EP4182138A1 - Method for producing a panel from secondary raw materials, panel formed from secondary raw materials, and panel formed from secondary raw materials produced by this method - Google Patents

Method for producing a panel from secondary raw materials, panel formed from secondary raw materials, and panel formed from secondary raw materials produced by this method

Info

Publication number
EP4182138A1
EP4182138A1 EP20751072.8A EP20751072A EP4182138A1 EP 4182138 A1 EP4182138 A1 EP 4182138A1 EP 20751072 A EP20751072 A EP 20751072A EP 4182138 A1 EP4182138 A1 EP 4182138A1
Authority
EP
European Patent Office
Prior art keywords
double
belt press
thin layer
plate
heat
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP20751072.8A
Other languages
German (de)
French (fr)
Inventor
Oliver Schmid
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Bosig GmbH
Original Assignee
Bosig GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bosig GmbH filed Critical Bosig GmbH
Publication of EP4182138A1 publication Critical patent/EP4182138A1/en
Pending legal-status Critical Current

Links

Classifications

    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/44—Compression means for making articles of indefinite length
    • B29C43/48—Endless belts
    • 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
    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
    • B29C44/30—Expanding the moulding material between endless belts or rollers
    • 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
    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
    • B29C44/32—Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements
    • B29C44/321—Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements the preformed part being a lining, e.g. a film or a support lining
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/26—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/0026—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting
    • B29B17/0042—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting for shaping parts, e.g. multilayered parts with at least one layer containing regenerated plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/04—Disintegrating plastics, e.g. by milling
    • B29B17/0412—Disintegrating plastics, e.g. by milling to large particles, e.g. beads, granules, flakes, slices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/04—Disintegrating plastics, e.g. by milling
    • B29B2017/042—Mixing disintegrated particles or powders with other materials, e.g. with virgin materials
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/44—Compression means for making articles of indefinite length
    • B29C43/48—Endless belts
    • B29C2043/483—Endless belts cooperating with a second endless belt, i.e. double band presses
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/28—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • 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
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/26—Scrap or recycled material
    • 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
    • B29K2475/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as filler
    • 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
    • B29K2995/0001—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular acoustical properties
    • B29K2995/0002—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular acoustical properties insulating
    • 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
    • B29K2995/0012—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
    • B29K2995/0015—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2007/00—Flat articles, e.g. films or sheets
    • B29L2007/002—Panels; Plates; Sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B29L2009/003—Layered products comprising a metal layer
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/26—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
    • B32B2037/268—Release layers
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B32B37/1027—Pressing using at least one press band
    • 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/62—Plastics recycling; Rubber recycling

Definitions

  • the invention relates to a method for producing a panel from secondary raw materials.
  • the invention also relates to a panel made from secondary raw materials and to a panel made from secondary raw materials according to the method.
  • a method of this type and a plate of this type are known from publication DE 100 19662 A1.
  • the disadvantage of the known production of Phonotherm® records is that you can only ever produce one record at a time and the dwell times in the press vary depending on the thickness of the record. This leads to annoying waiting times in the manufacturing process.
  • the object of the invention is to no longer produce the panels individually, ie panel by panel, but to produce them endlessly.
  • the aim is to increase the flexural rigidity of the endlessly produced panels many times over compared to conventionally manufactured Phonotherm® panels.
  • a board produced by the method according to the invention is specified in the independent patent claim 15 .
  • FIG. 1 shows a block diagram of a plant for the continuous production of boards according to the method according to the invention
  • FIG. 2 shows a cross section through an exemplary embodiment of a panel according to the invention and a panel produced by the method according to the invention.
  • boards 20 according to FIG. 2 are continuously produced from secondary raw materials on a double belt press 10, as will be described below.
  • panel is understood to mean panel-shaped materials which can be cut and processed into any shape with the desired width and length, into boards, planks, rods or the like.
  • a secondary raw material in particular in the form of waste or residues from cured polyurethane foam, is shredded in a shredder 2 and ground in a grinder 3, optionally together with other solid auxiliary materials, for example fibers, to give a defined ground material.
  • the ground material stored in a silo 4 is discharged in the desired amount from the silo 4 into a mixing chamber 6 by means of a screw conveyor 5, where it is mixed with water, liquid isocyanate and optionally other liquid additives such as polyol and/or or water, from tanks 7 is evenly mixed. Free-flowing additives, such as salts, can also be added to the mixture in the mixing screw.
  • the mixture is then applied as bulk material to a spreader 9 by means of a screw conveyor 8, where the bulk material is evenly distributed in terms of width and thickness.
  • the bulk material is then and continuously fed to the double belt press 10 (hot press).
  • the double-belt press 10 consists, in a manner not shown, of parallel endless belts made of steel or chain links, between which there is an adjustable press gap.
  • the mixed bulk material is continuously fed into the press gap, which is pulled through the double belt press 10 during the movement of the endless belts and is thereby subjected to a defined pressing pressure perpendicularly to the two endless belts.
  • the pressing pressure is in the range of at least 250 N/cm 2 up to 285 N/cm 2 .
  • a heating unit 11 heats the bulk material fed in as it passes through the double belt press 10 to an elevated temperature in the range from at least 120° C. to a maximum of 200° C and is preferably always 190 °C.
  • the thermal pressing process in the double-belt press 10 results in a homogeneous and evenly mixed strand of material in the form of a hot endless plate from the bulk material fed in at the outlet of the double-belt press 10 .
  • the hot endless plate at the exit of the double-belt press 10 is cooled in a subsequent further double-belt press 12 (cold press) under pressure and with the aid of a cooling unit 13 to a temperature of preferably 20° C., as a result of which the plate material hardens completely.
  • a subsequent further double-belt press 12 cold press
  • a cooling unit 13 to a temperature of preferably 20° C.
  • the remaining release agent can cause the panels to become detached splices come.
  • Another possibility is to insert separating foils made of Teflon or silicone between the bulk material and the metallic pressing surfaces of the endless belts, which are removed again at the discharge end of the double belt press 10 .
  • a wearing layer to the double-belt press 10, for example a paper layer, which remains on the plate after the pressing process but fulfills the purpose of protecting the metallic surfaces of the double-belt press 20.
  • paper has many negative properties, which have a disadvantageous effect in the later process of further processing of the plates 20, for example when gluing other materials.
  • a thin separating layer is introduced in the pressing process of the double belt press 10 between the metal surfaces of the endless belts and the bulk material.
  • the thin separating layer is impermeable to isocyanate and heat-resistant to temperatures of up to 200 °C. It is essential that the thin separating layer is designed in such a way that, in contrast to separating films made of Teflon or silicone, it is not pulled off the hot endless plate at the discharge end of the double-belt press 10, but is inseparably connected to the surfaces of the endless plate.
  • the thin separating layer thus remains as a thin layer on the top and bottom of the endless sheets.
  • a fleece made of glass fibres, carbon fibers or a knitted fabric made of heat-resistant, impermeable fibrous materials is preferably used as the thin separating layer.
  • a metal foil or with a fabric or a Fleece-reinforced, metallized foil can be provided, for example an aluminum foil.
  • a fleece made of glass fibers or carbon fibers is thermostable even at processing temperatures of up to 200 °C, in contrast to fleeces made of plastic such as polyethylene or polystyrene, which are usually not temperature-resistant and would melt.
  • the thin separating layer prevents the applied bulk material from sticking to the metallic surfaces of the endless belts of the double-belt press 10, which are thus perfectly protected against adhesion.
  • the thin separating layer chemically bonds to the surfaces of the manufactured endless sheet, since it sticks to the plate material of the pressed bulk material due to the isocyanate content of the bulk material and forms a permanent thin layer on the top and bottom of the endless sheet.
  • the preferred use of a fleece has the further advantage that the structure of the fleece used claws into the hot material of the bulk material fed in, which results in mechanical adhesion of the fleece to the finished endless plate that goes beyond the mere adhesive bond between the fleece and the pressed plate material results.
  • a fleece made of glass fibres, carbon fibers or a knitted fabric made of heat-resistant, impermeable fibrous materials By coating the finished panels with a fleece made of glass fibres, carbon fibers or a knitted fabric made of heat-resistant, impermeable fibrous materials, the modulus of elasticity, i.e. the flexural rigidity, of the coated panels increases many times over compared to conventional Phonotherm® panels. As a result, thinner Phonotherm® plates 20 can be used for many applications compared to conventional Phonotherm® plates.
  • the finished panel is coated with a metal foil or with a fabric- or fleece-reinforced, metallized foil, there is a particular advantage that a metal foil or the metallization acts as a sliding layer during manufacture of the endless panel.
  • the metal foil or the metallization on the surface of the finished board has the further advantageous effect of improving the thermal insulation properties compared to a conventional Phonotherm® board.
  • Phonotherm® plate 20 An example of a Phonotherm® plate 20 according to the invention and produced by the method according to the invention is illustrated in cross section in FIG.
  • the plate 20 shown has, as a plate core 21, a homogeneous structure made from the pressed and cured mixture of ground polyurethane material and isocyanate adhesive.
  • the panel core 21 is insensitive to moisture and offers excellent heat and sound insulation properties.
  • the panel core 21 is temperature and chemical resistant, non-aging, non-rotting, recyclable, formaldehyde-free, resistant to mold and rot and does not emit any physiologically relevant amounts of chemical substances.
  • the panel core 21 can be easily machined with conventional hard metal tools and can be sawed, ground and milled without the risk of breaking out. The resulting dusts are not fibrous and are therefore physiologically harmless.
  • the plate core 21 is coated with a thin layer 22 on its top and bottom.
  • the thin film 22 is in contact with the disk core underneath 21 is chemically inseparably connected by gluing due to its isocyanate component.
  • a fleece made of glass fibers, carbon fibers or a knitted fabric made of heat-resistant, impermeable fibrous materials is preferably used as the thin layer 22.
  • a metal foil or a metalized foil reinforced with a fabric or a fleece, for example an aluminum foil, can also be provided as the thin layer 22 . If a fleece is used, the fibers of the thin layer 22 are additionally mechanically connected to the underlying panel core 21 by clawing.
  • the modulus of elasticity, i.e. the flexural rigidity, of the coated panels increases many times over compared to conventional Phonotherm® panels. If the finished panel 20 is coated with a metal foil or with a fabric or fleece-reinforced, metallized foil, the metal foil or the metallization on the surfaces of the finished panel 20 has the advantageous effect of improving the thermal insulation properties compared to a conventional Phonotherm® panel.

Abstract

The invention relates to a method for producing a panel (20) from secondary raw materials, in particular from a ground material consisting of comminuted and ground polyurethane foam residues and optionally further solid auxiliaries. To perform the method, a mixture of ground material, isocyanate, water and optionally further liquid or pourable additives is pressed under high pressure and elevated temperature to form a panel. The mixture is continuously fed here in the form of a bulk material, uniformly distributed in width and thickness, to a press nip of a double-belt press (10) formed of endless belts running in parallel. As it passes through the double-belt press (10) the fed bulk material is subjected to a defined pressure perpendicular to the parallel endless belts and to an elevated temperature so as to form a hot endless panel at the discharge from the double-belt press (10). To protect the metallic surfaces of the endless belts from sticking, a separation layer is introduced during the pressing process of the double-belt press (10) between the metallic surfaces of the endless belts and the bulk material.

Description

Verfahren zur Herstellung einer Platte aus Sekundärrohstoffen,Method of manufacturing a board from secondary raw materials,
Platte aus Sekundärrohstoffen und nach diesem Verfahren hergestellte Platte aus Sekundärrohstoffen Board made from secondary raw materials and board made from secondary raw materials using this process
Die Erfindung bezieht sich auf ein Verfahren zur Herstellung einer Platte aus Sekundärrohstoffen. Die Erfindung bezieht sich ferner auf eine Platte aus Sekundärrohstoffen sowie auf eine nach dem Verfahren hergestellte Platte aus Sekundärrohstoffen. Ein Verfahren dieser Art und eine derartige Platte sind aus der Druckschrift DE 100 19662 A1 bekannt. The invention relates to a method for producing a panel from secondary raw materials. The invention also relates to a panel made from secondary raw materials and to a panel made from secondary raw materials according to the method. A method of this type and a plate of this type are known from publication DE 100 19662 A1.
Aus der Druckschrift DE 100 19 662 A 1 ist es bekannt, bei der Industrieproduktion anfallende Sekundärrohstoffe in Form von Abfällen oder Resten aus ausgehärtetem Polyurethan-Schaum zu recyceln, indem die Reste aus Polyurethan-Schaum zerkleinert und gemahlen werden und das Mahlgut unter Beimischung von Wasser und Isocyanat sowie weiteren Hilfsstoffen in einer Presse unter hohem Druck und erhöhter Temperatur zu großformatigen Platten gepresst wird. Derartige Platten sind unter dem Markennamen Phonotherm® im Handel erhältlich. Die Phonotherm® - Platten besitzen ein Raumgewicht von 300 bis 900 kg/cm infolge des erheblichen, genau definierten Drucks bei der Herstellung über die Presse. Phonotherm® - Platten finden Anwendung als konstruktive Wärme- und Schalldämmplatten im Bereich von Fassaden, im Türen- und Fensterbau und als Raumelemente zur Schallabsorption. Dabei verbinden sich die Vorteile einer hervorragenden Festigkeit infolge des hohen Raumgewichtes auf der einen Seite und der guten Wärme- und Schalldämmeigenschaft des Polyurethanmaterials auf der anderen Seite. It is known from the document DE 100 19 662 A1 to recycle secondary raw materials occurring in industrial production in the form of waste or residues from cured polyurethane foam by crushing and grinding the residues from polyurethane foam and mixing the ground material with water and isocyanate as well as other auxiliaries is pressed in a press under high pressure and elevated temperature to form large-format panels. Such plates are commercially available under the trade name Phonotherm®. The Phonotherm® panels have a density of 300 to 900 kg/cm due to the considerable, precisely defined pressure during production using the press. Phonotherm® panels are used as constructive heat and sound insulation panels in the area of facades, in door and window construction and as room elements for sound absorption. This combines the advantages of excellent strength due to the high density on the one hand and the good heat and sound insulation properties of the polyurethane material on the other.
Der Nachteil der bekannten Fertigung von Phonotherm® - Platten besteht darin, dass man immer nur eine Platte nach der anderen herstellen kann und die Verweilzeiten in der Presse je nach Plattenstärke variieren. Dies führt im Fertigungsprozess zu lästigen Wartezeiten . Die Aufgabe der Erfindung besteht darin, die Platten nicht mehr einzeln, also Platte für Platte herzustellen, sondern endlos zu produzieren. Dabei soll die Biegesteifigkeit der endlos produzierten Platten um ein Vielfaches gegenüber herkömmlich hergestellten Phonotherm® - Platten vergrößert werden . The disadvantage of the known production of Phonotherm® records is that you can only ever produce one record at a time and the dwell times in the press vary depending on the thickness of the record. This leads to annoying waiting times in the manufacturing process. The object of the invention is to no longer produce the panels individually, ie panel by panel, but to produce them endlessly. The aim is to increase the flexural rigidity of the endlessly produced panels many times over compared to conventionally manufactured Phonotherm® panels.
Die auf eine Endlosproduktion gerichtete Teilaufgabe wird erfindungsgemäß durch die kennzeichnenden Merkmale des Patentanspruch 1 gelöst. The sub-task aimed at continuous production is achieved according to the invention by the characterizing features of patent claim 1 .
Die auf eine Verbesserung einer Phonotherm® - Platte gerichtete Teilaufgabe wird erfindungsgemäß durch die kennzeichnenden Merkmale des nebengeordneten Patentanspruchs 11 gelöst. The sub-task aimed at improving a Phonotherm® plate is achieved according to the invention by the characterizing features of the independent patent claim 11 .
Eine nach dem erfindungsgemäßen Verfahren hergestellte Platte ist in dem nebengeordneten Patentanspruch 15 angegeben. A board produced by the method according to the invention is specified in the independent patent claim 15 .
Vorteilhafte Ausgestaltungen und Weiterbildungen des erfindungsgemäßen Verfahrens sind in den Unteransprüchen 2 bis 10 angegeben . Advantageous refinements and developments of the method according to the invention are specified in dependent claims 2 to 10 .
Vorteilhafte Ausgestaltungen der erfindungsgemäßen Platte nach dem nebengeordneten Anspruch 1 1 sind in den Unteransprüchen 12 bis 14 angegeben . Advantageous configurations of the board according to the invention according to the independent claim 11 are specified in the dependent claims 12 to 14.
Vorteilhafte Ausgestaltungen der erfindungsgemäß hergestellten Platte nach dem nebengeordneten Anspruch 15 sind in den Unteransprüchen 16 bis 18 angegeben. Die Erfindung wird nachstehend anhand der Zeichnungen näher erläutert. Es zeigt: Advantageous configurations of the panel produced according to the invention according to the independent claim 15 are specified in the dependent claims 16 to 18. The invention is explained in more detail below with reference to the drawings. It shows:
Fig. 1 ein Blockschaltbild einer Anlage zur kontinuierlichen Herstellung von Platten nach dem erfindungsgemäßen Verfahren , und 1 shows a block diagram of a plant for the continuous production of boards according to the method according to the invention, and
Fig. 2 einen Querschnitt durch ein Ausführungsbeispiel einer erfindungsgemäßen Platte und einer nach dem erfindungsgemäßen Verfahren hergestellten Platte. 2 shows a cross section through an exemplary embodiment of a panel according to the invention and a panel produced by the method according to the invention.
Mit der in Fig. 1 schematisch dargestellten Anlage 1 werden Platten 20 nach Fig. 2 aus Sekundärrohstoffen auf einer Doppelbandpresse 10 kontinuierlich hergestellt, wie im Folgenden beschrieben wird. Unter dem Begriff „Platte“ werden plattenförmige Werkstoffe verstanden, welche zu beliebigen Formen in gewünschter Breite und Länge, zu Brettern, Bohlen, Stangen oder dergleichen zugeschnitten und verarbeitet werden können. With the system 1 shown schematically in FIG. 1, boards 20 according to FIG. 2 are continuously produced from secondary raw materials on a double belt press 10, as will be described below. The term “panel” is understood to mean panel-shaped materials which can be cut and processed into any shape with the desired width and length, into boards, planks, rods or the like.
Zu Beginn des erfindungsgemäßen Verfahrens wird ein Sekundärrohstoff insbesondere in Form von Abfällen oder Resten aus ausgehärtetem Polyurethan-Schaum in einem Schredder 2 zerkleinert und in einem Mahlwerk 3 gegebenenfalls zusammen mit weiteren festen Hilfsstoffen, beispielsweise Fasen, zu einem definierten Mahlgut gemahlen. At the start of the process according to the invention, a secondary raw material, in particular in the form of waste or residues from cured polyurethane foam, is shredded in a shredder 2 and ground in a grinder 3, optionally together with other solid auxiliary materials, for example fibers, to give a defined ground material.
Da Sekundärrohstoffe im Gegensatz zu Primärrohstoffen nicht immer die gleiche Dichte und die gleichen spezifischen Eigenschaften im Materialfluss haben, ist es wichtig, die Vorbereitungen des Mahlgutes mittels einer oder mehrerer nacheinander geschalteter Mühlen des Mahlwerks 3 so zu gestalten, dass das Mahlgut zu 100 % stets die gleiche Körnung aufweist. Bei Klumpen im Mahlgut oder auch bei zu feinem Mahlgut würde es bei der anschließenden Verarbeitung in dem kontinuierlichen Prozess der Anlage 1 zu Störungen kommen. Um dies zu vermeiden, wird das Mahlgut des Sekundärrohstoffes immer in Bewegung gehalten und nach dem Mahlvorgang möglichst schnell verarbeitet. Since secondary raw materials, in contrast to primary raw materials, do not always have the same density and the same specific properties in the material flow, it is important to prepare the ground material using one or more mills connected in series in grinding mechanism 3 in such a way that the ground material is always 100% same grain. If there were lumps in the ground material or if the ground material was too fine, there would be disruptions in the subsequent processing in the continuous process of plant 1. In order to avoid this, the regrind of the secondary raw material is always kept in motion and processed as quickly as possible after the grinding process.
Das in einem Silo 4 gespeicherte Mahlgut wird mittels eines Schneckenförderers 5 in der gewünschten Menge aus dem Silo 4 in eine Mischkammer 6 ausgetragen, wo es beispielsweise mittels einer nicht gezeigten Mischschnecke mit Wasser, flüssigem Isocyanat und gegebenenfalls weiteren flüssigen Zusatzstoffen, wie beispielsweise Polyol und/oder Wasser, aus Tanks 7 gleichmäßig gemischt wird. Es können auch rieselfähige Zusatzstoffe, wie beispielsweise Salze, zur Mischung in der Mischschnecke beigegeben werden. Die Mischung wird sodann mittels eines Schneckenförderers 8 auf eine Streuanlage 9 als Schüttgut aufgebracht, wo das Schüttgut in der Breite und Stärke gleichmäßig verteilt wird. Das Schüttgut wird anschließend und kontinuierlich der Doppelbandpresse 10 (Heißpresse) zugeführt. The ground material stored in a silo 4 is discharged in the desired amount from the silo 4 into a mixing chamber 6 by means of a screw conveyor 5, where it is mixed with water, liquid isocyanate and optionally other liquid additives such as polyol and/or or water, from tanks 7 is evenly mixed. Free-flowing additives, such as salts, can also be added to the mixture in the mixing screw. The mixture is then applied as bulk material to a spreader 9 by means of a screw conveyor 8, where the bulk material is evenly distributed in terms of width and thickness. The bulk material is then and continuously fed to the double belt press 10 (hot press).
Die Doppelbandpresse 10 besteht in nicht gezeigter Weise aus parallel laufenden Endlosbändern aus Stahl oder Kettengliedern, zwischen denen sich ein einstellbarer Pressspalt befindet. In den Pressspalt wird das gemischte Schüttgut kontinuierlich aufgegeben, das bei der Bewegung der Endlosbänder durch die Doppelbandpresse 10 gezogen und dabei senkrecht zu den beiden Endlosbändern einem definierten Pressdruck ausgesetzt wird. Der Pressdruck liegt im Bereich von wenigstens 250 N/cm2 bis zu 285 N/cm2. Ein Heizaggregat 11 erhitzt das aufgegebene Schüttgut beim Durchlauf durch die Doppelbandpresse 10 auf eine erhöhte Temperatur, die im Bereich von wenigstens 120 °C bis maximal 200 °C liegt und vorzugsweise stets 190 °C beträgt. Durch den thermischen Pressvorgang in der Doppelbandpresse 10 entsteht aus dem aufgegebenen Schüttgut am Ausgang der Doppelbandpresse 10 ein homogener und gleichmäßig gemischter Materialstrang in Form einer heißen Endlosplatte. Die heiße Endlosplatte am Ausgang der Doppelbandpresse 10 wird in einer nachfolgenden weiteren Doppelbandpresse 12 (Kaltpresse) unter Druck und mit Hilfe eines Kühlaggregates 13 auf eine Temperatur von vorzugsweise 20 °C abgekühlt, wodurch das Plattenmaterial vollständig aushärtet. Beim Abkühlen der heißen Endlosplatte in der Doppelbandpresse 12 kommen im Wesentlichen dieselben Druckparameter wie beim Durchlauf durch die heiße Doppelbandpresse 10 zur Anwendung. Nach dem Erkalten kann die ausgehärtete Endlosplatte auf die gewünschte Größe und das gewünschte Format der fertigen Platte 20 zugeschnitten werden. The double-belt press 10 consists, in a manner not shown, of parallel endless belts made of steel or chain links, between which there is an adjustable press gap. The mixed bulk material is continuously fed into the press gap, which is pulled through the double belt press 10 during the movement of the endless belts and is thereby subjected to a defined pressing pressure perpendicularly to the two endless belts. The pressing pressure is in the range of at least 250 N/cm 2 up to 285 N/cm 2 . A heating unit 11 heats the bulk material fed in as it passes through the double belt press 10 to an elevated temperature in the range from at least 120° C. to a maximum of 200° C and is preferably always 190 °C. The thermal pressing process in the double-belt press 10 results in a homogeneous and evenly mixed strand of material in the form of a hot endless plate from the bulk material fed in at the outlet of the double-belt press 10 . The hot endless plate at the exit of the double-belt press 10 is cooled in a subsequent further double-belt press 12 (cold press) under pressure and with the aid of a cooling unit 13 to a temperature of preferably 20° C., as a result of which the plate material hardens completely. When the hot endless plate cools down in the double-belt press 12, essentially the same pressure parameters are used as during passage through the hot double-belt press 10. After cooling, the hardened continuous board can be cut to the desired size and the desired format of the finished board 20 .
Bei der beschriebenen Verwendung der Doppelbandpresse 10 ergibt sich eine Schwierigkeit daraus, dass sich das im Mischgut eingearbeitete Isocyanat beim Pressvorgang infolge der Erwärmung auf 120°C bis 200 °C untrennbar mit den Metalloberflächen der Endlosbänder der Doppelbandpresse 10 verbindet. Dadurch würden die Oberflächen der Endlosbänder verklebt und unbrauchbar. Um diese Schwierigkeit zu umgehen, bieten sich mehrere Möglichkeiten an. Die eine Möglichkeit besteht in der Verwendung von Trennmitteln, wie beispielsweise Silikonöl, welches man vor dem Eintrag des Schüttgutes auf die Metalloberflächen der Endlosbänder aufbringen könnte. Damit ergibt sich jedoch der Nachteil, dass die Trennmittel in die Oberflächen der fertigen Platten eindringen und letztendlich in den äußeren Bereichen der fertigen Platten verbleiben. Bei späteren Klebeverbindungen der fertigen Platten mit anderen Oberflächen kann es wegen des verbliebenen Trennmittels zu Ablösungen der Klebestellen kommen. Eine andere Möglichkeit besteht darin, zwischen dem Schüttgut und den metallischen Pressoberflächen der Endlosbänder Trennfolien aus Teflon oder Silikon einzubringen, die am Austragsende der Doppelbandpresse 10 wieder abgezogen werden. Alternativ könnte man auch eine Verschleißschicht mit in die Doppelbandpresse 10 geben, beispielsweise eine Papierschicht, welche zwar nach dem Pressvorgang auf der Platte verbleibt, den Zweck eines Schutzes der metallischen Oberflächen der Doppelbandpresse 20 aber erfüllt. Leider aber haben Papiere viele negative Eigenschaften, welche sich im späteren Prozess der Weiterverarbeitung der Platten 20 nachteilig auswirken, beispielsweise beim Verkleben mit anderen Werkstoffen. In the described use of the double-belt press 10, a difficulty arises from the fact that the isocyanate incorporated in the mixture during the pressing process is inseparably connected to the metal surfaces of the endless belts of the double-belt press 10 as a result of heating to 120° C. to 200° C. This would cause the surfaces of the endless belts to stick together and become unusable. There are several ways to circumvent this difficulty. One possibility is the use of release agents, such as silicone oil, which could be applied to the metal surfaces of the endless belts before the bulk material is introduced. However, this results in the disadvantage that the release agents penetrate into the surfaces of the finished panels and ultimately remain in the outer areas of the finished panels. When the finished panels are subsequently bonded to other surfaces, the remaining release agent can cause the panels to become detached splices come. Another possibility is to insert separating foils made of Teflon or silicone between the bulk material and the metallic pressing surfaces of the endless belts, which are removed again at the discharge end of the double belt press 10 . Alternatively, one could also add a wearing layer to the double-belt press 10, for example a paper layer, which remains on the plate after the pressing process but fulfills the purpose of protecting the metallic surfaces of the double-belt press 20. Unfortunately, however, paper has many negative properties, which have a disadvantageous effect in the later process of further processing of the plates 20, for example when gluing other materials.
Die Erfindung geht indessen einen anderen Weg, um die Verklebung der Oberflächen der Endlosbänder zu vermeiden. Hierzu wird eine dünne Trennschicht in den Pressvorgang der Doppelbandpresse 10 zwischen die metallischen Oberflächen der Endlosbänder und dem Schüttgut eingebracht. Die dünne Trennschicht ist für Isocyanat undurchlässig und für Temperaturen bis zu 200 °C hitzeunempfindlich. Wesentlich ist, dass die dünne Trennschicht so beschaffen ist, dass sie im Unterschied zu Trennfolien aus Teflon oder Silikon am Austragsende der Doppelbandpresse 10 von der heißen Endlosplatte nicht abgezogen wird, sondern sich untrennbar mit den Oberflächen der Endlosplatte verbindet. Die dünne Trennschicht verbleibt somit an der Ober- und Unterseite der Endlosblatte als Dünnschicht. However, the invention takes a different approach to avoiding the surfaces of the endless belts from sticking together. For this purpose, a thin separating layer is introduced in the pressing process of the double belt press 10 between the metal surfaces of the endless belts and the bulk material. The thin separating layer is impermeable to isocyanate and heat-resistant to temperatures of up to 200 °C. It is essential that the thin separating layer is designed in such a way that, in contrast to separating films made of Teflon or silicone, it is not pulled off the hot endless plate at the discharge end of the double-belt press 10, but is inseparably connected to the surfaces of the endless plate. The thin separating layer thus remains as a thin layer on the top and bottom of the endless sheets.
Als dünne Trennschicht kommt vorzugsweise ein Vlies aus Glasfasern, Kohlefasern oder einem Gewirke aus hitzeunempfindlichen, undurchlässigen Faserstoffen zum Einsatz. Alternativ kann als Dünnschicht auch eine Metallfolie oder eine mit einem Gewebe oder einem Vlies verstärkte, metallisierte Folie vorgesehen werden, beispielsweise eine Aluminiumfolie. Ein Vlies aus Glasfasern oder Karbonfasern ist selbst bei Verarbeitungstemperaturen von bis zu 200 °C thermostabil, im Gegensatz zu Vliesstoffen aus Kunststoff, wie Polyethylen oder Polystyrol, die in der Regel nicht temperaturbeständig sind und schmelzen würden. A fleece made of glass fibres, carbon fibers or a knitted fabric made of heat-resistant, impermeable fibrous materials is preferably used as the thin separating layer. Alternatively, as a thin layer, a metal foil or with a fabric or a Fleece-reinforced, metallized foil can be provided, for example an aluminum foil. A fleece made of glass fibers or carbon fibers is thermostable even at processing temperatures of up to 200 °C, in contrast to fleeces made of plastic such as polyethylene or polystyrene, which are usually not temperature-resistant and would melt.
Die dünne Trennschicht verhindert infolge ihrer Undurchlässigkeit für Isocyanat das Ankleben des aufgegebenen Schüttgutes an den metallischen Oberflächen der Endlosbänder der Doppelbandpresse 10, die auf diese Weise perfekt gegen Anhaftung geschützt werden. Die dünne Trennschicht verbindet sich bei dem thermischen Pressvorgang mit den Oberflächen der hergestellten Endlosplatte chemisch, da sie durch den Isocyanat-Anteil des Schüttgutes mit dem Plattenmaterial des gepressten Schüttgutes verklebt und auf der Ober- und Unterseite der Endlosplatte eine dauerhafte Dünnschicht bildet. Due to its impermeability to isocyanate, the thin separating layer prevents the applied bulk material from sticking to the metallic surfaces of the endless belts of the double-belt press 10, which are thus perfectly protected against adhesion. During the thermal pressing process, the thin separating layer chemically bonds to the surfaces of the manufactured endless sheet, since it sticks to the plate material of the pressed bulk material due to the isocyanate content of the bulk material and forms a permanent thin layer on the top and bottom of the endless sheet.
Bei der bevorzugten Verwendung eines Vlieses ergibt sich der weitere Vorteil, dass sich die Struktur des verwendeten Vlieses in das heiße Material des aufgegebenen Schüttgutes verkrallt, woraus eine über die bloße Klebeverbindung zwischen dem Vlies und dem gepressten Plattenmaterial hinausgehehde mechanische Haftung des Vlieses auf der fertigen Endlosplatte resultiert. Durch die Beschichtung der fertigen Platten mit einem Vlies aus Glasfasern, Kohlefasern oder einem Gewirke aus hitzeunempfindlichen, undurchlässigen Faserstoffen erhöht sich der E- Modul, also die Biegesteifigkeit, der beschichteten Platten um ein Vielfaches gegenüber herkömmlichen Phonotherm®-Platten. Dadurch lassen sich für viele Anwendungen gegenüber herkömmlichen Phonotherm®-Platten dünnere Phonotherm®-Platten 20 einsetzen. Im Falle einer Beschichtung der fertigen Platte mit einer Metallfolie oder mit einer gewebe- oder vliesverstärkten, metallisierte Folie kommt als besonderer Vorteil hinzu, dass eine Metallfolie bzw. die Metallisierung als Gleitschicht bei der Fertigung der Endlosplatte wirkt. Beim Einsatz der der fertigen Platte als Wärmedämmplatte hat die Metallfolie bzw. die Metallisierung auf den Oberflächen der fertigen Platte den weiteren vorteilhaften Effekt einer Verbesserung der Wärmedämmeigenschaften gegenüber einer herkömmlichen Phonotherm® - Platte. The preferred use of a fleece has the further advantage that the structure of the fleece used claws into the hot material of the bulk material fed in, which results in mechanical adhesion of the fleece to the finished endless plate that goes beyond the mere adhesive bond between the fleece and the pressed plate material results. By coating the finished panels with a fleece made of glass fibres, carbon fibers or a knitted fabric made of heat-resistant, impermeable fibrous materials, the modulus of elasticity, i.e. the flexural rigidity, of the coated panels increases many times over compared to conventional Phonotherm® panels. As a result, thinner Phonotherm® plates 20 can be used for many applications compared to conventional Phonotherm® plates. If the finished panel is coated with a metal foil or with a fabric- or fleece-reinforced, metallized foil, there is a particular advantage that a metal foil or the metallization acts as a sliding layer during manufacture of the endless panel. When the finished board is used as a thermal insulation board, the metal foil or the metallization on the surface of the finished board has the further advantageous effect of improving the thermal insulation properties compared to a conventional Phonotherm® board.
In Fig. 2 ist ein Beispiel für eine erfindungsgemäße und nach dem erfindungsgemäßen Verfahren hergestellte Phonotherm®-Platte 20 im Querschnitt veranschaulicht. An example of a Phonotherm® plate 20 according to the invention and produced by the method according to the invention is illustrated in cross section in FIG.
Die dargestellte Platte 20 weist als Plattenkern 21 eine homogene Struktur aus der gepressten und ausgehärteten Mischung von Polyurethan- Mahlgut und Isocyanat-Klebstoff auf. Der Plattenkern 21 ist feuchtigkeitsunempfindlich und bietet hervorragende Wärme- und Schalldämmeigenschaften. Darüber hinaus ist der Plattenkern 21 temperatur- und chemikalienbeständig, alterungsbeständig, unverrottbar, recycelbar, formaldehydfrei, Schimmel- und fäulnisfest und sondert keine physiologisch relevanten Mengen chemischer Stoffe ab. Der Plattenkern 21 lässt sich problemlos mit herkömmlichen Hartmetallwerkzeugen bearbeiten und ohne Ausbruchgefahr sägen, schleifen und fräsen. Die dabei entstehenden Stäube weisen keine faserige Form auf und sind daher physiologisch unbedenklich. The plate 20 shown has, as a plate core 21, a homogeneous structure made from the pressed and cured mixture of ground polyurethane material and isocyanate adhesive. The panel core 21 is insensitive to moisture and offers excellent heat and sound insulation properties. In addition, the panel core 21 is temperature and chemical resistant, non-aging, non-rotting, recyclable, formaldehyde-free, resistant to mold and rot and does not emit any physiologically relevant amounts of chemical substances. The panel core 21 can be easily machined with conventional hard metal tools and can be sawed, ground and milled without the risk of breaking out. The resulting dusts are not fibrous and are therefore physiologically harmless.
Im Unterschied zu herkömmlichen Phonotherm®-Platten ist der Plattenkern 21 an seiner Ober- und Unterseite mit einer Dünnschicht 22 beschichtet. Die Dünnschicht 22 ist mit dem darunter liegenden Plattenkern 21 durch dessen Isocyanat-Bestandteil chemisch durch Verklebung untrennbar verbunden Als Dünnschicht 22 kommt vorzugsweise ein Vlies aus Glasfasern, Kohlefasern oder einem Gewirke aus hitzeunempfindlichen, undurchlässigen Faserstoffen zum Einsatz. In contrast to conventional Phonotherm® plates, the plate core 21 is coated with a thin layer 22 on its top and bottom. The thin film 22 is in contact with the disk core underneath 21 is chemically inseparably connected by gluing due to its isocyanate component. A fleece made of glass fibers, carbon fibers or a knitted fabric made of heat-resistant, impermeable fibrous materials is preferably used as the thin layer 22.
Alternativ kann als Dünnschicht 22 auch eine Metallfolie oder eine mit einem Gewebe odereinem Vlies verstärkte, metallisierte Folie vorgesehen werden, beispielsweise eine Aluminiumfolie. Bei Verwendung eines Vlieses sind die Fasern der Dünnschicht 22 zusätzlich mechanisch mit dem darunter liegenden Plattenkern 21 durch Verkrallung verbunden. Alternatively, a metal foil or a metalized foil reinforced with a fabric or a fleece, for example an aluminum foil, can also be provided as the thin layer 22 . If a fleece is used, the fibers of the thin layer 22 are additionally mechanically connected to the underlying panel core 21 by clawing.
Durch die Beschichtung der fertigen Platten 20 mit einem Vlies aus Glasfasern, Kohlefasern oder einem Gewirke aus hitzeunempfindlichen, undurchlässigen Faserstoffen erhöht sich der E-Modul, also die Biegesteifigkeit, der beschichteten Platten um ein Vielfaches gegenüber herkömmlichen Phonotherm®-Platten. Im Falle einer Beschichtung der fertigen Platte 20 mit einer Metallfolie oder mit einer gewebe- oder vliesverstärkten, metallisierten Folie hat die Metallfolie bzw. die Metallisierung auf den Oberflächen der fertigen Platte 20 den vorteilhaften Effekt einer Verbesserung der Wärmedämmeigenschaften gegenüber einer herkömmlichen Phonotherm® - Platte. By coating the finished panels 20 with a fleece made of glass fibers, carbon fibers or a knitted fabric made of heat-resistant, impermeable fibrous materials, the modulus of elasticity, i.e. the flexural rigidity, of the coated panels increases many times over compared to conventional Phonotherm® panels. If the finished panel 20 is coated with a metal foil or with a fabric or fleece-reinforced, metallized foil, the metal foil or the metallization on the surfaces of the finished panel 20 has the advantageous effect of improving the thermal insulation properties compared to a conventional Phonotherm® panel.

Claims

Patentansprüche patent claims
1. Verfahren zur Herstellung einer Platte aus Sekundärrohstoffen, insbesondere aus einem Mahlgut bestehend aus zerkleinerten und gemahlenen Polyurethan-Schaumstoffresten und gegebenenfalls weiteren festen Hilfsstoffen, bei dem eine Mischung aus Mahlgut, Isocyanat, Wasser und gegebenenfalls weiteren flüssigen oder rieselfähigen Zusatzstoffen unter hohem Druck und erhöhter Temperatur zu einer Platte gepresst wird, dadurch gekennzeichnet, dass die Mischung in Form eines in der Breite und Stärke gleichmäßig verteilten Schüttgutes einem Presspalt einer Doppelbandpresse aus parallel laufenden Endlosbändern kontinuierlich zugeführt wird, dass das zugeführte Schüttgut bei Durchlauf durch die Doppelbandpresse einem definierten Pressdruck senkrecht zu den parallel laufenden Endlosbändern und einer erhöhten Temperatur unterworfen wird unter Ausbildung einer heißen Endlosplatte am Ausgang der Doppelbandpresse, und dass beim Pressvorgang der Doppelbandpresse eine Trennschicht zwischen die metallischen Oberflächen der Endlosbänder und dem Schüttgut eingebracht wird. 1. A method for producing a board from secondary raw materials, in particular from a ground material consisting of comminuted and ground polyurethane foam residues and optionally other solid auxiliary materials, in which a mixture of ground material, isocyanate, water and optionally other liquid or free-flowing additives under high pressure and increased temperature is pressed into a plate, characterized in that the mixture in the form of a bulk material uniformly distributed in terms of width and thickness is fed continuously to a press nip of a double-belt press made of endless belts running in parallel, that the bulk material fed in as it passes through the double-belt press is subjected to a defined pressing pressure perpendicularly is subjected to the parallel running endless belts and an elevated temperature to form a hot endless plate at the exit of the double belt press, and that during the pressing process of the double belt press a separating layer between the metalisc hen surfaces of the endless belts and the bulk material is introduced.
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass als Trennschicht eine für Isocyanat undurchlässige und für Temperaturen bis zu 200 °C hitzeunempfindliche Dünnschicht vorgesehen wird. 2. The method as claimed in claim 1, characterized in that a thin layer which is impermeable to isocyanate and heat-resistant to temperatures of up to 200° C. is provided as the separating layer.
3. Verfahren nach Anspruch 2, dadurch gekennzeichnet, dass als undurchlässige und hitzeunempfindliche Dünnschicht ein Vlies aus Glasfasern, Kohlefasern oder einem Gewirke aus hitzeunempfindlichen, undurchlässigen Faserstoffen vorgesehen wird. 3. The method according to claim 2, characterized in that a fleece made of glass fibers, carbon fibers or a knitted fabric made of heat-resistant, impermeable fibrous materials is provided as the impermeable and heat-resistant thin layer.
4. Verfahren nach Anspruch 2, dadurch gekennzeichnet, dass als undurchlässige und hitzeunempfindliche Dünnschicht eine Metallfolie oder eine mit einem Gewebe oder einem Vlies verstärkte, metallisierte Folie vorgesehen wird. 4. The method according to claim 2, characterized in that a metal foil or a metalized foil reinforced with a fabric or a fleece is provided as the impermeable and heat-resistant thin layer.
5. Verfahren nach Anspruch 4, dadurch gekennzeichnet, dass als Metallfolie eine Aluminiumfolie vorgesehen wird. 5. The method according to claim 4, characterized in that an aluminum foil is provided as the metal foil.
6. Verfahren nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, dass die erhöhte Temperatur im Bereich von wenigstens 120 °C bis maximal 200 °C liegt und vorzugsweise stets 190 °C beträgt. 6. The method according to any one of claims 1 to 5, characterized in that the elevated temperature is in the range of at least 120 °C to a maximum of 200 °C and is preferably always 190 °C.
7. Verfahren nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass der definierte Pressdruck im Bereich von wenigstens 250 N/cm2 bis 285 N/cm2 liegt. 7. The method according to any one of claims 1 to 6, characterized in that the defined pressing pressure is in the range of at least 250 N/cm 2 to 285 N/cm 2 .
8. Verfahren nacheinem der Ansprüche 1 bis 7, dadurch gekennzeichnet, dass die heiße Endlosplatte am Ausgang der Doppelbandpresse in einer anschließenden Kühlpresse unter Druck abgekühlt wird, wobei im wesentlichen dieselben Druckparameter wie beim Durchlauf durch die Doppelbandpresse zur Anwendung kommen. 8. Method according to one of Claims 1 to 7, characterized in that the hot endless plate is cooled under pressure at the outlet of the double-belt press in a subsequent cooling press, with essentially the same pressure parameters being used as when passing through the double-belt press.
9. Verfahren nach Anspruch 8, dadurch gekennzeichnet, dass die Kühltemperatur etwa 20°C beträgt. 9. The method according to claim 8, characterized in that the cooling temperature is about 20°C.
10. Verfahren nach Anspruch 8 oder 9, dadurch gekennzeichnet, dass die Endlosplatte nach dem Erkalten auf die gewünschte Größe und das gewünschte Format der fertigen Platte zugeschnitten wird. 10. The method according to claim 8 or 9, characterized in that the endless board is cut to the desired size and the desired format of the finished board after cooling.
11. Platte aus Sekundärrohstoffen, bestehend aus einer unter hohem Druck und erhöhter Temperatur gepressten Mischung von Mahlgut aus zerkleinerten und gemahlenen Polyurethan-Schaumstoffresten und gegebenenfalls weiteren festen Hilfsstoffen, mit Isocyanat, mit Wasser und gegebenenfalls mit weiteren flüssigen oder rieselfähigen Zusatzstoffen, dadurch gekennzeichnet, dass die Platte (20) an ihrer Ober- und Unterseite eine Oberflächenbeschichtung in Form einer Dünnschicht (22) aufweist, welche für Isocyanat undurchlässig und für Temperaturen bis zu 200 °C hitzeunempfindlich ist. 11. Board made of secondary raw materials, consisting of a mixture of ground material made of comminuted and ground polyurethane foam residues and optionally other solid auxiliary materials, with isocyanate, with water and optionally with other liquid or free-flowing additives, pressed under high pressure and elevated temperature, characterized in that the plate (20) has a surface coating on its top and bottom in the form of a thin layer (22) which is impermeable to isocyanate and heat-resistant to temperatures of up to 200°C.
12. Platte nach Anspruch 11, dadurch gekennzeichnet, dass als undurchlässige und hitzeunempfindliche Dünnschicht (22) ein Vlies aus Glasfasern, Kohlefasern oder einem Gewirke aus hitzeunempfindlichen, undurchlässigen Faserstoffen vorgesehen ist. 12. Plate according to claim 11, characterized in that a fleece made of glass fibres, carbon fibers or a knitted fabric made of heat-resistant, impermeable fibrous materials is provided as the impermeable and heat-resistant thin layer (22).
13. Platte nach Anspruch 11, dadurch gekennzeichnet, dass als undurchlässige und hitzeunempfindliche Dünnschicht (22) eine Metallfolie oder eine mit einem Gewebe oder einem Vlies verstärkte, metallisierte Folie vorgesehen wird. 13. Plate according to claim 11, characterized in that a metal foil or a metalized foil reinforced with a fabric or a fleece is provided as the impermeable and heat-resistant thin layer (22).
14. Platte nach Anspruch 13, dadurch gekennzeichnet, dass als Metallfolie eine Aluminiumfolie vorgesehen ist. 14. Plate according to claim 13, characterized in that an aluminum foil is provided as the metal foil.
15. Platte aus Sekundärrohstoffen, welche nach einem Verfahren gemäß einem der Ansprüche 1 bis 10 hergestellt ist und die Trennschicht als Oberflächenbeschichtung in Form einer Dünnschicht (22) aufweist. 15. Plate made of secondary raw materials, which is produced by a method according to any one of claims 1 to 10 and has the separating layer as a surface coating in the form of a thin layer (22).
16. Platte nach Anspruch 15, dadurch gekennzeichnet, dass als Dünnschicht (22) ein Vlies aus Glasfasern, Kohlefasern oder einem Gewirke aus hitzeunempfindlichen, undurchlässigen Faserstoffen vorgesehen ist. 16. Plate according to claim 15, characterized in that a fleece made of glass fibers, carbon fibers or a knitted fabric made of heat-resistant, impermeable fibrous materials is provided as the thin layer (22).
17. Platte nach Anspruch 15 oder 16, dadurch gekennzeichnet, dass als Dünnschicht (22) eine Metallfolie oder eine mit einem Gewebe oder einem Vlies verstärkte, metallisierte Folie vorgesehen ist. 17. Plate according to claim 15 or 16, characterized in that a metal foil or a metalized foil reinforced with a fabric or a fleece is provided as the thin layer (22).
18. Platte nach Anspruch 17, dadurch gekennzeichnet, dass als Metallfolie eine Aluminiumfolie vorgesehen ist. 18. Plate according to claim 17, characterized in that an aluminum foil is provided as the metal foil.
19. Platte nach einem der Ansprüche 11 bis 18, dadurch gekennzeichnet, dass die Dünnschicht (22) mit einem darunter liegenden Plattenkern (21) chemisch durch Verklebung und mechanisch durch Verkeilung untrennbar verbunden ist. 19. Plate according to one of claims 11 to 18, characterized in that the thin layer (22) is chemically inseparably connected to a plate core (21) lying underneath it by gluing and mechanically by wedging.
EP20751072.8A 2020-07-16 2020-07-16 Method for producing a panel from secondary raw materials, panel formed from secondary raw materials, and panel formed from secondary raw materials produced by this method Pending EP4182138A1 (en)

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PCT/EP2020/000134 WO2022012733A1 (en) 2020-07-16 2020-07-16 Method for producing a panel from secondary raw materials, panel formed from secondary raw materials, and panel formed from secondary raw materials produced by this method

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JP3388211B2 (en) * 1999-10-29 2003-03-17 松下冷機株式会社 Thermal insulation and method of manufacturing thermal insulation
DE10019662B4 (en) 2000-04-20 2011-07-14 BOSIG GmbH, 73333 Method for producing a plate and plate produced by this method
DE102004044595A1 (en) * 2004-09-13 2006-03-30 Basf Ag Process for the production of composite elements based on isocyanate-based foams
WO2017062815A1 (en) * 2015-10-07 2017-04-13 Magma Flooring LLC Method for producing composite substrates

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