DE102005011399B4 - Process for the production of molded articles and a molded article produced by such a process - Google Patents

Process for the production of molded articles and a molded article produced by such a process Download PDF

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Publication number
DE102005011399B4
DE102005011399B4 DE200510011399 DE102005011399A DE102005011399B4 DE 102005011399 B4 DE102005011399 B4 DE 102005011399B4 DE 200510011399 DE200510011399 DE 200510011399 DE 102005011399 A DE102005011399 A DE 102005011399A DE 102005011399 B4 DE102005011399 B4 DE 102005011399B4
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Prior art keywords
resins
sprayed
foam
filled
free
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DE200510011399
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DE102005011399A1 (en
Inventor
Zeki Incel
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Incel Yueksel 10969 Berlin De
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INCEL YUEKSEL
Incel Yueksel
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/16—Layered products comprising a layer of metal next to a particulate layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/02—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica the layer of fibres or particles being impregnated or embedded in a plastic substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/04—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material
    • B32B19/041—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material of metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/04—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material
    • B32B19/042—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material of wood
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/04—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material
    • B32B19/047—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/12—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board next to a particulate layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0038—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving application of liquid to the layers prior to lamination, e.g. wet laminating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/18—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
    • B32B37/182—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only one or more of the layers being plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/30—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being formed of particles, e.g. chips, granules, powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/025—Particulate layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/044—Water-setting substance, e.g. concrete, plaster
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/105—Metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/06—Open cell foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/022—Foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2318/00—Mineral based
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2451/00—Decorative or ornamental articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Landscapes

  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)

Abstract

Verfahren zum Herstellen von Formkörpern, insbesondere mineralischen Platten oder Matten, als Oberflächenschutz und/oder für die Oberflächengestaltung bei Innen- und Außenanwendungen,
dadurch gekennzeichnet,
dass auf ein festes oder flexibles Trägermaterial, ein retikulierter offenzelliger Weichschaum, vornehmlich aus PUR bestehend, in Stärken von insbesondere 3 mm, mit Porengrößen von insbesondere 1,0 bis 1,5 mm, fest oder abnehmbar, plan fixiert wird;
dass auf den Weichschaum rieselfähige, trockene Materialien, die insbesondere aus Sanden, Quarziten, Calciten, Graniten, Metallgranulaten oder dergleichen, mit Korngrößen von insbesondere 0,1 bis 0,5 mm, bestehen, die auch mit Zement, Gips, pulverförmigen künstlichen Silikat-Bindern vermischt werden können, aufgebracht werden und alle Zellen des Weichschaums damit aufgefüllt werden;
dass auf den so behandelten und mit rieselfähigem Material aufgefüllten Weichschaum entweder Wasser und/oder modifiziertes Wasser aufgesprüht oder genebelt wird, oder niedrigviskose, flüssige Kunst- oder Naturharze gegossen oder gesprüht werden,
oder flüssiges Wasserglas gesprüht oder gegossen wird, oder in das in...Process for the production of shaped articles, in particular mineral boards or mats, as surface protection and / or for surface design in interior and exterior applications,
characterized,
that fixed on a solid or flexible carrier material, a reticulated open-cell soft foam, mainly consisting of PUR, in strengths of in particular 3 mm, with pore sizes of in particular 1.0 to 1.5 mm, fixed or removable, fixed plan;
that on the flexible foam free-flowing, dry materials, in particular of sands, quartzites, calcites, granites, metal granules or the like, with particle sizes of in particular 0.1 to 0.5 mm, which also with cement, gypsum, powdered artificial silicate Binders can be mixed, applied and all cells of the soft foam are filled with it;
that either water and / or modified water is sprayed or fogged on the soft foam thus treated and filled with free-flowing material, or low-viscosity, liquid synthetic or natural resins are poured or sprayed,
or liquid water glass is sprayed or poured, or in the ...

Figure 00000001
Figure 00000001

Description

Die vorliegende Erfindung betrifft ein Verfahren zum Herstellen von Formkörpern, insbesondere mineralischen Platten und/oder Matten, als Oberflächenschutz und/oder für die Oberflächengestaltung bei Innen- und Außenanwendungen.The The present invention relates to a method for producing Moldings, especially mineral boards and / or mats, as surface protection and / or for the surface design Indoor and outdoor applications.

Die vorliegende Erfindung betrifft auch einen Formkörper gemäß Anspruch 6.The The present invention also relates to a molded article according to claim 6.

Ein solches Verfahren und ein daraus hergestellter Formkörper sind aus DE 195 08 318 A1 bekannt.Such a method and a molded article produced therefrom are made DE 195 08 318 A1 known.

Der darin beschriebene Formkörper ist ein Fliesenelement mit einem Schaumstoffkern und einer Quarz-Epoxydharzschicht als Glasurflächenelement auf der Sichtseite. Aufgrund der für die Abdeckung des Schaumstoffkerns notwendigen Härte der Glasurfläche sind solche Formkörper nicht flexibel.Of the Shaped body described therein is a tile element with a foam core and a quartz epoxy resin layer as glaze surface element the visible side. Due to the for the cover of the foam core are necessary hardness of the glaze surface such shaped bodies not flexible.

Aus DE 42 34 269 C1 ist ein Verfahren zur Herstellung von Verbundplatten bekannt. Auch eine solche Verbundplatte umfasst einen Schaumstoffkern und ein auf wenigstens einer Flachseite aufgebrachtes Glasfasergewebe und weist den gleichen Nachteil auf, wie der aus DE 195 08 318 A1 bekannte Stand der Technik.Out DE 42 34 269 C1 For example, a method for producing composite panels is known. Such a composite panel also comprises a foam core and a glass fiber fabric applied to at least one flat side and has the same disadvantage as that of US Pat DE 195 08 318 A1 known state of the art.

Aus DE 34 18 002 A1 ist ein zwei- oder mehrschichtiges Bauelement und ein Verfahren zur dessen Herstellung bekannt. Ein solches mehrschichtiges Bauelement weist eine Schicht aus Harzschaumstoff und eine Oberfläche aus kunststoffvergütetem Mörtel auf. Auch solche mehrschichtigen Bauelemente sind hinsichtlich ihrer Gestaltungsfähigkeit eingeschränkt und nicht flexibel.Out DE 34 18 002 A1 For example, a two-layered or multi-layered component and a method for its production are known. Such a multilayer component comprises a layer of resinous foam and a surface of plastic-coated mortar. Even such multilayer components are limited in terms of their design capabilities and not flexible.

Aus DE 43 34 108 A1 ist ein Verfahren zur Herstellung von Bauplatten bekannt. Eine solche Bauplatte wird durch einen mehrstufigen Mörtelauftrag hergestellt, wobei in die Mörtelschicht zur Armierung ein Textil eingebettet wird. Auch eine solche mehrstufige Mörtelschicht weist nur eine geringe Gestaltungsfähigkeit auf und ist nicht flexibel.Out DE 43 34 108 A1 is a method for the production of building boards known. Such a building board is produced by a multi-stage mortar application, wherein in the mortar layer for reinforcement, a textile is embedded. Even such a multi-stage mortar layer has only a low design ability and is not flexible.

Schließlich ist aus DE 102 48 307 A1 ein Verfahren zur Herstellung eines keramischen Schaumes bekannt. Ein solcher keramischer Schaum wird durch Umsetzung von organischen und/oder modifizierten organischen Polyisocyanaten mit einem Polyetherolgemisch und gegebenenfalls weiteren gegenüber Isocyonaten reaktive Wasserstoffatome aufweisenden Verbindungen in Gegenwart von Wasser und/oder Treibmitteln, Katalysatoren und weitern Hilfs- und Zusatzstoffen und anschließendes Trocknen und Brennen erzeugt. Auch ein solcher keramischer Schaum weist nur eine eingeschränkte Gestaltungsfähigkeit auf und verliert nach dem Trocknen und Brennen seine Flexibilität.Finally is off DE 102 48 307 A1 a method for producing a ceramic foam is known. Such a ceramic foam is produced by reacting organic and / or modified organic polyisocyanates with a Polyetherolgemisch and optionally other isocyanate-reactive hydrogen atoms having compounds in the presence of water and / or blowing agents, catalysts and other auxiliaries and additives and subsequent drying and firing. Even such a ceramic foam has only a limited design ability and loses its flexibility after drying and firing.

Die Aufgabe der vorliegenden Erfindung ist daher, ein Verfahren zum Herstellen von Formkörpern der Eingags genannten Art derart weiterzubilden, dass insbesondere Platten oder Matten hergestellt werden können, die hinsichtlich ihrer Formgebung ein größeres Maß an Gestaltungsfreiheit aufweisen als bisher bekannte Formkörper, die mit einem solchen Verfahren hergestellt wurden.The Object of the present invention is therefore to provide a method for Production of moldings The type mentioned at the beginning of such a way that in particular Plates or mats can be made in terms of their Shaping a greater degree of design freedom have as previously known moldings with such Procedures were made.

Die Aufgabe wird erfindungsgemäß dadurch gelöst, dass auf ein festes oder flexibles Trägermaterial, ein retikulierter offenzelliger Weichschaum, vornehmlich aus PUR bestehend, in Stärken von insbesondere 3 mm, mit Porengrößen von insbesondere 1,0 bis 1,5 mm, fest oder abnehmbar, plan fixiert wird; dass auf den Weichschaum rieselfähige, trockene Materialien, die insbesondere aus Sanden, Quarziten, Calciten, Graniten, Metallgranulaten oder dergleichen, mit Korngrößen von insbesondere 0,1 bis 0,5 mm, bestehen, die auch mit Zement, Gips, pulverförmigen künstlichen Silikat-Bindern vermischt werden können, aufgebracht werden und alle Zellen des Weichschaums damit aufgefüllt werden; dass auf den so behandelten und mit rieselfähigem Material aufgefüllten Weichschaum entweder Wasser und/oder modifiziertes Wasser aufgesprüht oder genebelt wird, oder niedrigviskose, flüssige Kunst- oder Naturharze gegossen oder gesprüht werden, oder flüssiges Wasserglas gesprüht oder gegossen wird, oder in das in den Weichschaum gefüllte rieselfähige Material thermoplastische Bindemittel vermischt werden können, wobei diese mittels Hitze und Druck aufgeschmolzen werden; dass zuviel aufgebrachtes, insbesondere 3 mm Stärke übersteigendes Material, durch Abziehen entfernt wird, und dass anschließend auf die so erhaltene Oberfläche eine Abdeckung aus Gewebe, Papier, Kunststoff oder dergleichen aufgebracht wird.The The object is achieved in that on a solid or flexible carrier material, a reticulated open-cell soft foam, mainly made of PUR consisting, in strengths in particular 3 mm, with pore sizes of in particular 1.0 to 1.5 mm, fixed or removable, plane fixed; that on the soft foam free-flowing, dry materials, in particular of sands, quartzites, calcites, Granites, metal granules or the like, with particle sizes of in particular 0.1 to 0.5 mm, which are also made with cement, gypsum, powdery artificial Silicate binders can be mixed, applied and all cells of the soft foam are filled with it; that on the sun treated and with free-flowing Material padded Soft foam either water and / or modified water sprayed or or low viscosity, liquid synthetic or natural resins poured or sprayed be, or liquid Sprayed water glass or poured into the free-flowing material filled in the flexible foam thermoplastic binders can be mixed, these by means of heat and pressure to be melted; that too much upset, especially 3 mm thick overcoming Material is removed by stripping, and then on the surface thus obtained a cover made of tissue, paper, plastic or the like applied becomes.

Mit dem Verfahren der vorliegenden Erfindung und einem solchen Formkörper sind die Vorteile verbunden:

  • a) der Produktionsvorgang mit trockenen und flüssigen Komponenten wird von der Einhaltung bestimmter Ablaufzeiten unabhängig;
  • b) der Produktionsvorgang kann jederzeit ohne Nachteil unterbrochen werden, um zum Beispiel alternative Fortsetzungen der Herstellung zu ermöglichen, insbesondere um einzelne Komponenten austauschen oder andere hinzufügen zu können;
  • c) die hergestellten Platten oder Matten sind saugfähig und erlauben eine vollständige Durchtränkung mit einem anderen Bindemittel, so dass die Platten oder Matten nebeneinander eine einheitliche Fläche durch die gleichmäßige Durchtränkung und Erhärtung bilden, um bei Ausgleich der Spannungen zwischen den Platten oder Matten eine einheitliche Verbindung zwischen Matten oder Platten und der darunter befindlichen Trägerschicht gewährleisten zu können;
  • d) die Matten oder Platten können im feuchten Zustand vor dem Abbinden auch auf Unebene zum Beispiel wellenförmige Träger aufgebracht werden, so dass sie nach dem Abbinden die Form des Untergrundes angenommen haben werden.
The advantages of the process of the present invention and of such a shaped article are as follows:
  • a) the production process with dry and liquid components is independent of the observance of certain expiration times;
  • b) the production process can be interrupted at any time without disadvantage, for example, to allow alternative continuation of the production, in particular to exchange individual components or to add others;
  • c) the panels or mats produced are absorbent and allow complete saturation with another binder so that the panels or mats form a uniform surface next to each other through the uniform saturation and hardening to compensate for stresses between the panels or mat to ensure a uniform connection between mats or plates and the underlying carrier layer;
  • d) the mats or plates can be applied in the wet state prior to setting on uneven, for example, wavy carrier, so they will have assumed the shape of the substrate after setting.

Eine Ausführungsform der vorliegenden Erfindung wird im Folgenden anhand der Zeichnungen näher beschrieben. Es zeigen:A embodiment The present invention will be described in more detail below with reference to the drawings. Show it:

1 eine schematische Darstellung eines flachen Formkörpers während eines Herstellungsprozesses gemäß vorliegende Erfindung, wobei auf der rechten Hälfte der Figur das Aufbringen rieselfähiger trockener Materialien und auf der linken Hälfte der Figur das Besprühen oder Benebeln das mit rieselfähigen materialgefüllten Weichschaums mit Wasser oder modifiziertem Wasser dargestellt ist; 1 a schematic representation of a flat shaped body during a manufacturing process according to the present invention, wherein on the right half of the figure, the application of free-flowing dry materials and on the left half of the figure, the spraying or fogging is represented with free-flowing material-filled soft foam with water or modified water;

2 eine schematische Darstellung eines nach dem erfindungsgemäßen Verfahren hergestellten Formkörpers in einer Wellenform. 2 a schematic representation of a molded article produced by the process according to the invention in a waveform.

In 1 sind schematisch zwei Verfahrensschritte zur Herstellung eines Formkörpers dargestellt. Ein auf die Stärke einer Matte oder Platte geschnittener retikulierter, offenzelliger Weichschaum, insbesondere PU-Weichschaum 1, in Stärken von insbesondere 3 mm, Porengröße insbesondere 1,0 bis 1,5 mm, wird auf ein Trägermaterial 2, 3, fest (Trägermaterial 3) oder abnehmbar (Trägermaterial 2) planfixiert.In 1 schematically two process steps for producing a shaped body are shown. A reticulated, open-cell soft foam, especially flexible PU foam, cut to the thickness of a mat or plate 1 , in thicknesses of in particular 3 mm, pore size, in particular 1.0 to 1.5 mm, is applied to a carrier material 2 . 3 , solid (carrier material 3 ) or removable (carrier material 2 ) fixed in plan.

Das Trägermaterial 2, 3 kann bestehen aus Kunststofffolien, Papier, Harzschaumplatten, Holz- oder Metallplatten oder dgl..The carrier material 2 . 3 can consist of plastic films, paper, resin foam boards, wood or metal plates or the like.

Auf den Weichschaum 1 werden aufgebracht rieselfähige, trockene Materialien 6, insbesondere Sande, mit den Korngrößen von insbesondere 0,1 bis 0,5 mm, bestehend aus Quarziten, Graniten, Metall-Granulaten oder dgl., die auch mit Zement, Gips oder pulverförmigen künstlichen Silikat-Bindern und pulverförmigen künstlichen duro- oder thermoplastischen Bindemitteln, trocken vermischt werden können, so dass alle Zellen der Weichschaummatte gefüllt sind.On the soft foam 1 are applied free-flowing, dry materials 6 , in particular sands, with the particle sizes of in particular 0.1 to 0.5 mm, consisting of quartzites, granites, metal granules or the like., Which also with cement, gypsum or powdered artificial silicate binders and powdered artificial duro- or thermoplastic Binders, can be mixed dry, so that all the cells of the soft foam mat are filled.

Der mit rieselfähigem Material gefüllte Weichschaum wird

  • a) mit Wasser und/oder modifiziertem Wasser besprüht oder benebelt;
  • b) mit niedrigviskosen, flüssigen Kunst- oder Naturharzen 7 besprüht oder begossen; die Kunstharze können jeweils bestehen aus: Epoxid-Harzen, Acryl-Harzen, PU-Harzen, Polyester-Harzen, Melamin-Harzen oder dgl.;
  • c) wobei die unter b) aufgeführten flüssigen Stoffe auch im trockenen, pulverförmigen thermoplastischen Zustand durch Hitze und Druck verfestigt werden können;
  • b) mit flüssigem Wasserglas besprüht oder begossen.
The filled with pourable material soft foam is
  • a) sprayed or fogged with water and / or modified water;
  • b) with low-viscosity, liquid synthetic or natural resins 7 sprayed or watered; the synthetic resins may each consist of: epoxy resins, acrylic resins, PU resins, polyester resins, melamine resins or the like;
  • c) wherein the liquid substances listed under b) can be solidified by heat and pressure in the dry, powdery thermoplastic state;
  • b) sprayed or doused with liquid water glass.

Soweit das an der Oberfläche befindliche Material die Stärke von insbesondere 3 mm übersteigt, wird es durch Abziehen entfernt und mit Gewebe und Papier 4, Kunststoff 5 oder sonstigen Materialien abgedeckt und verbunden. Die Abdeckung kann entweder vorübergehend dazu dienen, die Schicht beim Transport zu schützen, um dann später entfernt zu werden, oder sie verbleibt verbunden auf der Schicht.As far as the surface material exceeds the thickness of, in particular 3 mm, it is removed by peeling and with tissue and paper 4 , Plastic 5 or other materials covered and connected. The cover may either temporarily serve to protect the layer during transport, and then be removed later, or remain joined to the layer.

Die so hergestellten Matten oder Platten können mit einer Zwischenlage verschiedener Bewährungsschichten auch in mehreren Schichten übereinander produziert werden, um größere Tragkraft und Stabilität zu bewirken. Hierbei können die aufgeschichteten Platten oder Matten auch verschiedenartigen Materialien bestehen, um unterschiedlichen Anforderungsprofilen genügen zu können.The mats or plates produced in this way can be provided with an intermediate layer different probation layers also in several layers one above the other are produced to greater carrying capacity and stability to effect. Here you can the piled plates or mats also different Materials exist to meet different requirement profiles suffice to be able to.

Die so hergestellten Matten oder Platten werden in noch nicht abgebundenem Zustand auf wellenförmige, zylinderförmige oder unregelmäßig gestaltete Träger 3 aufgebracht und nehmen nach dem Abbinden die Gestalt des Trägers an.The mats or plates produced in this way are not yet set on wave-shaped, cylindrical or irregularly shaped carrier 3 applied and take after setting the shape of the wearer.

Claims (6)

Verfahren zum Herstellen von Formkörpern, insbesondere mineralischen Platten oder Matten, als Oberflächenschutz und/oder für die Oberflächengestaltung bei Innen- und Außenanwendungen, dadurch gekennzeichnet, dass auf ein festes oder flexibles Trägermaterial, ein retikulierter offenzelliger Weichschaum, vornehmlich aus PUR bestehend, in Stärken von insbesondere 3 mm, mit Porengrößen von insbesondere 1,0 bis 1,5 mm, fest oder abnehmbar, plan fixiert wird; dass auf den Weichschaum rieselfähige, trockene Materialien, die insbesondere aus Sanden, Quarziten, Calciten, Graniten, Metallgranulaten oder dergleichen, mit Korngrößen von insbesondere 0,1 bis 0,5 mm, bestehen, die auch mit Zement, Gips, pulverförmigen künstlichen Silikat-Bindern vermischt werden können, aufgebracht werden und alle Zellen des Weichschaums damit aufgefüllt werden; dass auf den so behandelten und mit rieselfähigem Material aufgefüllten Weichschaum entweder Wasser und/oder modifiziertes Wasser aufgesprüht oder genebelt wird, oder niedrigviskose, flüssige Kunst- oder Naturharze gegossen oder gesprüht werden, oder flüssiges Wasserglas gesprüht oder gegossen wird, oder in das in den Weichschaum gefüllte rieselfähige Material thermoplastische Bindemittel vermischt werden können, wobei diese mittels Hitze und Druck aufgeschmolzen werden; dass zuviel aufgebrachtes, insbesondere 3 mm Stärke übersteigendes Material, durch Abziehen entfernt wird, und dass anschließend auf die so erhaltene Oberfläche eine Abdeckung aus Gewebe, Papier, Kunststoff oder dergleichen aufgebracht wird.A process for the production of moldings, in particular mineral boards or mats, as surface protection and / or for surface design in interior and exterior applications, characterized in that on a solid or flexible support material, a reticulated open-cell flexible foam, mainly consisting of PUR, in starches of in particular 3 mm, with pore sizes of in particular 1.0 to 1.5 mm, fixed or removable, plane fixed; that on the flexible foam free-flowing, dry materials, in particular of sands, quartzites, calcites, granites, metal granules or the like, with particle sizes of in particular 0.1 to 0.5 mm, which also with cement, gypsum, powdered artificial silicate Binders can be mixed, applied and all cells of the soft foam are filled with it; that either water and / or modified water is sprayed or fogged onto the soft foam thus treated and filled with free-flowing material, or low-viscosity, liquid synthetic or natural resins are poured or sprayed, or liquid water glass is sprayed or poured, or into the flexible foam filled free-flowing material thermoplastic binder ver can be mixed, whereby these are melted by means of heat and pressure; that too much applied, in particular 3 mm thickness exceeding material is removed by peeling, and that subsequently on the surface thus obtained a cover of tissue, paper, plastic or the like is applied. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass die Abdeckung mit der Oberfläche verbunden wird und dauerhaft dort verbleibt oder später wieder von dieser entfernt wird.Method according to claim 1, characterized in that that the cover is connected to the surface and permanently stays there or later is removed from this again. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass als niedrig-vikose, flüssige Kunstharze, Epoxid-Harze, Acryl-Harze, PUR-Harze, Polyester-Harze oder Melamin-Harze verwendet werden.Method according to claim 1, characterized in that that as low-vikose, liquid Synthetic resins, epoxy resins, acrylic resins, PUR resins, polyester resins or melamine resins. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass als festes Trägermaterial eine Hartschaum-, Holz- oder Metallplatte und als flexibles Trägermaterial Kunststofffolie oder Papier verwendet wird.Method according to claim 1, characterized in that as a solid carrier material a hard foam, wood or metal plate and as a flexible carrier material Plastic film or paper is used. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass die in noch nicht abgebundenem Zustand befindliche Platte oder Matte auf einen wellenförmigen, einen zylinderförmigen oder einen eine unregelmäßige Oberflächengestaltung aufweisenden Träger aufgebracht wird, und dass nach dem Abbinden die Platte oder Matte die Gestalt der Oberfläche des Trägers annimmt.Method according to one of claims 1 to 4, characterized that in still unbundenem state located plate or Mat on a wavy, a cylindrical or an irregular surface design having carrier is applied, and that after setting the plate or mat the shape of the surface of the carrier accepts. Formkörper, hergestellt nach dem Verfahren nach einem der Ansprüche 1 bis 5.Moldings, prepared according to the method of any one of claims 1 to 5th
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DE3418002A1 (en) * 1984-05-15 1985-11-21 Polychemie-Gesellschaft mbH, 8900 Augsburg TWO OR MULTILAYERED COMPONENTS AND METHOD FOR THE PRODUCTION THEREOF
DE4234269C1 (en) * 1992-10-10 1994-04-21 Helmut Wedi Cpd. boarding material prodn. - by feeding foam core horizontally, applying cement mortar to core section surface with applicator station and spreading over side to be covered by reinforcement fabric
DE4334138A1 (en) * 1993-09-08 1995-03-09 Gefinex Jackon Gmbh Process for producing building boards
DE19508318A1 (en) * 1995-03-09 1996-09-12 Helmut Wedi Tile element and process for its manufacture
DE10248307A1 (en) * 2002-10-16 2004-04-29 Basf Ag Ceramic foams, useful as a filter medium, catalyst support and reactor insert, are prepared by reaction of polyisocyanates with a polyetherol mixture and an inorganic solid followed by drying and baking

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3418002A1 (en) * 1984-05-15 1985-11-21 Polychemie-Gesellschaft mbH, 8900 Augsburg TWO OR MULTILAYERED COMPONENTS AND METHOD FOR THE PRODUCTION THEREOF
DE4234269C1 (en) * 1992-10-10 1994-04-21 Helmut Wedi Cpd. boarding material prodn. - by feeding foam core horizontally, applying cement mortar to core section surface with applicator station and spreading over side to be covered by reinforcement fabric
DE4334138A1 (en) * 1993-09-08 1995-03-09 Gefinex Jackon Gmbh Process for producing building boards
DE19508318A1 (en) * 1995-03-09 1996-09-12 Helmut Wedi Tile element and process for its manufacture
DE10248307A1 (en) * 2002-10-16 2004-04-29 Basf Ag Ceramic foams, useful as a filter medium, catalyst support and reactor insert, are prepared by reaction of polyisocyanates with a polyetherol mixture and an inorganic solid followed by drying and baking

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