DE19818406C1 - Making panels of corrugated sheet composite based on unwoven fiberglass substrate material - Google Patents

Abstract

The fibrous substrate is a flat material with little dimensional stability. Before shaping, it is combined with heated thermoplastic, and is then formed and cooled. Preferred features: Forming is effected during cooling. The substrate is a fibrous material, with thermoplastic binder. Glass fibers are employed as they are nonwoven. A duroplastic binder is used. The substrate is continuously saturated with the thermoplastic and comprises many layers assembled together. Before shaping, one is treated differently from the others; it is not impregnated. After applying the thermoplastic but before shaping, a covering layer of weatherproof sheet is added. Cooled corrugating rollers form the sheet. All thermoplastics used, contain a high proportion of preferably inorganic powder filler.

Description

The invention relates to a method for producing egg ner corrugated sheet, in which a carrier material in a ge corrugated shape and brought with a thermoplastic Material is provided.

Such corrugated sheets are often used to Dä industrial buildings, warehouses or sheds cover. In the past, this has been done many times also used materials containing asbestos, their asbe is classified as carcinogenic. For this Basically, the corrugated sheets mentioned at the beginning also become to cover such asbestos-containing corrugated sheets ver turns.

The production of such corrugated sheets is relative to agile. The carrier material consists of a thick Cardboard, several layers of cardboard or a box and will preformed. Here, the shape durability of the is used deten carrier material of a certain importance, because  with the shape of the carrier material in the following Apply the thermoplastic material, as a rule Bitumen is preserved. To apply the thermopla The blank material becomes the material placed in an autoclave and there under increased Pressure and under elevated temperature with the thermopla soaked material. This is autoclaving necessary to make the preformed blanks based on Zel lulose completely and intimately with the thermoplastic soak. This soaking in turn is necessary dig to the blank for its actual use to make it suitable, namely a building against one penetrate from rainwater to seal and around the Blank itself (essentially made of cellulose) before Infestation of bacteria and fungi, i.e. before rotting, to protect. The autoclave must then be cooled and be relieved of pressure before the finished corrugated sheets can be removed.

It is obvious that this approach is one means considerable effort. For one, there is only one batch operation possible. On the other hand, that is Heating the autoclave and generating the necessary required energy lost so that the Manufacturing process is relatively energy consuming.

US 3,530,212 describes a method of manufacturing of glass fiber reinforced synthetic resin laminates, in which Glass fibers in the form of rovings from coils from one Gates are subtracted. The rovings are made by tanks drawn in which they are impregnated with synthetic resin. The soaked rovings then go through an oven and a preform before being in a press be shaped. The rovings are being executed  example one-piece springs for motor vehicles poses.

DD 40 140 describes a method and an apparatus for the continuous production of cross-corrugated Bah NEN made of fiber-reinforced plastic, with a pre advice roll pulled a film sheet and be with resin is layered. A fiber mat is placed on the resin layer and then put a second film on top of it Put on the package. The composite thus formed is through passed a preform zone which combed through each other mende gears is formed. Then the resin cured in ovens and then cooled.

AT 257 147 shows a similar device. Here will a release film is covered with a fibrous web, which then is soaked with synthetic resin. Then the with Resin-soaked fiber web with another release film covered. With the help of a wreath of scrolls parallel to the direction of movement of the thus formed Rotates composite, a wavy shape is created. Of the corrugated composite is passed through an oven.

FR 1 142 218 shows a method and an apparatus for the continuous deformation of plastic profiles. Here is an essentially flat plastic sheet heated in an oven and between two waves tapes held between two rails are clamped. At the end of the oven, a ge corrugated plastic sheet removed and wound up who the.

The invention has for its object a method to simplify the manufacture of a corrugated sheet.  

This task is ge in a process of the beginning mentioned type solved in that as a carrier material Sheet material with low shape retention is used is that in the unshaped state with heated thermo plastic material, then molded and abge is cooled.  

With this configuration, there are several advantages. Firstly, a relatively inexpensive carrier material al be used because it depends on the shape durability or the form stability of the surface material itself is not arrives. Accordingly, the sheet material can can be delivered as rolls. This can be easily handled, what with a material that has a higher shape retention, naturally so simple is not possible because this material as required for unwinding, an elevated one Opposed resistance. The surface material can be in unshaped state, for example when spread condition, with the heated thermoplastic material material. Accordingly, a conti Nuclear production possible because the application of the thermoplastic material can be done continuously. Only the one with the thermoplastic material Material is molded. The shape durability of this too composite material then results from the Cooling down. This is the thermoplastic Material provided surface material, so to speak, in its "Frozen" shape. The shape durability results then through the interaction of the thermoplastic Ma terials with its carrier material. An essential one Advantage of the construction of a corrugated sheet according to the invention based on glass fiber webs is their recyclability. In the event of structural changes, these panels can and then crushed using known methods be melted again. When crushing the glass fibers shortened so much that they then powder shaped like filler in the bitumen or polymer matrix lie. Corrugated sheets made of cardboard-containing materials can no longer allow for a new production be performed.  

Molding is preferably carried out on cooling. If the two process steps combined, you get a relatively quick procedure with a correspondingly high output.

Preferably, a with a thermoplastic binder bound fiber material used. The thermoplastic binder hardens when Cooling off too, so that in connection with the thermoplastic material has a very good shape retention speed is achieved.

The fiber material preferably has glass fibers from Fa on. Glass fiber substrates are easy to handle bar. Give because of their inorganic fiber structure the corrugated sheet has high mechanical stability. They are non-flammable, so corrugated sheets that are a glass have fiber carrier material, relatively stable against Flying fire, radiant warmth and burning from the inside are. The glass fibers can also have higher temperatures exposed to temperatures so that the thermopla material with a relatively high temperature can apply. The freezing point, i.e. H. the tempera in which the corrugated sheet is lost when it cools down then may be at a higher temperature, so that the corrugated sheets thus produced have a higher one Have temperature resistance.

The fiber material is preferably not woven. It is therefore a fleece or a fleece-like Material in which the individual fibers have a more or have less random alignment. Such a measure material has an almost constant stability in all directions.  

The fiber material advantageously has a thermoset between binders. This binder ensures that the Flat cohesion of the carrier material even then is not lost if the carrier material with the hot thermoplastic material is provided.

Advantageously, the carrier material is continuously added soaked in the thermoplastic material. As above says, it can be used as a continuous production Realization process. This stops the energy wall small, because the thermopla is only necessary to keep static material at the elevated temperature. It is not necessary to heat up large batches and cool down. Because the substrate is soaked there is a very intimate connection between the carrier material and the thermoplastic material.

The carrier material is preferably composed of several layers composed. This increases the shape durability the later corrugated sheets. If the multiple layers are ge deformed together, then locally small Shifting of the layers among themselves. If the one individual layers of the carrier material with these different exercises are fixed to each other, for example when Cooling down, then a change of shape would have to be repeated Moving the individual layer will result in what not because of the connection of the layers is possible. You can also use multiple layers achieve a greater thickness of the carrier material and very simple and without large stocks depending on the loading may have the most varied thicknesses of corrugated sheets produce. In many cases, this is easier than if you have a carrier that is already sufficiently thick material used.  

At least one layer of the carrier material is advantageous than behave differently than another layer before molding delt. Due to the location-wise structure you get to additional freedom in the design of the well plate You can not only do different carrier mats rialien in the individual layers, but also through different treatment of individual layers provide certain properties.

For example, you can at least one layer before Do not soak shapes, so leave them untreated. This applies in particular to a layer of nonwoven, preferably two se with thermoplastic binder. In this case it is for example, not necessary, the soaked carrier strip of layers of material to remove excess thermo remove plastic material. The excess can rather used to be an intimate connection with the non-soaked layers.

Preferably after the application of the thermoplastic material and a top layer before molding brings. Such a top layer does not have to be the same withstand the high temperature necessary to do this thermoplastic material for coating or soaking halves of the individual layers of the carrier material This is another advantage over the Her position of the corrugated sheets in the autoclave. The top layer can be adapted for later use. For example, it can be used for coloring become. It can also be used for gluing to prevent stacked corrugated sheets.

The top layer is advantageously made of weatherproof film educated. The film will, if on the with the  thermoplastic material soaked layers applied is glued to these layers, so to speak. When after The following forms and cooling then result in a practically one-piece design, in which by weatherproof cover film a high stability against Um world influences. It also means a significant simplification of the invention Manufacturing process and improvement of waterproof speed compared to the known and described above Process using press blanks. Here namely after removal from the autoclave in egg corresponding color or Protective layers are applied. These become nasty usually applied in liquid form from solvent or sprayed on, which leads to further energy requirements for Drying and thus costs and also environmental pollution not to mention elaborate recovery processes were for solvent vapor and its environmental impact If the solvent is not water.

An embossing device is preferably used for shaping cooled embossing rollers used. The embossing rollers are here designed as toothed rollers, their teeth on Stand gap to each other. By the distance of the embossing the thickness of the corrugated sheet can be defined. You can achieve two effects by cooling the embossing rollers te. Firstly, the shape of the corrugated sheets is frozen Ren. On the other hand, adherence of the thermoplastic material on the embossing rollers prevented.

Bitumen is an advantageous thermoplastic material used. Investigations by the manufacturers of Dachdich lifts prove that even in the strongest sunshine radiation practically never temperatures above 80 ° C on egg roof. Up to this range  a suitable bitumen but dimensionally stable, d. H. the well plates retain their shape once formed.

If all thermoplastic materials are of high quality part of - preferably inorganic, powdery - Contain filler, there are reductions and better rigidity.

The invention is based on an Ausfüh Example in connection with the drawing described. Herein shows the

single figure is a schematic representation of a ver driving for the production of corrugated sheets.

A device 1 shown in the figure for the manufacture of corrugated sheets 2 has a trough 3 in which a thermoplastic material, for example bitumen or a polyolefin, is held at an elevated temperature of about 150 ° to 220 ° C.

In a storage section 4 , several roles 5-9 are arranged. Each roll provides a layer 10-14 of a fiber backing material, such as a non-woven glass or other non-woven material. The individual layers 10-14 can be of the same design. However, differently designed carrier materials can also be used. For example, some rolls may contain glass fiber servliese, while other rolls may contain textile fiber servliese. Instead of fleece, one or the other roll can be equipped with a fiber fabric or a film. In contrast to fabric, fleece has better diagonal strength. A combination of fleece and fabric also gives a very good cross stiffness. The individual layers 10 to 14 are bad form durable itself. Although they can easily be wound up or unwound to form a roll 5-9 , they do not retain a shape in the long run if the shaping forces, for example the winding forces, are eliminated.

In order nevertheless to be able to produce corrugated sheets 2 , the individual layers 10-14 are passed through the trough 3 , specifically in the expanded or unshaped state. There they are soaked with bitumen or another polyol fin or generally a thermoplastic material. The approximately 150 ° to 220 ° C layers are passed through squeezing devices 15 in which the bitumen is stripped so that the individual layers have their original thickness or thickness again. The individual layers 10-14 are then passed through a nip or nip 16 of a pair of rollers 7 and pressed or laminated there. Here he already cools down because there is no further heating. The layers 10-14 pressed together are then fed to one or more embossing devices 18 , each of which has two meshing toothed wheel rollers 19 , 20 . The gear rollers 15 , 20 are arranged such that one tooth of a gear roller enters a tooth space of the other gear roller ze. Both gear rollers 15 , 20 are held at a defined distance from one another, so that the layers 10-14 lying on top of one another and impregnated with bitumen then have a corrugated shape with a predetermined thickness. The gear rollers 19 , 20 are cooled, for example to a temperature of below 50 ° C, so that the bitumen-soaked glass fiber carrier materials are frozen so to speak. By leaving the embossing device 18 they have a temperature at which they can also be handled manually if necessary. At this temperature they keep their corrugated sheet shape. This shape is stable up to about 90 ° C, so that the corrugated sheet can also be used outdoors with intensive solar radiation. The still connected corrugated sheets can be cooled further, for example by a water spray device 21 , before they can be cut to the desired length of, for example, 1000 mm by a cutting device 22 . The width of the corrugated sheets 2 , for example 2000 mm, is predetermined by the width of the individual layers 10-14 or the rollers 5-9 .

In addition, a further roller 23 can be provided, which emits a layer 24 which is passed through a trough 25 . This tub 25 may contain a different bitumen or a different thermoplastic material. The layer 24 impregnated in this way is also brought together by the pair of rollers 17 with the first layers 10-14 .

Finally, it is also possible to arrange further layers 26-29 of a glass fiber carrier material between the individual layers 10-14, which layers are unwound for this purpose from further supply rolls 30-33 . The illustration is only schematic here. Of course, other management options are possible for the individual layers.

The individual layers 26-29 are not further treated, ie they are not impregnated with bitumen. In this embodiment, a squeeze device 15 is only necessary for the outer layers 10 and 14 , which are guided through the bitumen trough 3 . Bitumen can remain in excess for the other layers. This excess bitumen is then used to soak the non-soaked layers 26-29 and to create a stable bond between the individual layers 10-14 and 26-29 .

Finally, a further roll 34 can also be provided, which emits a weatherproof cover film 35 . The weatherproof cover film 35 then forms a surface of the corrugated sheets 2 . It can also serve to prevent the individual corrugated sheets 2 from sticking to one another when they are stacked.

The glass fiber backing materials that form the individual layers 10-14 have a thermoplastic binding agent. This thermoplastic binder together with the bitumen serves to maintain the desired shape when cooling. In addition, the glass fiber support materials can also contain a thermosetting binder so that they are not destroyed when passing through the tub 3 .

Due to the multiple layers 10-14 and 26-29 , it is possible to produce corrugated sheets 2 which have a thickness of 1.5 to 2 mm. Depending on the glass fiber carrier material used, these corrugated sheets have a high diagonal and / or cross stiffness. The Deckfo lie z. B. consist of polymer or metal. Since with the surface can be easily adapted to the optical or technical requirements. You can e.g. B. be formed as copper foil, monochrome or colored polymer foils, UV-absorbing or reflecting foils. Since the cover film 35 can be carried and installed in one operation, there are no additional work steps.

The corrugated sheets 2 are, so to speak, designed as completely glass-fiber-reinforced bitumen sheets when they are stripped off after passing through the tub 3 . This enables high mechanical stability. In addition, there is a relatively high inorganic proportion when using glass fibers, which makes the corrugated sheets resistant to flying flames, radiant heat and the penetration of fire from the inside.

In particular when using several layers 10 - 14 there is a high dimensional stability of the corrugated sheets. When the waves are generated, there is inevitably a slight displacement of the individual layers to one another. It is not possible to destroy the waveform without undoing this shift. Such a shifting back is not possible due to the "frozen" bitumen.

The process can run continuously. It is sufficient here to keep the trough 3 at the elevated temperature and to cool the embossing device 18 . Both can be accomplished with a relatively small amount of energy.

Claims (16)

1. A method for producing a corrugated sheet, in which a carrier material is brought into a corrugated shape and provided with a thermoplastic material, characterized in that a sheet material with low shape durability is used as the carrier material, the material in the unformed state with heated thermoplastic material provided, then molded and cooled. 2. The method according to claim 1, characterized in net that the molding takes place when cooling. 3. The method according to claim 1 or 2, characterized records that as a carrier material with a thermoplastic binder bound fiber material is used. 4. The method according to claim 3, characterized in net that the fiber material glass fibers as fibers having.   5. The method according to claim 3 or 4, characterized records that the fiber material is not woven. 6. The method of any one of claims 3 to 5, characterized characterized in that the fiber material has a duro has plastic binder. 7. The method according to any one of claims 1 to 6, there characterized in that the carrier material kon continuous with the thermoplastic material is soaked. 8. The method according to claim 1 to 7, characterized records that the carrier material from several La gene is composed. 9. The method according to claim 8, characterized in net that at least one layer of the carrier material before molding differently than another layer delt is. 10. The method according to claim 9, characterized in net that the at least one layer before molding is not soaked. 11. The method according to any one of claims 8 to 10, there characterized in that after the application of the thermoplastic material and before molding a top layer is applied. 12. The method according to claim 11, characterized in net that the top layer as a weatherproof film is formed.   13. The method according to any one of claims 1 to 12, there characterized in that an embossing for molding device with cooled embossing rollers used becomes. 14. The method according to any one of claims 1 to 13, there characterized in that as a thermoplastic Material bitumen is used. 15. The method according to any one of claims 1 to 14, there characterized in that as a thermoplastic Material polymer-modified bitumen, polyolefin containing compositions or PVC-containing compositions become. 16. The method according to any one of claims 1 to 15, there characterized in that all thermoplastic Materials a high proportion of - preferably inorganic powder - filler included ten.