WO1996031330B1 - Process and device for the manufacture of pultruded building elements - Google Patents
Process and device for the manufacture of pultruded building elementsInfo
- Publication number
- WO1996031330B1 WO1996031330B1 PCT/CA1996/000188 CA9600188W WO9631330B1 WO 1996031330 B1 WO1996031330 B1 WO 1996031330B1 CA 9600188 W CA9600188 W CA 9600188W WO 9631330 B1 WO9631330 B1 WO 9631330B1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- surface forming
- foam core
- forming members
- support section
- steel framework
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract 4
- 238000004519 manufacturing process Methods 0.000 title claims 10
- 239000000463 material Substances 0.000 claims abstract 7
- 238000001816 cooling Methods 0.000 claims abstract 3
- 238000010438 heat treatment Methods 0.000 claims abstract 3
- 239000011248 coating agent Substances 0.000 claims abstract 2
- 238000000576 coating method Methods 0.000 claims abstract 2
- 229910000831 Steel Inorganic materials 0.000 claims 29
- 239000010959 steel Substances 0.000 claims 29
- 239000011162 core material Substances 0.000 claims 28
- 239000006260 foam Substances 0.000 claims 27
- 238000011144 upstream manufacturing Methods 0.000 claims 11
- 229920001903 high density polyethylene Polymers 0.000 claims 9
- 239000004700 high-density polyethylene Substances 0.000 claims 9
- 238000009826 distribution Methods 0.000 claims 6
- 230000001276 controlling effect Effects 0.000 claims 5
- 230000035515 penetration Effects 0.000 claims 5
- 229910000746 Structural steel Inorganic materials 0.000 claims 2
- 229910052782 aluminium Inorganic materials 0.000 claims 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminum Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims 2
- 238000010276 construction Methods 0.000 claims 2
- 238000005520 cutting process Methods 0.000 claims 2
- 238000007599 discharging Methods 0.000 claims 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims 2
- 229910052710 silicon Inorganic materials 0.000 claims 2
- 239000010703 silicon Substances 0.000 claims 2
- 239000004809 Teflon Substances 0.000 claims 1
- 230000001154 acute Effects 0.000 claims 1
- 150000001875 compounds Chemical class 0.000 claims 1
- 238000007906 compression Methods 0.000 claims 1
- 230000000875 corresponding Effects 0.000 claims 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims 1
- 230000000750 progressive Effects 0.000 claims 1
- 230000000284 resting Effects 0.000 claims 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims 1
- 239000004566 building material Substances 0.000 abstract 3
- 238000003780 insertion Methods 0.000 abstract 1
- 239000000203 mixture Substances 0.000 abstract 1
- 229920000642 polymer Polymers 0.000 abstract 1
- 239000011800 void material Substances 0.000 abstract 1
Abstract
A pultrusion process involving the insertion of a soft polymer core into a pultrusion mandrel, see figure 1. As the core (5) progresses, it is encased with a cementitious material (C), which is pumped into the top of the mandrel, thus filling the void between the outer surfaces of the core and the inner surfaces of the mandrel. The building material sets slightly in the pultrusion form and is conveyed through a curing process, consisting of adjustable concrete slabs (20) with the provision for either heating, cooling and steam inducement, or a combination of all three curing features. Furthermore, by using pressure elements (21a, 22) which compress the concrete slabs (20) against the cementitious coating, excess moisture is expelled from the building material. The finished building material emerges as a continuous single panel, which is strong enough to stand unsupported. The panel is then cut into predetermined lengths, prior to shrink wrapping, palletization and storage.
Claims
1. A continuous foam core pultrusion process and apparatus for the manufacture of pultruded building elements comprising a production line incorporating supporting steel framework with locator blocks and angle iron sections, steel beam, a pultrusion mandrel and core opening, an inlet guiding channel, seal plate, an inner forming assembly, conveyor, distribution reservoir and continuous mixing apparatus, curing line, cutting assembly shrink wrapping and palletizing facility.
2. The apparatus of claim 1 wherein said pultrusion mandrel includes an upper support section housed within and in parallel alignment with adjacent and surrounding supporting steel framework, means aligning said supporting steel framework and means sustaining said upper support section therein.
3. The apparatus of claim 2 wherein said pultrusion mandrel further includes a middle support section housed within and in parallel alignment with adjacent and surrounding supporting steel framework, means aligning said supporting steel framework, wherein said middle support section is positioned directly below but in parallel alignment with said upper support section and said adjacent and surrounding supporting steel framework.
4. The apparatus of claim 2 wherein said middle support section further includes a frame member on the topmost portion thereof, fixedly positioned equidistant from the respective opposite sides of said middle support section and means sustaining said middle support section therein.
5. The apparatus of claim 4 wherein said middle support section further includes a frame member on the lowermost portion thereof, fixedly positioned equidistant from the respective opposite sides of said middle support section and means sustaining said middle support section therein.
6. The apparatus of claim 5 wherein said pultrusion mandrel further includes a lower support section housed within and in parallel alignment with adjacent and surrounding supporting steel framework, means aligning said supporting steel framework and means sustaining said lower support section therein, wherein said lower support section is positioned directly below but in parallel alignment with said middle section and said adjacent and surrounding supporting steel framework.
7. The apparatus of claim 2 wherein said means sustaining includes a plurality of high density polyethylene tie rods extending transversely between said upper support section and said adjacent steel framework.
8. The apparatus of claim 4 wherein said means sustaining includes a singular high density polyethylene tie rod extending between said frame member on topmost section of said middle support section and lowermost portion of said adjacent upper support section. 1 6
9. The apparatus of claim 5 wherein said means sustaining includes a singular high density polyethylene tie rod extending between said frame member on lowermost portion of said middle support section and uppermost portion of said adjacent lower support section.
10. The apparatus of claim 6 wherein said means sustaining includes a plurality of high density polyethylene tie rods extending transversely between said lower support section and said adjacent steel framework.
11. The apparatus of claim 2 wherein said means aligning said supporting steel framework includes locator blocks of aluminum construction wherein said locator blocks are positioned within the corners of said supporting steel framework.
12. The apparatus of claim 11 wherein said locator blocks include means leveling said locator blocks, whereby said locator blocks may be positioned level, square and in alignment with and against said supporting steel framework.
13. The apparatus of claim 12 wherein said means leveling includes projecting a beam of light onto said locator blocks from remote laser equipment to establish uniformity of said locator blocks within and against said supporting steel framework.
14. The apparatus of claim 1 wherein said steel beam includes a continuous strip of high density polyethylene material attached to the uppermost face thereof to act as a running surface and further includes means adjusting said steel beam.
15. The apparatus of claim 14 wherein said means adjusting said steel beam includes projecting a beam of light onto said steel beam from remote laser equipment to thereby establishing accuracy of vertical adjustment on said supporting steel framework.
16. The apparatus of claim 1 wherein said conveyor comprises an upper section foam core surface engaging member and corresponding lower section foam core surface engaging member in parallel alignment with said upper section.
17. The apparatus of claim 16 wherein said upper section foam core surface engaging member and said lower section foam core surface engaging member each includes an endless moving belt trained about a plurality of adjustably yet fixedly supported rubber rollers and means adjusting said rubber rollers thereof.
18. The apparatus of claim 17 wherein said endless moving belt in said upper section further includes a means conveying said endless moving belt.
19. The apparatus of claim 18 where said means conveying includes a roller chain positioned immediately above said endless moving belt, adjustably yet fixedly secured to said steel beam, wherein said roller chain travels on said continuous strip of high density polyethylene material.
20. The apparatus of claim 17 wherein said endless moving belt in said lower section further includes a means conveying said endless moving belt.
21. The apparatus of claim 20 where said means conveying includes a roller chain positioned immediately below said endless moving belt, adjustably yet fixedly secured to said steel beam, wherein said roller chain travels on said continuous strip of high density polyethylene material .
22. The apparatus of claim 19 wherein said roller chain further includes means driving engagement wherein said means driving engagement includes generally drive pulleys and shafts powered by electrically operated motors.
23. The apparatus of claim 21 wherein said roller chain further includes means driving engagement wherein said means driving engagement includes generally drive pulleys and shafts powered by electrically operated motors.
24. The apparatus of claim 17 whereby said rubber rollers include spring loaded rubber rollers with needle bearing centres wherein said spring loaded rubber rollers are included within the loop of said endless moving belt on the lower portion thereof
25. The apparatus of claim 17 wherein said endless moving belt includes means controlling speed of said endless moving belt, whereby rotational velocity of calibrated timing wheels on the shaft of said drive sections is digitally monitored.
26. The apparatus of claim 24 wherein said rubber rollers are pivotally mounted in two parallel arms on the respective opposite sides of the lowermost portion of a square steel tube, by a bolt extending transversely to simultaneously penetrate the top portion of said parallel arms and said sides of the lowermost portion of said square steel tube thus providing an axis upon which said parallel arms may pivot.
27. The apparatus of claim 17 wherein said means adjusting includes twin spring tensioning devices located between a supporting steel frame portion and said rubber rollers, adjustably yet fixedly supported by a shaft which extends transversely above said rubber rollers between said tensioning devices whereby each of said tensioning devices comprises a tensioning threaded rod and nut with coiled biasing spring, pivotally mounted on the uppermost face of a square steel beam.
28. The apparatus of claim 1 wherein said guiding channel is adjustably yet fixedly positioned at the entry point of said foam core to said production line whereby said foam core in the horizontal plane may be placed therein, between the respective upper section foam core engaging member and said lower section foam core engaging member. 1
29. The apparatus of claim 1 wherein said pultrusion mandrel includes on the top portion between the respective opposite sides, acute angular channel attachments, wherein said angular channel attachments face the general upstream direction of said production line.
30. The apparatus of claim 1 wherein said distribution reservoir is positioned adjacent to said pultrusion mandrel and includes means distribution, comprising progressive cavity pump sets, continuous mixing apparatus and distribution connections to said angular channel attachments on the top portion of said pultrusion mandrel on the respective opposite sides.
31. The apparatus of claim 30 where said means distribution further includes means discharging of said cementitious material into said angular channel attachments on the respective opposite sides of said top portion of said pultrusion mandrel.
32. The apparatus of claim 31 wherein said means discharging is continuous and in simultaneity with the continuous introduction of said foam core into said pultrusion mandrel, whereby said cementitious material is pumped therein between the inner face of said inner forming assembly and the outer face of said foam core on the respective opposed sides of said pultrusion mandrel as said foam core progresses.
33. The apparatus of claim 1 wherein said seal plate at the foam core opening of said pultrusion mandrel includes an interchangeable, prefabricated template of high density polyethylene manufacture wherein said seal plate is generally of smaller overall dimension than that of said foam core, wherein said seal plate is located downstream from said foam core opening yet upstream from said angular attachments.
34. The apparatus of claim 33 wherein said seal plate further includes a means of maintaining pressure within said inner forming assembly when said cementitious material entering said inner forming assembly is forced back upstream in opposition to the flow path of said foam core.
35. The apparatus of claim 1 wherein said inner forming assembly includes a plurality of opposed surface forming members on the respective opposite sides of said inner forming assembly in parallel alignment with the flow path of said foam core material, downstream of the said inlet guiding channel.
36. The apparatus of claim 35 wherein said surface forming members consist of concrete forming slabs generally of rectangular cross sectional shape, mounted in juxtaposition on the respective opposed sides of said inner forming assembly along the full length thereof, in parallel alignment with and perpendicular to the flow path of said foam core, whereby the downstream end of one surface forming member is in contiguous abutment with the upstream end of the subsequent surface forming member along the full length of said inner forming assembly on respective opposite sides thereof. 1 9
37. The apparatus of claim 36 wherein said surface forming members have a top portion with removable profile forming plate and means removing said profile forming plate, wherein said profile forming plate is adjustably yet fixedly suspended over the innermost face of said surface forming members in parallel alignment with the flow path of the adjacent said foam core, whereby said profile forming plate incorporates a coating of teflon covered aluminum sheet construction, extending over the full face area of said innermost face of said surface forming members on respective opposed sides of said foam core within said inner forming assembly.
38. The apparatus of claim 33 wherein said means removing includes a plurality of removable yet replaceable dowel portions which, when withdrawn, facilitate efficient removal of said profile forming plates from said top portion of said surface forming members.
39. The apparatus of claim 38 wherein said surface forming members incorporate a lowermost portion with fixedly supported profile formers on the innermost face of said surface forming members in parallel alignment with the flow path of adjacent said foam core, and further includes a means horizontally adjusting said surface forming members uniformly towards and away from said foam core.
40. The apparatus of claim 39 wherein said means horizontally adjusting includes connection of said lowermost portion of said surface forming members at the respective upstream and downstream ends, to "U" channels resting upon adjacent high density polyethylene runners, whereby said "U" channels are positioned at right angles to said steel beam and further includes means adjustably moving said opposed surface forming members uniformly towards and away from the flow path of said foam core.
41. The apparatus of claim 40 wherein means adjustably moving includes a plurality of at least first and second bracing arms on the outermost face of said surface forming members, whereby said first and second bracing arms are fixedly connected from the respective downstream end and upstream end of said surface forming member to the respective opposed sides of a centered screw drive shaft and hand wheel assembly which is in parallel alignment with said "TJ" channels, and generally fastened to said angle iron attached to said supporting steel framework, whereby operation of said hand wheel in a clockwise or anti - clockwise direction, engages said screw drive shaft and dictates respective lateral movement of said surface forming members on said runners, towards and away from the flow path of said foam core, and further includes engagement of a locking device to thus secure the position of said surface forming members.
42. The apparatus of claim 38 wherein said profile forming plates are removable and replaceable in simultaneity with continuous operation of said production line 20
43. The apparatus of claim 35 wherein said surface forming members incorporate lateral preformed concave channels on the innermost face of said surface forming members, extending laterally between the respective upstream end and downstream end of said surface forming members, wherein said channels may accommodate therein, silicon heating elements and means controlling said silicon heating elements.
44. The apparatus of claim 43 wherein said means controlling includes a dedicated independent thermostatic temperature control facility adjacent to each said surface forming members.
45. The apparatus of claim 35 wherein said surface forming members incorporate lateral preformed concave channels on the innermost face of said surface forming member^ wherein said channels may accommodate cooling elements and means controlling said cooling elements.
46. The apparatus of claim 45 wherein said means controlling includes a dedicated independent thermostatic temperature control facility adjacent to each said surface forming members.
47. The apparatus of claim 35 wherein said surface forming members incorporate a preformed circular penetration at a point which is equidistant from the respective diametrically opposed corners of the respective upstream end and downstream end of said surface forming members, wherein said penetration further includes connection means on the outermost face of said surface forming members.
48. The apparatus of claim 47 wherein said connection means includes a circular fitting which is adhesively and fixedly secured to said penetration by a grouting compound, wherein said circular fitting corresponds to the diameter of said circular penetration and which further protrudes from said circular penetration beyond the outermost face of said surface forming members, for further connection to remote steam generation equipment.
49. The apparatus of claim 47 wherein said connection means further includes a gear compression clamp which secures a braided hose line to said circular fitting in said surface forming member, wherein said braided hose line is supplied from a valved connection to steam distribution pipework supplied from remote steam generation equipment.
50. The apparatus of claim 43 wherein said surface forming members are positioned downstream from said inner forming assembly on the respective opposed sides of said production line along the full length thereof, in parallel alignment with and perpendicular to the flow path of said foam core, whereby the downstream end of one surface forming member is in contiguous abutment with the upstream end of the subsequent surface forming member thereby forming part of a curing line on the respective opposite sides thereof. 2 1
51 The apparatus of claim 45 wherein said surface forming members are positioned downstream from said inner forming assembly on the respective opposed sides of said production line along the full length thereof, in parallel alignment with and perpendicular to the flow path of said foam core, whereby the downstream end of one surface forming member is in contiguous abutment with the upstream end of the subsequent surface forming member thereby forming part of a curing line on the respective opposite sides thereof.
52. The apparatus of claim 49 wherein said surface forming members are positioned downstream from said inner forming assembly on the respective opposed sides of said production line along the full length thereof, in parallel alignment with and perpendicular to the flow path of said foam core, whereby the downstream end of one surface forming member is in contiguous abutment with the upstream end of the subsequent surface forming member thereby forming part of a curing line on the respective opposite sides thereof.
53. The apparatus of claim 1 wherein said cutting assembly generally comprises a water bathed, carbide tipped traveling "wet saw" assembly and means synchronizing speed of said assembly with speed of said conveyor.
54. The apparatus of claim 53 wherein said means synchronizing includes generally electronic control methods.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU51398/96A AU5139896A (en) | 1995-04-07 | 1996-04-04 | Process and device for the manufacture of pultruded building elements |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB9508194.9 | 1995-04-07 | ||
| GB9508194A GB2299536A (en) | 1995-04-07 | 1995-04-07 | Forming building products by continuously moulding about a travelling soft polymer core |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| WO1996031330A1 WO1996031330A1 (en) | 1996-10-10 |
| WO1996031330B1 true WO1996031330B1 (en) | 1996-11-14 |
Family
ID=10773351
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/CA1996/000188 WO1996031330A1 (en) | 1995-04-07 | 1996-04-04 | Process and device for the manufacture of pultruded building elements |
Country Status (3)
| Country | Link |
|---|---|
| AU (1) | AU5139896A (en) |
| GB (1) | GB2299536A (en) |
| WO (1) | WO1996031330A1 (en) |
Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AU5220398A (en) * | 1996-12-13 | 1998-07-03 | Lubo Krizik | Method of making foam/concrete building panels |
| US5951805A (en) * | 1997-10-02 | 1999-09-14 | Nonis; Vittorino | Method and apparatus for coating a decorative workpiece |
| AU9334598A (en) | 1997-10-02 | 1999-04-27 | Oscar Chiarotto | Method and apparatus for coating a decorative workpiece |
| US6206965B1 (en) | 1997-10-02 | 2001-03-27 | Angelo Rao | Apparatus for coating a decorative workpiece |
| CN109356294B (en) * | 2018-12-17 | 2023-09-05 | 吉林建筑大学 | Volcanic slag light wallboard connecting component |
Family Cites Families (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| BE787370A (en) * | 1971-08-10 | 1973-02-09 | Saint Gobain | PROCESS FOR THE MANUFACTURING OF PLATES, PANELS OR SHAPED PARTS, USABLE IN PARTICULAR AS CONSTRUCTION ELEMENTS |
| GB1338536A (en) * | 1972-05-30 | 1973-11-28 | Shell Int Research | Method of producing an article of thermosetting resin |
| US4681722A (en) * | 1985-10-07 | 1987-07-21 | Owens-Corning Fiberglas Corporation | Method of making a lineal structural member |
| JP2592103B2 (en) * | 1988-07-01 | 1997-03-19 | 松下電工株式会社 | Extrusion molding die for foamed lightweight cement board and extrusion molding method using the same |
| JPH0791129B2 (en) * | 1989-01-11 | 1995-10-04 | 積水化学工業株式会社 | Manufacturing method for lightweight building materials |
| US5127980A (en) * | 1991-04-18 | 1992-07-07 | Graphite Design And Detail, Incorporated | Apparatus for continuously forming composite material into a rigid structural member |
| EP0619775A1 (en) * | 1992-10-05 | 1994-10-19 | Owens-Corning Fiberglas Corporation | Method for making a lineal member |
-
1995
- 1995-04-07 GB GB9508194A patent/GB2299536A/en not_active Withdrawn
-
1996
- 1996-04-04 AU AU51398/96A patent/AU5139896A/en not_active Abandoned
- 1996-04-04 WO PCT/CA1996/000188 patent/WO1996031330A1/en active Application Filing
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