EP2461957A1

EP2461957A1 - Double belt system and method for operation thereof

Info

Publication number: EP2461957A1
Application number: EP10732372A
Authority: EP
Inventors: Norbert Wechsler; Jens Kompe; Michael Loferer
Original assignee: KraussMaffei Technologies GmbH
Current assignee: KraussMaffei Technologies GmbH
Priority date: 2009-08-07
Filing date: 2010-07-15
Publication date: 2012-06-13
Also published as: DE102009036583B4; DE102009036583A1; US20120125516A1; WO2011015435A1

Abstract

The present invention relates to a double belt system for producing a prefabricated construction element (110), to a method for operating such a double belt system, and also to the prefabricated construction element itself. The double belt system comprises a feed device for discontinuously or continuously supplying a first panel, a feed device for supplying a first lateral limiting profile, a feed device for introducing an expanding plastic material onto the first panel and also, between the first lateral limiting profile and a lateral edge limitation lying opposite the first lateral limiting profile, a double belt device comprising an upper belt and a lower belt. According to the invention, at least one projection is rotatably provided in the belt of the double belt conveyor arrangement lying opposite the panel so as to form, in the expanding plastic material, a receiving receptacle (24) that is recessed with respect to an even surface.

Description

description

title

Double belt system and method for its operation

The present invention relates to a double belt plant for producing a prefabricated structural element and a method for its operation.

Especially in the construction of very low-cost houses, especially in areas with poorer population, increasingly simple design precast elements are used, the combined walls, ceilings, roofs, etc. form.

In an in-house known construction finished element for such a prefabricated house, which is used for example as a wall element and which is shown in Figs. 1 to 3, it is known to assemble two outer plates 12 and 14 with the interposition of foam cores 16 and also with lateral statements, said the lateral terminations are formed so that two adjoining prefabricated structural elements can be assembled accurately and mutually fixable, as shown in Fig. 3.

From Fig. 1, the structure of such an in-house known design finished element can be seen. On a plate 12, two previously prepared, foamed plastic core elements 16 are arranged, which serve for spacing and holding the other plate 14. At the two lateral edges U-shaped profiles 18 are each arranged with inside pointing to the plate legs, which complete the construction finished elements laterally. In this case, the two plates 12 and 14 are alternately laterally over such that adjoining adjacent to the abutting edges adjacent construction finished elements partially overlapping directly to each other, as can be seen in Fig. 3. In an open space between the two plastic core elements 16, an insert element is inserted after assembly of the plate itself, which has a groove-like recess 24 in which a number of supply lines 26 are arranged or can be.

The production of such finished components shown in FIGS. 1 and 3 is usually discontinuous, so that first a plate 12 is prepared on which then the core elements 16 and the U-profile elements 18 are arranged and covered with the plate 14. Then the U-profiles 18 are inserted and secured (e.g., bolted). In a subsequent processing step, the insert element 22 is inserted.

As can be seen from Fig. 3, both the plates 12 and 14 are screwed by means of screws 28 with the U-shaped profiles. On the other hand, the U-shaped profiles 18 are also bolted together.

This production method has several disadvantages. On the one hand, it does not allow a continuous process, for example by means of a double belt press, which is usually more efficient than a batch process. On the other hand, because of the manufacturing process, free spaces 20, where the prefabricated structural element has poor sound and heat insulation, can usually not be avoided.

For the general state of the art, reference is made to US Pat. No. 5,453,231, DE-OS No. 2 423 792 and DE-OS No. 2 246 185.

In US 5,453,231, inter alia, a method for producing a foamed plate with venting channels is described. The ventilation channels are embossed with an endless conveyor. The endless conveyor has conveyor chains and attached conveyor plates. Moreover, a number of transversely to the direction of rotation are equidistant zueinaner arranged and down projecting channel forming plates arranged to stamp transverse channels in the foamed plates can.

DE-OS 2 423 792 describes a method for producing construction boards made of composite material. First, a continuous tape is made by joining plates together. On this band are used at standstill same intermediate pieces, between which discontinuously applied foam body and glued. After passing through further process steps, in which, inter alia, lateral boundaries are attached, then an outer side prepared in parallel is applied to this intermediate product. Finally, in a partially moving press, a pressing step takes place before the continuous strip thus produced is cut to length.

In DE-OS 2 246 185 an apparatus for the continuous production of a laminated foam strand is described in a consisting of upper and lower band and laterally moving boundary bands double band system.

The object of the present invention is to provide a device and a method for producing a prefabricated structural element, which avoids the abovementioned disadvantages.

This object is achieved by the features mentioned in claims 1 and 8 device or procedurally.

A core idea of the present invention can be seen in the fact that a prefabricated structural element can be produced efficiently and inexpensively in a continuous double-belt method and has sound and heat optimized insulation.

In the manufacturing method, at least one lateral boundary profile is applied to a first plate, which serves as formwork for the intumescent plastic material to be subsequently introduced. Either one such lateral boundary profile is also arranged for the second lateral boundary or alternatively, the lateral boundary on one side is realized by a sealing chain of a double belt device.

In the areas between the two lateral boundaries, the foamable plastic material is then introduced by means of a suitable introduction device (e.g., mixing head) and applied to the plate. After entry into the double belt, this plastic material foams with a top and a bottom belt in such a way that the space between the lateral boundaries of the disk and a belt (usually the top belt) of the double belt is completely filled.

In this case, the plate of the opposite band of the double-belt device is continuously and circumferentially in the circumferential direction of the belt completely circumferentially provided with at least one projection which serves to form an opposite to an otherwise substantially flat surface recessed receptacle in the foamed plastic material

With this technology, continuous insulation is ensured from one side to the other side of the prefabricated construction element, at the same time incorporating necessary channels for inserts or supply lines.

Thus, the prefabricated construction element can be produced in a continuous manner efficiently and inexpensively using the double-belt method known per se. It must only be fed to a plate of the finished construction element and the corresponding boundary profiles and arranged accordingly, through which then a spatially limited Aufschäumprozess within the double band is readily possible.

Either before or alternatively after the double band then the other (eg upper) plate can be applied, so that then there is a complete finished finished construction element, which is additionally adhesively connected by the foamed plastic. In a first embodiment, lateral boundary profiles may be provided on both side edges, which form the lateral edge boundary of the finished structural element. Alternatively, it is also possible to provide a lateral limiting profile only on a first side and, on the other side, to realize the limitation in the double band via a lateral sealing chain which runs along with the double band. This embodiment is particularly advantageous if - as will be shown later - the one used lateral boundary of the finished construction element projects into a recess of an adjacent plate, whereby a good connection of both plates is made possible.

Preferably, the projection on the band of the double belt device is formed by attachment elements, which are applied to the tape, for example screwed on and in their entirety form a continuous in the circumferential direction of the tape projection. The advantage of such projections is their interchangeability. By attaching different attachment elements namely differently configured recesses can be achieved with different cross-section. Thus, by using different attachment elements per double-band plate element, it is readily possible to form two or more smaller receptacles, which preferably run parallel to one another.

Moreover, it is possible to offset the attachment elements on the belt between two productions in their side orientation, whereby the recesses can be introduced at different positions in the prefabricated structural element.

Especially in the field of house exterior walls, it is often necessary to provide a vapor barrier. For this purpose, between the first plate and the foamed plastic material or the second plate and the foamed plastic material, a preferably over the entire width of the element extending film web may be provided. This can production technology already before the double-band device as a train with a Feed device to be supplied. In this case, it is glued to the foaming plastic material. Alternatively, the application is also possible after the double belt device, but before the application of the second plate.

Since it is desired to avoid thermal bridges, for example, the profiles, ie the lateral boundary profiles or the intermediate profiles made of an insulating material or they may be additionally coated with an insulating layer, at least at their areas, with the first and / or second plates come in contact.

A concrete embodiment of the present invention will be explained with reference to the accompanying drawings. The drawings show in

Fig. 1 is a schematic sectional view through a

Prefabricated structural element according to the prior art,

Fig. 2 shows an insert element with channel recess in section according to the

State of the art,

Fig. 3 is a schematic sectional view of several intermittently joined together construction elements gem. Fig. 1,

4 shows a schematic sectional view of a first embodiment of a finished construction element according to the invention without a second plate,

Fig. 5a to

FIG. 5c shows schematic sectional views of the first embodiment of the prefabricated structural element according to the invention according to FIG. 4 at different construction stages, FIG.

Fig. 6 is a schematic sectional view of a second embodiment of a finished construction element according to the invention without a second Plate,

7 shows a schematic sectional view of a third embodiment of a prefabricated construction element according to the invention without a second plate,

Fig. 8 is a schematic sectional view of several assembled

Prefabricated construction elements according to FIG. 7.

FIG. 4 shows a schematic sectional view of a construction of a first embodiment of a prefabricated structural element according to the present invention.

The prefabricated structural element is shown with a first plate 112 at the bottom, two U-shaped delimiting profiles 118 forming the lateral boundary, and one foamed areas with the sections 116, 117 and 122.

The lower plate 112 projects slightly beyond the left-hand boundary profile (in the figure), but does not extend to the outer boundary of the right-hand boundary profile on its right edge. In this embodiment, the intermediate product can be removed from the double belt device.

The completion of the finished finished construction element is shown in FIGS. 5a to 5c.

First, the supply lines 126 are arranged in the recess 124 (FIG. 5b). Subsequently, an upper plate 114 is applied to the intermediate product substantially point-symmetrically with respect to the lower plate 112, i. the upper plate 114 protrudes slightly beyond the right-hand boundary profile (in the figure), but does not extend to the left border of the left-hand boundary profile.

By this lateral configuration, two identical prefabricated construction elements can intermittently put together and over the protruding Plate tabs connected to each other, for example, be screwed, wherein the respective screw connections through the respective plate (112 or 114) and an adjacent, adjacent U-shaped element 118 (of the other structural finished element) can take place. The protruding plates also have a guiding function when joining, so that a flush joining is ensured.

As an alternative to the procedure in FIGS. 5a to 5c, the application of the plate 114 can also take place prior to the introduction of the supply line, which are then inserted at the construction site as required from above or below into the recess.

Alternatively, a solid profile can be inserted into the recess 124, in particular if no supply lines are to be introduced.

The procedure for producing the prefabricated structural element from FIG. 4 is very simple. First, the plate 112 is placed on a table or a feeding device for the double band before the entry of a known double-belt device. The plate 112 is suitably fed with the respective profiles 118 and connected to the plate 112, e.g. bonded.

If the profiles are arranged on the plate 112, a polyurethane material is introduced into the region of the later foam-filled sections 116, 117 and 122 and foams shortly before entering the known double strip with an upper belt and a lower belt. In this case, the reaction time is selected so that before the entry into the double belt is still no complete foaming occurs. The full foaming happens after entering the double band, in the present case, the upper band forms the upper limit of the foam.

By the projection or the projections on a band of the double belt device, the recess is continuously formed and formed. After passing through the double band of polyurethane foam is so far hardened, that the second plate could be placed on the foam and then preferably still adheres to the adhesive foam.

In Fig. 6, an alternative embodiment of both a manufacturing method as well as the construction finished element itself is provided. The prefabricated construction element differs in that in FIG. 5 on the right side the boundary profile is missing and on the left side preferably a profile in I-shape or in double C-shape is supplied. Since there is no switching function by a profile on the right side due to the absence of the limiting profile, this side is ensured by a lateral sealing chain or bead of the double-belt device. This sealing chain 140 runs along with the double belt and ensures that the material necessary for forming the core section 116 in this region does not foam further than necessary.

In the assembly of intermittently adjacent prefabricated structural elements (analogous to FIG. 2), the left part of the I-shaped side profile 118 'is now inserted into the free space between the two plates 112 and 114 after removal of the Seitenabdichtkette so that he there with readily the plates can be screwed. This results in a very strong connection of two adjacent plates. In this case, the foam in this edge region is preferably shaped in such a way that the engaging profile of the adjoining prefabricated construction element adjoins the foamed material in a form-fitting manner.

Another embodiment for a prefabricated structural element is shown in FIG. In this case, this prefabricated construction element does not differ in its manufacturing process but only the shape of its two side edges. These are each formed by a stepped profile 118 ", wherein a protrusion of one profile can be respectively received in a recess or a recess of an adjacent profile (similar to a shiplap or tongue and groove connection) As shown in Fig. 8 can be seen, so know in part a supernatant as it has already been described above. 7 allows two adjacent prefabricated construction elements to be joined by screwing together so that the profiles 118 "themselves are connected to one another known Stufenfalz- or tongue-and-groove variant.

With the present invention can be easily and inexpensively produced with a continuous process using a double belt device, a finished construction element, which is variable in use and has good sound insulation and heat insulation properties. Moreover, supply lines can be integrated in a pre-installation, preferably in the area of production of the construction elements.

PREFERENTIAL PREPARATION Construction Prefabricated Element (Prior Art) First plate

Second plate

core

Side profile (completion and reinforcement) Clearance

Insert element with channel recess Kanalausnehmung

supply lines

Screw connection of the first kind

Screw connection of the second type, 110 ', prefabricated construction element acc. the invention "

First plate

Second plate

First section of foamed section Second section of foamed section, 118 ', side profile or deckle profile "

Third core section with channel recess Kanalausnehmung

supply lines

screw

Side sealing chain of the double belt system

Claims

claims

1. Double belt plant for producing a prefabricated structural element comprising

a supply device for the discontinuous or continuous supply of a first plate,

a feeding device for supplying a first lateral limiting profile serving as shuttering,

- Following a delivery device for introducing a foaming plastic material on the first plate and between the first lateral, serving as formwork limiting profile and a first side

Boundary profile opposite, lateral edge boundary

a double band device with a top and a bottom band,

characterized,

in that at least one projection for the formation of a receptacle which projects back in relation to a flat surface in the foamed plastic material is provided in the band of the double-band apparatus opposite the plate in the circumferential direction of the band.

2. double belt plant according to claim 1,

characterized,

in that the projections are formed by attachment elements on the band or band plates.

3. double belt plant according to claim 2,

characterized,

that the projections are removable, interchangeable and / or displaceable.

4. double belt system according to one of claims 1 to 3,

characterized,

a further supply device is provided for supplying a second boundary profile opposite the first lateral boundary profile, wherein the second lateral boundary profile forms the edge boundary.

5. double belt installation according to one of claims 1 to 3,

characterized,

that the double-belt device comprises a lateral sealing chain, which forms the lateral edge boundary.

6. double belt system according to one of the preceding claims,

characterized,

the double belt device downstream of a supply device for discontinuous or continuous supply of a second plate is provided on the profiles and the foamed or intumescent plastic material.

7. Double belt installation according to one of the preceding claims,

characterized,

a supply device is provided for feeding a film web as a vapor barrier, wherein the film web can be introduced between the first or the second plate and the foamed or foaming plastic material.

8. A method for producing a prefabricated structural element in the

a first plate is fed with a discontinuous or continuous feed,

- Subsequently, by means of a feed device, a first lateral serving as formwork limiting profile is supplied,

- Subsequently, a foaming plastic material is applied to the first plate and introduced into a double-belt device with a top and a bottom band, wherein a side boundary of the first lateral boundary profile opposite is formed,

characterized,

in that a receptacle which projects back in relation to a flat surface in the foamed plastic material is formed by at least one projection running around in the circumferential direction of the band on the band of the double band device.

9. The method according to claim 8,

characterized, that different shots are formed by the use of different projections.

10. The method according to any one of claims 8 or 9,

characterized,

in that a second limiting profile opposite the first lateral limiting profile is fed, the second lateral limiting profile forming the marginal boundary.

11. The method according to any one of claims 8 or 9,

characterized,

12. The method according to any one of the preceding claims,

characterized,

that is connected downstream of the double belt device discontinuous or continuous a second plate on the profiles and the foamed or intumescent plastic material.

13. The method according to any one of claims 8 to 12,

characterized,

that between the first or the second plate and the foamed or foaming plastic material, a film web is introduced as a vapor barrier.