CA2125557C

CA2125557C - Process for producing composite boards

Info

Publication number: CA2125557C
Application number: CA002125557A
Authority: CA
Inventors: Helmut Wedi
Original assignee: Individual
Current assignee: Individual
Priority date: 1992-10-10
Filing date: 1993-10-09
Publication date: 2005-09-20
Anticipated expiration: 2013-10-09
Also published as: DE59304991D1; ES2096955T3; GR3022488T3; EP0625088A1; TR28182A; PL172313B1; WO1994008767A1; HUT69446A; CA2125557A1; ATE147005T1; DK0625088T3; HU9401321D0; EP0625088B1; HU215374B; RU2102240C1

Abstract

A method of manufacturing composite board whereby a continuous coat of mortar reinforced with glass cloth or a similar material is laid onto a continuous core. The still fluid mortar dribbles onto the core at a specific viscosity and is distributed over the core. The rate at which the mortar dribbles is regulated.

Description

METHOD OF MANUFACTURING COMPOSITE BOARD
The present invention concerns a method of manufacturing composite board.
Austrian Patent No. 242,581 discloses a method of manufacturing composite boards with cores of expanded material. The cores are positioned and introduced horizontal and coated with soft mortar. The mortar is compacted with a pivoting cylinder. Downstream of the cylinder glass cloth is removed from a roll, forced down against the top of the mortar, and entrained by the advancing web.
Farther downstream another coating of mortar is applied loosely to the first coating and the glass cloth and compacted with another pivoting cylinder.
The two coats of plastic over the expanded-material core of a composite manufactured by the method disclosed in Austrian Patent No. 242,581 are together much thicker than their framing. They are heavy and inappropriate for such interior structures as tiled walls. Such composites are accordingly primarily employed on flat roofs and facades. In other words, much more mortar is used to embed and attach the glass cloth than is needed for interior construction.
German Patent No. 3 423 006 discloses a method of manufacturing light-weight structural boards. A woven or knitted fabric is stretched tight over an expanded-material component and covered with a thin coating of water-resistant mortar.
The mortar is then smoothed and adheres tight to the fabric. One drawback is that, while the fabric is being stretched, forces can be exerted between it and the plastic that tend to separate the two. Another drawback is that each board is separately covered with fabric and coated with mortar. Such discontinuous production is expensive.
A method of manufacturing similar boards is known from British Patent No.
1,459,575. A mixer pours a base onto a belt that advances at a constant speed.
A
doctor distributes the material to a prescribed thickness. A sealant is similarly applied to the base and a surface to the sealant. One drawback to this approach is that the thickness of each layer depends on the speed of the belt and on the skill of the personnel.
German Patent No. 3 136 935 describes a method of manufacturing board. The core of the board essentially comprises layers of adjacent and parallel mineral fibers. The fibers are oriented at an angle of 10 to 60° to the surface of the board. A sheet of r aluminum or plastic is applied to the layers of fiber and a coating of fireproof mortar to the aluminum or plastic.
One drawback to method is that the board is flexible and accordingly appropriate only for wrapping pipes or covering flat and even surfaces.

German Patent No. 3 444 881 discloses a method of manufacturing board. The core is a layer of mineral fiber, glass staple or wadding for example. The core is more or less compacted to a fraction of the thickness of the final board. A layer of mortar is applied to each side of the core. Glass fibers have been blended into the mortar.
This board is not very strong and is appropriate only for surfacing solid concrete walls.
There is a need therefore, for a method of manufacturing composite board that will provide satisfactory insulation of both noise and heat, that will have satisfactory mechanical properties, that will be relatively light in weight, smooth, and flat, and that is comprised of little material.
Accordingly, the invention relates to a method of producing composite boards, wherein a core web is coated in a continuous process with a layer of mortar reinforced with glass fibre fabric or the like, the core web, which is of plastic foamed material and/or fibres, balls, chips, strips or pieces of organic and/or inorganic materials, being supplied horizontally in the form of an endless web and hardening mortar flowing in a liquid state and being distributed on the side of the core web for coating, characterised in that a glass fibre fabric web is laid sufficiently tightly on the surface of the core web to leave just one adhesive layer between the glass-fibre fabric web and the core web, a stripper distributes the mortar so that the layer of mortar embeds the web of glass fibre fabric and the still-wet mortar layer then dries and sets.
A method of manufacturing composite board comprising a substantially planar core having opposite flat sides, a coat of solidified, cement-like mortar disposed on at least one of said sides and a layer of cloth embedded within said mortar, said mortar and said cloth forming a reinforcement for said core and providing a supporting surface for a covering material, said method comprising the steps of continuously introducing said core into manufacturing apparatus in a horizontal direction;

dribbling said mortar in a fluid condition onto one side of said core and distributing said mortar over said one side to form a layer; applying an endless web of cloth in a substantially tension free condition to said layer of mortar at a speed which is the same as a speed of movement of said core in said horizontal direction;
impressing and embedding said endless web into the mortar layer to provide reinforcement;
wiping off, with a doctor, the mortar which exceeds a prescribed layer thickness, thereby forming a lip of mortar upstream of the doctor; sensing the quantity of mortar contained in the mortar lip; controlling the rate of mortar dribbled onto the core in dependence upon the sensed quantity; cutting a still moist mortar layer and embedded cloth to selected lengths; and drying and solidifying the mortar layer with the embedded cloth.
Some of the present invention s advantages will now be described. The core can be of expanded material alone or of expanded material with a layer of fibers, glass wadding for example, with a layer of beads, chips, flakes, fragments, etc. of organic or inorganic materials, or with an extruded layer of more expanded material.
Since the core is in the form of a web and the mortar is preferably dribbled onto it at a rate that matches the speed it is advancing at, the -3a-212~~~~
t. glass cloth can be embedded in the mortar while it is still 2 moist and there will be no internal stress to buckle the 3 board. Once the mortar is dry, accordingly, the board will 4 be strong and will satisfactorily insulate both heat and noise. It can be employed not only to surface existing 6 walls, but as a wall in its own right. It can also be 7 plastered, papered, or tiled.

9 One particular advantage is that a layer of reinforced mortar can be applied to the smooth surface of the core to produce 11 boards that are especially practical in the construction 12 industry, for erecting partitions for example. Such 13 partitions will be strong enough to support tiles, 14 coverings, and fixtures.
16 It is of essential significance that, although the mortar on 17 one side of the core is very fluid while. it is being applied 18 and accordingly very thin, it will dry extremely strong. Tt 19 has been demonstrated practical for the mortar to be applied fluid enough to spread 22 to 28 cm as measured with the 21 Wicker cup in accordance with DIN 1060.

23 It is practical in the foregoing event for the liquid mortar 24 to flow onta the core between two close-together cylinders that preferably rotate in the same sense. The cylinders keep 26 the mortar homogeneous enough to harden uniformly and only 27 once it has spread. The cylinders can also be spaced and 212ja~7 rotated to precisely regulate the flow of the mortar.
3 The flow of mortar can for example be regulated by opening 4 and closing a device that comprises the aforesaid cylinders.
6 Compacting the layer of beads, chips, flakes, fragments, etc.
7 of organic or inorganic materials is also practical. This 8 procedure will result in a core essentially as thick as the 9 finished board and strong enough to be exposed to static or dynamic stress of the extent to be expected when employed for 11 the purposes discussed herein.

13 It is of advantage when the layer of beads, chips, flakes, 14 fragments, etc. of organic or inorganic materials is coated with an expanded extrudate for the extrudate to permeate or 16 bind the beads etc. The result will be a core or sandwich of 17 organic or inorganic materials wherein at least one surface 18 of the mineral fibers, which are not particularly strong ~I9 mechanically, will be in contact with the more durable and homogeneous expanded extrudate.

22 The expanded extrudate can be polystyrene or glass, a 23 recycled bulk or expanded extrudate, or a wood-bonding sheet.
24 Other similar materials can also be employed. Some examples are recycled bulk or expanded and compressed recycled 26 materials, expanded polyurethane, and such solid blends as 27 wood-bonding and similar materials. It is essential in this event as well for the expanded-material core to be provided at some point with a rigid and reinforced sandwich structure that will render it not only fireproof but also able to have tiles for example cemented or otherwise fastened to it or to be plastered, wallpapered or painted.
It is of advantage for the layer of reinforced mortar to be very thin, as thin as 0.2 mm for example. There is on the other hand essentially no upper limit.
To ensure relaxed but uniform embedding of the glass cloth, it can be introduced by way of a tension equalizer.
The glass cloth can be woven or non-woven. Fabrics of aramid, polyester, and similar materials can also be employed when sufficiently stable. Metal gauze, copper or stainless steel for example, can also be employed.
Embodiments of the present invention will now be specified by way of example with reference to the drawings, wherein Figure 1a illustrates a production line for manufacturing a continuous core, Figure 1b illustrates another version of a production line for manufacturing a continuous core, 2~2 ~~5 i a- Figure 2 illustrates machinery for manufacturing board out of 2 a continuous core, 4 Figure 3a is a cross-section through a section of board with a core of expanded material, 7 Figure 3b is a cross-section through a section of board with 8 a core of mineral staple or wadding, Figure 3c is a cross-section through a section of another 11 type of board with a core of mineral staple or wadding, and 12 Figure 3d is a cross-section through a section of still 13 another type of board with a core of mineral staple or 14 wadding.

17 The creation of a continuous core 2 will now be discussed 18 with reference to Figure la. An extruder 31 extrudes a layer 19 of expanding extrudate 21 onto a roller pavement 30. A fiber distributer 32 deposits staple ' 21 or wadding 22 or 22' onto the advancing expanding extrudate 22 21. The staple or wadding can be mineral or plastic fiber, 23 sheep's, llama's, or other animal wool, fiber from recycled 24 clothing etc. or a combination thereof. Fiber distributer 32 can deposit staple or wadding 22 or 22' onto expanding 26 extrudate 21 loose or tight.

-The core can be a core 2 "' with two layers instead of a 2 core 2 with one layer. Core 2 " ' can comprise a layer of 3 expanding extrudate 21 and a layer of staple or wadding 22 or 4 22'. Another layer of expanding extrudate 21 can be extruded over staple or wadding 22 or 22', producing a core 2 " " in 6 the form of a sandwich with a layer of staple or wadding 7 between two outer layers of expanding extrudate.

9 Another type of core is illustrated in Figure lb. Mineral or animal staple or wadding 22 or 22' is compressed into a 11 web by a fiber compactor 32'. Upon leaving the compactor, 12 staple or wadding 22 or 22' will be relieved of pressure and 13 expand again, and individual fibers will project out of the 14 upper surface of the core. When an extruder or extruders 31' and 32' extrude expanding extrudate 21 onto this loosely 16 compacted core of staple or wadding 22 or 22', the projecting 17 fibers enter into an intimate bond with the extrudate. The I8 result is a continuous core 2 " " that rests on pavement 30' 19 and exhibits the positive properties of a hardened expanding extrudate 21 in conjunction with staple or wadding 22 or 22',' 21 specifically satisfactory insulation of noise and heat along 22 with static and dynamic endurance.

24 Fiber distributer 32 or fiber compactor 32' can also compact the staple or wadding 22 or 22'in a core 2 " or 2 " ' until 26 the surface is smooth and resistant.

_ g _ '~ Core 2, 2 " , 2 " ', or 2 " " can be further processed in the 2 equipment illustrated in Figure 2. Composite board can be 3 produced therein from a continuous core 2. The core is 4 deposited on a driven roller pavement and can be trimmed into separate panels or sections. A mortar hopper 3 is positioned 6 above a colander 4. Between colander 4 and the surface of 7 core 2 is a flow regulator 5. Flow regulator 5 comprises two ~8 narrowly separated cylinders 105 and 106 that rotate in the 9 same sense. Cylinders 105 and 106 are jacketed with water-repellent rubber with a Shore hardness of W 1357. Their 11 diameter is approximately 200 mm. They are synchronized by a I2 variable-speed motor.

14 The viscosity of the mortar flowing out of hopper 3 and through colander 4 and flow regulator 5 is extremely 16 critical. The mortar is a shallow-bed mortar based on cement 17 and containing plastic to render the hardened mortar more 18 elastic. The mortar also contains fillers to improve its 19 thixotropic properties, which must be maintained precisely constant. Especially appropriate for this purpose are 21 powdered quartz or chalk for example. Recipes for various 22 purposes can be obtained from specialized firms.

29 The spread of the mortar is measured in a frustroconical Wickert ring 40 mm high and with an ugper inside diameter of 26 79 mn and a lower inside diameter of 65 mm resting on a 27 Hegmann surface in accordance with DIN 1060 (EN 196). The _ g ~w diameter of the pancake should range between 22 and 28cm and 2 preferably between 23 and 27cm.The thready consistency of the 3 mortar is homogenized or maintained by the rotation of 4 cylinders 105 and 106. The mortar flows onto core 2 through the gap between the cylinders and is evenly distributed over 6 the surface of the core by a doctor 6 downstream of the 7 cylinders.

9 Downstream of doctor 6 a continuous web 7 of woven or non-woven glass cloth is introduced practically free of stress, 11 subject, that is, only to its_own weight and advancing at the 12 same speed as core 2. The cloth is obtained from a roll 18 13 and travels through a tension equalizer 19 of a type in 14 itself known from textile engineering. A beam 8 lays web 7 just (approximately 2 mm) above core 2 and accordingly 16 slightly embeds it in layer 9 of mortar. The mortar is 17 forced against the bottom of the web and between its 18 interstices, ensuring satisfactory adhesion in that the 19 distance from web 7 of woven or non-woven glass cloth is such that precisely one more layer of adhesive is maintained 21 between the cloth and the upper surface of the web.

23 Another doctor 10 scrapes excess mortar off the upper 24 surface of the cloth and smoothes it into a layer that not only embeds web 7 of woven or non-woven glass cloth but also 26 rises slightly above it, leaving the cloth as a 27 reinforcement in the still wet mortar 9, which nevertheless contacts the surface of the web only by ~ ~ ~of~a thin layer 2 of mortar. The excess mortar 11 scraped off by second doctor 3 10 creates a downstream demarcation in the form of a lip 12 4 that can be detected by an optico-electronic or capacitative sensor 13.

7 When lip 12 moves too far from second doctor 10, sensor 13 8 emits a signal to a data processor 14, which reduces the flow 9 through flow regulator 5 by decelerating cylinders 105 and 106.

12 When lip 12 moves back toward second doctor 10., data 13 processor 14 will reestablish the speed of the cylinders, and 14 flow regulator 5 will emit more mortar.
16 The layer 9 of mortar on care 2 downstream of second doctor 17 10 is accordingly highly uniform.

19 Core 2 now arrives below a lengthing position 15, where a knife blade 15' cuts through the still moist layer 9 of 21 mortar and its reinforcing web 7 of woven or non-woven glass 22 cloth and optionally through core 2 " , 2 "'. or 2 " " as 23 well, creating an edge at regular intervals for edge-to-edge 24 modular mounting or at other convenient points when the board is to be continuous. Core 2 is now dried and solidified 26 along with its glass-reinforced layer 9 of mortar in a kiln 27 16. The reinforced layer 9' of mortar is accordingly firmly 21~~5~ r~
anchored into 2' , 2" , 2" ' , or 2" " . If the core is to be 2 coated on only one surface, the composite board can be 3 employed as is. Usually, however, the core is coated on both 4 sides. The core coated on one side is accordingly returned upside-down to the upstream end of roller pavement 1, and the 6 aforesaid procedure is repeated. Composite board with a core 7 of mineral fiber or of any other organic or inorganic 8 materials can be produced as hereintofore specified.
9 Appropriate are various in-themselves known mixtures of cement, water, and plastic that can be made into shallow-bed 11 mortars. Although their recipes could be specified, they 12 will not be herein because they do not constitute part of the 13 invention. Such shallow-bed mortars resemble the usually 14 water-resistant mortars employed for laying tile.
16 The thickness of the core is relatively uncritical. It can 17 be between a few millimeters and a few centimeters, between 18 20 and 100 mm for example, depending on its purpose. Layer 9 19 of mortar will generally be applied as economically as possible, just enough to cover the glass cloth.

22 Figures 3a through 3c illustrate various composite boards of .
23 types that can be produced in accordance with the present 24 invention.
26 The core 2' of expanded extrudate 21 illustrated in Figure 3a 27 has a layer 9' of mortar reinforced with an embedded web 7 of 1 r non-woven glass cloth on each s~~~ ~ ~
woven o 3 The board illustrated in Figure 3b on the other hand has a 4 core 2" of mineral or animal staple or wadding 22 or 22' with a layer 9' of mortar reinforced with an embedded web 7 6 of woven or non-woven glass cloth on each side.

8 The core 2 " ' illustrated in Figure 3c combines mineral or 9 animal staple or wadding 22 or 22' with a layer of expanded extrudate. It is also coated on each side with a layer 9' of 11 mortar reinforced with an embedded web 7 of woven or non-12 woven glass cloth.

14 The core 2" " of the composite board illustrated on Figure 3d is particularly practical. A layer of mineral or animal 16 staple or wadding 22 or 22' is sandwiched between two coats 17 of expanded extrudate 21. The fibers project like those 18 illustrated in Figure 3c into each coat of extrudate. The 19 result is a very intimate and solid bond between mineral or animal staple or wadding 22 or 22' and the coats of expanded 21 extrudate 21. The two coats prevent the fibers from 22 escaping.
23 .
24 Escape can be further inhibited by mixture with wool or by wool alone.

27 It is also possible to chemically coat or impregnate each r ~-~~~ individual fiber. Board made of chemically treated fiber 2 does not need to be coated with expanded extrudate, mortar, 3 or cloth. A coat 9' of mortar reinforced with an embedded 4 web 7 of woven or non-woven glass cloth can also be applied to each side of such a highly stable core 2 " "

7 One particular advantage of all four composite boards 8 specified herein is the common interface between the mortar 9 and the glass cloth. This common interface ensures that the glass cloth will be intimately secured to the care by the 11 mortar and that the mortar will have a surface appropriate 12 for papering, tiling, etc.

Claims

1. A method of producing composite boards, wherein a core web is coated in a continuous process with a layer of mortar reinforced with glass fibre fabric, the core web, which is composed of one or more materials selected from the group consisting of plastic foamed material, fibres, balls, chips, strips or pieces of organic materials, and strips or pieces of inorganic materials, being supplied horizontally in the form of an endless web and hardening mortar flowing in a liquid state and being distributed on the side of the core web for coating, characterised in that a glass fibre fabric web is laid sufficiently tightly on the surface of the core web to leave just one adhesive layer between the glass-fibre fabric web and the core web, a stripper distributes the mortar so that the layer of mortar embeds the web of glass fibre fabric and the still-wet mortar layer then dries and sets.

2. A method according to claim 1, characterised in that the consistency of the mortar, which is applied in the liquid state as measured with a Wicker ring in accordance with, to DIN 1060 and results in a spread of 22 to 28 cm.

3. A method according to claim 1, characterised in that the mortar, which is applied in the liquid state, runs through two closely adjacent rotating rollers on to the core web.

4. A method according to claim 1, characterised in that the rollers rotate in the same direction.

5. A method according to claim 3 or 4, characterised in that the distance between and the speed of rotation of the rollers are controllable.

6. A method according to claim 1, characterised in that a sensor records the extent of the surge of mortar forming in front of a stripper and the amount of mortar flowing out of a supply device is adjusted by opening or closing a metering device on the supply device.

7. A method according to claims 5 and 6, characterised in that the speed of the rollers is altered in order to control the metering process.

8. A method according to any one of claims 1 to 7, characterised in that the core web bearing the still-wet mortar layer and the glass-fibre reinforcement is cut in the region of joints or at chosen intervals and then dries and is hardened by heat-treatment.

9. A method according to claim 1, characterised in that a core web is produced by compacting a layer of fibres, balls, chops or pieces of organic or inorganic materials.

10. A method according to claim 9, characterised in that the layer of fibres, balls, chips, strips or pieces of organic or inorganic materials, is so coated with extruder foam that the extruder foam permeates the fibres, balls, chips, strips, or pieces of organic or inorganic materials.

11. A method according to any one of claims 1 to 9, characterised in that the foamed material comprises polystyrene foam, foam glass or loose or foamed recycling material or wood-bonding board material.

12. A method according to claim 8, characterised in that after the reinforced mortar layer has dried and been left to set on one flat side of the core web, the composite board, which is finished on one side, is turned and the method is repeated on the other, hitherto uncoated, flat side.

13. A method according to any one of claims 1 to 12, characterised in that the mortar is initially coarsely distributed and the glass fibre web is embedded in the coarsely-distributed mortar.

14. A method according to any of claims 1 to 13, characterised in that the thickness of the set reinforced mortar layer is at least 0.2 mm.

15. A method according to any one of claims 1 to 14, characterised in that the glass fibre fabric is conveyed via a web reservoir.

16. A method of manufacturing composite board comprising a substantially planar core having opposite flat sides, a coat of solidified, cement-like mortar disposed on at least one of said sides and a layer of cloth embedded within said mortar, said mortar and said cloth forming a reinforcement for said core and providing a supporting surface for a covering material, said method comprising the steps of:

(a) continuously introducing said core into manufacturing apparatus in a horizontal direction;

(b) dribbling said mortar in a fluid condition onto one side of said core and distributing said mortar over said one side to form a layer;

(c) applying an endless web of cloth in a substantially tension free condition to said layer of mortar at a speed which is the same as a speed of movement of said core in said horizontal direction;

(d) impressing and embedding said endless web into the mortar layer to provide reinforcement;

(e) wiping off, with a doctor, the mortar which exceeds a prescribed layer thickness, thereby forming a lip of mortar upstream of the doctor;

(f) sensing the quantity of mortar contained in the mortar lip;

(g) controlling the rate of mortar dribbled onto the core in dependence upon the sensed quantity;

(h) cutting a still moist mortar layer and embedded cloth to selected lengths; and (i) drying and solidifying the mortar layer with the embedded cloth.

17. A method as in claim 15, wherein the mortar dribbles fluid enough to spread 22 to 28 cm as measured with a Wicker ring in accordance with DIN 1060.

18. A method as in claim 15, wherein the still fluid mortar dribbles onto the core through two close-together cylinders.

19. A method as in claim 18 wherein the distance between the cylinders and the speed they rotate at can be varied.

20. A method as in claim 16, wherein a sensor detects how much excess mortar is upstream of the doctor and accordingly opens and closes a flow regulator to regulate how much mortar dribbles through a colander.

21. A method as in claim 19, wherein the speed the cylinders rotate at is varied to regulate the flow of mortar.

22. A method as in claim 16, wherein a layer of fibers, beads, flakes, or fragments of organic or inorganic materials are compacted to create the core.

23. A method as in claim 22, wherein the layer of fibers, beads, flakes, strips, or fragments of organic or inorganic materials is coated with foamed extrudate such that their fibers project into it.

24. A method as in claim 16, wherein, once the reinforced layer of mortar has been dried and solidified on one side of the core, the core is turned upside down and the procedure repeated on the uncoated side.

25. A method as in claim 16, wherein the mortar is initially only roughly distributed and in that the cloth is embedded in the roughly distributed mortar.

26. A method as in claim 16, wherein the dried reinforced mortar is at least 0.2 mm thick.

27. A method as in claim 16, wherein the cloth is introduced by way of a tension equalizer.

28. A method as in claim 16, wherein the core is formed of a foamed material selected from the group consisting of foam plastic, glass foam and foamed recycled material.

29. A method as in claim 28, wherein the foamed recycled material is polystyrene, glass, or bulk or foamed recycled material or wood-bonding board material.

30. A method as in claim 16, wherein said cloth is selected from the group consisting of non-woven cloth and woven cloth.

31. A method as in claim 30, wherein the non-woven cloth is fleece.