WO2019009756A1

WO2019009756A1 - Production line for manufacturing multi-layered thermal insulation roof tiles

Info

Publication number: WO2019009756A1
Application number: PCT/RU2017/000534
Authority: WO
Inventors: Анатолий Владимирович БЕСПЯТЫЙ; Кирилл Викторович ЕВСТЕГНЕЕВ
Original assignee: Общество с ограниченной ответственностью "Термочерепица"
Priority date: 2017-07-07
Filing date: 2017-07-17
Publication date: 2019-01-10
Also published as: RU2668901C1

Abstract

The invention relates to the building materials industry and can be used for manufacturing multi-layered roof tiles with thermal and acoustic insulation properties. A production line for manufacturing thermal insulation roof tiles comprises, arranged sequentially in the manufacturing direction and operationally interconnected, a crystallizer with a means for receiving ingredients of the starting material from containers thereof, intended for the mixing and crystallization of said ingredients followed by feeding the resulting mixture to an automatic feeder of a drier mounted above the feed hopper of an extruder with a flat-slot die equipped with heaters and temperature sensors, wherein an extruder screw is configured with heating zones up to 300°C and a threaded shaft intended to increase screw pressure and to create a melt backflow thus homogenising the mixture; a three-roll calender producing an infinitely long flat sheet from the flat sheet formed by the flat-slot die; a take-off assembly; a sheet reheating station; a sheet vacuum blow moulding device which places the sheet in moulds and shapes it into roof tiles; a foam moulding machine with a mixing die and a table for filling moulds with a polyurethane foam; a conveyer comprising two belts, a lower carrying and pulling belt and an upper pressure belt which holds down a protective polyethylene terephthalate film or a metallized polyethylene terephthalate film or a polyvinyl chloride film, the film being automatically pulled from the roll; a cutting press installed downstream from the conveyor, which severs and separates the mould along with an article moulded therein, which is filled with the cured foamed polyurethane from the sheet, wherein a knife is embedded into the mould and moves with it; and a conveyor for returning the moulds. The invention makes it possible to enhance the thermal insulation and acoustic insulation properties of the roofing, to reduce the article weight, to impart reflecting properties to the roof tiles, to increase productivity due to the continuous process, and to improve product manufacturing precision.

Description

TECHNOLOGICAL PRODUCTION LINE

MULTI-LAYERED PIECE ROOF THERMAL CELLULAR TERMINAL

The technical field to which the invention relates.

The invention relates to the construction materials industry and can be used for the production of multi-layer roofing heat and sound insulation of shingles.

The level of technology

Known production line for the production of polymeric roof tiles (see [1] RF patent N ° 2483873, IPC V29S51 / 00, publ. 10.06.2013), containing placed sequentially in the course of the process and technologically interconnected mixer with a receiving device from bunkers components of the raw materials for mixing these components and filling the receiving hopper with a mixed bulk mixture, an automatic loader for feeding the mixed bulk mixture into a receiving bin of an extrusion machine made with six heating zones up to 300X and with the possibility of implementing the function of heating the granular mixture and issuing the molten mass under pressure to a slit head with heating zones in the slots for forming the formation of the molten mixture and directing it to a three-roll calender with heated rollers to calibrate this layer, the first pulling device to direct the calibrated layer on the table additional heating, molding machine to give the layer a form of tile, receiving table for cooling tiles, the second pulling device for sending cooled tile to the knife for trimming the finished tile with its subsequent receipt on the receiving table of the finished product. Roof tile is designed for roofing of pitched roofs with a slope of at least 15 ° in residential and industrial facilities operated in all climatic regions, as well as in conditions of increased chemical aggression.

The disadvantages of the above analogue, taken as a prototype, are the impossibility of producing a piece coating, the impossibility of producing multi-layer foam-filled tiles, a large weight of the product, the absence of reflective properties and low heat and sound insulating properties.

Summary of Invention

The objective of the claimed invention is the creation of a technological line for the production of multilayer foam-filled roofing material with improved performance characteristics. The technical result is to increase the insulating and sound insulation properties of the roofing, reducing the weight of the product, giving the tile reflective properties, increasing productivity due to the continuity of the process, improving the accuracy of manufacturing the product.

The task is solved, and the technical result is achieved due to the technological line for the production of piece roofing tiles that include successively arranged along the technological process and technologically interconnected mold with a device for receiving these components from the containers of the raw material for mixing and crystallization and the resulting mixture in the automatic loader of the dryer installed above the extruder throat with a slot die head with heaters and temperature sensors, the extruder screw being made with heating zones up to 300 ° C and a screwed shaft to increase the pressure in the screw and create a reverse melt flow to homogenize the mixture; a three-roll calender that receives a flat web formed by a flat-slot extrusion die and an issuing sheet of infinite length; broaching mechanism; sheet heating device; a vacuum forming-blowing device for a sheet that lays the sheet in shape and gives it the shape of a tile; foam filler with mixing head and table for pouring polyurethane foam into molds; a conveyor belt consisting of two belts, a lower carrier and a pulling belt, and an upper clamping belt providing a pressure film of polyethylene terephthalate or metallized polyethylene terephthalate or polyvinyl chloride protective film, automatically drawn from the roll; after the conveyor, a cutting press is installed, which cuts off and separates the mold with the product molded into it, filled with polymerized polyurethane foam from the sheet, with the knife embedded in the mold and moving with it; mold return conveyor.

Brief Description of the Drawings

Figure 1 shows the block diagram of the technological line for the production of multi-layered shingles.

The figures indicate the following positions:

1a - capacity with dyes; 16 - capacity with UV stabilizers; 1c - tank with fire retardants; 1g - capacity with polymer granules; 2 - crystallizer; 3 - dryer; 4 - extruder; 5 - flat head; 6 - three-roll calender; 7 - sheet heating device; 8 - zone of vacuum forming-blowing sheet; 9 - polyurethane foam (PUF) mixing head; 10 - table pouring PPU; 11 - PPU preparation machine (foam filling machine); 12 - return conveyor forms; 13 - lower conveyor belt; 14 - upper conveyor belt; 15 - cutting press; 16 - filling forming cutting forms (form); 17 - a roll of metallized polyethylene terephthalate (PET) cloth; 18 - the lingering mechanism.

The implementation of the invention

The technological line can be divided into several sections:

· Preparation of raw materials (containers with raw materials (1a, 16, 1b, 1g), mold (2)).

• Preparation of the working mixture (dryer (3)).

• Formation of flat web (extruder (4), flat-die die (5)).

• Preparation of the workpiece (three-roll calender (6), drawl mechanism (18)).

• Molding of the product (device for heating the web (7), vacuum forming and blowing sheet (8)).

• Filling two-component polyurethane foam (PPU mixing head (9), filling foam table (10), foam filling machine (11)).

· Polymerization of polyurethane foam in a closed form (16) (lower and upper conveyor belt (respectively 13 and 14), roll (17) of metallized PET cloth).

• Cutting of the finished product (die-cutting press (15), die-casting die-cutting forms (16), form return conveyor (12)).

All sections of the process line are placed sequentially along the process and are technologically interconnected.

For the preparation of raw materials, a dosing, crystallization and mixing system is used, which includes a mold (2) with a device for receiving bulk components from raw materials from containers (1а, 16, 1 в, 1 g) for receiving and storing bulk materials. From the containers (1a, 16, 1b, 1g), such components as dyes, UV stabilizers, flame retardants, polymer granules are continuously fed into the crystallizer (2), where they are mixed and crystallized. Polyethylene terephthalate (PET) or polyvinyl chloride (PVC) can be used as a polymer. The entire dosing, crystallization and mixing process is fully automated and continuous.

To prepare the working mixture, a dryer (3) is used, which, using an automatic loader, obtains mixed components of dyes, UV stabilizers, flame retardants and polymer granules. The dryer (3), installed above the mouth of the extruder (4), dries the mixed components and supplies the working mixture to the extruder (4).

For the formation of a flat web and the preparation of a workpiece (sheet), an extruder (4) with a flat-die extrusion head (5), a three-roll calender (6) and a reheating device for the web (7) are used. The extruder (4) contains a screw, made with heating zones up to 300 ° C to obtain a melt, the screw-screw shaft of different pitch and depth increases the pressure in the screw and creates a reverse melt current to maximize the homogenization of the mixture of flame retardants, UV stabilizers, dyes in the polymer melt (working mixture). At the outlet of the screw, a melt pump is installed, which increases the pressure and uniformly distributes the working mixture (a mixture of dyes, UV stabilizers, flame retardants homogenized in the polymer melt) into the flat-die extrusion head channels (5) with heaters and temperature sensors, with the possibility of automatic temperature control areas of the flat die head (5), which allows you to control the flow of material by changing its temperature and, as a consequence, the viscosity, thereby leveling the thickness of the material over the entire width ploskoschelevoy extrusion head (5). A flat die extrusion head (5) with heaters and automatic maintenance of a given temperature forms a flat web that is fed to a three-roll calender (6) with heated / cooled rolls (a thermostat is turned on in the line to maintain the set temperature on the rolls by supplying or discharging hot or cold water ). An adjustable gap between the middle and lower rolls of the calender (6) allows you to adjust the thickness of the sheet (workpiece), and the shagreen that is applied to the lower roll makes the sheet surface matte, while the other side is glossy due to the polished surface of the middle roll.

Thus obtained sheet of infinite length, bending around the upper roll of the calender (6), by the lingering mechanism (18) (this mechanism, pulling the sheet, creates sufficient fit for heat transfer between the sheet and the rollers), is fed into the zone of vacuum forming-blowing the sheet, in which : zone warming up the sheet to a state of softening; forming zone; zone filling form two-component polyurethane foam (PUF).

The zone of heating the sheet to the softening state includes a device for heating the sheet (7), which receives it from the broaching mechanism (18).

In the molding zone (8), forms (16) are fed into which the sheets are laid and the shape of the tile, which has been previously softened in the device (7), is given. The shape of the tile is given in the vacuum forming-blowing device of the sheet by simultaneously acting on the sheet with increased pressure on the one hand and vacuum on the other, and the vacuum simultaneously removes the remaining air from the mold cavities, which allows to obtain a product with a uniform thickness and precise geometry .

Forms (16) are made concave (the material is drawn in / blown into the form, and does not fit them outside), which increases the geometric accuracy of the product regardless of the thickness of the web - the external dimensions of the product always correspond exactly to the size of the form. Forms (16) are made collapsible, consisting of several parts, two of which are responsible for shaping, and the third part is made of a carbide material and is a cutting knife fixed on the surface of the form, which solves the problem of precise cutting (cutting of the cutting knife exactly to the place of cutting) is located (initially fixed) in the place of the future cutting of the formed product from the sheet. During molding, the mold (16) is compressed by a pneumatic / hydraulic drive and cannot open due to air pressure.

After the molding process is followed by a step of casting a mold with two-component polyurethane foam. The form (16) together with the formed sheet inside it moves to the table for filling the PUF (10) (at this stage the form lies freely on the table, and the formed canvas inside the form keeps the form from disassembling). Two-component polyurethane foam is preliminarily prepared in a PU foam preparation machine (11) (it can also be called a foam filling machine) and poured into a mold (16) through a mixing head (9). Preparation of PU foam consists in preheating and stirring to optimum temperatures and having achieved homogeneity.

The tile filling zone (namely, the table (10)) with two-component polyurethane foam immediately follows the molding zone (8), the material inside the mold remains heated, which improves the spreading of polyurethane foam over the surface of the molded inside shape of the product and allows you to achieve maximum foaming of the two-component polyurethane foam and the best spreading polyurethane foam on the inner surface of the product, increasing the foaming area, thereby preventing the formation of bubbles voids.

Further, the form with molded tiles, filled with polyurethane foam, enters the conveyor consisting of two belts, the lower (13) (carrying and pulling) tape and the upper (14) clamping tape, which provides pressure on the protective film of PET or metallized PET or PVC, automatically drawn from the roll ( 17) and protecting the tape of the upper pressure conveyor from contact with two-component polyurethane foam. At the same time, the PET film or the metallized PET or PVC is opposite, relative to the formed sheet, surface. The length of the conveyor is designed in such a way that the form with the product filled with polyurethane foam is sandwiched between two belts during the entire time of polymerization of two-component polyurethane foam. The conveyor moves discretely, synchronously with the cycles of the molding zone. After passing through the entire length of the conveyor, the mold with a product molded from polymer, filled with polymerized two-component polyurethane foam, gets onto the worktable of a punching machine (15) installed perpendicular to the line of movement of the molds along the conveyor. The width of the working table of the press is twice the width of the form, which ensures the impact of the impact plate of nylon rigid plates, regardless of precision feed conveyor forms on the desktop. The cyclical nature of the press work is related to the molding work cycle. A knife located on the surface of the mold and moving with the mold when in contact with a shock plate of rigid nylon materials chops off / separates the mold with the product molded in it filled with polymerized polyurethane foam from the sheet. The sheet remains after cutting the product are wound on the coiling device and then go to the crusher for further preparation for reuse. And the form with the product inside comes to the opening section of the upper part of the form, where the form is opened and the finished product is taken out of it. Next, the mold closes and returns the molding line through the mold return pipeline (12). Using a sufficient number of forms allows you to make the process continuous.

The technological line can operate in fully automatic, semi-automatic or manual mode. Automation of the line is achieved by controlling the technological process with the help of sensors and mode control due to the information received from them. The line may include sensors for monitoring / measuring the thickness of the web, temperature, web integrity, and so on. Information from the sensors goes to the control panel or processor to change / regulate the modes of operation if necessary.

The use of metallized PET improves the reflective properties of the tile. Increased productivity is achieved due to the continuity of the process of manufacturing / molding tiles and by synchronizing all processes, while improving the accuracy of manufacturing the product is achieved through the use of interchangeable moving forms with a cutting knife placed on them. Improving the thermal insulation and sound insulation properties of roofing is achieved through the use of thermal insulating fillers (two-component polyurethane foam). Improving the accuracy of manufacture of the product is achieved through the use of concave collapsible forms, as well as through the use of molding and polymerization of two-component polyurethane foam in the same form. Thermal insulation and sound insulation properties are achieved through the use of a multi-layered tile and a polymer layer on all sides of the product. Due to the use of the form, the absolute elongation / expansion decreases with a change in the operating temperature in comparison with sheet materials.

Claims

CLAIM

1. Technological line for the production of roofing shingles, includes placed sequentially in the course of the technological process and technologically related to each other:

· A mold with a device for receiving raw materials from the tanks for mixing and crystallizing these components and directing the mixture into an automatic dryer loader installed above the extruder throat with a flat-die extrusion head with heaters and temperature sensors, the extruder screw being made up to 300 ° C heating zones and screwed shaft to increase the pressure in the screw and create a reverse melt flow to homogenize the mixture,

• a three-roll calender that receives a flat web formed by a flat-slot die head and an issuing sheet of infinite length,

• lingering mechanism

· Device for heating the sheet,

• a device for vacuum molding-blowing a sheet, laying the sheet in shape and giving it the shape of a tile,

• foam filler with mixing head and table for pouring polyurethane foam into molds,

· A conveyor consisting of two belts, a lower carrier and a pulling belt, and an upper clamping belt, which presses the protective film of polyethylene terephthalate or metallized polyethylene terephthalate or polyvinyl chloride, automatically drawn from the roll,

• after the conveyor, a cutting press is installed, which cuts off and separates the mold with the product molded into it, filled with polymerized polyurethane foam from the sheet, with the knife embedded in the mold and moving with it,

• return conveyor forms.