) , keeping said internal layer (10) in a flat position, gluing on a first flat face (101) of said internal layer (10) a surface layer (9) , with a laminar shape, waterproof, so as to obtain a covering layer (8) ; e) forming on said covering layer (8) a second through opening (11) , arranged in such a way as to be facing and in fluid communication with said first through opening (7) when said covering layer (8) is fixed to said upper face (4) of said base layer ( 2 ) ; f) making on said internal layer (10) , in correspondence to each of said connection lines (6) of said upper face (4) of said base layer (2) , a respective cut (12) , which affects the entire thickness of said internal layer (10) , wherein at least one section of said cut (12) has a conformation in plan equal to said, respective, connection line (6) for the entire extension ofthe latter; g) following said steps e) and f ) , gluing said internal layer (10) of said covering layer (8) to said upper face (4) of said base layer (2) , by arranging said sections of said one or more cuts (12) in correspondence to said respective one or more connection lines (6) , and exerting pressure on said covering layer (8) towards said base layer (2) .11) Method, as in claim 10, wherein said base layer (2) is made of expanded or extruded polystyrene or expanded polyurethane or another polymeric foam.12) Method, as in claim 11, wherein said base layer (2) is made of expanded or extruded polystyrene with a density equal to or lower than 40 kg / m3or equal to or lower than 35 kg / m3.13) Method, as in one of claims 10 to 12, wherein said surface layer (9) is or comprises a multilayer membrane .14) Method, as in claim 13, wherein said multilayer membrane comprises a core, made of high-density polyethylene (HDPE) or polypropylene (PP) or high- impact polystyrene (HIPS) or other plastic or set of plastics, covered with an external layer of non-woven fabric .15) Method, as in one of claims 10 to 14, wherein said internal layer (10) is made of expanded or extruded polystyrene or expanded polyurethane or another polymeric foam, or comprises a first layer (10a) , made of expanded or extruded polystyrene or expanded polyurethane or another polymeric foam and a second layer (10b) consisting of or comprising a multilayermembrane .16) Method, as in claim 15, wherein said internal layer (10) or said first layer (10a) are made of expanded or extruded polystyrene with a density equal to or lower than 40 kg / m3or equal to or lower than 35 kg / m3.17) Method, as in claim 15 or 16, wherein said multilayer membrane comprises a core, made of high- density polyethylene (HDPE) or polypropylene (PP) or high-impact polystyrene (HIPS) or other plastic or set of plastics, covered with an external layer of nonwoven fabric.

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