Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
  • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
  • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
  • B29C44/1228—Joining preformed parts by the expanding material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
  • B29C44/30—Expanding the moulding material between endless belts or rollers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
  • B29C67/02—Moulding by agglomerating
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
  • B29C70/021—Combinations of fibrous reinforcement and non-fibrous material
  • B29C70/025—Combinations of fibrous reinforcement and non-fibrous material with particular filler
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
  • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
  • B29C35/0261—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using ultrasonic or sonic vibrations
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
  • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
  • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
  • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
  • B29K2105/16—Fillers

Definitions

• the present invention relates to a method for manufacturing building element, and of the type described in the introductory part of claim 1.
• a building element consisting of particle-shaped filler of Leca- clinkers and a stiffened foaming agent in the form of foam plastic material is known, which material in liquid state is consistent with the filler before filling into a mould and compression during the foaming of the binding agent, at which the particles of the filler have become so firmly compressed, that they form a coherent, carrying skeleton, in which the particles are cemented together by the foaming agent.
• a foaming, liquid plastic mixture is consistent with the solid, particle-shaped filler, before this is continouosly filled into a row of moulds, which in proportion to the filling position are moved in longitudinal direction, whereafter the material is compres- sed in the moulds, and where all components are injected under pressure into the moulds through a common mixing nozzle, through which loose particles of the filler are blown in and mixed with pre-mixed injected foaming agent, and then are pressed so firmly together in the moulds, that the particles after foaming form a coherent, carrying unit.
• a lightweight building plate member which is manu ⁇ factured by compression of a mixture of Perlite and polyurethane foam in a mould, as the plastic foam is compressed mechanically, by lowering of the upper part of the mould - like a piston - into the lower part of the mould at the same time as the foaming takes place.
• this known lightweight building plate is manufactured 0 from a mixture of 60% Perlite and 40% polyurethane foam. It concerns a building plate member, which primarily has a high thermic insulating power, and which has good tooling properties - but has not got ⁇ oticable strength.
• the method according to the invention is distinctive in that ideal distribution of the part o components of the fillers are obtained through intensive mechanical mixing supplemen ⁇ ted by ionizing-affection of the mixture, that surfaces of the fillers are coated with opposite ionized binding agent spray, that part components of the fillers by continouos mixing are fixed finally by means of the binding agent, that a suitable dose of the mixture is exposed to mechanical compression by moulding in regular vibration tools, and that final activation and hardening of the binding agent is obtained by ultrasound af ⁇ fection.
• the building element has a solid and almost monolithic structure; but anyway the building element or plate member may be tooled with cutting tools.
• the buildin element may be manufactured with high breaking strength and tensile strength, respecti vely, as the building element appears as neutral member seen from a thermical point o view, that is without a measurable thermic coefficient of expansion.
• the mixture after coatin with the binding agent spray advantageously may be further conditioned into a homoge neous, plastic substance by means of low-frequency ultrasound affection.
• filler preferably 95 - 98% filler and 2 - 5% bindin agent are used.
• the method according to the invention light-clinkers may be used as filler preferably in such a sorting, that about 75% of the content consist of 4 - 10 m fractions, and about 25% of the contents consist of 0 - 4 mm fractions.
• granulated Perlite, sand, or calcinated flint may be used as filler.
• bindin agent containing about 1 % armoured fibres, for instance Kevlar, coal fibres or glas fibres to secure a further strength of the building element.
• the invention also relates to a system for continouosly manufacturing of the building e- lements cf. the method according to claim 1, and comprising stock silos for fillers and binding agents, dosing devices, a tunnel mixer with combined transport and mixing worm, and moulds, which system is distinctive in that the tunnel mixer after a pre- mixing section, where the mixing of the respective part components takes place, comprises a first ionizing chamber for ionizing and ideal distribution of the part compo ⁇ nents and a second ionizing chamber for coating the mixed fillers with an opposite ionized binding agent, a conditioning or after mixing section for mutually fixing of the part components, means for distribution of the mixture to moulds, preferably compri- sing regular calibration tools, vibration and ultrasound equipment for ideal embeddi and final activation and hardening of the binding agent.
• the system may be such provided that said means for distribution and pl cement of the mixture comprise one in the transverse direction preferably funnel-shape section for pre-compression of the mixture.
• the invention furthermore relates to a building element consisting of a granulated fille and an expanding binding agent, for instance a foaming polymer, and where th percentage content of varying grain sizes of the used filler is optimized, that is wher considerations are made concerning tight packing and minimum porosity, whic building element is distinctive in that ideal distribution of the part components of th filler is obtained by intensive mixing supplemented with ionizing affection of th mixture, that the surfaces of the part components of the filler are coated with opposite i o ⁇ izing binding agent, that the part components of the filler by continouos mixing ar fixed, permanently by means of the binding agent and possibly affection by low-fre ⁇ quency ultrasound, that the element is produced by means of moulds and/or by mecha ⁇ nical compression between regular vibration tools, and that final activation and harde ⁇ ning of the binding agent are obtained by ultrasound affection.
• a building element consisting of a granulated fille and an expanding binding agent, for instance a foaming polymer, and
• silo system 2 with a number of silos 4 and a system of worm conveyors 6 filler material is supplied to a process conveyor or tunnel mixer 8, which stretches through or is integrated with a number of treatment chambers, namely a primarily ionizing chamber 10, a coating chamber 12, and a conditioning or after-mixing chamber 14.
• a silo system 16 consisting of silos 18, 20, and 22 a spray of binding agent an possible armouring fibres are supplied via a combined atomizing or pulverizin apparatus 24 to the coating chamber 12 via a secondary ionizing chamber 26.
• Atomizing and pulverizing apparatus 24 comprises atomizing nozzles, which by mean of ultrasound are adapted to produce a very thin spray of binding agent, and a rotatin knife for devision of the armouring fibres.
• the latter may be supplied from the silo 18 while the silos 20 and 22 may contain binding agent in the form of metal powder an liquid polymer, respectively.
• Silos 4 may each contain a fraction (grain size) of a filler, for instance light-clinker (Leca); but in order to make the manufacturing system more flexible each silo contain preferably ready mixtures of filler, which fulfil Fuller's formula, that is where th quantity of the single grain sizes is optimized, so that an ideal tight packing of the fille material and a minimum of cavity are obtained.
• a filler for instance light-clinker (Leca); but in order to make the manufacturing system more flexible each silo contain preferably ready mixtures of filler, which fulfil Fuller's formula, that is where th quantity of the single grain sizes is optimized, so that an ideal tight packing of the fille material and a minimum of cavity are obtained.
• the pre-mixed, ionized filler material is united with th binding agent spray, which also is ionized - but with opposite polarity - by placing th binding agent spray in a very thin coat on the surfaces of the individual part component of the filler material.
• the tunnel mixer 8 which is built up as a rotary kiln wit transport worms, forwards the mixture into the conditioning or after-mixing chambe 14, where the coated part components of the mixture through affection with low frequency ultrasound are fixed to a homogeneous, plastic substance.
• the homogeneous, plastic substanc is lead to a mould section 28, which - as intimated - is adapted to manufacturing of a plate-shaped building element, or via a side conveyor 30 to an alternative mould section
• mould sections 28 and 32 and possible more mould sections would be movably arranged in proportion to the tunnel conveyor 8, for instance similar the tools of a turret lathe.
• the mould section 28 comprises a funnel-shaped pre-compressing part 34, from wher the form substance extrudes through a horisontal slot between mould rollers 36 as a pl te-shaped member 40.
• the latter is inserted between a number of sets of co-operatin vibration rollers 38, by means of which rollers the plate-shaped member 40 is calibrate into regular thickness size.
• Final hardening and fixing of the binding agent is hereafte obtained by exposure of the member 40 to treatment with high-frequency ultrasound for instance between contact soles in a short, transverse tunnel 42, whereby an inne welding fixing of the total binding agent skeleton through molecular friction is produ ced, so that the plate material appears as a monolithic solide material with high E -modulus ° ⁇ U P t0 ⁇ -500 kp/cm and tensile and compression strength of about 20 *-> kp/cm .
• the material may further be tooled with cutting tools and be interconnected b means of ultrasound glueing and/or welding.
• the mould section 32 comprises -as intimated - a tube-extruder for manufacturing o pre-isolated tubes, for instance from a mixture, where both metal powder and polymer have been used as binding agent, and where Perlite or calcinated flint for example are used as filler material.
• the totally closed cell structures are synthesized around an active rhomb-shaped figure material, which function - firstly - in the mixing and hardening process - is to form geographical mathematicl defined carrier medium for the micro armoured foaming polymeric/metallic bindin agent.
• the carrier medium consists of expanding, unorgani material such as clay (Leca-clinkers) and/or vulcanized ashes (Perlite) - to be sound ab sorbing and compression reinforcing, when the carrier medium consists of ordinar quartz and/or calcinated flint.
• regular moulds may be used for the manufac turing of steady members such as pre-isolated distant heating tubes or isolating, carryin construction plate members for housing elements, doors, windows, cabinets, furniture or possible complete hulls.
• the coated/atomized carrier medium (filler) for instance Leca may be ultra-vibrated t 100% ideal embedding, during fixing in continouos mould bands and successiv ultrasound welding/recasting to the final regular product through a micro integra process.

Applications Claiming Priority (2)

Publications (1)

Family

ID=8109945

Family Applications (1)

Country Status (3)

Cited By (2)

Citations (4)

• 1991
  • 1991-12-30 DK DK208091A patent/DK208091A/da not_active Application Discontinuation
• 1992
  • 1992-12-23 AU AU33454/93A patent/AU3345493A/en not_active Abandoned
  • 1992-12-23 WO PCT/DK1992/000395 patent/WO1993012922A1/en active Application Filing

Patent Citations (4)

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