JP2006205734A - Manufacturing method and apparatus of architectural lightweight board - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method and apparatus, which enable to manufacture an architectural multilayer lightweight board, particularly, by a simple and inexpensive means. <P>SOLUTION: The continuous manufacturing method of the cement-based architectural multilayer lightweight board having a core layer (2) and a cover layer (3a; 3b) arranged on at least one main surface of the core layer (2) is provided. The process comprises following processes: a step of manufacturing the core layer of ready-mixed concrete by applying the ready-mixed concrete on a first support which moves continuously, a step of manufacturing the cover layer (3b) on a second support which moves continuously to mount the previously manufactured cover layer (3b) on the core layer (2), a step of cutting the layer strip into individual boards, and a step of solidifying the boards, or drying the boards depending on the situation. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method and a production device for producing a cement-based multi-layer lightweight board for construction comprising a core layer and at least one covering layer.

  A common problem when using cement-containing building lightweight boards under moist environmental conditions is the high capillary water absorption due to capillary grooves that occur during the hydraulic hardening process and capillary openings in the hardened cement paste matrix. It is sex. This water absorption leads to expansion of the board and expansion cracking of the cement-containing material, thus causing loss of strength and peeling to the coating applied on the building lightweight board, for example the collapse of the applied tile covering. Also occurs at the same time. Furthermore, such cement-containing lightweight boards for construction have very low freezing resistance.

A further problem in producing cement-containing lightweight boards for construction is that shrinkage cracks occur in the hardened cement paste matrix. This is due to the fact that some of the water taken up is absorbed into the matrix but is not chemically bound. When this unbound capillary water evaporates from an already cured product, the resulting stress can cause cracking (shrinkage cracking) when the shrinkage stress is greater than the tensile strength of the cement matrix. The capillary water absorption of the cement paste matrix hardened by this shrinkage cracking can be further increased.
Nevertheless, there are many known solutions for using cement-containing lightweight boards for construction in damp environments.

  The lightweight board for construction known from DE 197 04 961-C2 consists of a lightweight concrete core layer which is coated on both sides with coating layers of various lengths embedded with alkali-resistant glass fiber fabrics. In this core layer, expanded clay pearls made of expanded clay granules fired as lightweight aggregates are used and alkali-resistant fibers such as glass fibers and / or synthetic fibers are used as reinforcements, Improves the bond between the coating layer and the core layer. The clay pearl in the core layer reduces the water absorption of the lightweight board for construction due to its independent pore structure.

  U.S. Pat. No. 3,284,980 discloses an architectural multilayer lightweight board and its method of manufacture, particularly for use in wet environments. The board comprises a concrete layer made of hydrated cement and aggregate, preferably a lightweight concrete core layer, and two covering layers substantially thinner than the core layer on the main surface on both sides of the core layer. The covering layer comprises a reinforcing fabric, for example a glass fiber fabric with an alkali-resistant coating, which is cement-based as well as the core layer and incorporates and reduces the water absorption of the core layer. For example, perlite, vermiculite, expanded slag (Blaehschlacke) or expanded slate (Blaehschiefer) can be used as the aggregate for the relatively light and porous core layer, especially 2: 1 relative to the volume of the cement component. Used in ratio. The coating layer may contain fine additives such as sand or finely expanded slag to a minor extent. Because of its weather resistance, lightweight building boards according to US Pat. No. 3,284,980 are used in the construction of walls and swimming pools. The water absorption of about 10% by weight of this kind of building lightweight board is still relatively high.

  The lightweight building board according to US Pat. No. 3,284,980 has a consistency suitable for placing the fabric covering in a mold, preferably coated with polyethylene, and on which the fabric is infiltrated It is produced by introducing a mixture of coating layer materials. A mixture of core materials is placed thereon, the surface is leveled and another fabric coating is placed thereon and cement sludge and additives are placed thereon. A polyethylene layer or similar layer is then placed on top of the last layer or the board is evaporated and cured to retain moisture during curing. Then remove the cured board from the mold.

German Patent No. 1804325-C2 discloses a cement-based multilayer lightweight board for construction and a method for producing the same, which also comprises a core layer comprising hydrated cement and lightweight aggregate, Consists of two comparatively thin cement-based coatings placed on the major faces on both sides of the core layer, which contain a built-in reinforcing fabric, with at least the cement component of the core layer being a suitable hydrophobizing agent. Hydrophobized by the addition, and as a result, the capillary water absorbency of the lightweight board for construction is 1 kg / m ² or less in 24 hours. According to DE 1984 325-C2, metal stearates, in particular zinc stearate, -calcium and / or -aluminum, and oleates, in particular sodium oleate, are particularly suitable as hydrophobizing agents. Is known. This is because they cause a chemical interaction with the cement component and, for example, form a metal soap. In this case, the proportion of hydrophobizing agent based on the solid component to be hydrophobized in the core layer is less than 1% by weight. Furthermore, a particularly advantageous distribution of the hydrophobizing agent in the cement matrix is achieved when the moisture content in the core layer is relatively small, based on DE 19804325-C2. Aggregates include lightweight aggregates such as perlite, vermiculite, especially in the expanded state, such as expanded slate, foam glass or similarly hydrated to further reduce the water absorption of lightweight boards for construction. A crushed expanded clay which may be used is used. Furthermore, the cement component of the covering layer disposed on the main surfaces on both sides of the core layer of the lightweight board for construction may be hydrated as well. The reinforcing fabric of the covering layer is, for example, a glass fiber fabric treated with an alkali-stable coating, such as a synthetic resin.

  In the production of lightweight boards for construction according to German Patent No. 1804325-C2, a mixture of ceramic materials is placed on a first coating layer made of glass fiber fabric in cement sludge and is applied to the cement sludge. Cover with a second coating layer made of glass fiber fabric. The board is then cut to the desired dimensions.

  In addition, according to Aestuver's instruction manual “AESTUVER Die universelle Brandschtzplatte”, November 1994, a lightweight concrete fireproof multilayer board with expanded glass and glass fibers in the form of fine glass hollow spheres as an aggregate in the matrix structure Is known. This board is a layer with little water absorption.

Another method for producing architectural multilayer lightweight boards, in particular architectural lightweight boards according to US Pat. No. 3,284,980, is described in German Patent No. 1804325-C2. According to this method, a first continuous fabric, for example a glass fiber fabric, is first passed through a cement-containing mortar bath and the ripening of the mortar on the fabric is achieved by stripping strips or knife edges. The fabric is then placed on the foil strip on a number of adjacent transport strips, with the mortar remaining in the middle of the fabric by the tow bar and a certain amount still above the fabric. It is pushed in. A core material consisting of lightweight concrete consisting of cement and lightweight aggregate is then placed on the impregnated fabric and optionally compressed by one or more distributors placed one after the other and bonded to the first fabric. Let A second woven layer impregnated with mortar is then placed and pressed onto the core layer in the same manner as the first woven layer. The strips formed in this way are cut with a cutting device into individual plates across the conveying direction between adjacent sheeting of conveying plates, which are then stacked to further compress and bond the layers together. Then cure.

  Another method for producing a cement-based architectural multi-layer lightweight board with an incorporated reinforcing mat is described in DE 3840377-A1. According to this method, the reinforcement is continuously pulled on a continuously moving support by a first coating layer and rolls, for example made of a pasty cement mixture containing hardening accelerators and / or fly ash. A reinforcing mat is incorporated into the cement mixture in order for the cement mixture to have a moderate consistency. The resulting first coating layer is flattened and grooved, for example by a roller. When the support is moved further in succession, at least one aggregate, such as sand and / or fly ash and / or perlite and / or vermiculite and / or Styropor or these on the first covering layer An intermediate layer consisting of a paste-like ingot cement mixture containing similar and optionally also hardening accelerators and liquefaction agents, flattening and grooving and overlying the first reinforcement Another reinforcing mett, similar to the mat, is placed under pressure and flattened and fluted. Then another pasty cement mixture is applied, flattened and fluted to bond the second covering layer and the second reinforcing mat. The resulting strip is passed through a curing channel for precuring and then divided into individual boards and stored in a conditioning station in a stacked state.

  In the case of the multi-layer building lightweight boards mentioned above, the water absorption is certainly small compared to conventional cement-based building lightweight boards, but the capillary water absorption is still relatively low, especially in the hot layer. Many waters can penetrate the core layer through the coating layer.

  Although the water absorption of the core layer can indeed be significantly reduced by the hydrophobization of at least the cement-containing component of the core layer proposed in German Patent No. 1804325-C2, this method is relatively Since a sexualizing agent is required, a relatively large cost is required.

  Furthermore, due to the high proportion of cement paste in the coating layer, shrinkage cracks occur in the coating layer, which increases the amount of water absorbed and further adversely affects the bond between the hardened cement paste and the reinforcing fabric, reinforcing It can adversely affect the bond between the fabric and the hardened cement paste matrix and reduce the strength of the building lightweight board. The coating applied to the coating layer can also peel off due to shrinkage cracking.

  Due to the different physical and chemical properties, especially the different Young's modulus (E-Moduli) and strength properties, of the different matrix configurations of the core layer and the coating layer, there is a load, especially temperature variation, between the two layers. And can be exacerbated by stresses that occur between the two layers when exposed to moisture and when affected by moisture.

  The object of the present invention is to clearly reduce the water absorption of a multilayer lightweight board for construction without making the cement component of the board hydrophobic, and at the same time reduce the weight of the lightweight board for construction as much as possible. TECHNICAL FIELD The present invention relates to a method of manufacturing multilayer multi-layer lightweight boards, particularly cement-based multi-layer lightweight boards for construction, and an apparatus used therefor, in which anchoring of reinforcing fabrics in the core and bonding between a core layer and a covering layer are improved and peeling is reduced.

  The object of the present invention was to solve the method and the device by which a multilayer lightweight board for construction can be produced in a particularly simple and inexpensive way.

  This problem is solved by the features of claim 1 and also with respect to the device by the features of each claim. Advantageous further embodiments of the invention are indicated in the dependent claims.

  Architectural multilayer lightweight boards that can be produced according to the invention have a core layer and at least one, preferably two coating layers, which are arranged on one or both major surfaces of the core layer and the core layer. Covering. Furthermore, the coating layer is formed extremely thin compared to the core layer.

  The core technical idea of the lightweight board for construction lies in that the coating layer is changed by mechanical / physical means so that it is physically more durable than the core layer. This consists essentially of a solid mortar-matrix consisting of a cement paste with a hardened coating and in particular at least one lightweight aggregate formed in a closed-cell and / or closed-pore state, This is achieved by embedding at least one type of reinforcing material made of, for example, water-impermeable fibers, for example, a reinforcing fabric, in the coating layer.

  By closed cell is meant an expanded object having a sealed outer surface. An independent hole is an object having a closed expansion hole.

  The lightweight aggregate formed in a closed cell state means an expanded glass granule that is not crushed, particularly in a state of a fine glass hollow sphere or an expanded glass pearl. The lightweight aggregate in the independent pore state is, for example, expanded clay pearls made of baked clay granules or expanded clay granules that are crushed or not crushed in the form of expanded clay granules.

  The lightweight aggregate used in this case advantageously has a particle size of 0-5 mm, in particular 0.5-2 mm.

  The reinforcement or reinforcement incorporated in the solid mortar matrix is preferably a glass fiber fabric, in particular comprising E-glass and / or AR-glass, advantageously having an alkali-proof coating, or a synthetic resin And preferably has a mesh width of 2 to 8 mm, particularly preferably 4 to 6.5 mm, and preferably 0.5 to 1.5 mm, particularly preferably 0.6 to 0.7 mm. And preferably a multifilament having a thickness of 0.1 to 0.5 mm, particularly preferably 0.15 to 0.3 mm or preferably 0.1 to 0.5 mm, particularly preferably 0.15 to 0.3 mm. A woven fabric made of monofilaments having a diameter. In this case, the reinforcement in the present invention is generally a textile fabric having a lattice-like and / or lattice-like opening, such as a fleece, a spinning fleece and / or generally a net, braid, knit or knitted fabric.

  However, as the reinforcing material, for example, fibers, straw, fleece, mat, paper, metal lattice, perforated sheet or the like can be used.

  In order to improve processability in particular, further additives are added to the raw mortar of the coating layer, such as pozzolans, such as fly ash, in particular coal fly ash and / or blast furnace ash and / or fine silica and / or customary additions. Containing agents such as cell formers and / or flow agents such as polycarboxylate ethers and / or stability such as methylcellulose and / or dispersants such as ethylene, vinyl laurate and vinyl chloride. It is advantageous to use Portland cement as the cement.

  The following shows a particularly advantageous composition of the raw mortar of the coating layer according to the invention:

Adjusted to a water / solid value (w / f) of 0.35-0.6, in particular 0.4-0.5, the raw mortar for applying the coating layer is free-flowing and sprayable and According to DIN, it preferably has a flow property of 21 to 24 cm, particularly preferably 21.5 to 23 cm.

  In addition, the following shows a particularly advantageous composition of the cured coating layer:

  The sum of the proportion of closed-cell and / or closed-pore lightweight aggregates, in particular expanded glass granules and fabric, in the hardened coating layer is preferably 8-20% by weight, particularly preferably 10-15% by weight. is there.

  The proportion of the porosity in the cured coating layer produced by the use of the bubble forming agent is preferably 5 to 30% by volume, particularly preferably 8 to 15% by volume.

  The core layer of an architectural lightweight board that can be produced according to the invention consists essentially of a hardened cement paste, preferably a hardened Portland cement paste and in particular at least one lightweight aggregate of closed cells and / or closed pores. Uncorrupted expanded clay pearls and / or expanded clay particles having a particle size of preferably 0 to 5 mm, particularly preferably 0 to 2 mm and a particle size distribution of It is particularly advantageous to do:

  Furthermore, as a further raw material for the core layer ready-mixed concrete, preferably customary additives such as pozzolans, such as fly ash, in particular coal fly ash and / or blast furnace ash and / or fine silica, and / or, for example, foam formers. And / or dispersants such as terpolymers consisting of ethylene, vinyl laurate and vinyl chloride and / or flow agents such as polycarboxylate ethers.

  The following shows a particularly advantageous composition of ready-mixed concrete in the core layer of a lightweight building board produced according to the invention:

Adjusting to a water / solids value (w / f) of 0.15-0.3, especially 0.2-0.25, the raw mortar for the core layer has a wet consistency and according to DIN For example, it is advantageous to adjust so as to have a small flowability of 16 to 18 cm.

  Furthermore, a particularly advantageous composition of the cured core layer of a lightweight building board that can be produced according to the invention is shown below.

  The proportion of closed-cell and / or closed-pore lightweight aggregates, in particular expanded clay granules, in the hardened core layer is preferably 40 to 60% by weight, particularly preferably 45 to 55% by weight.

  The proportion of bubbles in the hardened core layer resulting from the use of the cell former is in the range of 10-50% by volume, preferably 15-25% by volume.

  Furthermore, the core layer and the covering layer may additionally be hydrophobized with a hydrophobizing agent, preferably based on silicone oil and / or based on silane / siloxane. In this case, the aggregates of the respective layers are, inter alia, before being mixed with closed cell and / or closed pore aggregates, such as expanded glass granules and / or expanded clay granules, with cement components and optionally additives and additives. It is preferable to make it hydrophobic. The proportion of hydrophobizing agent in the raw mortar for the coating layer is 0.1 to 0.5% by weight, preferably 0.2 to 0.3% by weight and that in the raw concrete for the core layer is Advantageously, it is 0.1 to 0.5% by weight, preferably 0.2 to 0.3% by weight.

  The proportion of hydrophobizing agent in each cured layer is from 0.1 to 0.7% by weight in the coating layer, in particular from 0.3 to 0.5% by weight and in the core layer from 0.1 to 0.6% by weight. %, In particular 0.3 to 0.4% by weight.

  Hereinafter, the present invention will be described in detail with reference to the drawings.

  FIG. 1 is a cross-sectional view of a portion of a lightweight building board that can be manufactured in accordance with the present invention.

  FIG. 2 is a schematic longitudinal sectional view of a part of an apparatus according to the invention for producing the coating layer and the core layer of an architectural multilayer lightweight board.

  FIG. 3 is a schematic longitudinal sectional view of the device of the present invention in the region for producing the second coating layer.

  The lightweight building board 1 that can be produced according to the invention according to FIG. 1 consists essentially of a core layer 2 that is preferably coated on both sides with coating layers 3a; 3b, respectively. Each of the covering layers 3a; 3b has a hardened cement paste 5, unbroken expanded glass granules 6 and a reinforcing fabric 7 with warp yarns 4 and weft yarns (not shown) incorporated in a matrix. The core layer 2 substantially consists of a matrix composed of hardened cement paste 8 and uncrushed expanded clay granules 9 embedded in the cement paste 8. Furthermore, the coating layers 3a; 3b and the core layer 2 have voids 10; 11.

  Advantageously, the coating layer 3a; 3b has a thickness of 1 to 3 mm, preferably 1.3 to 2 mm, and the core layer has a thickness of 5 to 100 mm, preferably 8 to 60 mm.

The bulk density of the lightweight board for construction of the present invention is preferably 500 to 1200 kg / m ³ , particularly preferably 600 to 1050 kg / m ³ .

The apparatus 100 of the present invention for producing an architectural multilayer lightweight board shown in FIGS. 2 and 3 in accordance with the present invention is substantially a main transport path for transport, such as a main feed rate V _A.
A main conveyor belt 114 movable in the main feed direction and a U-shaped cross section die 115 on the conveyor belt 114 and a sub-conveying passage 102 disposed above and preferably parallel to the main conveying passage 101. The sub-transport passage 102 is a transport sub-conveyor belt that is fed in parallel to the main conveyor belt 114, for example, a sub-feed speed V _B that corresponds quantitatively to the sub-feed direction opposite to the main feed direction A and the main feed speed _VA. And a sub-conveyor belt, particularly a synthetic resin sheet path 127, which is towed and transported by appropriate driving means. The film path 127 is supported and / or operated underneath it by suitable means such as rolls and / or other conveyor belts and / or sheets. The thickness of the synthetic resin sheet path 127 is preferably 0.1 to 0.3 mm, and the width thereof preferably corresponds to the width of the mold 115.

  The mold 115 located on and conveyed by the conveyor belt 114 preferably has two side walls 116a, a bottom wall 116b and two stirkanten 117 and is open at the front and rear, At this time, they are arranged on the belt conveyor 114 of the belt path 101 one after another so as to abut against each other at the front edge 117 thereof. The side wall 116a is advantageously exchangeable, for example by being able to be mounted by means of a rod at the bottom wall 116b. Thereby, the mold 115 can be matched to the corresponding thickness of the lightweight building board to be manufactured. The mold 115 is made of metal, preferably steel, in particular stainless steel, and has an advantageous wall thickness of 3 to 5 mm. Furthermore, the mold 115 preferably has a length of 2000 to 3000 mm, in particular 2500 to 2700 mm and a width of for example 1000 to 1500 mm, in particular 1200 to 1300 mm.

  Above the conveyor belt 114, a first coating layer manufacturing apparatus 103 for manufacturing and applying the first coating layer 3a of the lightweight board for construction on the mold bottom 116b is disposed. Similarly, it is arranged above the main conveyor belt 114 and followed by a first coating layer production device 103 in the main feed direction A, and the core layer production device 104 is used for the production and coating of the core layer 2. It is equipped on the coating layer 3a.

  In the main feed direction A, the secondary belt path 102 is disposed above the main belt path after the core layer manufacturing apparatus 104. This is because the second coating layer manufacturing apparatus 105 for manufacturing and coating the second coating layer 3b is first above the film path 127 in the sub-feeding direction B, and above the synthetic resin sheet path 127 with the reinforcing mesh. And a turn-over device 106 for applying the second coating layer 3b on the core layer 2 and an overlay device 106, in which case the coating layer change-and overlay device 106 is a core layer production device. 104 is arranged rearward in the feed direction A and above the main conveyor belt 114. Accordingly, the secondary belt path 102 is connected to the main belt path 101.

  The first coating layer production device 103 consists essentially of an injection device 103a having a pre-storage vessel 111 in which premixed mortar for the coating layer 3a is facilitated and to this via a pump conduit 112, for example. A vibrating jet nozzle 113 is connected above the bottom wall 116b and across the entire width of the mold 115 and across the main feed direction A.

Further, the first coating layer manufacturing apparatus 103 includes a first reinforcing material supply apparatus, for example, a substantially first reinforcing material, for example, a first belt-shaped woven fabric, which is disposed later with respect to the main feed direction A of the spraying apparatus 103a. A first fabric laying device 103b comprising a first fabric roll 118a around which the 119 is wound, and preferably at a position obliquely below the fabric roll 118a and preferably from the bottom wall 116b. Thus, the first belt-shaped fabric 119 is sent while being pulled on the laying roll. The rotational direction and the rotational speed of both rolls 118a and 118b preferably correspond to the main feed direction A or the main feed speed V _A.

  The fabric laying device 103b is followed by a first pushing device 103c, which has a pushing rod 120 that can be moved up and down, and this pushing rod 120 preferably extends from the bottom wall 116b to the first covering layer 3a. It is arranged to be movable up and down at a distance up to half of the thickness.

  The pushing device 103c arranged in the main feed direction A is provided with a core layer manufacturing device 104 behind, and this device 104 is also used for premixing the ready-mixed concrete 121 of the core layer 2 of the first coating layer 3a. A perforated wheel type gate (Zellradschleuse) 122 for application on top and a first coating layer, for example, which oscillates across the width of the die 155 across the main feed direction A and is located behind the perforated wheel type gate A doctor blade 123 for evenly distributing raw concrete 121 on 3a is provided. The doctor blade 123 above the first coating layer 3a is advantageously arranged away from the coating layer by the desired thickness of the core layer 2.

  The second coating layer manufacturing apparatus 105 disposed above the synthetic resin sheet belt 127 pulled by the supply roll 128 substantially crosses the two feeding directions A and B and is made of a synthetic resin sheet. A second spray device 105a for spray coating the raw mortar of the second coating layer 3b on the synthetic resin sheet belt 127 by a spray nozzle that vibrates over the width of the belt 127 is provided. For example, raw mortar is again supplied from a storage container through a pump conduit (not shown). Furthermore, the coating layer manufacturing apparatus 105 includes a reinforcing material supply apparatus, for example, a second fabric laying apparatus 105a, which is disposed downstream in the sub-feed direction B of the second spraying apparatus 105a, and the apparatus substantially includes There is a laying roll 130b disposed obliquely below the wound belt-like woven fabric 131 and the second woven fabric roll 130a and above the synthetic resin sheet belt 127, and a second material is provided as a reinforcing material through the roll. The belt-like fabric 131 is likewise fed under pretension. Further, the coating layer manufacturing apparatus 105 is inserted on the second pushing apparatus 105c, in particular, in the state of the second vertically movable pushing bar 132 in order to incorporate the belt-like fabric 131 into the coating layer 3b. The push bar is preferably arranged to move up and down away from the synthetic resin seat belt (127) up to half the thickness of the first covering layer (3a).

The pushing device 105C arranged rearward in the sub-feed direction B is substantially free from rotation in order to rotate the pushing belt 135, which is preferably driven by the direction change roll 133, in the tensioned state at the main feed speed _VA. There is a direction change-and-overlay device 106 consisting of a direction change roll 133 and a pressing roll 134 which are driven by the same.

  In accordance with the present invention, the diverting roll 133 is above the conveyor belt 114 so as to be approximately equal to the thickness of the second coating layer 3b, spaced from the upper side of the core layer 2, or almost insignificant. Subsequent pressing rolls 134 in the main feed direction A at the turning rolls 133 are preferably arranged farther away from the core layer surface than the turning rolls 133.

Using the apparatus 100 according to the present invention, a continuous manufacturing method according to the present invention for a lightweight building board is performed as follows:
The raw mortar 110 for producing the first coating layer 3a, which has been premixed, preferably already kept in the storage vessel 111, which can be pumped, jetted and flowable, is fed through the pump conduit 112 to the main feed. Supplied to a first injection nozzle 113 that vibrates across direction A and is injected into a mold 115 moving in the main feed direction A with a thin layer of compressed air jets, where the layer thickness is the vibration velocity, It can be adjusted by the feed rate of the belt and / or the flow rate of mortar through the injection nozzle 113.

  The endless belt-like fabric 119 is then withdrawn from the fabric roll 118 for the first coating layer and placed on the mortar layer present in the mold 115 under a slight pretension. In order to embed, the belt-shaped fabric 119 is pushed into the raw mortar 110 with a pressing rod 120 that is movable up and down.

  A premixed, preferably ready-mixed ready-mixed concrete 121 for the core layer through a perforated wheel mold lock is applied over the first coating layer 3a present in the mold 115 and preferably crosses the main feed direction A. Are uniformly distributed by a doctor blade 123 that vibrates.

  In order to produce the second coating layer 3b, the raw mortar 110, which can be pumped, jetted and flowable, is premixed, for example in a storage container and already stored, and is fed through the pump conduit in the secondary feed direction. Pump into the second jet nozzle 125 that oscillates across B and jets onto a synthetic resin sheet belt 127 moving in the subfeed direction B and preliminarily pulled by suitable means. The synthetic resin sheet belt 127 is pulled by the supply roll 128.

  In the mortar layer for the second coating layer 3b, the second fabric belt 131 is pulled under preliminary tension from the second fabric roll 130a in the same manner as in the case of the first coating layer 3a. , Preferably through a driven laying roll 130a, first placed on the mortar layer, and then preferably embedded and incorporated into the mortar layer by a push bar 132.

  As a result, the second covering layer 3b is placed against the core layer 2 so that the outer surface of the lightweight construction board that can be formed therewith is arranged at the bottom and in particular on the belt 127 made of synthetic resin sheet. Manufactured mirror-inverted or inverted and preferably parallel or simultaneously.

Next, the belt 127 made of a synthetic resin sheet rotates together with the main feed speed V _A of the belt path 101 together with the second covering layer 3b composed of the raw mortar 110 and the belt-like fabric 131 applied thereon. The direction of rotation and the speed of the synthetic resin sheet belt are changed downward by, for example, 180 ° through the direction change roll 133, and the main feed direction A or the main feed speed is changed together with the coating layer 3b after the direction change roll 133. Consistent with V _A and a synthetic resin sheet belt 127 is present on the second covering layer and the second covering layer 3b on the outer side of the building lightweight board is located on the uppermost side.

  Accordingly, a belt 127 made of a synthetic resin sheet is placed on the core layer 2 existing in the mold together with the coating layer 3b above the direction changing roll 133 and is preferably formed by the pressing roll 134 and the pressing belt 135. 2 is pressed.

  For example, at the cutting device entrance (not shown) located behind the direction change roll 133 and / or the secondary belt path 102 in the main feed direction A, the manufactured endless board strip is the leading edge of the mold 115. 117 is divided into individual boards, for example by cutting gears.

  At the next time, the individual molds of the belt path are removed, stacked one on top of the other and fed into the coagulation groove where the individual molds are allowed to stay, for example for 5-15 hours, for example at 40-50 ° C. until solidified (not shown). ). Thereafter, the synthetic resin sheet belt is peeled off from the second covering layer and the building lightweight board is taken out of the mold. Synthetic resin sheet belts, among other things, cover the surface of the second coating layer during the coagulation process, so that the water required for hydration can be retained in the building lightweight board or the building board sludge prematurely. Helps prevent drying out.

  The lightweight board for construction is then dried at, for example, 50-60 ° C. in a dryer. The mold is purified and sent fresh to the belt path.

  In particular, by forming a lightweight board for construction according to the invention with a high proportion of fabric, for example a high proportion of glass fiber fabric consisting of water-impermeable fibers, and expanded cell granules of closed cells, in the covering layer. Since the expanded glass granules of woven fabric and closed cells do not absorb water, a lightweight board for construction can be obtained that has a sufficiently low water absorption or water absorption capacity without adding a hydrophobizing agent.

  Accordingly, water is physically sufficiently prevented from penetrating the core layer through the covering layer, and as a result, swelling of the lightweight board for construction and expansion cracking due to the swelling and peeling of the covering can be prevented.

  Furthermore, the high proportion of glass fiber fabrics and expanded glass granules in the coating layer allows a low water / solid-value (w / f) during manufacture, which makes most of the shrinkage cracks especially in the coating layer. The result is that it can be completely avoided.

  The cement and expanded glass granules in the coating layer form a solid mortar-matrix that firmly and well embeds and anchors the reinforcing fabric, resulting in a firm bond even under the influence of load and moisture Is done.

  The lightweight building board produced in accordance with the present invention has a relatively uniform, mostly monolithic, and therefore uniform, low Young's modulus matrix structure, so that the core layer and under the influence of load and moisture The stress in the structure generated between the coating layer and the coating layer can be eliminated without causing cracks.

  Furthermore, the light absorbency of the building lightweight board is based on the use of additionally closed cells and / or closed pore expanded clay granules in the core layer which absorbs little water, especially compared to conventional open pore lightweight aggregates. Can be reduced.

  Furthermore, both surfaces of the coating layer have relatively few holes, which are relatively flat, especially for closed-cell lightweight aggregates and by making them on metal molds and on plastic sheet belts. It is. This is due to the fact that the closed-cell lightweight aggregate has a relatively smooth surface so that the cement adhesive can easily flow through the side and forms a thin layer of cement adhesive on the surface due to gravity. Is.

  These surfaces are thereby more relatively wear resistant. Thin plaster can also be applied to these surfaces without problems and without undulations.

  With a mold that matches the board thickness in each case, stacking boards that still exist in the mold only requires space to be determined by the board thickness.

  The production of a lightweight building board with the method of the invention is therefore very simple and economical. In particular, a great deal of time and belt length is saved by simultaneously producing two coating layers in parallel using opposite feed directions.

  The method of the present invention describes a method for building lightweight boards having a special layer structure. However, this layer structure is not important. Rather, by the method of the present invention, an architectural multilayer lightweight board having only one covering layer can be produced by first applying the core layer and applying the covering layer thereon. Furthermore, the introduction of a reinforcing material can be omitted, or a material different from the above-mentioned reinforcing material can be introduced into the coating layer. The structure of the device of the present invention can be adapted to this.

FIG. 2 is a cross-sectional view of a portion of a lightweight building board that can be manufactured according to the present invention. FIG. 2 is a schematic longitudinal sectional view of a portion of an apparatus according to the present invention for producing a coating layer and a core layer of an architectural multilayer lightweight board. FIG. 2 is a schematic longitudinal sectional view of an apparatus of the present invention in an area for producing a second coating layer.

Explanation of symbols

DESCRIPTION OF SYMBOLS 2 ... Core layer 3a; 3b ... Covering layer 100 ... Apparatus 101 for manufacturing a lightweight board for construction ... Main transport path 102 ... Sub transport path 103 ... First coating Layer manufacturing apparatus 105 ... Second coating layer manufacturing apparatus 106 ... Coating layer direction change-and dislocation apparatus 111 ... Storage container 114 ... Main transfer means 115 ... Mould 116b ... Bottom Wall 118a ... first reinforcing material belt roll 119; 131 ... belt-like fabric
DESCRIPTION OF SYMBOLS 120 ... Pushing rod 122 ... Perforated wheel type lock gate 135 ... Pressing belt 127 ... Synthetic resin sheet belt

Claims (29)

In a continuous production method of a cement-based multi-layer lightweight board for construction having a core layer (2) and a covering layer (3a; 3b) arranged on at least one major surface of the core layer (2), the following method steps :
-Manufactured by applying ready-mixed concrete on a first support that moves continuously through the core layer of ready-mixed concrete;
The coating layer (3b) is produced on a continuously moving second support and a preformed coating layer (3b) is placed on the core layer (2);
-Cut this strip into individual boards;
-Solidify the board;
-The method as described above, characterized in that the board is optionally dried. The process according to claim 1, wherein the first covering layer (3a) is first produced by applying green mortar on a first continuously moving support. 3. The method according to claim 2, wherein a reinforcing material, preferably a belt-like fabric, is introduced into the green mortar of the covering layer (3a). 4. The method according to claim 1, wherein a reinforcing material, in particular a belt-like woven fabric, is introduced into the second coating layer (3b). The second covering layer (3b) is manufactured in the mirror-reversed position or in the opposite position so that the outer surface of the building lightweight board to be formed is placed on the bottom and in particular on the continuously moving support For this purpose, for example, the core layer (2) or the first coating layer (3a) and the core layer (2) are placed on a support moving in the main feed direction A and the second coating layer (3b) Manufacturing on a support moving in the secondary feed direction B opposite to the feed direction A and with the covering layer preferably turning 180 ° and placing it on the core layer (2). The method as described in any one of 1-4. 6. The reinforcing material of the first and second coating layers (3a; 3b), for example a belt-like fabric (119; 131), is pressed into each coating layer (3a; 3b). The method described. Raw mortar is used for the coating layer (3a; 3b) and aggregates such as pozzolans such as fly ash, in particular coal fly ash and / or blast furnace ash and / or fine silica, and preferably customary additives such as eg 2. A cell-forming agent and / or a flow agent, such as polycarboxylate ethers and / or stabilizers, such as methylcellulose and / or dispersants, such as terpolymers of ethylene, vinyl laurate and vinyl chloride. The method as described in any one of -6. 8. The process according to claim 7, wherein the following particularly advantageous composition of raw mortar for the covering layer (3a; 3b) is used:

Adjusting the water / solids-value (w / f) of the raw mortar according to DIN for the coating layer (3a; 3b) to 0.35 to 0.6, in particular 0.4 to 0.5. 9. The method according to any one of 8. 10. The process as claimed in claim 1, wherein the raw mortar for the coating layer (3a; 3b) is adjusted to a flowability of 21 to 24 cm, particularly preferably 21.5 to 23 cm. For the core layer (2), customary additives such as pozzolans, such as fly ash, in particular coal fly ash and / or blast furnace ash and / or fine silica, and preferably customary additives such as bubble formers and / or 11. Use of a concrete containing a dispersant, for example a terpolymer comprising ethylene, vinyl laurate and vinyl chloride and / or a flow agent, for example polycarboxylate ether. The method described in 1. 12. The method according to claim 11, wherein the following particularly advantageous composition of ready-mixed concrete for the core layer (2) is used:

The water / solids-value (w / f) of the ready-mixed concrete for the core layer (2) is adjusted to 0.15-0.3, in particular 0.2-0.25. The method according to one. 14. A method according to any one of the preceding claims, wherein the flowability according to DIN is adjusted to 16-18 cm for ready-mixed concrete for the core layer (2). 15. Coating layer 3a with a thickness of 1 to 3 mm, preferably 1.3 to 2 mm; 3b and a core layer (2) with a thickness of 5 to 100 mm, preferably 8 to 60 mm, are produced. The method described in one.       After turning the second covering layer (3b) and placing it on the core layer (2), it is pressed against the core layer (2), in particular flatly, for example using a movable pressing belt (135). The method according to any one of 1 to 15. On the support on which the raw mortar for the covering layer (3a; 3b) is moved each time, in particular across the main feed direction A or the sub-feed direction B and 17. A method according to any one of the preceding claims, wherein the spraying is performed by a spray nozzle (113, 125) that vibrates over its entire width. The method according to claim 1, wherein the ready-mixed concrete for the core layer (2) is evenly distributed by means of a doctor blade device that vibrates across the main feed direction A. Cement-based architectural multilayer having a core layer (2) and a covering layer (3b) arranged on the main surface of the core layer (2) and preferably embedded with a reinforcing material, for example a belt-like fabric (119; 131) In an apparatus (100) for manufacturing a lightweight board, in particular a building lightweight board according to any one of claims 1-18,
a) main transport means moving in the main feed direction _A at a main feed speed V _A , eg a main transport path having a conveyor belt (114) and preferably a mold (115) mounted on the main transport means (114); For example, main belt path (101)
b) a secondary conveying path to the secondary belt path (102), which is arranged above and preferably parallel to the primary transport path (101); this secondary belt path (102) is responsive to the primary feed speed V _A Sub-feeding speed V _B that coincides with the main-feeding direction A and can be operated in the sub-feeding direction B opposite to the main-feeding direction A. ) In the form of
In this case, the first transport layer manufacturing apparatus (103) in which the main transport path (101) is c) preferably disposed above the main transport means (114),
d) a core layer production device (104) which is likewise preferably arranged above the conveying belt (114) and possibly arranged after the coating layer production device (103) in the main feed direction A,
e) a cutting device for dividing the manufactured board strip into individual boards;
f) a curing device or -section and g) preferably having a drying device,
The sub-transport path (102) is preferably arranged in the sub-feed direction B, preferably before and after.
h) second coating layer production device (105) and i) coating layer redirection and dislocation device (106)
In this case, preferably the coating layer redirecting and overlaying device (106) is arranged later in the main feed direction A of the core layer production device (104) and before the cutting device the main conveying belt (114) Wherein the secondary transport belt (102) interacts with the main transport belt (101). The first coating layer manufacturing apparatus (103) includes a first reinforcing material laying device (103b) and preferably a first pushing device (103c) behind the first injection device (103a) in the main feed direction A. The apparatus of claim 19, comprising: A first injector (103a) is disposed above the storage vessel (111) and the bottom wall (116b) of the mold (115) and vibrates across the entire width of the mold (115) and across the main feed direction (A). 21. The device according to claim 20, comprising an injection nozzle (113) connected to the storage container (111) via a pump conduit (112). The first laying device (103b) is located obliquely below the first reinforcement belt roll (118a) and preferably the roll (118a) around which a first reinforcement belt, for example a woven belt (119), is wound. And preferably, it has a laying roll (118b) arranged away from the bottom wall (116b) in accordance with the thickness of the first covering layer 3a, and the first reinforcing material belt (119) is placed on the laying roll. 22. The device according to claim 20 or 21, wherein is sent in a particularly tensioned state. The first pushing device (103c) has a pushing rod (120) movable up and down, and the pushing rod (120) preferably extends from the bottom wall (116b) to half the thickness of the first covering layer (3a). The device according to any one of claims 20 to 22, wherein the device is arranged to be movable up and down apart. The core layer manufacturing apparatus (104) vibrates across the width of the perforated wheel type lock (122) and the main feed direction A across the main feed direction A (155) and in the main feed direction A (perforated wheel type lock gate ( 122) having a doctor blade (123) arranged behind the coating layer (3a), preferably spaced apart from the coating layer (3a) by a desired thickness of the core layer 2 on the first coating layer (3a). 24. A device according to any one of claims 19 to 23. The second coating layer manufacturing device (105) deploys the second fabric laying device (105b) and the second pushing device (105c) behind the second injection device (105a) in the sub-feed direction B. 25. Apparatus according to any one of claims 19 to 24. 26. The second spraying device (105a) comprises an injection nozzle (125) and preferably a storage vessel and a pump conduit crossing the secondary feed direction B and oscillating across the width of the plastic sheet belt (127). The device described. The second laying device (105b) is, for example, a second belt roll having a wound belt-like fabric (131), and preferably obliquely below the second roll (130a) and a synthetic resin sheet belt (127 27. A device according to claim 25 or 26, comprising a laying roll (130b) arranged above the second belt-like fabric (131). The second pushing device (105c) has a second vertically movable pushing rod (132), which is preferably from the synthetic resin seat belt (127) up to half the thickness of the first coating layer (3a). 28. The apparatus according to any one of claims 25 to 27, wherein the apparatus is arranged to be movable up and down apart. The coating direction change-and overlay device (106) has a direction change roll (133) and a pressure roll (134), with a pressure belt (135) in tension around it, in particular the main feed speed V _A The device according to any one of claims 1 to 3, which is capable of rotating around.

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