EP0758944B1 - Process and device for the continuous production of fibre-reinforced moulded bodies from hydraulic materials - Google Patents

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

The invention relates to a method and an apparatus for the continuous production of fiber-reinforced Shaped body from hydraulically settable masses, these in at least one layer of predetermined width and Thickness from one or more dispensers to a moving one Underlay to be applied and glass fibers as reinforcement to serve.

DE-A-34 31 143 describes a method for Manufacture of moldings, e.g. B. plates fiber-reinforced hydraulically settable masses, in which the Mass without fibers in a given thickness on a base is applied to what comes from a cutter Fiber chips in a doped amount on the surface of the Scattered mass and with one over the entire Working width working tool pressed into the mass be, whereby the mass is compressed at the same time. Only a relatively small proportion of is disadvantageous Reinforcement material and also only in an outer area the plate in a structurally unfavorable arrangement.

Furthermore, DE-A-24 56 712 describes a method for Manufacture of moldings from fiber concrete known in which Fibers sprayed onto not yet hardened concrete, sprinkled or sprinkled and then rolled or be smoothed. The fibers are cut with a cutter cut continuously from fiberglass rovings. she can be applied in several layers and then cement be powdered to absorb excess water. The fibers are said to be crack-free, better water-insulating Concrete surface can be achieved. The sprinkling and The fibers are rolled in in a manual process a cutting tool and a hand roller.

The known methods and devices are apart from unfavorable arrangement of the fiber layer the disadvantage common that they have only one "good side", namely on the surface facing the forming documents. In addition the proportion of fibers in the concrete matrix is approx. 5-6 Mass percent limited.

Methods are also known in which hydraulic bindable matrix material and separately conveyed glass fibers be sprayed onto a pad at the same time. It is it is relatively difficult to get an exact mix ratio Adjust and maintain matrix and glass fibers. Furthermore, a thickness calibration is required manufactured plates of an additional Procedural step with additional funds, moreover, is only a "good side" exists.

Finally, it is known to be called a "premix" Mixed material, which is a homogeneous mixture of fresh concrete and contains glass fibers, on a base in uniform Apply layer thickness. Processing of "premix" finds its limits with the amount to be added Glass fibers, because the higher proportions Difficult to process the mixture or impossible and the reinforcement content for thin slabs in the Is usually too low.

Slabs with different reinforcement are sometimes used assembled after their manufacture in a fresh state in order thereby either obtaining a double thick sheet or to achieve two approximately good surfaces. Here the plates become a "sandwich" produced, for which a staggered Work step is necessary, the manufacturing cost significantly more expensive.

So in FR-A-2442115 a method of manufacture described by plates, in which two counter-rotating stacked conveyor belts mass layers and Fibers laid to layers and by deflecting the upper layer package this with the lower layer package is combined into a plate. Because with this well-known Process the fibers on the outer surface of the finished Plate are arranged, are not "good surfaces" with this procedure achievable. Another disadvantage is that only in time and place after joining the two shift packages in a separate work step Compression of the layer packets for the final Thickness calibration is done.

Also in DE-A-3331715, in which a method for Manufacture of a composite panel is described in Working steps shifted in time and place placed on top of each other and compacted individually, whereby here too the achievement of a "good surface" is not in the The foreground is because the outer surface of the finished Plate made from strands of glass fibers or from a fabric or fleece consists of glass fibers.

The invention has for its object a method and to provide a device with which it is possible fiber-reinforced panels with precisely specified and occasionally also produce small thickness, these in If necessary, two smooth or structured "good pages" have and with controllable dosing of proportions of reinforcement material, especially with higher ones Reinforcement proportions and with exact positioning of the Reinforcement in statically stressed zones of the Plate layer can be produced at high output. Here the plates should immediately or afterwards, however in fresh condition, further to three-dimensional shaped bodies can be processed.

The problem is solved with a method of Preamble of claim 1 type with the invention by the characterizing features of claim 1.

The method gives the advantage that the work steps compared to known processes in a continuous Sequence rationalized into one another and Inaccuracies such as those caused by the interaction of several temporally shifted and interdependent Work steps caused are largely avoided will. Fiber parts of the reinforcement in the new Proceed the so far regarded as the maximum limit Quantity of about 5% by weight to the total matrix without restriction far exceed.

If the alternative is used that the Fabrics on which documents are presented, penetrates the matrix mass in or through the laid fiber mats. Preferably, each first matrix layer on a permanently installed and with Feeding device provided in front of the Conveyor belt applied. This enables an even more precise one Thickness calibration than on the conveyor belt and one guaranteed surface quality through the possibility of Shaking from below.

The use of flat structures eliminates the need for complex Technique for cutting the fibers and becomes a higher one Dosage enables. This can be a comparative thin laminate with higher strength can be produced. Also can be due to the use of fabrics high production speed with a correspondingly high Output can be achieved. Thanks to the exact positioning of the reinforcement fabrics in statically stressed Zones is created by effectively using fiber reinforcement achieved maximum strength. The emergence of Fiber and cement dust is eliminated by cutting and Spraying process largely avoided.

One embodiment provides that the mass at their Preparation mixed with a small amount of glass fibers becomes. Prepared as a premix with the addition of fibers Concrete matrix, for example, already favors under 1 % By weight fiber the cohesiveness and the Plasticity of the first highly compressed from the donors Layer emerging mass, so that it in their Sequence of movements as a dimensionally stable, non-tearing film works. The spreading of this kind continues to avoid unwanted entrapment of air between the pad and a first matrix layer. For example, the Mass of glass fibers in an amount of 0.01 to 4% by weight, preferably between 1 and 1.5% by weight can be added.

The mass is in a continuous mass flow on the shaping base applied and extruded from case to case, with the donor at a defined distance progressive documents are discontinued. Hereby becomes a predetermined thickness of the first laminate layer achieved and adhered to high accuracy.

Glass fibers made of AR, E, C, or ECR glass, also metal fibers (Fibraflex), Micro steel fibers, plastic fibers, aramid fibers or Carbon fibers are used. The fabrics can continuous yarns, rovings, bonded fiberglass mats, Nonwovens, woven fabrics, lattice woven fabrics, non-woven fabrics (also multiaxial), Complex fiber mats or combinations of these delivery forms act.

An embodiment essential to the invention provides that between the reinforced layers during their union a mass layer can be injected. Through this or e.g. Styrofoam blocks or other organic or too mineral material in the form of plates or blocks becomes an inseparable bond of each other unifying layers reached, their binding process promoted and in the case of a subsequent shaping the Plasticity of the plate improved, which makes it even more so unbound plate-like product easily one Shaping into three-dimensional structures, for example can be subjected. Such a shape can for example for the production of corrugated sheets, channels, Pipes and similar products are used.

Be advantageous when using glass fibers as Reinforcement in the concrete mass inhibiting alkalization Components in an amount equivalent to the alkali reaction added, preferably pozzolana, blast furnace slag, reactive silicon dioxide or other equivalent Additions. This ensures long-term stability Glass fibers ensured without corrosion.

To achieve a one-sided or two-sided Surface profile of the product can be profiled Documents and / or to redirect when merging the two layers of profiled cylindrical rollers are used will. The calibration of the individual matrix layers is done by setting a distance between the Mouthpiece of a dispenser or funnel and the base. The end product is determined by the dimension of the gap exactly forward and by means between the deflection roller cylinders Recalibrated fine calibration rollers.

Another measure essential to the invention provides that the masses in the dispensers are degassed by shaking and / or be compressed. Furthermore, the Matrix layers during or after their application to the Documents are shaken and thus further compressed, whereby at the same time the applied vibrations Sheets intimately with the matrix layer receiving them get connected.

The layers are under during their union Use of cylindrical rollers deflected and between the Documents with specified pressure on both Outside surfaces shaped and connected at the same time. In this way, an exact parallelism of the Surfaces of the product as well as a given Panel thickness automatically with no further steps achieved great accuracy. Furthermore, they can be fresh joined layers in the deflection area Discharge direction using at least one Support roller supported and recalibrated. Both the Pre-calibration in the defined gap between the Deflection cylinder rollers, as well as the recalibration is facilitated by the fact that as a fabric Nets, mats, fiber complex mats, scrims (uni / multiaxial), Fabrics, fleeces or cut parts thereof are used which, as a result of their cohesion, are contrary to embedded, sprinkled or sprayed on cut fibers have a significantly higher strength surrender. And finally after finishing the Production of the product in a final step the documents preferably from both sides of the finished Be detached from the body.

A great advantage of the process is still that it runs "clean", largely the emission of fiber and Cement dust avoids less or no waste results and thus the required workplace hygiene enough.

A device for continuous production fiber-reinforced molded body made of hydraulically bindable Masses for carrying out the method according to the invention, comprising at least one movable base and above from this hopper for the order one Mass layer on the base as well as fiber discharge and Allotment devices and means for introducing the fibers into the mass layer is characterized in that it two oppositely movable to a few drivable Cylinder rollers guided documents and at least a feed hopper assigned to each document and an allocation device for fiberglass fabrics and Means for their integration into the layered applied mass, and that the cylinder rollers form an adjustable gap between them. In Training essential to the invention is above the gap a feed hopper is arranged on the cylinder rollers. Further are advantageous embodiments of the devices provided according to the subclaims.

The device is of great advantage compared to that easy to manufacture multi-layer product, compact and allows for relatively large Production speed with a high output extreme accuracy of the layer sequence in the end product.

The invention is shown in schematic drawings in shown preferred embodiments, wherein from the Drawings further advantageous details of the invention are removable.

Fig. 1

eine Seitenansicht der Vorrichtung nach Art eines Stammbaums,

Fig. 2

eine weitere Ausgestaltung der Anlage gemäß Fig. 1,

Fig. 3

ein weiteres Anlageschema welches nicht zur Erfindung gehört.

Show it:

Fig. 1

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

Fig. 2

a further embodiment of the system according to FIG. 1,

Fig. 3

another investment scheme which is not part of the invention.

Figure 1 shows a device for continuous Manufacture of fiber-reinforced molded parts from hydraulic settable masses. This includes two opposing ones movable cylinder rollers (30, 31) which can be driven by a pair deflectable documents (20, 21) and at least one feed hopper (10,) assigned to each support (20, 21) 11), further allocation devices (14, 15) for Glass fiber sheet (3, 4). The feed hopper (10, 11) are arranged vertically and each have one in the width and the gap width with adjustable Distance to the documents (20, 21) trained Gap opening. The documents (20, 21) can be tapes any material, they can be on the surface with the sticking of the concrete mass to be applied preventive coating, for example with silicone, be equipped and are occasionally to form the Structured outer surfaces of the product to be formed (7). The documents (20, 21) determine the desired optical quality of the Layers (1, 2) and should bring them together enable. In cooperation with the pro Unit of time applied amount of matrix from the funnels (10 and 11) in relation to the transport speed of the Documents (20, 21) are obtained with an adjustable distance between the gap opening of the funnels (10, 11) and the Documents (20, 21) an individual thickness adjustment of the Matrix layers (1 or 2). The fiber allocators (14, 15) for fabrics (3, 4) can around Deflection pulleys (16, 17) be guided endless belts.

Above the between the cylinder rollers (30, 31) formed gap (32) is advantageously a further feed hopper (12) arranged. With this one between the prefabricated layers (1, 2) inclusive the fiber layers (3, 4) an intermediate layer (5) introduced, which the composite of the layers (1, 2); (3, 4) for the sandwich structure of the end product (7).

Below the documents (20, 21) are in the area of overlying hopper (10, 11) and the Allocation devices (14, 15) supports (25, 26) arranged. These serve both as sliding support for the documents kept about it (20, 21), but they are also advantageously equipped with vibrators, which the applied layers (1, 2) simultaneously with the Reinforcement layers (3, 4) in strong vibrations move, thereby compacting the matrix layers (1, 2) and degas and an intimate connection between each a matrix layer (1, 2) and the assigned layer (3, 4) from fiber sheets to a homogeneous composite shake together.

The documents (20, 21) and / or the cylindrical rollers (30, 31) can have a smooth or textured surface exhibit. This is at the same time as the continuous Manufacture of the plate-shaped product (7) on the both surfaces have an intended condition - either completely smooth or with a textured pattern - manufactured, this surface texture free selectable on both surfaces or only on one Surface provided or on both surfaces is different.

A void-free and dense nature of the end product (7) is achieved in that both supports (25, 26), Feed hopper (10 - 12) and / or cylindrical rollers (30, 31) are each formed with vibrators (24).

Figure 2 shows a slightly changed design of the Contraption. In this case, the supports (25, 26) with the documents thereon (20, 21) and the funnel (10, 11) raised on one side and diagonally downwards inclined towards each other. Supports (25, 26) and documents (20, 21) have means (not shown) to adjust the inclination in any adjustable angle alpha and for lifting the funnel (10, 11). Due to the inclination of the aforementioned Plant parts, with the fiber allocations (14 and 15) with the deflection rollers (16 and 17) of the angle adjustment Alpha follow will be achieved on the dossier (20, 21) formed matrix layers (1, 2) with the Glass fiber reinforcements (3, 4) and the middle layer (5) using the force of gravity in the gap (32) form-fitting to an intimate bond with each other be united. Otherwise, the device of Fig. 2 basically the same design as the device 1, wherein the same elements with the same Reference numbers are designated.

Figure 3 shows a further embodiment of the device.

These are in front of the supports (25, 26) each Task tables (50, 51) are arranged, the task tables (50, 51) are each equipped with vibrators (54). Vibrators (54) can be at any point, preferably on Discharge will be provided. above the task table (50, 51) the funnels (10, 11) are arranged and between them the documents (20, 21) promoted to the respective the fabrics (3, 4) are given in at an angle from above on which the layers (1, 2) from the Matrix dispensers (10, 11) are applied. On the shift (2) and for example also on layer (1) - not shown - can in turn one or more Flat structures (4 ') are given up on the in the here shown embodiment from a further matrix layer (2 ') the feed hopper (11 ') is donated, covered by another fabric (4 ''). The sandwich pack is redirected over the cylinder roller and on the in Area of the cylindrical roller (30) abandoned polystyrene blocks (5 '). The finished product (7) is formed with removed from the device by the conveyor belt (27), after it was last used by the Recalibration rollers (34) for a fine calibration has undergone.

In the method according to the invention, without the known Spray technology and without trickling and pressing fibers worked.

The plates that can be produced with the invention have a lot beneficial properties. You can in simpler Extremely thin, yet very stable, can continue with a filling, especially under Use of lightweight concrete, light and thick, with smoother or textured surface one-sided or double-sided trained and suitable for further shaping. The method enables a very high one if necessary Fiber doping through the incorporation of fiber sheets and their exact positioning. During further processing fresh fiber-reinforced laminates can do this Wrap, press, lay on or fold various shapes accept. It proves to be particularly advantageous exact definition of the panel thickness by compacting and Squeezing between the cylinder rollers (30, 31) and Fine calibration rollers (33, 34). With a premix matrix, which contain fiber contents between 0.01 and 4% by weight can, up to 20 wt .-% fabrics between the Matrix layers (1 and 2) are inserted. The Matrix predominantly made of cement, normal cement or Special cement with addition of plaster, occasionally with Light aggregate substances such as pumice or expanded clay, foam glass, Additives, water, polymers and agents for Achieve resistance to aging. Through the Invention opens up the plates produced afterwards a broad area for economic Applications and new products. In this respect, the Invention in an optimal manner, the above Task.

The measures according to the invention are not based on those in the Exemplary embodiments shown in the drawings limited. Possible modifications of the invention The method and the device can consist in that any layers and / or fabrics in any Number before or after the first or further funnels can be abandoned. Also are different Arrangements of the cylindrical rollers conceivable, for example, too one above the other, with or without shifting against each other towards the vertical. The respective constructive Design is in line with special uses the device free to the specialist.

Claims (15)

1. Process for the continuous production of fibre-reinforced mouldings (7) made of materials which may be hydraulically set, these being applied in predetermined width from at least two dispensers (10, 11) with a defined thickness in at least two separate layers (1, 2) on transport means movable in opposite directions, and fibres serving as reinforcement, characterised in that

   a) the transport means are substrates (20, 21), which determine the desired optical character of the layers (1, 2) and onto which the layers (1, 2) and sheets (3, 4) made of fibres are applied,

   b) the reinforced layers (1, 2) are conveyed towards one another with the substrates (20, 21) and using cylinder rollers (30, 31) are conveyed through the adjustable gap (32) formed by the cylinder rollers (30, 31) with simultaneous injection of a further material layer as an intermediate layer (5), and the reinforced layers (1, 2) and the substrates (20, 21) are combined at predetermined controlled pressure to form a product (7) formed out on both outer faces, and are connected to one another and subjected to a thickness calibration,

   c) directly after passing through the roller gap (32), the formed product (7) is deflected in a discharge direction using the cylinder rollers (30, 31), and transported away with the adhering substrates (20, 21).
2. Process according to Claim 1, characterised in that the product (7) calibrated by the cylinder rollers (30, 31) is supported and subsequently calibrated using fine calibration rollers (33, 34).
3. Process according to Claim 1 or 2, characterised in that the reinforced layers (1, 2) are conveyed towards one another at a spacing and the connection of these layers (1, 2) is brought about by inserted material blocks which fill out the interstice between the layers (1, 2).
4. Process according to one or more of Claims 1 to 3, characterised in that glass fibres are added to the material during its preparation 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 material is discharged onto the shaping substrate (20, 21) in a continuous flow and, according to case, is extruded, the dispensers (10, 11) being adjusted at a defined spacing from the movable substrate (20, 21).
5. Process according to one or more of Claims 1 to 4, characterised in that the still unset product (7) in slab form is subjected to a shaping process, for example, to form three-dimensional entities.
6. Process according to one or more of Claims 1 to 5, characterised in that in the case of glass fibre reinforcement of the material, components inhibiting alkalisation are added in an amount equivalent to the alkali reaction, preferably pozzuolana, blast furnace slag, reactive silicon dioxide or other additions with the same action.
7. Process according to one or more of Claims 1 to 6, characterised in that to achieve a single-sided or double-sided surface profile of the product (7), profiled substrates (20, 21) and/or profiled cylinder rollers (30, 31) are used.
8. Process according to one or more of Claims 1 to 7, characterised in that the highly compressed material in the dispensers (10, 11) and also the layers (1, 2) are degasified after application onto the substrates (20, 21) by vibration and/or are compressed.
9. Process according to one or more of Claims 1 to 8, characterised in that meshes, mats, fibre complex mats, woven fabrics, nonwovens or cut parts thereof, are used as fibre sheets.
10. Process according to one or more of Claims 1 to 9, characterised in that after production, the substrates (20, 21) are preferably detached from both sides of the finished product (7).
11. Device for carrying out the process according to one or more of the preceding claims, comprising transport means movable in opposite directions, and above these discharge hoppers (10, 11) for application of at least one material layer (1, 2) onto each of the movable transport means, as well as fibre discharge and distribution devices (14, 15) and means (16, 17) for applying the fibre sheets (3, 4) to the material layer (1, 2), characterised in that

    a) the substrates (20, 21), which are movable in opposite directions, with the layers (1, 2) located thereon are guided from the top downwards via supports (25, 26) arranged in the region of the discharge hoppers (10, 11) lying above them and fibre discharge and distribution devices (14, 15) to a pair of drivable cylinder rollers (30, 31) with smooth and/or profiled surfaces and through the gap (32) constructed to be adjustable by the cylinder rollers (30, 31), and deflected thereby,

    b) a discharge hopper (12) is arranged directly above the gap (32) for injection of the material of the intermediate layer (5),

    c) the supports (25, 26) with the substrates (20, 21) located on them may be inclined to slope downwards towards one another at any desired adjustable angle alpha and have means for adjusting the angle and for raising the discharge hopper (10, 11).
12. Device according to Claim 11, characterised in that fine calibration rollers (33, 34) are possibly arranged downline of the cylinder rollers (30, 31).
13. Device according to Claim 11 or 12, characterised in that the supports (25, 26), discharge hoppers (10, 11, 12) and/or cylinder rollers (30, 31) are provided with vibrators (24).
14. Device according to one or more of Claims 11 to 13, characterised in that only substrate (21) is guided downwards around cylinder roller (31) and thereby deflected, while substrate (20) is guided without deflection over cylinder roller (30) and under cylinder roller (31), whereby, because of the vertical spacing between the two cylinder rollers (30, 31), the spacing between substrate (20) and substrate (21) with the material layers (1, 2) and fibre sheets (3, 4) located thereon is so great that an interstice between the material layers (1, 2) remains for filling out with material blocks.
15. Device according to one or more of Claims 11 to 14, characterised in that distributing tables (50, 51) are respectively arranged in front of the supports (25, 26) and equipped with vibrators (54).

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