CN112512766A

CN112512766A - Method and system for producing material boards and press pad

Info

Publication number: CN112512766A
Application number: CN201980050415.0A
Authority: CN
Inventors: F·霍夫曼; J·卡姆; J·卡斯滕
Original assignee: Dieffenbacher GmbH Maschinen und Anlagenbau
Current assignee: Dieffenbacher GmbH Maschinen und Anlagenbau
Priority date: 2018-05-28
Filing date: 2019-05-28
Publication date: 2021-03-16
Anticipated expiration: 2039-05-28
Also published as: DE102018112727A1; CN112512766B; WO2019229007A1; DE102018112727B4; EP3802035A1

Abstract

The invention relates to a method for producing a material sheet (6), comprising the following steps: producing a press-formed material mat (1) on a forming belt (10), wherein the press-formed material mat (1) comprises at least one main material (2) which is optionally mixed with a binder, transversely to the production direction (9); transporting the press material mat (1) into a press (14), preferably a continuously operating press (14); and pressing the press pad (1) under the action of pressure and/or heat into a pressed board (5), after which the pressed board is trimmed into a material board (6). The method is characterized in that the pressed material mat (1) further comprises an auxiliary material (3), which is applied alongside the main material (2) in the production direction (9), and in that the auxiliary material (3) is at least partially, preferably completely, separated from the pressed board (5) after pressing, and in that the main material (2) constitutes the material board (6). The invention further relates to a system (20) for producing a material sheet (6) and to a press material mat (1).

Description

Method and system for producing material boards and press pad

The present invention relates to a method for manufacturing a material panel according to the preamble of claim 1, a system for manufacturing a material panel according to the preamble of claim 13, and a press pad according to the preamble of claim 18.

Material panels of any kind, such as particle boards, fiber boards and acoustic panels or fiber composite panels consisting of synthetic or natural fibers embedded in thermosetting or thermoplastic plastics, or rubber panels are nowadays used in many fields, such as furniture construction, residential construction or lightweight construction of automobiles. To produce such a material sheet, a starting material is first applied to a base as a mat and subsequently pressed and/or hardened under the action of pressure and/or heat into a material sheet. This is usually done in a continuous process, where an endless (endless) mat is first discharged onto a forming belt and after pressing and/or hardening the endless strip is divided into panels of limited length.

Of particular note are the plate edges extending along the production direction. By means of the pressing process, in particular when using flowable starting materials or when using starting materials which develop flowability during the pressing process, undefined sheet edges are formed, the properties of which fail differently for the produced material sheet, for example due to different densities or changing material compositions. Since such irregularities also affect the properties of the material sheet, the pressed and/or hardened strip is extensively trimmed at the sheet edges after pressing, removing the non-uniformities.

Thus, it is known, for example, from DE 19805996 a1 that the resulting (applied) mat is sealed with respect to the forming belt or with respect to another coating belt by means of the coating belt, so that an enlargement of the width of the mat during pressing is avoided.

Alternatively, it is known, for example from DE 3347877 a1 or DE 2923036 a1, to arrange wires (steel wires) or lateral delimitations (bands) (lateral delimitations) laterally along the press gap in a continuously operating press, or to run the wires or lateral delimitations together in the press. The pressing gap is thereby sealed laterally and the material to be pressed can only move in a defined frame, so that the formation of uneven edge regions is avoided.

In the field of fiber composite materials, it is known, for example, from DE 102013105296 a1 to produce fiber-reinforced molded parts from a resin filler layer, wherein narrow strips are fed together along the edges in the felted and impregnated region, so that lateral limiting elements for the fibers to be mixed and the resin filler layer are formed. The narrow strips running together achieve complete wetting of the fibers, so that in particular the edge regions can be kept free from trimming before further processing.

DE 19847814B 4 discloses a method for producing press plates, in which the forming and transport of the press material mat on the forming belt takes place in a space delimited at the longitudinal sides by a co-operating vertical lateral support belt, so that a defect-free lateral delimitation (lateral delimitation) of the press material is ensured until the finished plate is removed from the press.

The use of lateral tapes, wires or the like has basically proven useful. However, the manufacture of different material sheets on a press is also significantly limited. Thus, the lateral bands are most often only specific to a particular width and a particular height (adjusted only to fit a particular width and a particular height). Although there are side strips which can be compressed together, for example, the required width is thereby increased and thus the width of the material sheet to be manufactured is reduced, furthermore the use of side strips can be associated with increased expenditure for maintenance and cleaning of the side strips.

The object of the invention is therefore to provide a method, a device and a press pad in which the lateral edge sealing can be flexibly adapted to various requirements, in particular height variations, width variations and/or material variations.

Another object of the invention is to provide a method, a device and a press material mat, in which maintenance and cleaning costs are minimized.

Another object of the invention is to provide a method, a device and a press blank in which the width increase of the press blank during pressing is limited.

These objects and other objects are achieved by a method and a system for manufacturing a material sheet and a press pad as described in the independent claims.

As a first solution, a method of manufacturing a material sheet is provided, comprising the steps of: the method comprises the steps of producing a press material mat on a forming belt, wherein the press material mat comprises at least one main material, optionally mixed with a binder, transversely to the production direction, conveying the press material mat into a press, preferably a continuously operating press, and pressing the press material mat into a pressed board under the action of pressure and/or heat, and after pressing trimming the pressed board into a material board. The method is characterized in that the pressed blank also comprises a secondary material, which is applied next to the primary material in the production direction and which is at least partially, preferably completely, separated from the pressed board after pressing, and the primary material forms a material board.

By using auxiliary material, which is likewise applied to the molding belt as part of the press material mat, the auxiliary material can be adapted to the respective mat height of the main material as required. The secondary material may be applied laterally to the primary material even when the width of the primary material changes. Thereby, flexible material sheets of different widths and heights can be manufactured in the same system (with the same equipment). The auxiliary material, although part of the pressed material mat, is removed again after pressing, so that the material sheet is formed mainly of the main material. The use of auxiliary materials can also be integrated without problems into existing processes and systems without the need for greater retrofitting measures.

A preferred embodiment is characterized in that, after pressing of the press pad, a preferably inhomogeneous transition region is formed between the primary material and the secondary material. By applying pressure and/or heat, a movement of the primary material occurs precisely in the flowable material, so that the primary material can flow into the secondary material in small portions at the boundary region of the primary material and the secondary material and can be connected (joined) to the secondary material.

Preferably, the primary material and the secondary material are applied simultaneously to the forming belt, whereby the system can be constructed compactly. Alternatively, the primary material and the secondary material can be applied to the forming belt after each other (successively). This makes it possible to apply precisely the respective material with a defined width and to apply precisely the secondary material next to the primary material.

Preferably, the primary material is trimmed after it is applied, and the secondary material is then applied. By trimming the primary material after application to the forming belt, a precision pad is produced, with the secondary material (provided) at the trimmed edge of the pad.

In a preferred embodiment, the primary and secondary materials are different in their chemical and/or physical properties. In particular, the secondary material relates to a material different from the primary material. The main material can be, for example, chips or fibers composed of cellulose-containing material, in particular lignocellulose-containing material, plastics, resin fillers or natural or artificial fibers. Mixtures of these materials may also form the primary material. The main material may be present in solid form, for example as chips, fibres or particles, or else in flowable form, in particular in viscous flowable form. The auxiliary material may be composed of the same material. Preferably, only one material type is used as auxiliary material, which contains only insignificant proportions of other materials. The auxiliary material should preferably be present in solid form, so as to ensure a corresponding sealing against the edge.

Another embodiment is characterized in that the application of the main material and/or the auxiliary material is carried out by means of scattering. The main material may be interspersed as a single layer of a press mat or a multi-layer press mat. The auxiliary material is preferably only a single layer.

Alternatively or in combination, a press pad is applied to the intermediate layer and/or covered with the intermediate layer prior to pressing. Contamination on the forming belt and/or in the press, for example due to caking, can be avoided by the intermediate layer. The intermediate layer is preferably made of plastic, fiber or paper.

Preferably, the intermediate layer is removed from the pressed board after pressing. Alternatively, the intermediate layer disposed on the press pad may be removed at least before pressing. Furthermore, the upper intermediate layer or the lower intermediate layer can be cyclically constructed and the intermediate layer is (can be (cyclically)) consumed.

The method is further characterized in that the auxiliary material is applied with a width of less than 80mm, preferably less than 60mm, particularly preferably less than 45mm, most preferably less than 30 mm. The use of the auxiliary material can be optimized by the small width. The desired width may depend on the flowability of the primary material and the desired seal.

Preferably, the secondary material is free of binder and/or residual material from the preparation (recycling) of the primary material. The fact that the auxiliary material is free of binder makes it easier for the auxiliary material to be separated from the main material and for the auxiliary material to be fed back more easily to its production (recycling) or processing. In order to achieve a good edge sealing by the auxiliary material, the auxiliary material can in particular have intermeshing properties, so that a sealing of the main material is achieved. When the main material is obtained in the recycling process or the decomposing process, it is in consideration of resource efficiency that the main material obtained in the further process is utilized as the auxiliary material in the backlog. In this case, the auxiliary material can also have a residual material attached to it, which can contribute to the adhesion of the auxiliary material particles to one another.

The pressed plate is preferably trimmed a plurality of times, wherein, in particular in a first step, substantially only the auxiliary material is separated from the pressed plate and in a second step at least the transition region is separated. By multiple trimming (trimming), the materials used can be better separated.

Alternatively or in combination, the separated auxiliary material and/or the separated transition region are treated (recovered) and fed back into the method. Valuable primary material can be recovered from the transition zone. In particular, pure auxiliary material can be immediately fed back into the process again.

As a further solution, a system for manufacturing a material sheet, in particular for performing the method as described above, is proposed, which system comprises: forming a belt; a device for applying at least one main material (optionally mixed with a binder) for producing a mat of compacted material on a forming belt; preferably a continuously operating press for pressing the mat of compacted material into a board under the influence of pressure and/or heat; and an edging device for edging the sheet into a sheet of material. The system is characterized in that a further device for applying an auxiliary material as part of the press pad is arranged beside the main material before the press.

A further embodiment of the device is characterized in that the equipment for applying the main material is arranged before and/or after the device for applying the auxiliary material. The arrangement may also depend on the primary material used. For the primary material to be already flowable at the time of application, it is advisable to apply the secondary material before the primary material. Alternatively, it is also conceivable that the primary material to be dispensed is first precompacted in a precompressor and only then the secondary material is dispensed.

Preferably, the device for applying the primary material and the device for applying the secondary material are arranged in combination in one unit. Whereby the length of the entire system can be reduced.

A preferred embodiment is characterized in that the device for applying the primary material and/or the secondary material is a spreading device which preferably comprises a spreading wall in which the primary material and/or the secondary material is spread. By using a spreading wall, the primary material and/or the secondary material can be spread in exactly the desired width.

Alternatively or in combination, the trimming device comprises at least two devices for trimming the pressed board, which are preferably arranged one after the other. In this way, the plate can first be trimmed by means of the first device, so that the auxiliary material is removed, and the removal of the transition region from the plate can be carried out by means of the second device. Whereby the desired material sheet is obtained after edging.

As a further solution, a press-material mat is proposed which is pressed in a press to form a plate, which is produced in particular according to one of the above-described methods, wherein the press-material mat is constructed from at least one main material and at least one auxiliary material, and the auxiliary material is at least partially, preferably completely, separated from the pressed plate after pressing.

Alternatively or in combination, the secondary material is arranged next to the main material in the production direction and/or the secondary material divides the main material into at least two sections. The auxiliary material can be arranged at a distance from the main material or next to (adjacent to) the main material.

Preferably, the secondary material is free of binder and/or residual material from the preparation (recycling) of the primary material.

A preferred embodiment of the press pad is characterized in that the auxiliary material is applied in a width of less than 80mm, preferably less than 60mm, particularly preferably less than 45mm, most preferably less than 30 mm.

Further advantageous measures and embodiments of the subject matter of the invention emerge from the dependent claims and the following description and the drawings. The present invention will be described in detail below with reference to the accompanying drawings.

Shown in the attached drawings:

fig. 1 shows a first embodiment of a system according to the invention for producing material boards in a side view;

fig. 2 shows an embodiment according to the invention according to fig. 1 in a top view;

FIG. 3 shows a further design configuration of the system according to the invention in a top view;

FIG. 4 shows a cross section through an extruded preform mat; and

figure 5 shows a section through a pressed panel.

Fig. 1 shows a side view of a system 20 according to the invention for producing a material sheet 6. For this purpose, the primary material 2 is first applied to the forming belt 10 by means of a device 11. The primary material 2 may be placed or discharged onto the forming belt 10, for example, by means of a device 11. Alternatively, the device 11 can also be configured as a spreading device, so that the main material 2 is spread onto the forming belt 10. Depending on the type of primary material 2, it may be expedient if, when applying the primary material 2, one or more lateral limiting members (lateral limits), for example discharge boxes or distributor walls, are arranged directly above the forming belt 10, which serve to limit the spatial development (spatial extension) of the primary material 2. Furthermore, this is relevant mainly in the case of viscous or light materials as the main material 2.

In the exemplary embodiment shown here, a further device 12 for dispensing the auxiliary material 3 is arranged adjacent to the device 11 for dispensing the main material 2 in the production direction 9. The apparatus 12 is arranged to apply the secondary material 3 alongside the primary material 2 on the forming belt 10. Like the primary material 2, the auxiliary material 3 can also be applied, deposited (laid) or spread onto the forming belt 10, and the device 12 is correspondingly designed as a dispensing device or application device, spreading device or nozzle. Furthermore, the auxiliary material 3 can also be applied in a laterally delimited space which for this purpose delimits the auxiliary material 3 toward and/or opposite the main material 2. As an alternative to the embodiment shown here, the

devices

11 and 12 can also be designed as a common unit, so that the primary material 2 and the secondary material 3 can be applied simultaneously to the forming belt 10.

As the main material 2, each material used for producing the material plate 6 can be considered first. Thus, the main material 2 may be a lignocellulose-containing material, such as chips or fibres. It is also conceivable to use plastics, in particular resin fillers or fiber-reinforced plastics, or mixtures in solid form or in viscous fluid form as the main material 2. The main material 2 can also be mixed with a binder, for example urea or isocyanate glue or hot-melt fibres, for creating a composite (union) between the individual components of the main material 3. The secondary material 3 differs from the primary material 2, in particular with regard to its chemical and/or physical properties. This makes it possible to clearly separate (distinguish) the main material 2 and the auxiliary material 3, and after pressing the press pad J, the auxiliary material 3 is removed from the pressed board 5. The auxiliary material 3 can be, in particular, a cost-effective (low-cost) material or a waste material from an upstream (preceding) preparation process (recycling process) for the main material 2. The auxiliary material 3 may be mixed with a binder. However, mixing of the binder in the auxiliary material 3 is preferably avoided, whereby the auxiliary material 3 can be more easily separated from the pressed board 5 and can be fed again to a possible recycling process.

After the press mat 1 is manufactured, it is fed to a press section in a continuously operating press 14. Instead of the continuously operating press 14, a single-stage (single-stage) press or a multistage (multi-stage) press may also be used. Depending on the primary material 2 and the secondary material 3 used, the press pad 1 can be precompacted in a precompressor 13 before the press 14. Preheating the press mat 1 by means of steam or microwaves or spraying the press mat 1 with a liquid, such as water, an aqueous solution or an emulsion, can also have a positive effect on the pressing of the press mat 1 into the pressed board 5 in the press 14.

Fig. 4 and 5 show exemplary cross sections through the pressed mat 1 (fig. 4) or the pressed plate 5 (fig. 5), respectively. The press material mat 1 shown in fig. 4 resting on the forming belt 10, which is not yet fed to the press 14 or prepress, comprises a main material 2, which is enclosed at the sides by an auxiliary material 3. The auxiliary material 3 is arranged here directly adjacent to the main material 2, wherein, even in the case of the application of material, a gap can be formed between the main material 2 and the auxiliary material 3, using lateral limiting elements. The use of the auxiliary material 3 should be minimized so that the width of the strip of auxiliary material 3 is less than 80mm, preferably less than 60mm, particularly preferably less than 45mm, in particular less than 30 mm.

The pressed board 5 shown in fig. 5 is produced by pressing the press mat 1 according to fig. 4, in which pressed board 5, in addition to the areas for the primary material 2 and the secondary material 3, a transition area 4 is formed, which consists of a mixture of the primary material 2 and the secondary material 3. By means of the pressure acting on the press pad 1 in the prepress 13 and/or the press 14, the main material 2 and the auxiliary material 3 are moved towards each other in the boundary region and are partially mixed into the transition region 4.

The primary material 2 and the secondary material 3 may have the same height in the press pad 1. Depending on the density of the primary material 2 or the secondary material 3, the height of the individual sub-areas of the press pad 1 may be different. In particular, the mat height of the partial regions of the press mat 1 with the secondary material 3 can be up to 20% higher relative to the partial regions with the primary material 2, so that the secondary material 3 better retains the primary material 2 in its shape or exerts less pressure on the primary material 2 during pressing.

As shown in fig. 1, after the press 14, the pressed plate 5 is fed to the edge-trimming device 15 by a further conveying device 18, which may be configured as a roller conveyor or as a conveyor belt. In the trimming apparatus 15, the edge of the pressed sheet 5 is trimmed (edge cut), and the pressed sheet is divided into the material sheets 6. Preferably, the trimming device 15 consists of two

devices

16 and 17 for trimming (trimming) the pressed plate 5, wherein in the first device 16 only a region of the auxiliary material 3 is separated from the pressed plate 5, while in the second device 17 the transition region 4 is removed from the plate 5. The separated auxiliary material 3 can be fed directly to the device 12 for discharging the auxiliary material 3, so that a circulation can be formed there. The separated transition region 4 may be fed to a preparation (recovery) section where it may be separated into a primary material 2 and a secondary material 3 and at least partially fed to a re-processing (section) in the system 20. After trimming the pressed sheet 5, a sheet of material 6 is finally obtained which can be constructed from the main material 2.

The system 20 according to fig. 1 is shown in fig. 2 in a top view from above. The partial press material mats 1 of the main material 2 are spread over a defined width of the forming belt 10 onto the forming belt 10 by means of a device 11. Alternatively, the main material 2 may not be applied directly to the forming belt 10, but for example to an intermediate layer, which rests on the forming belt 10. Two devices 12 for applying the auxiliary material 3 are then arranged in the production direction 9, which place the auxiliary material 3 laterally adjacent to the main material 2 on the forming belt 10 or on an intermediate layer. After the application of the auxiliary material 3, a further intermediate layer can also be placed on the press material mat 1, alternatively before pressing in the prepress 13 or in the press 14. The upper and lower intermediate layers, which may be configured as a single layer or as a circumferential band, may be removed again after pressing, or may also be left on the pressed board and removed only after another process, for example after curing, by polishing or grinding the material board 6.

Furthermore, fig. 2 shows, after the prepress 13, the transition region 4 in the press mat 1 or the pressed plate 5 between the inner edge of the auxiliary material 3 and the dashed line running in the main material 2.

Fig. 3 shows a further alternative embodiment of a system 20 according to the invention. This system 20 differs from the previous embodiments in that a device 19 for trimming (trimming) the edge of the applied primary material 2 is arranged directly after the device 11 for applying the primary material 2. In particular, if the main material 2 is not spread in a defined manner by means of the side edges of the spreading space or spreading surface of the device 11, this can lead to a blurred edge and to an outward reduction in the height of the spread press mat 1. The edge of the main material 2 is precisely defined by the device 19 and the auxiliary material 3 can be applied better in abutment with this edge. The transition region 4 produced in the subsequent process can thus also be kept smaller.

List of reference numerals P1589 DE:

1 pressing material pad

2 main material

3 auxiliary materials

4 transition region

5 plate

6 sheet of material

7

8

9 production direction

10 Molding belt

11 device

12 device

13 Pre-compression machine

14 press

15 trimming device

16 device

17 device

18 conveying device

19 device

20, system.

Claims

1. A method for manufacturing a material sheet (6), the method comprising the steps of:

producing a press-formed material mat (1) on a forming belt (10), wherein the press-formed material mat (1) comprises at least one main material (2) that is mixed, if necessary, with a binding agent, transversely to a production direction (9),

transporting the press material mat (1) into a press (14), preferably a continuously operating press (14), and

pressing the press pad (1) under the action of pressure and/or heat into a pressed board (5), trimming the pressed board after pressing into a material board (6),

the press pad (1) further comprises an auxiliary material (3) which is applied next to the main material (2) in the production direction (9) and after pressing the auxiliary material (3) is at least partially, preferably completely, separated from the pressed board (5) and the main material (2) constitutes the material board (6).

2. The method according to claim 1, characterized in that after pressing the press pad (1), a preferably inhomogeneous transition region (4) between the primary material (2) and the secondary material (3) is formed in the pressed board.

3. Method according to any one of the preceding claims, characterized in that the primary material (2) and the secondary material (3) are applied simultaneously or one after the other.

4. The method according to any one of the preceding claims, wherein the primary material (2) and the secondary material (3) are different in their chemical and/or physical properties.

5. Method according to any one of the preceding claims, characterized in that after the application of the primary material (2), the primary material (2) is trimmed and then the secondary material (3) is applied.

6. Method according to any one of the preceding claims, characterized in that the application of the primary material (2) and/or the application of the secondary material (3) is carried out by spreading.

7. A method according to any one of the preceding claims, characterized in that the press pad (1) is applied to an intermediate layer and/or the press pad (1) is covered with an intermediate layer before pressing.

8. A method according to any one of the preceding claims, characterised in that after pressing the intermediate layer is removed from the pressed board (5).

9. Method according to any of the preceding claims, characterized in that the auxiliary material (3) is applied with a width of less than 80mm, preferably less than 60mm, particularly preferably less than 45mm, most preferably less than 30 mm.

10. The method according to any one of the preceding claims, wherein the secondary material (3) is free of binder and/or residual material from the preparation of the primary material (2).

11. Method according to any one of the preceding claims, characterized in that the pressed board (5) is trimmed a plurality of times, wherein in particular in a first step substantially only the auxiliary material (3) is separated from the pressed board (5) and in a second step at least the transition region (4) is separated.

12. The method according to any of the preceding claims, characterized in that the separated auxiliary material (3) and/or the transition zone (4) is recovered and conveyed again to the method.

13. A system (20) for manufacturing a material sheet (6), in particular for performing a method according to any one of claims 1 to 12, the system comprising:

forming a belt;

-a device (11) for applying at least one main material (2), mixed if necessary with an adhesive, for making a pad of compacted material (1) on the forming belt (10);

a press, preferably a continuously operating press (14), for pressing the press mat (1) into a panel (5) under the action of pressure and/or heat; and

a trimming device (15) for trimming the sheet (5) into a sheet of material,

characterized in that a further device (12) for applying an auxiliary material (3) as part of the press pad (1) beside the main material (2) is arranged before the press (14).

14. The system (20) according to claim 13, wherein the device (11) for applying the primary material (2) is arranged before and/or after the device (12) for applying the secondary material (3).

15. System (20) according to claim 13, characterized in that said device (11) for applying the primary material (2) and said device (12) for applying the secondary material (3) are arranged in combination in one unit.

16. The system (20) according to any one of the preceding claims 13 to 15, wherein the device (11) for applying a primary material (2) and/or the device (12) for applying a secondary material (3) is a scattering device, preferably comprising a scattering wall in which the primary material (2) and/or the secondary material (3) is scattered.

17. The system (20) according to any one of claims 13 to 16, wherein the trimming device (15) comprises at least two means (16, 17) for trimming the pressed plate (5), preferably arranged one after the other.

18. A press pad (1) which is pressed in a press (14) to a board (5), in particular manufactured by means of a method according to any one of claims 1 to 12, characterized in that the press pad (1) is constructed from at least one main material (2) and at least one auxiliary material (3), and that after pressing the auxiliary material (3) is at least partially, preferably completely, separated from the pressed board (5).

19. Press pad (1) according to claim 18, wherein the secondary material (3) is arranged beside the primary material (2) in the production direction (9) and/or the secondary material (3) divides the primary material (2) into at least two sections.

20. Press pad (1) according to any one of claims 18 to 19, characterised in that the secondary material (3) is free of binder and/or free of residual material from the preparation of the primary material (2).

21. Press pad (1) according to any one of claims 18 to 20, characterised in that the auxiliary material (3) is applied with a width of less than 80mm, preferably less than 60mm, particularly preferably less than 45mm, most preferably less than 30 mm.