GB1592677A

GB1592677A - Mould and moulding method for producing mounting panels for heating and cooling ducting

Info

Publication number: GB1592677A
Application number: GB33714/79A
Authority: GB
Original assignee: Individual
Current assignee: Individual
Priority date: 1977-05-06
Filing date: 1977-11-25
Publication date: 1981-07-08
Also published as: CH628700A5; DE2723793A1; DE2723793C2

Abstract

The invention relates to a mounting plate (22) with cams (26) of relatively large diameter and cams (30) of relatively small diameter arranged on one side. These cams are arranged in an alternating manner in mutually parallel rows. Heating-medium and/or coolant tubes (58, 60) are laid between the cams (26, 30). The free space between the cams (26, 30) and their surface are dimensioned such that the tubes are laid as required and, nevertheless, are adequately fixed in their desired position and, furthermore, there is provided a sufficient supporting surface area for metal plates to be laid on the cams. <IMAGE>

Description

MOULD AND MOULDING METHOD FOR PRODUCING MOUNTING PANELS FOR HEATING AND COOLING DUCTING (713 I, ARTUS FEIST, a Citizen of the Federal Republic of West Germany, of Weidenweg 9, 5060 Bensberg-Refrath, West Germany, do hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement:- This invention relates to a mould and moulding method for producing mounting panels for securing heating and cooling ducting.

A mounting panel for securing heating medium ducting in floors is known from German Patent Specification No. 1,929,529, made of a base plate with planar parallel sides, with cylindrical projections arranged on one side, between which the heating medium ducting can be secured (DT-AS 1,929,529). These mounting panels are laid in a bu-ilding on a supporting base made of concrete, wood or the like, or on an insulating layer. Heating medium ducting which is connected at its ends to the flow and return of a central heating system is inserted according to a specific layout between the projections and is held in place by them. Steel plates are laid on the projections. These form the floor which is actually walked on. In the known mounting panel the cylindrical projections have a uniform diameter.This diameter is determined by two factors, which determine the maximum and minimum diameters which can be used. From the point of view of high load-bearing capacity and in order to -give a substantial support for the structural panels (typically steel plates) laid thereon, the projections should have a large diameter.

Only then will the steel plates be adequately supported and, particularly with point loading, be prevented from bending down in between the individual projections and rising -up along their edges. However, projections with a large diameter restrict the free laying of the heating medium ducting. The space occupied by large diameter projections is no longer available for the ducting This does not affect so much the straight runs of ducting as it does loops and return bends. At points where the ducting reverses its laying direction, it should follow the widest possible curve. In the known mounting panel a compromise has therefore to be made in establishing the diameter of the projections. This means that either the supporting of the steel plates or the possibility of laying the heating ducting freely must suffer.

My Specification No. 1592676 (Application No. 49102/77) provides a mounting panel on which structural sheets can be optionally supported and in which heating or cooling medium ducting can be laid with optimum freedom.

Thus, according to the invention of my aforementioned specification, an improved mounting panel is provided wherein the projections are of two or more respective -diameters.

It is an object of the present invention to provide a mould and moulding method especially suited to the production of my improved mounting panel.

According to the present invention, there is provided a mould for use in producing a mounting panel of foamed plastics material and comprising a planar baseplate with cylindrical projections on one side, said mould consisting of upper and lower parts of which the upper part contains hollow spaces for forming cylindrical projections some of one diameter and some of a different diameter, said upper mould part being adapted to fit to the lower mould part with a predetermined spacing between the respective lower and upper surfaces thereof for forming the baseplate.

Preferably, the lower mould part carries upstanding projections for forming central openings in some of the cylindrical projections. Conveniently, the said projections also engage with the upper should part when the latter is fitted to the lower mould part to define said predetermined spacing. Furthermore, the lower mould part preferably also carries upstanding projections for forming recesses in the edges of some of the cylindri cal projections.

For producing a preferred construction of panel, the upper mould part contains hollow spaces arranged in rows for forming rows of cylindrical projections of larger diameter alternating with rows of cylindrical projections of smaller diameter. Preferably, the hollow spaces in the upper mould part are staggered between adjacent rows, and the upstanding projections are positioned on the lower mould part to cooperate with the spaces for forming the larger diameter projections.

There is a dry and wet method for producing a mounting panel according to the invention. A problem to be solved here consists in the fact that the plastics material granules have to be foamed in the mould to different depths. Thus, the granules in the vicinity of the projections have to be foamed to a greater depth and to a greater volume. Uneven filling of the mould with more granules in the vicinity of the projections would be very time-consuming and therefore expensive.

To eliminate this problem, in one method (the dry process) according to the invention the granules to be foamed in the mould are heated by the introduction of dry heat and the supply of heat to individual points in the mould is controlled by the use of inserts of a material with poor thermal conductivity.

Thus, the bottom box for the mould has inserts in the vicinity of the projections, made of material with poor thermal conductivity.

This means that where the mould is heated from below the granules located above these inserts are not heated to foaming temperature until later, whilst the granules in the flat parts of the final mounting panel between the inserts, are heated and foam, earlier. This foam flows laterally over the still-cold granules lying in the hollow spaces in the mould which form the projections. After a specific delay, the granules located on top of the inserts then also foam and finally fill up any hollow spaces in the mould.

In another method (the wet process), the granules are foamed by the introduction of hot vapour into the mould.

The mould for carrying out the abovedescribed dry process comprises top and bottom halves and the base of the bottom half has inserts made of material with low thermal conductivity, which are located at the points where the granules have to foam to a large volume. In another development, the same aim is achieved by inserting displacement plates in the mould at the points where the granules have only to foam to a small volume. The mould is filled to an even depth with the granules, but the volume of the plates causes foaming granules to flow into the hollow spaces in the mould which form the projections.

A preferred plastics material which may be foamed to fill the mould is polystyrene.

The invention will now be described by way of example with reference to the embodiments shown in the drawings, wherein Fig. 1 is a cross-section through a first embodiment of a mould for producing a mounting panel by a so-called dry method, Fig. 2 is a cross-section similar to Fig. 1 through a second embodiment of mould for producing the mounting panel by the socalled dry method.

Fig. 3 is a cross-section through a mould using a so-called wet method, Fig. 4 is a perspective view of part of one embodiment of a mounting panel, for example produced using the mould of Figs. 2 or 3, and Fig. 5 is a reverse plan view of a mounting panel, i.e. as viewed from below, for example produced by the mould of Fig. 1.

For assistance in understanding the construction of the mould, the mounting panel of Fig. 4 will be briefly described initially.

The mounting panel shown in Fig. 4 consists of the base panel 24 which has moulded onto it wide or large diameter projections 26 with bearing surfaces 28 and narrow or small diameter projections 30, with bearing surfaces 32. The larger and smaller diameter projections lie in alternating rows, with the projections in staggered positional relationship from one row to the next. In the wide, large-diameter projections 26 there are conical central openings 36. In the circumference of the large-diameter projections 26 there are recesses 38, the upper ends of which are defined by overhanging parts of the surface of the projections, which form protuberances 40. The mounting panel 22 is moulded of foamed plastics material 34.

The mould of Fig. 5 is similar, but has rectangular recesses 69 on the underside of the base panel, located in the plane of the base panel between the projections 36. This panel is also moulded of foamed plastics material.

The present invention is concerned with the mould constructions to be used in production of the panels of Figs. 4 and 5, and with methods of using such moulds.

Figs. 1 and 2 show two construction forms of a mould 76 operating by the dry method to produce the mounting panel. The mould 76 consists of the bottom box 77 and the upper box 78. The upper box 78 encloses the hollow space 79 of the mould. The hollow spaces 79 for forming the wide projections 26 lie in the plane of the section. There is a central core 80 to form the conical central opening 36 and shorter edge cores 82 to form the recesses 38.

Above the hollow spaces 79 in the mould there are venting openings 84. They are closed off by gauze inserts 86. In Fig. 1, producing the panel of Fig. 5, displacement plates 88 are inserted between the hollow spaces 79 in the mould. As a special feature, the construction form shown in Fig. 2, producing the panel of Fig. 4, has inserts 90 made of a material with low thermal conductivity. These inserts are located under the hollow spaces 79 in the mould. They can be used in the hollow spaces 79 in the mould both for the wide projections and for the narrow projections.

The mould is filled with granules of polystyrene or other plastics material, closed and then heated. In the construction form shown in Fig. 1 the softened granules pressed by the displacement plates 88 flow away laterally and enter into the hollow spaces 79 in the mould. This means that there are sufficient granules in these to obtain the desired high density. In the construction form shown in Fig. 2, the granules located on top of the inserts 90 are not heated up until later. The granules located between the inserts are heated up without any delay, so that they are therefore softened, and flow over the stillcold granules located in the hollow spaces 79 in the moulds, on top of the inserts 90. After a time lag, these granules located on top of the inserts 90 also foam.In this way the hollow spaces 79 in the mould are also filled, in this instance with additional granules penetrating from the sides, and a high density is ensured.

In Fig. 3, producing the panel of Fig. 4, a mould operating by the so-called wet method is shown. The mould 76 is installed in a water bath 92. This is located in a box 94, which is closed by a covering plate 96. The mould stands on supports 98. Heating elements 100 heat the water bath. Foam granules 102 are shown in the mould. During the heating process, water vapour penetrates into the mould through the gauze inserts 86, from above. This is indicated with arrows. Under the effect of this heating vapour the granules foam and completely fill the hollow spaces in the mould.

In another method of producing the panel using one of the above-described moulds, granules of plastics material to be foamed are mixed with water to which 0 2 to 0 5 % by weight of an emulsifier has been added, in the ratio of from 0 5 to 1 part by weight of water plus emulsifier to 1 part by weight of granules, and the mixture is heated.

For further details as to the construction of the mounting panel and usage thereof my Specification No. 1592676 (Application No.

49102/77) should be referred to.

WHAT I CLAIM IS: 1. A mould for use in producing a mounting panel of foamed plastics material and comprising a planar baseplate with cylindrical projections on one side, said mould consisting of upper and lower parts of which the upper part contains hollow spaces for forming cylindrical projections some of one diameter and some of a different diameter, said upper mould part being adapted to fit to the lower mould part with a predetermined spacing between the respective lower and upper surfaces thereof for forming the baseplate.

2. A mould according to claim 1, wherein the lower mould part carries upstanding projections for forming central openings in some of the cylindrical projections.

3. A mould according to claim 2, wherein the said projections also engage with the upper mould part when the latter is fitted to the lower mould part to define said predetermined spacing.

4. A mould according to claim 2 or claim 3, wherein the lower mould part also carries upstanding projections for forming recesses in the edges of some of the cylindrical projections.

5. A mould according to any of claims 1 to 4, wherein the upper mould part contains hollow spaces arranged in rows for forming rows of cylindrical projections of larger diameter alternating with rows of cylindrical projections of smaller diameter.

6. A mould according to claim 5, wherein the hollow spaces in the upper mould part are staggered between adjacent rows.

7. A mould according to claim 5 or claim 6 when appendant to claim 2 or claim 3 or claim 4, wherein the upstanding projections are positioned on the lower mould part to cooperate with the spaces for forming the larger diameter projections.

8. A mould according to any of claims 1 to 7, wherein the lower mould part has inserts of thermal conductivity lower than that of the main body of the lower mould part, said inserts being positioned below some of the hollow spaces in the upper mould part when the latter is fitted to the lower mould part.

9. A mould according to claim 8 when appendant to claim 5 or claim 6 or claim 7, wherein the inserts are positioned below the hollow spaces for forming the larger diameter projections.

10. A mould according to any of claims 1 to 7, wherein displacement plates are carried on the lower mould part to displace moulding material into the hollow spaces in the upper mould part where foaming is required.

11. A mould according to claim 10, wherein the displacement plates are positioned to form recesses in the surface of the panel base plate on the side thereof opposite to the cylindrical projections, which recesses are located in the plane of the base plate between the cylindrical projections.

12. A method of producing a mounting panel using the mould of any of claims 1 to 11, according to which granules of plastics material to be foamed are inserted in the

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Claims

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the construction form shown in Fig. 2, producing the panel of Fig. 4, has inserts 90 made of a material with low thermal conductivity. These inserts are located under the hollow spaces 79 in the mould. They can be used in the hollow spaces 79 in the mould both for the wide projections and for the narrow projections.

The mould is filled with granules of polystyrene or other plastics material, closed and then heated. In the construction form shown in Fig. 1 the softened granules pressed by the displacement plates 88 flow away laterally and enter into the hollow spaces 79 in the mould. This means that there are sufficient granules in these to obtain the desired high density. In the construction form shown in Fig. 2, the granules located on top of the inserts 90 are not heated up until later. The granules located between the inserts are heated up without any delay, so that they are therefore softened, and flow over the stillcold granules located in the hollow spaces 79 in the moulds, on top of the inserts 90. After a time lag, these granules located on top of the inserts 90 also foam.In this way the hollow spaces 79 in the mould are also filled, in this instance with additional granules penetrating from the sides, and a high density is ensured.

In Fig. 3, producing the panel of Fig. 4, a mould operating by the so-called wet method is shown. The mould 76 is installed in a water bath 92. This is located in a box 94, which is closed by a covering plate 96. The mould stands on supports 98. Heating elements 100 heat the water bath. Foam granules 102 are shown in the mould. During the heating process, water vapour penetrates into the mould through the gauze inserts 86, from above. This is indicated with arrows. Under the effect of this heating vapour the granules foam and completely fill the hollow spaces in the mould.

In another method of producing the panel using one of the above-described moulds, granules of plastics material to be foamed are mixed with water to which 0 2 to 0 5 % by weight of an emulsifier has been added, in the ratio of from 0 5 to 1 part by weight of water plus emulsifier to 1 part by weight of granules, and the mixture is heated.

For further details as to the construction of the mounting panel and usage thereof my Specification No. 1592676 (Application No.

49102/77) should be referred to.

WHAT I CLAIM IS: 1. A mould for use in producing a mounting panel of foamed plastics material and comprising a planar baseplate with cylindrical projections on one side, said mould consisting of upper and lower parts of which the upper part contains hollow spaces for forming cylindrical projections some of one diameter and some of a different diameter, said upper mould part being adapted to fit to the lower mould part with a predetermined spacing between the respective lower and upper surfaces thereof for forming the baseplate.
2. A mould according to claim 1, wherein the lower mould part carries upstanding projections for forming central openings in some of the cylindrical projections.
3. A mould according to claim 2, wherein the said projections also engage with the upper mould part when the latter is fitted to the lower mould part to define said predetermined spacing.
4. A mould according to claim 2 or claim 3, wherein the lower mould part also carries upstanding projections for forming recesses in the edges of some of the cylindrical projections.
5. A mould according to any of claims 1 to 4, wherein the upper mould part contains hollow spaces arranged in rows for forming rows of cylindrical projections of larger diameter alternating with rows of cylindrical projections of smaller diameter.
6. A mould according to claim 5, wherein the hollow spaces in the upper mould part are staggered between adjacent rows.
7. A mould according to claim 5 or claim 6 when appendant to claim 2 or claim 3 or claim 4, wherein the upstanding projections are positioned on the lower mould part to cooperate with the spaces for forming the larger diameter projections.
8. A mould according to any of claims 1 to 7, wherein the lower mould part has inserts of thermal conductivity lower than that of the main body of the lower mould part, said inserts being positioned below some of the hollow spaces in the upper mould part when the latter is fitted to the lower mould part.
9. A mould according to claim 8 when appendant to claim 5 or claim 6 or claim 7, wherein the inserts are positioned below the hollow spaces for forming the larger diameter projections.
10. A mould according to any of claims 1 to 7, wherein displacement plates are carried on the lower mould part to displace moulding material into the hollow spaces in the upper mould part where foaming is required.
11. A mould according to claim 10, wherein the displacement plates are positioned to form recesses in the surface of the panel base plate on the side thereof opposite to the cylindrical projections, which recesses are located in the plane of the base plate between the cylindrical projections.
12. A method of producing a mounting panel using the mould of any of claims 1 to 11, according to which granules of plastics material to be foamed are inserted in the

mould and the latter is heated by application of dry heat.
13. A method according to claim 12, according to which said dry heat is supplied to different regions in the mould at different rates in order to produce differential foaming rates within the mould.
14. A method according to claim 12, using the mould of claim 8 or claim 9, according to which the said inserts are employed to control said differential supply of dry heat.
15. A method according to claim 12, using the mould of claim 10 or claim 11, according to which the displacement plates are employed to displace the granules into the hollow spaces in the upper mould part.
16. A method of producing a mounting panel using the mould of any of claims 1 to 7, according to which granules of plastics material to be foamed are mixed with water to which 0-2 to 0 5 % by weight of an emulsifier has been added, in the ratio of from 0.5 to 1 part by weight of water plus emulsifier to 1 part by weight of granules, and the mixture is heated.
17. A method of producing a mounting panel using the mould of any of claims 1 to 7, according to which granules of a plastics material to be foamed are placed in the mould and hot vapour is introduced into the mould to produce the required foaming.
18. A method according to any of claims 12 to 17, using polystyrene as the plastics material.
19. A mould for producing a mounting panel substantially as hereinbefore described with reference to Figs. 1 to 3 of the accompanying drawings.
20. A method of producing a mounting panel using the mould of claim 19.