WO1993018908A2

WO1993018908A2 - Double-walled synthetic resin panel and process for producing it

Info

Publication number: WO1993018908A2
Application number: PCT/CH1993/000052
Authority: WO
Inventors: Werner Fritz Dubach
Original assignee: Alfatechnic Patent Ag
Priority date: 1992-03-24
Filing date: 1993-03-02
Publication date: 1993-09-30
Also published as: CH686421A5; EP0586628A1; AU3490793A; WO1993018908A3

Abstract

A lower wall (22) is arranged at a distance beneath an upper wall (21). The lower wall (22) is convex from a central region (23) and then at least approximately espouses the shape of the upper wall (21). An overlap region (27) is thus formed. On the opposite side the lower wall (22) is bent upwards parallel to and flush with the longitudinal edge (26) towards the upper wall (21) and follows the latter back to the centre of the plate. A second overlap region (28) is thus formed. This design avoids the formation of a hollow space in the bonding region of the neighbouring metal plate. In addition, it permits the insertion of metal strips running parallel to the longitudinal edges of both walls. It is also possible to fit a spacer extending over the entire central region (23) in the space between the upper (21) and lower (22) walls to reinforce the entire structure.

Description

Double-skin synthetic resin sheet and process for its production

The present invention relates to a method for producing glass fiber reinforced plastic plates.

The present invention also relates to a double-skin, glass fiber-reinforced synthetic resin plate which is produced by the method and in particular one for connection to corrugated, insulated, double-skin metal plates on structures, preferably on roofs, the upper shell made of plastic being uniform over the entire width Shaped waveform direction is formed and the lower, also made of plastic spaced from the upper shell is connected to this running.

In the manufacture of glass fiber reinforced plastic sheets, it was previously assumed that the glass fiber reinforced plastic had a shape that did not have a curvature or bend of more than 90 ° from the horizontal to the top This has to do with the fact that the upper shape required for production in the overlap area of the plate can no longer support it. The shaped material therefore only has to get into the correct shape, supported on one side, in the overlap area.

This object is now achieved by a method according to claim 1. In this case, the final shaping of the plate is thus carried out towards the end of an inlet section, in which gelling has already started.

Double-skin, glass fiber reinforced synthetic resin sheets of the type mentioned are known and are successfully offered on the market. They serve to realize heat-insulated light openings, in particular in roofs, with metal sheets consisting of a corrugated top sheet and a flat sheet Bottom plate with the interposition of insulating foam are created. The synthetic resin plates attached to the light openings are usually made of transparent, glass fiber-reinforced material.

FIG. 1 shows a known, two-shell, glass fiber-reinforced synthetic resin plate in the installed state, from which the thermal problems can be seen. The marketable, corrugated, heat-insulated metal plates adjoining the light opening on both sides are shown in broken lines in the figure. The one that covers the light opening double-shell glass fiber reinforced synthetic resin plate is drawn with continuous lines. The metal plates delimiting the light opening are denoted overall by 1. They consist of a corrugated top plate 2 and an essentially flat bottom plate 3, between which a foamed insulation 4 is applied over the entire surface. At least the longitudinal edges 5 of the top plate 2 and the bottom plate 3 are arranged slightly overlapping and connected to one another in this area. The top plate 2 and the bottom plate 3 are terminated flush on one side, while on the other longitudinal edge the top plate 2 is extended in the same wave shape by more than half a wavelength beyond the bottom plate 3. The overlap strip 6 thus formed is used for the form-fitting laying of adjacent metal plates 1. If there is a light opening between two adjacent metal plates 1, this is filled by a double-shell, glass fiber-reinforced synthetic resin plate 7. This synthetic resin plate according to the prior art consists of an upper shell 8 and a lower shell 9. The upper shell 8 is a simple corrugated plate without a special formal design. It is dimensioned in such a way that it overlaps the last lateral shaft of the metal plate 1 almost completely on one side with an overlap area 10. The other longitudinal edge of the upper shell 8 is also formed by a shaft that comes completely under the overlap strips 6 of the top plate 2 of the metal plate 1. The lower shell 9 extends at a distance from the upper shell 8 and is essentially flat on its base. The side edge of the lower shell 9 is bent upwards on the longitudinal edges just before the respective last shaft of the upper shell 8 and follows at least along a portion of this last shaft in a form-fitting manner.

With this design of the double-skin, glass fiber-reinforced synthetic resin plate, a cavity 11 is formed on one side in the region of the connection of such a plate 7 to a metal plate 1. This cavity 11 is not insulated from the outside and forms a relatively large cold bridge. If this cavity 11 is left unfilled, condensation water also forms here. Accordingly, corrosion of the metal plate 1 cannot be ruled out. Although this problem has been known for years, no reasonable solution has yet been offered. So far, it has been limited to temporarily filling this cavity 11 with an additional insulation material. Another problem is that it is precisely in this area of overlap of the metal plate 1 and the double-skin, glass fiber-reinforced synthetic resin plate 7 that the outer skin formed in this way should be connected to the roof structure underneath. However, since the cavity 11 is located precisely at this connection location, the fastening screws 12 are usually tightened too much due to the lack of noticeable resistance, so that the two edges of the upper and lower shells 8, 9 located underneath deform too much and cracks will form accordingly in the panels. This is not only unsightly, but also questions the tightness of the double-shell plate 7. Due to the weather-related influences on the plastic shell, these cracks expand over the years and can destroy the entire double-shell synthetic resin plate.

It is therefore a further object of the present invention to design a synthetic resin plate of the type mentioned at the outset in such a way that the aforementioned disadvantages are eliminated without a subsequent sealing being necessary.

This object is achieved by a two-shell glass fiber-reinforced synthetic resin plate produced by the method according to the invention with the features of claim 8.

If spacers made of heat-insulating, foamed material and extending across the entire width of the plates are arranged at regular intervals between the two shells, the double-skin synthetic resin plate can be placed on the purlins below with a reduced risk of cracking Fasten the roof structure. The bar-shaped spacers can be laid exactly between the two shells according to the purlin distance.

The upper and lower shell of the two-shell synthetic resin plate are usually glued together. So in addition to this non-positive between the two shells also a positive connection is created, it is advantageous to design the overlaps of the upper and lower shell at least approximately the width of half a wavelength.

So that the pressure distribution on the two shells of the synthetic resin plate in the area of the fastening with the purlins along the longitudinal edges of the double-shell plate does not only occur selectively, it makes sense to arrange a metal strip between them in the overlapping areas of the two shells extends in parallel over the entire length of the panel over the longitudinal edges. However, this can also be achieved by arranging metal plates in the overlapping areas of the two shells above the respective spacers.

The most stable shape of the double-skin synthetic resin plate is achieved if the spacer is exactly adapted to the contours of the space between the upper and lower shell. This is possible thanks to the cutting or punching technology available today.

In the following description, the basic design of the double-shell synthetic resin sheet according to the invention, as well as a preferred exemplary embodiment in a misplaced form, are explained with reference to the attached drawings. It shows: FIG. 1 shows a double-shell synthetic resin plate in a laid arrangement according to the prior art, as described above;

Figure 2 is a schematic representation of the two-shell synthetic resin plate according to the invention with sinusoidal corrugation and

Figure 3 shows a preferred embodiment with trapezoidal corrugation in the installed state;

Figure 4 shows a detail of the plate of Figure 3 and

Figure 5 is a top view of a two-shell, glass fiber reinforced synthetic resin plate.

The production of glass fiber reinforced plastic sheets has been known for many years. Various reasons have led to industrial production declining in recent years. This has to do with the hygienic conditions at work and the supposedly low formal design options, although the panels have significant advantages, such as transparency, long service life and good insulation values.

The plates according to the invention are manufactured as follows. In a first station, a flexible carrier, preferably a paper coated with silicone or a Foil, just spread out. Liquid synthetic resin is poured onto the paper web, the coated side of which faces upwards, and is evenly distributed. A cut glass fiber roving is placed on the liquid synthetic resin. The fibers are coated with a silane size which slowly dissolves in the solvent of the synthetic resin, as a result of which the glass fiber is only fully wetted. If the glass fiber roving is completely saturated, an upper, flexible covering layer is applied. This usually consists of the same paper coated with silicone. Thus, a temporary laminate is created from the three layers: paper plastic with embedded glass fiber paper. After completing ^'the production, the paper layers can deduct what the ge wished pure glass fiber reinforced plastic plate vorliegt-

The temporary laminate is now drawn through two superimposed shapes that have a complementary shape. The two forms each have an inlet section. The inlet section of the lower mold preferably begins before the inlet section of the upper mold begins. The inlet section is the distance at which the form slowly changes into its definitive shape. This must be done as continuously as possible so that the still liquid synthetic resin deforms uniformly and in the same thickness and the two flexible outer layers of paper are not destroyed by cracks or folds! With the previously simple design forms, hardly any importance was attached to the inlet sections and they were relatively short designed .

The upper form and lower form can be heated. Thus, the gelling process begins at the latest when the temporary laminate is introduced into the inlet section.

To transport the continuously running, temporary laminate, it is pulled on the paper layers. The distance that the material web from the position at which the top paper layer is applied to the point in time that the gelation of the liquid resin covers until the first hardening is called the gelation line. The inlet section, that is to say the section of the shaping, has hitherto usually been a fraction of the gelling section. The inlet section is now lengthened in relation to the gelling section and the shaping is carried out in two stages, or is completed relatively late. The partial gelation is consequently used to enable a shape that results in an overlap area. Only when this last shaping step has taken place is the gelling completed and the hardening continued to such an extent that it is 90% complete when the molds are left. Only then is the web passed through a continuous furnace. This not only serves to complete the curing, but at the same time an artificial aging is carried out here. This means that the stresses present in the sheet-like plate are reduced become .

Finally, the sheet-like, finished panels are cut to the desired size and the paper layers of the temporary laminate are removed.

The synthetic resin used is preferably UV light stabilized polyester resin.

In this way, glass fiber-reinforced synthetic resin sheets can now be produced for the first time, in which there is a bend of over 90 ° on the longitudinal edges, so that an overlap area is created. Here, however, the area of overlap is not understood to mean a direct superimposition, but rather only the part of the plate lying at a distance above one another, so that an overlap occurs in the projection. This also makes it possible to manufacture double-skin panels that fit into one another in a form-fitting and non-positive manner, thus resulting in a box profile, for example.

In contrast to the two-shell, glass fiber-reinforced synthetic resin plate according to the prior art, the synthetic resin plate according to the invention is designated by 20. This in turn consists of an upper shell 21 which is shaped over the entire width with a constant wave shape. The individual waves W have a sinusoidal shape here. Below the upper shell 21 there is a lower shell 22, also made of plastic, which extends in a central area and is distant from the upper shell 21. The middle region 23 is delimited on both sides by a fold 24, each fold running parallel to the longitudinal edges 25 and 26 of the upper shell 21. In this case, the lower shell 22 is spaced on one side at a distance from the longitudinal edge of the upper shell 21 and extends to the level of the upper shell and then follows its contour along at least a partial area of a shaft W. This creates a double-layered overlap area 27 In the area of the opposite longitudinal edge 26, the overhang 24 runs at least approximately flush with the longitudinal edge 26. From there, the lower shell 22 extends back over the entire length to the first-mentioned longitudinal edge 25 and thus forms a second overlap area 28. Also in this second overlap area 28 area follow the upper shell 21 and the lower shell 22 and thus run congruently. Likewise, the width of the overlap in the second overlap region corresponds to at least one partial wavelength. The difference between the two overlap regions is thus that on the one side the lower shell extends in the direction of extension of the upper shell in the direction of the longitudinal edge 25, while on the other side the lower shell 22 extends from the longitudinal edge 26, likewise following the upper shell, again extends back towards the center. The width of the two overlap regions 27 and 28 must at least be dimensioned such that there is a sufficiently wide contact area for the adhesive bonding of the two shells 21, 22. In addition to this positive connection, you also want to cause a positive connection, the overlap areas should extend over at least half a wavelength. This positive connection is particularly advantageous for manufacturing reasons.

In the perspective view according to FIG. 3, the synthetic resin plate 20 according to the invention is shown laid in a partially perspective view. The width B of the light opening to be covered corresponds to the central region 23 of the plate 20. The overlap region 27 overlaps part of the adjacent metal plate 1. On the opposite side, the second overlap region 28 is overlapped by the overlap strip 6 of the other metal plate 1. The upper shell 21 here has a trapezoidal wave shape. In addition, a metal strip 30 running parallel to the longitudinal edges is inserted between the upper shell 21 and the lower shell 22 in both overlap regions 27, 28. This is shown again in detail in FIG. 4. As can be seen, the adhesive connection 31 between the upper shell 21 and the lower shell 22 can be arranged only on one side along a wave flank or along both wave flanks with respect to the metal strip 30. In the middle area 23, in which the upper shell 21 and the lower shell 22 are spaced apart from one another, bar-shaped spacers 33 are arranged here. These are advantageously made of heat-insulating, foamed material. These are in FIG. 5 dotted. In the simplest case, these bar-shaped spacers can only fill the height between a wave valley and the base of the lower shell 22, as is indicated by the dashed line 34. Since it is now possible to cut relatively soft foamed plastics precisely using water jet cutting technology, the spacer 33 is preferably followed exactly the contour between the upper shell 21 and the lower shell 22. The distance between two adjacent bar-shaped spacers 33 is designed such that it corresponds to the specified distance between two adjacent purlins of a roof structure.

Instead of the metal strips 30 extending over the entire length of the double-shell plate, it is also possible to attach only metal plates 35, which should then be arranged exactly over a respective spacer 33. The metal strips 30, or the metal plates 35, are intended to prevent the glass fiber-reinforced shells 21, 22 from being torn out. Screws with a self-tapping thread are advantageously used for the connection.

Claims

PATENT CLAIMS

1. Process for the production of sheet-shaped glass fiber reinforced plastic plates with the following steps: a) plane spreading of a flexible carrier; b) application of a liquid synthetic resin to the flexible carrier; c) spreading a glass fiber roving over the liquid synthetic resin; d) allow the liquid synthetic resin to act on the glass fiber plate until it is completely soaked; e) applying an upper flexible cover layer to form a temporary layer material; f) continuous pulling of the temporary laminate through an inlet section on a lower mold and an upper mold; g) final shaping before completion of the gelling process; h) passing the finished molded, temporary laminate through a continuous furnace; i) Removal of the flexible carrier and the upper cover layer.

2. The method according to claim 1, characterized in that a paper web provided with a release agent is used as the flexible carrier.

3. The method according to claim 1, characterized in that a paper web provided with a release agent is used as the upper flexible covering layer.

4. The method according to claim 1, characterized in that the pull-through speed is such that the gelling process of the temporary laminate is not yet completely completed at the end of the inlet section.

5. The method according to claim 1, characterized in that the final shaping before the end of the gelation process is an additional bend which leads to a partial overlap of the web of the temporary laminate.

6. The method according to claim 1, characterized in that steps b) to d) and f) take place with supply of heat.

7. The method according to claim 1, characterized in that the synthetic resin of the temporary laminate is already 90% cured before being introduced into the continuous furnace, and that artificial aging is carried out in the continuous furnace.

8. Glass fiber reinforced plastic plate produced by the method according to at least one of claims 1-7, characterized in that the • longitudinal edges of the plate have at least one side with a longitudinal bend of at least 90 °.

9. Double-skin, glass fiber reinforced synthetic resin plate (20) according to claim 8, for connection with corrugated, insulated, double-skin metal plates on buildings, in particular on roofs, the upper shell (21) made of plastic over the entire width in identically Shaped wave direction is formed and the lower, also made of plastic shell (22) spaced from the upper shell (21) is connected to this, characterized in that the lower shell (22) on a longitudinal edge (25) across the width of at least one partial wavelength is overlapped flatly by the upper shell (21) and then extends distantly from the upper shell to the other longitudinal edge (26) of the plate and is bent up to the upper shell (21) there and over the width of at least one Partial wavelength flatly follows the upper shell in the direction of the first-mentioned longitudinal edge (25), with the two shells in the area their overlaps on both sides (27, 28) are connected.

10. Double-skin synthetic resin plate according to claim 9, characterized ge indicates that between the two shells (21,22) at regular intervals bar-shaped, over the entire Width of the plates, extending spacers (23) made of heat-insulating, foamed material are arranged.

11. Double-skin synthetic resin plate according to claim 9, characterized ge indicates that the overlaps (27,28) of the upper and lower shell (21,22) corresponds at least approximately to half a wavelength.

12. Double-skin synthetic resin sheet according to claim 9, characterized in that in the overlap areas (27, 28) of the two shells, a metal strip (30) is arranged between the two shells, which is parallel to the longitudinal edges (25 , 26) extend.

13. Double-skin synthetic resin plate according to claims 10 and 11, characterized in that in the overlapping areas (27, 28) of the two shells above the respective spacers (33) metal plates (35) are arranged.

14. Double-skin synthetic resin plate according to claim 10, characterized ge indicates that the spacer (33) is precisely adapted to the contours of the space between the upper and lower shell (21, 22).