RU2602628C1 - Method of making construction slabs - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: invention relates to construction, namely to processes of making construction boards, based on polymer materials of various functional purposes. Method of making construction boards involves use of long hollow rectangular type modules, extruded from thermoplastic polymer, which are arranged in lines at base with serial connection of adjacent modules at side faces, oriented in direction of longitudinal-vertical planes, parallel to respective symmetry plane of module, and formation of working surfaces of plates along edges of adjacent modules, oriented in direction of longitudinal-horizontal planes, parallel to base. Working width of formed plate is set at total amount of hollow modules, laid on base. Wherein long modules with profiled side faces, oriented in direction of above longitudinal-vertical planes, which are contact jointed with similar faces of adjacent modules, when placing on base, to form wedge gaps on side of working surfaces of formed plate, oppositely oriented along adjacent modules, which are filled with melt polymer material.

EFFECT: technical result consists in expansion of technological capabilities of manufacturing of slabs of various technological purposes at simultaneous reduction of material costs for their manufacturing.

6 cl, 4 dwg

Description

Technical field

The invention relates to the field of construction, in particular to technological processes for the manufacture of building plates based on polymeric materials used:

for the design and formation of collapsible pavements, temporary crossings and sites designed to provide passage and / or placement of heavy and special equipment in difficult geological conditions;

for the manufacture of structural elements of enclosing structures, partitions, pontoons, pedestrian road decks, railway bridges, pedestrian walkway flooring decks, railway platform decks, ramps for people with disabilities, various wall panels, roof structural elements, heat-insulating and sound-absorbing structures, etc. .

State of the art

The construction industry occupies a special niche in the use of modern materials based on polymers, the use of which in construction is determined by their operational characteristics and which, unlike traditional building materials, are more durable, durable and less material-intensive.

It is the low material consumption of structures based on polymeric materials, their high durability, including to corrosion processes, that determine the direction of industrial use of these materials in the manufacture of building products for various purposes, including in the form of building plates.

Preferably, for the manufacture of slabs based on polymeric materials, a pultrusion process is used, based on the production of products with a constant cross-sectional area. This technology is based on the use of polymer resins and reinforcing agents mainly in the form of fibers of glass, carbon, basalt.

As an example of the implementation of this technical direction for the manufacture of building plates, which are used, for example, as flooring in bridge building, we can cite:

US patent No. 6912821, publ. 07/05/2005), in accordance with which a flooring is proposed comprising an upper flat plate and composite panels interconnected, having a lower flat base and vertically arranged ribs with supporting platforms on which the upper plate rests. The upper panel can optionally be connected to composite panels by a detachable or non-detachable connection and forms longitudinal channels with them;

RU patent No. 2403336, publ. November 10, 2010, patent holder of LLC “Scientific and Technological Testing Center“ ApATEK-Dubna ”(RU). The technical solution proposes a flooring made of interconnected pultruded profiles, each of which contains an upper deck, based on vertical ribs made along the pultruded profile, in the lower part of which are located strips of supporting platforms. The upper surface of the flat part and the lower surface of the supporting platforms are made flat. Locks are made along the longitudinal edges of the pultruded profiles, for which there are longitudinal grooves at the junction of one pultruded profile in the decking and in the supporting platform, and protrusions respectively in the other. Neighboring pultruded profiles are connected by mechanical connection along the vertical ribs of adjacent pultruded profiles.

Significant drawbacks in the manufacture of building products using pultruded profiles include a fairly complex design of products based on a set of profiles that require mutual connection, including using mechanical means of bonding, glue or other locking compounds.

A significant number of structural elements in construction products of this type increases their material consumption and limits the technological capabilities of their use in slabs designed for designing and forming collapsible pavings, temporary crossings and sites designed to provide passage and / or placement of heavy and special equipment in difficult geological conditions.

From the prior art it also follows that for the construction of the roadway on waterlogged soils, for the creation of technological driveways, temporary roads during construction and installation works, collapsible road surfaces based on slabs of polymer materials are most suitable (see, for example, RF patent No. 131734, publ. 08/27/2013).

The plate for a collapsible road surface according to this technical solution is made on the basis of a polymeric material in the shape of a rectangular parallelepiped, along the perimeter of the side faces of which there are fixation means for adjacent plates of the formed road surface.

The slabs according to this technical solution are made of monolithic (homogeneous) polymers and with overall parameters optimized for the operational reliability of the formed road surface and for safe passage on vehicles formed road surfaces, including construction equipment. However, slabs for collapsible pavements when used in their manufacture of monolithic polymers have significant material consumption, which significantly increases the complexity of installation and dismantling operations when forming a pavement, and limits the technological possibilities of using these slabs on soils with significant moisture.

At the same time, a technical solution is known for the manufacture of building plates, for the manufacture of which long-length hollow rectangular modules extruded from thermoplastic polymer are used, which are arranged in a row to form a plate in a row on a base base with a series connection of adjacent modules along lateral faces oriented in the direction of longitudinally vertical planes parallel to the corresponding plane of symmetry of the long module, and with the formation of the working surfaces of the plate along the faces odules which are oriented towards the longitudinal-horizontal planes parallel to the base substrate, the working width of the formed plate is set at an amount generally laid on the foundation base of the hollow modules (see. WO 2014167184, publ. 16.10.2014). This technical solution is selected as the closest analogue of the claimed invention.

The connection of adjacent modules (see WO 2014167184) is carried out either using mechanical means or when welding the modules along the side faces, preferably with discreetly located welding points between the side faces of adjacent modules, which are placed on the base for these purposes with the formation of a technological clearance.

A plate made according to a well-known technological process is used as the flooring of a pedestrian bridge.

However, the presence of a technological gap between adjacent modules in an in-line arrangement on a base base limits the technological possibilities of using slabs formed by this process, including those intended for the design and formation of collapsible pavings, temporary crossings and platforms for providing passage and / or accommodation heavy and special equipment in difficult geological conditions, for the manufacture of pontoons, wall panels, heat-insulating and noise-absorbing structures .

Building plates for this type of structural product preferably have monolithic (solid) work surfaces. The manufacture of building plates with monolithic work surfaces using the technological process presented in WO 2014167184 for this purpose can be carried out provided that the technological gap between the side faces of adjacent modules is filled with a continuous layer of molten polymer material, as, for example, is provided in the technical solution for patent RU No. 2383810, publ. 05/27/2009. This technical solution claims a technological process for the use of long rectangular hollow modules extruded from a thermoplastic polymer in the construction and repair of pipelines by winding and welding of adjacent adjacent modules on a cylindrical mandrel. When winding, the side faces of adjacent modules have a technological gap into which the molten polymer material is extruded. However, when implementing this technical solution, the consumable part of polymeric materials for the manufacture of structural products is significantly increased.

Disclosure of invention

The technical result of the present invention is aimed at expanding the technological capabilities for the manufacture of building boards for various technological purposes, while reducing material costs for their manufacture.

To solve the technical result, we propose a method of manufacturing building plates, which consists in the use of long rectangular hollow modules extruded from thermoplastic polymer, which are placed in a row on a base base with a series connection of adjacent modules along side faces oriented in the direction of longitudinally vertical planes parallel to the corresponding plane symmetry of the module, and the formation of the working surfaces of the plate along the faces of adjacent modules, to which are oriented in the direction of longitudinally horizontal planes parallel to the base base, the working width of the plate being formed is specified for the total number of hollow modules laid on the base base, while long modules are used having profiled side faces oriented in the direction of the indicated longitudinally vertical planes that are joined to with similar faces of adjacent modules when placing them on a base base with the formation of the opposite plate from the working surfaces oriented along adjacent modules of wedge gaps, which are filled with a melt of polymer material.

According to the invention, the wedge gaps between adjacent modules are filled when the polymer material is extruded therein.

According to the invention, a polymer rod is laid in the wedge gaps between adjacent modules, followed by welding it with long modules.

According to the invention, the tops of the wedge gaps formed during the contact docking of adjacent modules are oriented to the longitudinally horizontal plane of symmetry of the plate parallel to the base base.

According to the invention, for the manufacture of a building board, long rectangular hollow modules are used, the side profiled faces of which are convex with the greatest convexity in the longitudinally horizontal plane of symmetry of the module.

According to the invention, for the manufacture of a building board, long rectangular hollow modules are used, the lateral profiled faces of which have protrusions with grooves located between them, the distance between the inner contour of the extreme protrusions on one side of the module corresponds to the distance between the outer contour of the extreme protrusions on the other opposite face of the module.

When implementing the invention, due to the above-described technological methods, it is provided:

- the possibility of designing and manufacturing a different range of building plates with cast-in-place working surfaces having a wide range of their industrial applications in the construction of road surfaces, bridges, buildings;

- the ability to design and manufacture building plates at a lower cost part of the polymer materials used for their manufacture while ensuring their operational reliability;

- the possibility of designing and manufacturing a different range of building plates with cast-in-place working surfaces based on the well-known technological base for the manufacture of long rectangular hollow modules extruded from thermoplastic polymer. The equipment traditionally used for these purposes will make it possible to obtain hollow modules with technologically specified parameters, including cross sections, wall thickness.

In the analysis of the prior art, no technical solutions have been identified that have a set of features similar to the claimed technical solution for solving the claimed technical result, which indicates the compliance of the claimed technical solution with the criteria of the invention: "novelty", "inventive step".

When implementing the invention using traditionally known technological equipment, which indicates compliance with its criterion of "industrial applicability".

The implementation of the invention

The invention is confirmed by the following description and explanatory drawings, where:

fig. 1 is a general view of a building slab;

fig. 2, 3, 4 - embodiments of hollow modules with profiled surfaces.

To implement the technological process for the manufacture of building slabs, the following materials and equipment are used:

thermoplastic polymers (thermoplastics), the choice of which takes into account their cost, technical characteristics that meet the requirements for the creation of structural products, their functional purpose. Industrial thermoplastics may contain various processing aids and, when using thermoplastics, additional processing aids are added to improve the quality of structural products, for example, various reinforcing agents.

To implement the method using thermoplastic polymers, preferably polyethylene pipe grades: PE-100 and PE2NT11-9.

a production line for the manufacture of long hollow modules of a rectangular type by extrusion, for example, in the embodiment described in technical solution according to patent RU No. 2383810.

Using the specified thermoplastic on a production line containing a screw extruder with a forming device, at the output of which a calibrating head is placed, hollow rectangular modules extruded from a thermoplastic polymer are obtained with technologically specified parameters for the cross section, wall thickness and with a given profile of two opposite lateral faces . In the process of manufacturing hollow modules, the length of the resulting semi-finished products for the manufacture of the slab is set taking into account the technological requirements for their functional purpose. For these purposes, use an automatic cutting device.

Extruded from a thermoplastic polymer, hollow modules 1 of a rectangular type with technologically defined parameters are placed in a row on a base base 2 by orienting the profiled faces of 3 modules in the direction of longitudinally vertical planes parallel to the corresponding plane of symmetry of module II 1. The working surfaces of the plate are formed along the faces of adjacent modules, which oriented in the direction of the longitudinal-horizontal planes II-II parallel to the base base 2. The working width of the formed plate is set by and the total number of hollow modules laid on the base base. The modules for a plate formed along the working width are technologically maintained on a base base, preferably for thermoplastic shrinkage.

At a subsequent stage, the profiled lateral faces of 3 adjacent modules are contacted together to form wedge gaps 4 opposite on the working surfaces of the formed plate, the apex of which from the formed working surfaces is oriented to the longitudinal-horizontal plane of symmetry II-II of the module cross sections , the formed plate is fixed on the base 2 to eliminate the relative displacement of the modules.

The resulting wedge gaps are filled with a molten polymer material, preferably by extruding into the wedge gaps 4 of the polymer material.

A variant is possible in which a polymer rod is laid in the wedge gaps 4 between adjacent modules, followed by welding it with long modules.

The filling of the wedge gaps 4 with a melt of polymer material is carried out during the alternate processing and preparation of the working surfaces, while the filling of the wedge gaps from the other working surface of the formed plate is preferably carried out after it has been technologically soaked on a base to prevent damage, cracking of the molten polymer material in the wedge gaps at the previous working plate surface.

For the manufacture of a building board, long rectangular hollow modules are used, the side profiled faces 3 of which are convex (Fig. 2) with the greatest convexity in the longitudinal-horizontal plane of symmetry of II-II transverse sections of the modules. This embodiment of profiling the side faces is the most technologically advanced and ensures the stability of contact joining of the side faces of adjacent modules during plate formation, while the wedge gap formed during contact interaction of the faces has the parameters that are most optimal for the flow rate of the polymer melt.

At the same time, other options are possible for profiling the side faces of the modules, which, for example, is shown in Fig. 3. In this embodiment, the side profiled faces of the module have protrusions with grooves located between them, the distance between the inner contour of the extreme protrusions on one side of the module corresponds to the distance between the outer contour of the extreme protrusions on the other opposite face of the module.

The wedge gap between adjacent modules in this embodiment is provided, for example, by bevels on the upper part of the profiled surfaces.

Depending on the functional purpose of the formed slab, the construction end faces of the slab (from the side of the open cross sections of the modules) are welded with a polymer material, as, for example, as provided for in patent WO 2014167184.

As a result of the described technological process, using rectangular long-length hollow modules extruded from a thermoplastic polymer, construction plates with monolithic work surfaces that are optimal in terms of consumption of polymeric materials are made, which, depending on the technological requirements for them, can be used:

- for the design and creation of collapsible pavings in difficult geological conditions. The plates used for these purposes must meet certain requirements for material consumption, buoyancy and high operational reliability, taking into account the force loads acting on the formed coating from various vehicles;

- for the design and creation of bridge decking, energy-saving wall panels, as well as for the design and creation of building slabs of other functional purposes, for example, as noise-attenuating panels.

Claims (6)

1. A method of manufacturing building plates, which consists in the use of long, rectangular hollow modules extruded from a thermoplastic polymer, which are arranged in a row on a base base with a series connection of adjacent modules along side faces oriented in the direction of longitudinally vertical planes parallel to the corresponding plane of symmetry of the module, and the formation of the working surfaces of the plate along the faces of adjacent modules, which are oriented in the direction of longitudinally-horizontal plates parallel to the base base, the working width of the formed plate is set for the total number of hollow modules laid on the base base, while long modules are used that have profiled side faces oriented in the direction of the indicated longitudinal vertical planes, which contact with similar faces of adjacent modules when placed them on a basic basis with the formation from the side of the working surfaces of the formed plate opposite oriented along the adjacent modules of the wedge gaps ditch, which is filled with a molten polymer material. 2. The method according to p. 1, characterized in that the filling of the wedge gaps between adjacent modules is carried out during the extrusion of a polymer material. 3. The method according to claim 1, characterized in that a polymer rod is laid in the wedge gaps between adjacent modules, followed by welding it with long modules. 4. The method according to p. 1, characterized in that the tops of the wedge gaps formed during the contact docking of adjacent modules are oriented to the longitudinally horizontal plane of symmetry of the plate parallel to the base base. 5. The method according to p. 1, characterized in that for the manufacture of the building board using long hollow modules of a rectangular type, the side profiled edges of which are convex with the greatest convexity in the longitudinally-horizontal plane of symmetry of the module. 6. The method according to p. 1, characterized in that for the manufacture of a building slab use long rectangular hollow modules whose lateral profiled faces have protrusions with grooves located between them, the distance between the inner contour of the extreme protrusions on one face of the module corresponds to the distance between the outer contour extreme protrusions on another opposite face of the module.

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