DE19716298A1 - Manufacture of tanks for e.g. swimming pools and ponds in polyurethane - Google Patents

Abstract

A new method manufactures tanks e.g. for plastic swimming pools and ponds. A moulding core is coated with parting wax, and plastic layers are then applied successively. The finished moulding is completed with static systems (various fittings) and the core is removed. The novel method comprises spraying a fluid gel coat of polyurethane, which dries solid. A similar layer containing filler is applied. Polyurethane foam is then added. At the same time, previously-located static systems (e.g. fittings including reinforcements) are covered and bonded-in. Also claimed is equipment to carry out the procedure, including the smooth-surfaced (16) mould core (15), coating unit (18) and spray pistols (23) moved by hand or machine. The nozzle (25) has an interchangeable intensive mixing chamber (24).

Description

The invention relates to a method for producing swimming pools, Pond moldings and similar containers made of plastic, in which the shape of the Container core is initially provided with a release wax layer and then layers of plastic are applied one after the other, and then through the use of appropriate static systems supplemented and finally cored to become. The invention also relates to a device for carrying out the Method with a hollow body, preferably the swimming pool, specify the core and a coating device.

Swimming pools and larger pond shapes or similar containers with a corresponding The large open page will meet the respective wishes and thus manufactured largely individually, whereby a core is produced in advance, which then surrounded with several layers of plastic and often also glass fiber or similar tissue becomes. When the plastic hardens, a correspondingly stable tub is created dung, which gives the possibility, for example, of the corresponding swimming pool as Appropriate molded part to move on a truck or low loader and on Place in the ground or otherwise set up. It is necessary that glass fiber mats or similar systems used in the Roll in still wet plastic, which is why skilled workers with rollers Apply pressure over the surface until the layer has hardened and the static system is embedded. It is not only the necessary that it is disadvantageous considerable time and the necessary manual work, but also the Problem that the individual layers do not have the entire length and width harden at the same time, but according to the progress of the work. Another disadvantage is that the corresponding static systems only with great care also give the necessary scaffolding that secures such a container, if it is then inserted into the ground and then filled with water. We Such swimming pools and other containers are used against the high labor costs often manufactured abroad, for example in Spain or Portugal, so that the ent  talking finished parts are then burdened with significant transportation costs.

The present invention is therefore based on the object of a method and to create a device with which even larger, multilayer hollow bodies, like swimming pools, simplified, with optimized uniform structure and largely mechanized can be produced.

According to the method, the object is achieved in that on the release wax first a Geelcoat layer of liquid, solid polyurethane is sprayed on and that after drying a compact layer of polyurethane and fill material is applied, the compact layer then being covered by PU foam is supplemented or expanded with simultaneous wrapping and integration previously arranged static systems.

With such a method it is possible for the first time, largely mechanically such a structure, d. H. to make a container by simply following it other corresponding layers on top of each other, d. H. first of all on the core are brought, these individual layers approx. seen over the entire area harden at the same time and thus also have a uniform structure. It is also advantageous that the static systems are not as such in the Plastic must be pressed in and rolled in, but rather in the still liquid, sprayed PU foam can be embedded, so that they do exactly that Give the system that is necessary for the stabilization of the entire container. There when embedding or wrapping, there is no load as in the previous method, remains the respective static system, which is correspondingly simple in terms of structure can be trained, fully preserved and its static effect can be completely eliminated All in all, there is the possibility of a multi-layer container create, which as such not only has layers of uniform thickness, but the in its outer skin or layer also contains static systems that are integrated accordingly and no longer due to other influences can be affected. Advantageously stable, easy to transport and also otherwise easy to handle containers, especially swimming pools can be used for ver  be made available. Because manual work can no longer be done in this sense now the appropriate containers, especially swimming pools near the Auf site and even on site and then processed immediately be so that long transport routes are eliminated. This gives you the opportunity to build very individual forms in terms of structure, in order to meet the wishes of the customer.

According to an appropriate embodiment of the invention it is provided that the geelcoat layer with a color component specifying the visible surface of the container ver or different color components before spraying is mixed. This creates the possibility of the actually only recognizable view surface of the container, d. H. So practically to design the inner wall in such a color that in subsequent use, d. H. for example after filling the water an impression is created, as the customer had imagined. For example it is thus also possible to integrate white stripes in the otherwise blue floor To draw swimming lanes. Since this Geelcoatschicht as the first and practically without Support scaffold is applied, is a correspondingly dense and continuous color uniform design secured.

It was pointed out earlier that the static systems are advantageous can be integrated into the outer wall of the container by using the PU foam be encased or embedded. To the exact position of this static To ensure systems, the invention provides that after spraying the Compact layer first the static systems on the outside wall of the tank and that only then is the PU foam applied. Since the compact layer is a ge If it takes some time to harden, the adhesive effect can be eliminated in the meantime be used to fix the static systems on it so that they then can advantageously be encased by the PU foam.

According to the invention it is with one goal, the shape of the respective Kun to subjugate with, which is particularly possible if as static systems bendable and deformable supporting structures are used, which over the PU foam  fixed and at the same time integrated into the outer wall of the container. This Accordingly, static systems can be installed so that they are outside wall, but possibly also influence the inner wall and shape give or adapt to this form favorably.

Especially with swimming pools, but also with other containers it can be advantageous to arrange supply pipes on the outside, for example wise water leaks in the side wall or at certain heights Water withdrawals become possible. At the same time, the supply pipes can Static systems are also, if provided according to the invention, with the static systems also supply pipes, supply lines and hooks and similar parts can be fixed with the PU foam. The supply pipes, utility power lines u. Parts are not only integrated into the PU foam, son stabilize the PU foam and the entire wall of the container advantageous. Any hooks or other fasteners can also be integrated be grilled, either being pressed into the still soft PU foam or but are parts of the static system in advance and are thus advantageously determined can.

To be able to work more or less with a uniform core, see the invention proposes that the visible surface before spraying the Geelcoatschicht on the core of the container design-defining molded parts are arranged on the core, the one surface coated with Teflon or epoxy resin or similar plastic exhibit. These molded parts thus complement the core as such in each case seen or desired way, so that the shape of the container Overall, the individual wishes can be changed without it is required to provide a new core. Through the coating with Teflon or epoxy resin or with a suitable release wax is safe asked that after the application of the various plastic layers of the container can still be easily separated from the core, then the attached form parts either remain at the core immediately or afterwards from the container must be removed. Since the separation layer is provided, a sol  Removal is no longer a problem.

A change according to the respective customer requirements is also then still possible when the container or swimming pool has been gutted. Here The invention additionally provides that after the coring on the visible surface Molded parts applied and then covered with a geel coat and with the Containers are connected. For example, in the respective swimming pool afterwards, a bench can be integrated or other projections or similar, all the more to change the interior of the pool accordingly or to optimize it ren.

So far, it has proven difficult to implement such processes, because the polyurethane is extremely difficult, especially when filler is added or could not be processed at all by spraying. According to the present This is additionally ensured by the invention that the polyurethane with the Hardener of an intensive mix is subjected to short distances by the two Components are pressed with pressure through a ball packing. The ball pack gives the guarantee that the two components are even and intense are mixed together so that they leave an optimal degree of mixing when leaving the nozzle exhibit. This gives you the opportunity to use this material evenly and safely to be applied to every surface in order to then create a specific wall thickness and a specific to reach th wall structure.

A device with a hollow body is used to carry out the method, preferably the core specifying the swimming pool and a coating device tung. In addition, it is pointed out that this coating device has so far in the brushes and the impression rollers of the skilled workers, about which in particular the static systems in the plastic layer applied with a brush or spatula were embedded. According to the invention it is now provided that the core with is equipped with a smooth or smoothable surface and that the coating is direction one or more by hand and / or mechanically pivoted and moved Bare pistol or similar molded part, the nozzle of which is exchangeable  formed intensive mixing chamber is arranged. With such a trained Vorrich First of all, there is the option of working on the core that has been prepared beforehand to build a wall that consists of several layers and yet over seen the entire area evenly thick or in certain places one in front given thickness reached. In addition, the swiveling and sliding pisto le or the correspondingly movable coating device also the possibility given to inject or integrate the necessary static systems in order to so a uniform, yet correspondingly stable structure of the wall of the Container or swimming pool. The pistol or the Beschich device can be the smoothed or the from the optimal position brush the smooth surface of the core anyway and with the intensive one Spray the prepared and mixed plastic components into the mixing chamber to build up the individual layers of the wall of the container. Just the spray over the gun ensures an even build-up of the individual layers thus ensure both the necessary tightness of the entire container, as well as for the necessary stability.

The individual layers can be applied by hand or largely done mechanically because a correspondingly movable coating device in front is given, with the same coating device at the same time necessary static systems can be brought into their position if a manipulator to the coating device as provided according to the invention is arranged, the static systems to be assigned to a magazine for the swimming pool having. This manipulator, for example, takes the respective from the magazine required static systems, whether they are lattice girders, pipes or rods acts and brings them into the respective position on the outer wall of the container or on the Outside wall of the part body already finished. He either holds them in this position or it is ensured that a supporting structure or the like is created overall, so that then subsequently with the coating device of the PU foam can be brought, which also envelops the static systems and then locks fixed and integrated into the wall.  

Because of their good positioning, but also because of the fact the possibility that they can be integrated into the wall itself is given static systems in the form of cardboard or aluminum constructions to use before or finally while attaching to the partial body of the pool Operating conditions are shaped accordingly. It is of considerable advantage that the cardboard or aluminum construction is easily deformable as long as it is not in the PU foam be embedded. They can be adapted well, but they emulate integrating into the PU foam the necessary stabilizing elements and brin the necessary stability for the overall system.

It was pointed out earlier that the PU foam layer can also be used for necessary hooks and other fasteners to attach and fix. The invention now provides in addition that a station wagon nation with the static systems is possible in that they with approaches are provided, which ver outside of the subsequently applied PU foam layer remain and serving as hooks, eyes and brackets for pipes and lines forms are. Since they remain outside the PU foam layer, they can be avoided fer of the coating device or manipulator can be fixed and also during the application of the PU foam layer, so that a further advantageous It is possible to position the individual static systems and to keep where they have their effect or in the wall formed below can optimally fulfill their task.

The invention is particularly characterized in that a method and a device is also created with which large, multilayer hollow bodies per, like swimming pools, created with high precision and largely mechanized can be. Since the individual layers of the swimming pool or other Container sprayed or sprayed is an approximately simultaneous and safe curing of the layers possible, so that overall a very homogeneous Layer structure results. After the first Geelcoat layer has hardened, a com pact layer of polyurethane and filler applied, then through the PU foam to be supplemented when the compact layer has hardened. Advantage  The necessary static systems can be integrated into the wall be, so that not only the homogeneous structure of the individual mentioned above Layer, but results in the entire wall, in which, as mentioned, the static system me are integrated. Pipes or electrical lines that may be required gene or other supply lines can simultaneously in the wall be integrated, so that a total container optimized for the consumer or a Swimming pool is available, which corresponds to the final installation less additional effort. In general, the effort for that Manufacture of such pools significantly reduced and largely Ma Machine work limited, so that such containers even in labor-intensive areas can be easily produced.

Further details and advantages of the subject matter of the invention result from the following description of the accompanying drawing, in which a preferred Embodiment with the necessary details and items shown is. Show it:

Fig. 1 is a plan view of a swimming pool,

Fig. 2 is a side view of the swimming pool according to FIG. 1,

Fig. 3 shows a coating device with core for the system shown in Fig. 1 and Fig. 2 swimming pools,

Fig. 4 static systems in two embodiments in side view,

Fig. 5 more static systems, in side view,

Fig. 6 shows a section through a completed wall and

Fig. 7 an intensive mixing chamber in section.

Fig. 1 shows a trained as a swimming pool 1 hollow body 2 in plan view and practically in the installed state. The overflow edge 3 can be seen , to which the drainage channel 13 connects, which is secured by a cover 14 .

The inner wall 4 of the swimming pool 1 is colored blue, for example, so as to influence the water present in the swimming pool 1 accordingly. The outer wall 5 , which can be seen in particular in FIG. 2, is, for example, black, brown or otherwise colored. The drain 6 can be seen on the floor, while the indicated vertical ladder 7 projects beyond the overflow edge 3 . It can also be integrated into the wall, which will be discussed further below.

A corresponding visible surface 8 can be seen , which practically results in the interior of the swimming pool 1 and which can be interrupted by additional coloring or corresponding lines, as shown in FIG. 1.

Fig. 2 shows a side view of the swimming pool 1 not yet installed, it being clear that static systems 9 , 10 and speaking hooks 11 are integrated into the side walls. This is given here again for clarification. As such, the wall 12 , viewed from the outer wall 5 , can also be designed in such a way that there is a continuous wall because it is formed by the PU foam. This will also be discussed further below.

Fig 3 finally., An apparatus 1 is for the production of swimming pools according to Fig. And Fig. 2. For this purpose the core 15 shown is used first of all with a polished surface 16, which may be but also provided with a release wax layer to the subsequently applied pool 1 to be able to safely lift off from core 15 after completion.

The core 15 is assigned a coating device 18 , which here has a manipulator 17 , which can be used both for the spraying process and for attaching or supplying the static systems 9 , 10 . For this purpose, it has a telescopic support 20 and a multi-articulated swivel arm 19 . In addition, it is equipped with a trestle 21 so that it can be moved on the rails 22 in the longitudinal direction of the core 15 .

The pivot arm 19, which may also be telescopic or at the same time but which is correspondingly disassembled, wears the gun 23 with the pre-arrange th intensive mixing chamber 24 and the end of the intensive mixing chamber 24 forming nozzle 25th In addition, the swivel arm 19 is still equipped with a gripper 26, detected via the static systems 9 , 10 and can be brought into the respective position. It is understood that the coating device 18 or the entire device is shown here only schematically in Fig. 3.

FIGS. 4 and Fig. 5 indicate static systems 9, 10 of different training again. It is important that these static systems 9 , 10 are equipped with support structures 27 which allow flow and wrapping with polyurethane foam. The shape, as shown in FIG. 4, can also be influenced afterwards in order to be able to represent or influence different walls 12 for swimming pools 1 .

On the front 28 these static systems 9 , 10 Hakenbefestigun conditions 29 or simple approaches 30 are assigned to attach either pipes or cables or other things afterwards, especially when the static systems 9 , 10 are embedded in the PU foam layer . Both in the representations according to FIG. 4 and also according to FIG. 5 it is made clear that the corresponding static systems 9 , 10 have openings which allow the PU foam to pass through and penetrate. FIG. 4 also shows a special holder 31 for pipes which enables such pipes to be clamped in, that is to say a particularly simple assembly.

Fig. 6 shows a wall 12, for example, of a swimming pool 1 in section and at any point, whereby it should be clarified here in particular that the layer structure is very uniform, even if there are curves or corners. In addition, it is made clear that an integration of static systems 9 , 10 , but also of pipes 54 is possible, specifically in the outer PU foam layer 34 . The middle layer is the compact layer 33 consisting of polyurethane and filler material, while the geel coat layer 32 consists only of polyurethane, which is enriched or mixed with color components if necessary.

Static systems 9 , 10 of different structures are integrated in the PU foam layer 34 and, as already mentioned, also a pipeline 54 , which can have nozzles, which are not shown here, in order to enable a connection from the outside . In addition, a hook 11 is shown , which is securely fixed in the PU foam layer 34 via the fixing part 35 .

Fig. 7 shows an intensive mixing chamber in section. This intensive mixing chamber 24 has a housing 36 which is shown cut open. This shows that the material feed opening 37 is provided in the upper region, specifically in the connection region of the gun 23 , while the outlet 38 is provided at the lower end of the housing 36 .

The wall 39 of the housing 36 is provided in such a way that it projects above the upper intermediate wall 40 , so that one time a kind of sealing shaft 43 is formed, in which the gun 23 can be safely inserted from above and, on the other hand, also a kind of prechamber which enables the premixing of the two inflowing components. As a result, it is generally possible, without a positive connection between the gun 23 and the intensive mixing chamber 24, to securely connect the two parts to one another in such a way that only an indentation is required in order to effectively connect the two parts to one another. As a result, such an intensive mixing chamber 24 can be easily replaced if necessary or when the components to be introduced are changed.

The first intermediate wall 40 has a central bore 44 , so that the two components already premixed in the region of the prechamber or the material feed opening 37 penetrate into the first chamber 46 in the direction of flow 45 .

The first mixing chamber 46 , like the subsequent mixing chambers 50 , is filled with mixing elements 47 , 48 in the form of balls. These mixing elements 47 , 48 have deflection surfaces 49 of large dimensions. The two components, ie in premix, thus flow over the arranged mixing ball levels and continue to divide up. The mixture flows around the individual spherical Mischele elements 47 , 48 in the upper -, lower - and in the two side planes of the balls. The separation or mixing factor can be seen in the arrangement of the balls or the mixing elements 47 , 48 .

After passing through the first mixing level, ie the chamber 46 , the mixture is then introduced into the second chamber 50 via the edge holes 52 serving as inlet and at the same time as outlet 51 , where the same dividing and mixing effect as in chamber 46 is achieved. Since the inlets and outlets 51 are designed as edge bores 52 , the mixture is forced to pass the balls in the chamber 50 or the mixing elements 47 , 48 completely. The edge bores 52 are formed in the second intermediate wall 41 , while the next intermediate wall then again has a central bore. The last intermediate wall 42 again has Randbohrun conditions 52 , so that the nozzle 25 or the outlet 38 which then attaches to the center again acts as a type of central bore. It is conceivable to reduce or increase the number of mixing levels, depending on which effect is desired.

All of the above-mentioned features, including those that can only be taken from the drawings, alone and in combination are regarded as essential to the invention.

Claims (12)

1. A process for the production of swimming pools, pond shaped bodies and similar containers made of plastic, in which the shape of the container is given, the core is first provided with a separating wax layer and then layers of plastic are applied one after the other, in order to then use appropriate static systems to be supplemented and finally cored, characterized in that a gel coat layer of liquid, solid polyurethane is sprayed onto the partition wall layer and that a compact layer of polyurethane and filler material is then applied after drying, the compact layer then being supplemented or filled with PU foam ... is expanded, with simultaneous encapsulation and integration of previously arranged static systems. 2. The method according to claim 1, characterized, that the Geelcoatschicht with a color area specifying the visible surface of the container component or successively different color components before spraying is mixed. 3. The method according to any one of the preceding claims, characterized, that after spraying the compact layer, the static systems on the Container outer wall fixed and that only then the PU foam is applied. 4. The method according to any one of the preceding claims, characterized, that used as static systems bendable and deformable support structures that are fixed with the PU foam and at the same time in the outside of the container  be integrated into the wall. 5. The method according to any one of the preceding claims, characterized, that with the static systems also supply pipes, supply lines and Hooks and similar parts can be fixed with the PU foam. 6. The method according to any one of the preceding claims, characterized, that before spraying the geel coat layer on the core, the face of the container is designed Terically predetermined molded parts are arranged on the core, one with Teflon or Have epoxy resin or similar plastic coated surface. 7. The method according to any one of the preceding claims, characterized, that after coring, moldings are applied to the visible surface and then covered with a layer of gelcoat and connected to the container. 8. The method according to one or more of the preceding claims, characterized, that the polyurethane with the hardener of an intensive mix under short is thrown by pushing the two components through a ball pack be pressed. 9. Device for performing the method according to claim 1 to claim 8 with a hollow body ( 2 ), preferably the swimming pool ( 1 ), predetermined core ( 15 ) and a coating device ( 18 ), characterized in that the core ( 15 ) with a smooth or smoothable surface ( 16 ) and that the coating device ( 18 ) has one or more hand-held and / or mechanically pivotable and movable pistol ( 23 ) or similar injection-molded part, the nozzle ( 25 ) of which is an exchangeable intensive mixing chamber ( 24 ) is upstream. 10. The device according to claim 9, characterized in that the coating device ( 18 ) is associated with a manipulator ( 17 ) having a magazine for the swimming pool ( 1 ) to be assigned static systems ( 9 , 10 ). 11. The device according to claim 10, characterized in that the static systems ( 9 , 10 ) are made of cardboard or aluminum structures, which are finally shaped according to the conditions of use before or during attachment to the partial body of the swimming pool ( 1 ). 12. Device according to one of the preceding claims, characterized in that the static systems ( 9 , 10 ) are provided with lugs ( 30 ) which remain outside the subsequently applied PU foam layer ( 34 ) and as hooks ( 11 ), eyelets and Brackets ( 31 ) for pipes and lines are designed to serve.