Procedure for manufacturing a building element, and the building element

A light weight sealed and structurally rigid building element, comprising:

• an outer frame component;
• two surface sheets affixed and sealed to opposite sides of said frame, at least one of said surface sheets having apertures therein and a sheet part and frame covering each aperture in a plane separate from said surface sheet;
• and
• an insulation material located between said sheets and sheet parts, said insulation consisting of polyurethane which has been injected into the interspace between the frame, and the surface sheets and sheet parts to fill all the space therebetween, and foamed and cured so that said polyurethane insulation is glued fast and sealed to said frame and to the sheets and the sheet parts to provide the sole fixing and sealing means for making a sealed and rigid element.

A procedure for manufacturing a light weight and rigid building element, comprising:

• (a) providing a mould having at least one depression therein and placing a sheet part in each depression in said mould;
• (b) placing a supporting frame around each sheet part;
• (c) placing a first surface sheet into said mould, said surface sheet having at least one aperture therein located in alignment with said supporting frame;
• (d) placing a frame component onto said surface sheet within said mould;
• (e) placing a second surface sheet over said frame, leaving an interspace between said sheet parts, said surface sheets and said frame;
• (f) closing said mould with a cover;
• and
• (g) injecting polyurethane into said interspace, foaming and curing the polyurethane within the closed mould and thereby glueing the sheet parts, the surface sheets to the frame together with the polyurethane to produce a rigid building element.

A light weight sealed and rigid building element, comprising:

• (a) an outer frame component;
• (b) two surface sheets affixed and sealed to opposite sides of said frame, one of said sheets having apertures therein with each aperture covered by a sheet part, thereby providing an interspace between said frame and the sheets;
• and
• (c) insulation material located in said interspace, said insulation consisting of polyurethane which has been injected into said interspace under pressure, to fill all gaps, whereby said polyurethane is glued fast and sealed to said frame and to said surface sheets;
• and thereby providing a sealed and rigid building element.