EP0758944A1

EP0758944A1 - Process and device for the continuous production of fibre-reinforced moulded bodies from hydraulic materials

Info

Publication number: EP0758944A1
Application number: EP95919428A
Authority: EP
Inventors: Wolfgang Weiser; Gerd Joy; Melanie Gerling-Joy; Frank Cipriani
Original assignee: Durapact Gesellschaft fur Glasfaserbetontechnologie mbH
Current assignee: Durapact Gesellschaft fur Glasfaserbetontechnologie mbH
Priority date: 1994-05-09
Filing date: 1995-05-09
Publication date: 1997-02-26
Anticipated expiration: 2015-05-09
Also published as: PL316780A1; WO1995030520A1; PL177600B1; US5814255A; ATE168313T1; DK0758944T3; HU9602843D0; DE59502836D1; ES2121387T3; EP0758944B1; JPH09512758A; HUT77972A; SK137496A3; BR9507578A; DE4416160A1; CZ309296A3

Abstract

PCT No. PCT/EP95/01741 Sec. 371 Date Nov. 8, 1996 Sec. 102(e) Date Nov. 8, 1996 PCT Filed May 9, 1995 PCT Pub. No. WO95/30520 PCT Pub. Date Nov. 16, 1995A process and a device for the continuous production of fiber-reinforced molded bodies from hydraulically setting materials, wherein the setting materials are applied in a given width from at least two dispensers with a defined thickness in at least two separate layers on conveyors moving in opposite directions. The conveyors are substrates whose color and external constitution corresponds to the outer surface of the molded body and on which the layers and surface structures of reinforcing fibers are applied. With the simultaneous injection of another material layer as an intermediate layers, the layers with the substrates are conveyed through the adjustable gap formed by a pair of cylinder rollers and the layers and substrates are united under predetermined pressure to form the molded body. Immediately after passing the gap, the molded body is deflected in a discharge direction using the cylinder rollers and is discharged with the adhering substrates.

Description

Process and device for the continuous production of fiber-reinforced molded articles from hydraulically settable compositions

The invention relates to a method and an apparatus for the continuous production of fiber-reinforced body from hydraulically settable compositions, which are applied in at least one layer of a predetermined width and thickness from one or more dispensers to a moving surface and glass fibers as reinforcement.

DE 34 31 143 C2 describes a process for the production of moldings, for. B. plates, made of fiber-reinforced hydraulically settable masses, in which the mass is applied without fibers in a predetermined thickness on a base, whereupon coming from a cutting device sprinkled fiber chips in a doped amount on the surface of the mass and with a tool over the entire working range e be pressed into the mass, the mass being compressed at the same time. The disadvantage here is only a relatively small proportion of reinforcement material and also only in an outer area of the plate in a structurally unfavorable arrangement.

Furthermore, DE-AS 24 56 712 discloses a method for producing molded articles from fiber concrete, in which

ORIGINAL DOCUMENTS Fibers are sprayed onto concrete that has not yet hardened, sprinkled or sprinkled on and then rolled or smoothed. The fibers are continuously cut with a cutting unit from G lasfasers rovi ngs. They can be applied in multiple layers and then cement can be powdered to absorb excess water. The fibers are intended to achieve a crack-free, better water-insulating concrete surface in the pool. The fibers are scattered and rolled in in a manual process with a cutting tool and a manual roller.

In addition to the unfavorable arrangement of the fiber layer of the night part l, the known methods and devices have in common that they only have one “good side”, namely on the surface facing the forming documents. In addition, the proportion of fibers in the concrete matrix is limited to approx. 5-6 percent by mass.

Methods are also known in which hydraulically set matrix material and separately conveyed glass fibers are simultaneously sprayed onto a base. It is relatively difficult to set and maintain an exact mixture ratio of matrix and glass fibers. Furthermore, a thickness calibration of the plates produced with this requires an additional one

Process step with additional funds, in addition there is only a "good side".

Finally, it is known to apply a mixture known as a "premix", which contains a homogeneous mixture of fresh concrete and glass fibers, to a base in a uniform layer thickness. Processing of "premix" finds its limits with the proportion of glass fibers to be added, because higher proportions make it difficult or impossible to process the mixture and the reinforcement content for thin slabs is generally too low.

Slabs with different reinforcement are sometimes put together in their fresh state after they have been manufactured, in order to either obtain a double-thick slab or to achieve two approximately good surfaces. A "sandwich" is subsequently produced from the plates, a time-shifted working step being necessary for this, which significantly increases the manufacturing costs.

The invention has for its object to provide a method and an apparatus with which it is possible to produce fiber-reinforced panels with exactly predetermined and occasionally also small thickness, which if necessary have two smooth or structured "good sides" and with controllable dosing of Proportions of reinforcement material, especially with higher reinforcement proportions and with exact positioning of the reinforcement in statically stressed zones of the slab layer can be produced with high yield. The plates should be able to be processed into three-dimensional moldings immediately or subsequently, but in a fresh state.

The problem is solved in a method of the type mentioned in the preamble of claim 1 with the invention in that a) a matrix mass consisting of at least two dispensers with a defined thickness is applied in at least two separate layers to substrates which can be moved in opposite directions,

b) fiber structures are applied to the layers and / or the structures are placed on the underlays, whereupon the layers are applied,

c) the layers are conveyed against one another and combined with a controlled pressure to form a product formed on both outer surfaces, subjected to thickness calibration, deflected in a discharge direction and removed.

The method yields the advantage that the work steps compared to known processes are rationalized into one another in a continuous sequence, and inaccuracies such as are caused by the interaction of several work steps which are shifted in time and which are dependent on one another are largely avoided. In the new method, fiber components of the reinforcement can far exceed the amount of about 5% by weight of the total matrix, which was previously regarded as the maximum limit, without restriction.

If it is used by the alternative that the flat structures are placed on the underlays, the matrix mass penetrates into or through the laid-up fiber mats. Preferably, the respective first matrix layer is placed on a permanently installed feed table with Rütte devices in front of the Conveyor belt applied. This enables an even more precise thickness calibration than on the conveyor belt and a guaranteed surface quality thanks to the possibility of rutting from below.

The use of flat structures eliminates the need for a complex technology for cutting the fibers and enables higher dosing. This enables a comparatively thin laminate with higher strength to be produced. A high production speed with a correspondingly high output can also be achieved due to the use of F surface areas. The exact positioning of the reinforcement fabrics in statically stressed zones ensures maximum strength through effective use of the fiber reinforcement. The formation of fiber and cement dust is largely avoided by eliminating the cutting and spraying process.

One embodiment provides that a small proportion of glass fibers is added to the mass when it is being prepared. The concrete matrix prepared as a premix with the admixture of fibers, for example, already favors the cohesiveness and plasticity of the mass emerging from the dispensers as the first highly compressed layer, with a fiber content of less than 1% by weight, so that it acts in its movement as a dimensionally stable, non-tearing film. The application of this type further avoids undesirable trapping of air between the base and a first matrix layer. For example, the mass of glass fibers can be mixed in an amount of 0.01 to 4% by weight, preferably between 1 and 1.5% by weight. The mass is applied to the shaping base in a continuous mass flow and extruded from case to case, the dispensers being set at a defined distance from the progressive documents. As a result, a predetermined thickness of the first laminate layer is achieved and maintained with high accuracy.

Glass fibers made of AR, E, C, or ECR glass, metal fibers (Fibraflex), Mi krostah if fibers, plastic fibers, aramid fibers or carbon fibers can be used as the fiber material. The flat structures can be continuous yarns, rovings, bonded glass fiber mats, nonwovens, fabrics, grid fabrics, scrims (also multiaxial), fiber complex mats or combinations of these delivery forms.

An embodiment essential to the invention provides that a mass layer can be injected between the reinforced layers during their union. Through this or e.g. Styrofoam curl or other organic or mineral material in the form of plates or blocks, an inseparable bond between the layers to be combined is achieved, the setting process is promoted and, in the case of a subsequent shaping, the plasticity of the plate is improved, which means that the still unbound plate-like product has no problem can be subjected to shaping, for example, into three-dimensional structures. Such a shape can be used, for example, for the production of corrugated sheets, channels, pipes and similar products.

Be advantageous when using glass fibers as Reinforcement in the concrete mass admixing the components inhibiting the alkalization in an amount equivalent to the reactivity, preferably pozzolans, blast furnace slag, reactive silicic acid and other additives having the same effect. This ensures long-term resistance of the glass fibers without corrosion.

To achieve a one-sided or two-sided surface profile of the product, profiled underlays and / or for deflecting when combining the two layers, profiled cylinder rollers can be used. The individual matrix layers are calibrated by setting a distance between the mouthpiece of a dispenser or funnel and the base. The end product is precisely pre-calibrated by the dimension of the gap between the deflecting rollers and recalibrated using fine calibration rollers.

A further measure according to the invention provides that the masses in the dispensers are degassed and / or compressed by shaking. Furthermore, the matrix layers can also be shaken on the substrates during or after their application and thus further compacted, the sheet-like structures being intimately connected to the matrix layer receiving them at the same time by the shaking movements.

The layers are deflected while they are being combined using cylindrical rollers and are formed between the bases with a given pressure on both outer surfaces and are simultaneously connected to one another. In this way, an exact parallelism of the Surfaces of the product and a specified sheet thickness are achieved automatically with great accuracy without any further work steps. Furthermore, the freshly assembled layers can be supported and recalibrated in the area around the direction of discharge to the discharge direction using at least one support roller. Both the pre-calibration in the defined gap between the steering cylinder rollers and the recalibration is facilitated by the fact that nets, mats, fiber-complex mats, scrims (un i / mu 11 i ax ial), fabrics are used as the flat fiber structures , Nonwovens or cut parts thereof are used which, due to their cohesion, result in a considerably higher strength in contrast to embedded, roughened or sprayed cut fibers. And finally, once the production of the product has ended, the documents can preferably be detached from both sides of the finished body in a final step.

A major advantage of the process is that it runs "cleanly", largely avoids the emission of fiber and cement dust, produces little or no waste and thus satisfies the required workplace hygiene.

A device for the continuous production of fiber-reinforced molded articles from hydraulically settable masses, for carrying out the method according to the invention, comprising at least one movable base and above this feed hopper for the application of a mass layer on the base as well as fiber discharge and component devices and means for introducing the fibers into the mass layer is characterized in that these two counter-movable documents guided by a couple of drivable cylinder rollers and at least one application device assigned to each document, as well as an allocation device for glass fiber flat materials and means for integrating them into the visually applied mass has, and that the cylinder rollers form an adjustable gap between s ch. In an embodiment essential to the invention, a feed hopper is arranged above the gap of the cylinder rollers. Further advantageous embodiments of the devices are provided in accordance with the subclaims.

The device is, with great advantage, uncomplicated, compact in comparison to the multi-layer product that can be produced with it, and, at a relatively high production speed, enables high output with extreme accuracy of the layer sequence in the end product.

The invention is shown in schematic drawings in preferred embodiments, further advantageous details of the invention being apparent from the drawings.

Show it :

1 is a side view of the device in the manner of a family tree,

2 shows a further embodiment of the system according to FIG. 1, F ig another investment scheme according to the invention

FIG. 1 shows a device for the continuous production of fiber-reinforced molded articles from hydraulically settable compositions. This comprises two oppositely movable supports (20, 21) guided around a pair of drivable cylinder rollers (30, 31) and at least one feed device (10, 11) assigned to each support (20, 21), and further allocation devices (14 , 15) for fiberglass fabrics (3, 4). The feed funnels (10, 11) are arranged vertically and each have a gap opening in the width and the gap width with an adjustable distance to the documents (20, 21). The underlays (20, 21) can be strips of any material, they can be provided on the surface with a coating preventing the adhering of the concrete mass to be applied, for example with silicon, and are occasionally used to form the outer surfaces of the product to be formed (7) structured. However, the underlays (20, 21) can also be drainage mats (e.g. ZemDrain), which are used to dewater the matrix layer (1 or 2) thereon by means of vacuum, whereas other underlays (20, 21) only do so Determine the desired optical properties of the layers (1, 2) and enable them to be brought together. In cooperation with the amount of matrix applied per unit of time from the funnels (10 and 11) in relation to the transport speed of the documents (20, 21), the distance between the gap opening of the funnels (10, 11) and the documents (20, 21 ) an individual thickness setting of the Matrix layers (1 or 2). The fiber allocation devices (14, 15) for flat areas (3, 4) can be endless belts guided around the deflection rollers (16, 17).

Above the gap (32) formed between the cylinder rolls (30, 31), a further feed device (12) is expediently arranged. With this, an intermediate layer (5) is introduced between the prefabricated layers (1, 2) including the fiber layers (3, 4), which interconnects the layers (1, 2); (3, 4) for sandwich-making of the end product (7).

Supports (25, 26) are arranged underneath the documents (20, 21) in the area of the loading judges (10, 11) lying above and the allocation devices (14, 15). These are used both for the sliding support of the documents (20, 21) carried over them, but they are also advantageously equipped with vibrators, which at the same time set the applied layers (1, 2) with the reinforcement layers (3, 4) in strong vibrating movements compress and degas the matrix layers (1, 2) and shake an intimate connection between each matrix layer (1, 2) and the associated layer (3, 4) of fiber sheet material to form a homogeneous composite.

The underlays (20, 21) and / or the cylinder rollers (30, 31) can have a smooth or structured surface. Thus, with the continuous production of the plate-shaped product (7) on its two surfaces, an intended condition - either completely smooth or with a structural pattern - Manufactured, this surface quality is freely selectable on both surfaces or only on one surface or is different on both surfaces.

A void-free and dense quality of the end product (7) is achieved by the fact that both supports (25, 26), feeder straighteners (10 - 12) and / or cylinder rolls (30, 31) each with vibrators (24) are trained.

Figure 2 shows a slightly changed embodiment of the device. In this case, the supports (25, 26) with the documents (20, 21) thereon and the funnels (10, 11) are raised on one side and inclined downwards towards one another. In this embodiment, supports (25, 26) and documents (20, 21) have means (not shown) for adjusting the inclination to an angle Alpha which can be set as desired and for lifting the funnels (10, 11). Due to the inclination of the above-mentioned system parts, the fiber allocations (14 and 15) with the deflecting rollers (16 and 17) also following the setting in the angle alpha, it is achieved that the matrix layers (1, 2 ) with the glass fiber reinforcements (3, 4) and the middle layer (5) with the help of gravity in the gap (32) positively and positively combined to form an intimate bond. Otherwise, the device of FIG. 2 has basically the same design as the device of FIG. 1, the same elements being designated with the same reference numbers.

Figure 3 shows a further embodiment of the device. In this case, feed tables (50, 51) are arranged in front of the supports (25, 26), the feed tables (50, 51) each being equipped with vibrators (54). Vibrators (54) can be provided at any point, preferably on the discharge, the funnels (10, 11) are arranged above the feed tables (50, 51) and in between the documents (20, 21) are conveyed, each at an angle from above the fabrics (3, 4) are applied, to which the layers (1, 2) from the matrix dispensers (10, 11) are then applied. On the layer (2) and for example also on the layer (1) - not shown - in turn one or more flat areas (4 ') can be applied, onto which, in the embodiment shown here, a further matrix layer (2') from the application ri rte r (11 ') is covered, covered by a further area (4''). The sandwich pack is deflected over the cylinder roller and placed on the discontinued in the region of the cylinder roller (30) Styrofoam blocks (5 ^1). The finished product (7) formed is removed from the device by the conveyor belt (27) after it has been subjected to a final calibration by the recalibration rollers (34) if required.

In the process according to the invention, work is carried out without the known spraying technique and without trickling and pressing in fibers.

The plates that can be produced with the invention have very advantageous properties. You can be extremely thin in a simple design, and yet be very stable, can continue with a filling, especially under Use of lightweight concrete, light and thick, with a smooth or structured surface on one or both sides and suitable for further shaping. If necessary, the process enables a very high fiber doping by installing fiber areas and their exact positioning. When processing fresh fiber-reinforced laminates, they can take a variety of forms by winding, pressing, laying on or folding. Particularly advantageously, the absolutely precise definition of the plate thickness by compacting and ^Q proves uetschen between the cylinder rollers (30, 31) and the Fe i NKA li brierungswa lzen (33, 34). With a Premi x-Mat ri x, which can contain fiber contents between 0.01 and 4% by weight, up to 20% by weight of flat structures can be inserted between the matrix layers (1 and 2). The matrix can consist mainly of cement, normal cement or special cement with the addition of gypsum, occasionally with light aggregate substances such as pumice or expanded clay, foam glass, additives, water, polymers and agents to achieve aging resistance. The invention opens up a wide range of fields for economic applications and new products for the plates produced thereafter. In this respect, the invention optimally fulfills the task set out above.

The measures according to the invention are not limited to the exemplary embodiments shown in the drawing figures. Possible modifications of the method and the device according to the invention can consist of any number of layers and / or flat structures in any number in front of or behind the first or further funnels can be abandoned. Different arrangements of the cylinder rollers are also conceivable, for example also one above the other, with or without displacement relative to the vertical. The particular structural design is free to the person skilled in the art in adaptation to special uses of the device.

Claims

1. A process for the continuous production of fiber-reinforced molded bodies (7) from hydraulically settable compositions, these being applied in at least one layer of a predetermined width and thickness from one or more dispensers to a moving base (20, 21) and serving as glass reinforcement characterized in that

a ⁾ a matrix mass of at least two dispensers (10, 11, 11 ' ⁾ with a defined thickness is applied in at least two separate layers (1, 2, 2') to oppositely movable substrates ⁽ 20, 21),

b) applied to the layers (1, 2, 2 ') flat structures (3, 4, 4', 4 '') made of fibers or the flat structures (3, 4, 4 ', 4' ') onto the bases (20, 21) are presented, whereupon the layers (1, 2, 2 ') are applied,

c) the layers (1, 2, 2 ') are conveyed against one another and combined with controlled pressure to form a product (7) formed on both outer surfaces, subjected to a thickness calibration, deflected in a discharge direction (40 ⁾ and conveyed away.

2. The method according to claim 1, characterized in that the mass of glass fibers are mixed in a small amount between 0.01 and a maximum of 4% by weight, preferably between 0.1 and 1.0% by weight, and the Mass in continuous flow on the shaping Support (20, 21) is applied and extruded from case to case, the dispensers (10, 11, 11 ') being set at a defined distance from the movable support (20, 21).

3. The method according to claim 1 or 2, characterized in that between the reinforced layers (1, 2, 2 ' ⁾ another layer (5) of mass is injected during their union or, for example, styrofoam curl (5') placed on them before their union become.

4. The method according to one or more of claims 1 to

3, characterized in that the still unbound plate-like product (7) is subjected to a shaping, for example to form three-dimensional structures.

5. The method according to one or more of claims 1 to

4, characterized in that in the case of glass fiber reinforcement of the mass, the components inhibiting alkali dissolution are added in an amount equivalent to the alkali reaction, preferably pozzolans, blast furnace slag, reactive silicon oxide, or other additives having the same effect.

6. The method according to one or more of claims 1 to

5, characterized in that profiled documents (20, 21) and / or profiled cylinder rollers (30, 31) are used to achieve a one-sided or two-sided surface profile of the product (7).

7. The method according to one or more of claims 1 to 6, characterized in that the highly compressed mass in the dispensers (10, 11, 11 ') and the layers (1, 2, 2 ¹⁾ after application to the documents (20, 21), degassed and / or compressed by shaking.

8. The method according to one or more of claims 1 to

7, characterized in that the layers (1, 2, 2 ') are deflected when they are combined using cylindrical rollers (30, 31), being shaped and connected between the bases (20, 21) with a predetermined pressure on both outer surfaces and by a gap (32) between the rollers (30, 31) calibrated and using

Fei nka l i bri erungswalzen (33, 34) supported and recalibrated.

9. The method according to one or more of claims 1 to

8, characterized in that nets, mats, fiber complex mats, fabrics, nonwovens or cut parts thereof are used as the fiber sheet.

10. The method according to one or more of claims 1 to

9, characterized in that after the production the documents (20, 21) are preferably detached from both sides of the finished product (7).

11. Device for performing the method according to one or more of the preceding claims, comprising at least one movable base (20, 21) and above this Aufgäbet ri chter (10, 11, 11 ') for the application of at least one mass layer (1, 2nd , 2 ') and fiber discharge and allocation devices (14, 15) and means (16, 17) for applying the fibers (3, 4, 4', 4 ' ¹⁾ to the mass layer (1, 2, 2'), characterized in that these two oppositely movable to be driven by a pair Zy L inderwa lzen (30, 31) can be deflected out substrates (20, 21) and at least one above each pad (20, ²¹⁾ arranged Aufgäbet ri daughters (10, 11, 11 ') and metering devices (14, 15) for the fiber sheet material ( 3, 4, 4 ', 4'') that the cylinder rollers (30, 31) form an adjustable gap (32) between them, and that another Aufgäbet ri chter (12) is arranged above the gap (32).

12. The apparatus according to claim 11, characterized in that the cylinder rollers (30, 31) optionally

Fe i nka l i ri erungswalzen (33.34) are subordinate.

13. The apparatus according to claim 11 or 12, characterized in that below the documents (20, 21) in the area of the lying Aufgäbet ri chter (10, 11, 11 ') and allocation devices (14, 15) supports (25, 26 ⁾ are arranged, and that supports (25, 26),

Aufgäbet judges (10 - 12) and / or cylindrical rollers (30, 31) are preferably formed with vibrators (24).

14. The device according to one or more of claims 11 to 13, characterized in that the supports (25, 26) with the supports (20, 21) can be inclined downwards towards each other, and means for adjusting the inclination on iron.

15. The device according to one or more of claims 11 to 14, characterized in that in front of the supports ⁽ 25, 26) in each case feed tables (50, 51 ⁾ are arranged and equipped with vibrators (54).