Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
  • E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
  • E04C2/205—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/34—Auxiliary operations
  • B29C44/56—After-treatment of articles, e.g. for altering the shape
  • B29C44/5627—After-treatment of articles, e.g. for altering the shape by mechanical deformation, e.g. crushing, embossing, stretching
  • B29C44/5654—Subdividing foamed articles to obtain particular surface properties, e.g. on multiple modules
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
  • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
  • B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
  • B26D7/27—Means for performing other operations combined with cutting
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/34—Auxiliary operations
  • B29C44/56—After-treatment of articles, e.g. for altering the shape
  • B29C44/569—Shaping and joining components with different densities or hardness
• • 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
  • B32B38/00—Ancillary operations in connection with laminating processes
  • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
  • B29K2995/0037—Other properties
  • B29K2995/0094—Geometrical properties
  • B29K2995/0097—Thickness
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
  • Y10T156/10—Methods of surface bonding and/or assembly therefor
  • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
  • Y10T156/1062—Prior to assembly
  • Y10T156/1075—Prior to assembly of plural laminae from single stock and assembling to each other or to additional lamina
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/249921—Web or sheet containing structurally defined element or component
  • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T83/00—Cutting
  • Y10T83/04—Processes
  • Y10T83/0405—With preparatory or simultaneous ancillary treatment of work

Definitions

• the present invention is a fabric-reinforced rigid foam support element, a process for its preparation and its use.
• Hard foam support elements which are also referred to as foam boards, are well known in the prior art. These elements, which are usually made of foamed polystyrene, polyurethane or mixtures thereof, are widely used in construction for heat and / or sound insulation.
• German Offenlegungsschrift DE10 2004 050635 A1 discloses a rigid foam support plate which is used for receiving heating pipes of a floor heating system.
• this document describes the tools required for incorporation of the laying channel and a method for laying heating tubes in these rigid foam carrier plates.
• DE 4317871 A1 deals with a similar subject matter of the invention: in this case it is construction boards which are provided with a layer of mortar and which have marking lines on the surface. These marking lines are created by grooving the plastic foam panels and coating the panels with a suitable mortar so that the grooves become visible on the surface of the mortar due to mortar shrinkage.
• both sides fabric-backed or fabric-armored plates are used.
• the foam boards are given a higher rigidity and thus a higher intrinsic strength.
• These plates are therefore well suited for receiving larger loads and consequently also for constructive structures. For example.
• the walling of bath and shower trays with a subsequent covering with tiles on the support elements allows.
• the described fabric reinforcement achieves a high rigidity of the rigid foam support elements, so that they can also be used in thin-walled form, ie as plates with a small layer thickness.
• hard foam support elements are used with a layer thickness of less than 10 mm.
• the fabric reinforcement or fabric lamination of hard foam support elements with greater layer thicknesses is generally carried out by machine:
• the rigid foam boards are coated on a strip line via a Räkelsystem with adhesive material, which is usually the said special mortar coated.
• the reinforcing fabric is automatically inserted into the wet mortar bed.
• the excess adhesive material is achieved subtracted from a predetermined layer thickness.
• the plates thus prepared are then passed through a thermal zone, whereby the curing of the adhesive material or adhesive mortar is accelerated.
• the biggest disadvantage of this automated method is that the systems used for this purpose can not process carrier elements with a layer thickness of ⁇ 10 mm.
• the manufacture of thin-walled and fabric-laminated rigid foam support elements has therefore not been mechanically possible, since the low layer thicknesses of the unbacked rigid foam support elements cause too low stiffness, whereby these thin foam support elements are unsuitable for the mechanical manufacturing process.
• the rigid foam support elements are first provided on one outer side with the laminating fabric by laying. With the help of a Traufei then a special mortar is then applied to the fabric and the plate manually. As a result of the subsequent hardening of the special mortar, the fabric is permanently fixed to the support plate as well as in the mechanical process. After curing the one-sided Gewebekaschtechnik eventually the opposite and non-laminated outer surface is also reinforced manually with a tissue.
• Hard foam support elements with a thin total layer thickness ⁇ 10 mm is extremely time-consuming and costly, the plate qualities also fluctuate greatly due to the manual process steps.
• Object of the present invention was to provide fabric-reinforced rigid foam support elements with a total layer thickness ⁇ 10 mm, which are economical to produce and also have a consistently high product quality. This problem has been solved with appropriate support elements that have been fully machined.
• the hard foam support elements so produced not only fully meet the task, but that they also have a rigidity at even the lowest total thicknesses, making them accessible to all applications, as they are the rule for rigid foam support elements with a layer thickness> 10 mm .
• a preferred variant of the claimed rigid foam support element is that it is fabric-armored on both outer surfaces.
• the rigid foam support element made of foamed polystyrene and / or polyurethane, with extruded shapes are particularly suitable.
• the present invention also includes a variant in which the support element is closely linked to its production process:
• the rigid foam support element should namely be prepared by a) a hard foam plate with a layer thickness> 10 mm on at least one of its outer surfaces is fabric-reinforced, and then b) obtained from process step a) and at least one side fabric-reinforced foam board in Individual plates each having a layer thickness ⁇ 10 mm is cut, and if necessary c) two of the rigid foam panels obtained from process stage b) are glued flat to each other on non-fabric-treated surfaces in such a way that a rigid foam support element is obtained, which is fabric-armored on at least one outer surface and which has a total layer thickness ⁇ 10 mm.
• Hard foam cores with a layer thickness of> 10 mm are thus used as the starting material in this process since they have the required rigidity for a machine fabric arming.
• rigid foam boards having a layer thickness of 10 to 60 mm and in particular those having a layer thickness of 10, 20, 40 or 50 mm are preferably used in process step a).
• the tissue lamination can be done on these plates either one-sided, but of course on both outer surfaces of the plates. However, the unilateral machine lamination is to be regarded as preferred.
• the foam-laminated rigid sheets thus obtained in process stage a) are subsequently cut into the required thickness in a machine-like manner and separated from the carrier foam core down to a thin foam layer.
• the fabric-reinforced rigid foam board is cut into individual boards which have a layer thickness of ⁇ 5 mm in each case. This cutting to the desired plate thickness is carried out according to the common methods of the prior art. Reference may be made by way of example to a cutting device as described in DE 19906225 A1.
• the rigid foam sheets cut to size in process stage b) and laminated on at least one side have a layer thickness of less than 10 mm and in particular ⁇ 5 mm. Due to the one-sided Gewebekaschleiter these relatively thin-walled foam support elements, however, have a pronounced stiffness and strength despite low layer thickness.
• a rigid foam carrier element which is fabric-treated on an outer surface and which has the desired overall layer thickness of ⁇ 10 mm. Due to their rigidity, which has been achieved by the reinforcement, such single-sidedly laminated carrier elements produced in this way can be additionally coated with tissue and mortar in a known manner in addition to the resulting cut surface. In this way you get two-sided laminated foam boards that were completely machined.
• step c) one-sided laminated support elements with single layer thicknesses ⁇ 10 mm so flat to glue together that hard foam support elements are obtained with a total layer thickness ⁇ 10 mm, which finally on both themselves opposite outer surfaces are fabric laminated.
• one-sided tissue-laminated rigid foam panels are connected to one another in an automatic continuous system in process stage c) in such a way that a two-sided outer fabric-laminated rigid foam panel having the desired total layer thickness of less than 10 mm is produced.
• the present invention is also not limited. However, it has proved to be advantageous if, in process step a), the lamination has been carried out with a textile plastic and / or a glass fiber fabric.
• the sole selection criterion here is the required stiffness of the to see desired foam boards. For this reason, therefore, a glass fiber fabric is used in most cases, which is considered by the present invention to be preferred.
• the fixing of the reinforcing fabric in process step a) by gluing should preferably take place with the aid of an adhesive material.
• Adhesives based on aqueous dispersions of styrene, acrylate, butadiene, vinyl acetate, vinyl versatate and ethylene are equally suitable for this, as are solvent-free reaction resins and in particular epoxy resins and polyurethanes.
• adhesive materials based on hydraulic, but not hydraulically hardening inorganic binder such. As lime, gypsum, water glass, anhydrite and cement. Cement-based, hydraulically setting adhesive materials are to be regarded as being particularly preferred.
• the above-mentioned adhesive materials can likewise be used for the bonding of the fabric-laminated rigid foam panels cut to size in step c).
• aqueous adhesive materials based on water-soluble polymers such as starch ethers, cellulose ethers, xanthan, alginates and sugar derivatives. Adhesive materials based on aqueous polymer dispersions have proven to be particularly suitable.
• the present invention still includes the use of the claimed foam carrier element.
• the claimed foam carrier element in question here is in particular a use as insulation material in construction generally and preferably indoors.
• Particularly suitable is the hard foam support element described for structural structures and / or for thermal insulation, but also for sound insulation.
• a glass fiber fabric was applied by means of a special mortar based on Portland cement in a conventional manner. After hardening of the mortar, the glass-fiber-coated foam board was cut to a layer thickness of 2 mm by means of a heating wire as a cutting device. Two hard foam boards thus obtained, each one-sided glass fiber-laminated, were glued to one another mechanically at the two cut surfaces with the aid of an adhesive based on an aqueous styrene-acrylate dispersion. In this way, a two-sided glass fiber tissue-laminated rigid foam support element with a total layer thickness of 4 mm and a pronounced rigidity was obtained inexpensively.

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Citations (5)

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• 2006
  • 2006-12-20 DE DE200610060284 patent/DE102006060284A1/de not_active Withdrawn
• 2007
  • 2007-09-07 CN CNA2007800470908A patent/CN101563200A/zh active Pending
  • 2007-09-07 WO PCT/EP2007/007807 patent/WO2008083728A1/de active Application Filing
  • 2007-09-07 US US12/514,081 patent/US20100233459A1/en not_active Abandoned
  • 2007-09-07 JP JP2009541786A patent/JP2010513072A/ja active Pending
  • 2007-09-07 EP EP07802199A patent/EP2104603A1/de not_active Withdrawn
• 2012
  • 2012-11-02 US US13/667,477 patent/US20130097954A1/en not_active Abandoned

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