DE2657010A1 - METHOD AND DEVICE FOR MANUFACTURING ELEMENTS WITH TWO PROFILED SURFACES - Google Patents

Description

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Frankenforster S: .o! J3 137 5060 Bensbarg-ReiValJi

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December 14, 1976 Hg./kr

EUEOG DEVELOPMENT AB Malmö, Sweden

"Method and device for the production of elements with two profiled surfaces"

The invention relates to a method for producing an element, that has two profiled surfaces. In the production of building wall parts, it is known to use a fiber-reinforced setting material, such as a cement-water mixture that Contains glass fibers to be sprayed onto a mold surface. The molding surface can be flat, curved or double curved and so on. Usually the side of the injected gets

70982B / 0926

Product that lies against the mold surface has a sufficient or good surface quality, provided that the surface of the Shape and the product has appropriate separating or lifting properties. To obtain a highly homogeneous product, however, it is appropriate to subsequently spray the applied material in one way or the other treat. For this purpose, various steps can be taken during the spraying process or immediately afterwards. For example Air bubbles in the sprayed material can be removed by applying a partial vacuum to the material by pressing the Material or by compacting the material already applied to the mold by a roller. When applying However, such techniques usually do not allow a good surface finish on the surfaces of the material that faces the nozzle of the spray device. Immediately after the spraying process, this surface is uneven and wavy. When the material is pressed, it is not possible for the air to be trapped in the irregularities of the surface can escape. Rather, it will remain in the material and form pores. It is true that the material is applied by means of a roller can be compacted and setting material optionally simultaneously with the spraying on a flat form or on a those that are only profiled on one side are shaken. If the latter technique is used, however, the properties of the setting material be such that the material

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does not adhere to the roller and is lifted off by it.

Each of a known technique can spray the setting material with a steel plate using simple process steps be pressed, jogged and smoothed. It is possible to get a good surface finish this way, though the reproducibility with regard to the strength of the sprayed, pressed and cured product is low or for certain Applications is completely unacceptable.

It is also known to obtain a flat and uniform surface by one or more cutting edges above a conveyor belt are arranged on the molds, which are filled with the setting material by spraying, with uniform Speed can be moved forward. This process is easy to perform and is useful for making certain types building wall panels is satisfactory but has unacceptable disadvantages for other types of building wall panels where the main surfaces of the building wall part must have a particularly good surface quality and where the strength within must be more precise limits. In the production of building wall parts, the surfaces with double profiling or other complicated surface structure can desired surface quality of the building wall part cannot be achieved by the aforementioned technology.

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Although building wall parts made according to the "known spraying techniques of the type described are made, the strength of which Does not have the precision required for certain applications, can be used in some other areas, these building wall parts have a large number of disadvantages, which are of different severity. The product obtained must be relatively thick and heavy. It must be sized according to the worst result of a production series. It is expensive to manufacture this way. This is particularly important when the sprayed material is itself or a the additive contained therein is expensive. Other disadvantages include those from a purely functional standpoint or from a purely purely functional standpoint aesthetic kind.

In the case of a sprayed setting material that contains glass fibers, the contact is between the material and the fibers often insufficient, especially when the material contains a large amount of fibers and the setting material contains a relatively large amount has high viscosity. This problem can be solved to a certain extent, for example by using an aluminum roller with which the glass fibers are rolled and pressed into closer contact with the setting material. However, it is not possible with this method to obtain a high grade product of uniform strength and with a smooth one Surface and a good surface quality.

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It has now been recognized as possible to eliminate these disadvantages of products by using hardening material, which is optional Additives can be obtained at the same time on two mutually adjacent, preferably horizontally cooperating mold halves to be sprayed on in the usual way, which have surface profiles that correspond to the two desired main surface shapes of the Product. After spraying the material into the mold, optionally while vibrating the mold halves the mold halves are pressed together with the sprayed material in between until the distance between the two mold halves is equal to desired strength of the product. The material pressed in this way then becomes what is required for setting or hardening Allowed time and then separated the mold halves from one another in order to be able to remove the pressed and cured product.

The invention relates to a method for the production of objects, which have two profiled surfaces, made of setting material, in which a small amount of this material is on applied a mold half having a surface that corresponds to one of the profiled surfaces of the article, and is left in the mold half to set.

This method is improved according to the invention to eliminate the disadvantages of the known methods in that also on one mold half, which has a surface that of the second

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corresponding to the profiled surface of the object, a small amount of this setting material is applied and then, As long as the material in the mold halves is still malleable, they can be joined together to form a form in which the quantities of malleable Material are pressed against each other to form the desired article, which is then removed from the mold.

This process according to the invention makes it possible to produce a product to produce inter alia, precise strength, good surface quality, a high degree of homogeneity and high density with successive use of pressing, setting and removal from the mold.

TJm to prevent air pockets or air pores from being at the interface or interface between the in the two Form halves introduced amounts of material when the mold halves are pressed against each other, the mold halves are before and after the start of the pressing process including one moved against each other at a certain angle. In this way, it is possible to prevent air in the Material included and the formation of pores in the pressed and set product is included.

According to a further feature of the invention, at least one of the mold halves is flexible and is curved, for example in

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a parabolic shape "before the two mold halves against each other be moved. After the start of the pressing process, the mold halves are progressively flattened and are optionally after completion of the pressing process completely flat. When a shape is malleable or pliable and bent in that way a high degree of precision must be expected from the press platen which is pressed against the curved shape by the press is printed. The press plate cooperates with the flexible mold as the mold itself. During the pressing process, one of the Mold halves, both of which lie essentially horizontally on a support surface after the spraying process, by a gripping device or the like rotated by 180 ° and moved against the other mold half, so that the quantities of sprayed material, contained in the two mold halves touch each other in a completely overlapping manner. It is assumed that the material introduced is of a high viscosity and that the adhesion between the surface the rotated mold half and the applied material is good, so that the contours of the material of the rotated mold halves will not be deformed, or the material will drip or fall off the mold surface of the mold halves.

If it is likely that the contours will be deformed or that the material will not adhere adequately to the mold surface, each of the two mold halves is rotated by 90 ° by two gripping devices and returned to their rest position.

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moved towards each other, with setting material being sprayed between the mold halves is applied.

A short time after the pressing process has been completed the package containing the two mold halves and the pressed material can be removed from the press and allowed to cure rotated to a horizontal position.

It has been found particularly advantageous in the process according to the invention to have several layers of different setting or to apply hardening material mixtures to each of the two mold halves and the laminated material composition pressed between the mold halves in a single step. In this way it is possible to get relatively complicated laminated products / su obtained that are well combined into a whole and are symmetrical and have good structural properties.

In addition, non-sprayable material, such as liquid adhesive, Plastic binder compositions and rigid, preferably porous Building boards, between the layers applied by spraying before the start of the pressing process or in connection be placed at the beginning of the pressing process, in this latter case the mold halves at a certain angle should be moved towards each other.

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The "layered compositions of matter can be of numerous Way can be varied. First, for example, a thin layer can be sprayed on that contains an active ingredient, which gives the layer favorable release properties from the mold, which preferably makes a special binder unnecessary. Thereafter A setting or hardening material, such as a setting material, dies A mixture containing cement or gypsum or a hardening plastic, the mixture if it is a cement mixture, a strengthening additive, such as short glass fibers can have, sprayed on in a thicker layer. This can optionally be repeated when using two or more similar sprayable and curable material mixtures will.

The layers adjacent to the surfaces of the mold, but not forming the outermost surface layer, should be very amplified. The great structural stress occurs in the vicinity of the surface of a building wall part. For reasons of economy, fibers can be used in the strength and / or sound and / or heat insulation serving middle layers are omitted, or the amount of fibers that are incorporated into such layers, can be significantly less than the amount of fibers introduced into the layers adjacent to the molding surfaces will.

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If an additional, non-sprayable material, such as a porous plate or plastic composite, is in between If the layers are applied which have been applied by spraying, the material itself is normally called Sufficient bonding system for the additional material will serve as the material that was applied by spraying before is still damp during the pressing process and has not set or hardened is. Furthermore, the contact between the additional material and the applied material is a result of the pressing pressure good, which is exercised on it during the pressing process. In the case of different material combinations, it can It may be advantageous to use a special adhesive, even if additional, non-sprayable material is used will, should be the case. Me adhesives can be used between the applied layers of material on the surface the mold half can be poured or sprayed against it before the pressing process.

The inventive method can also be used advantageously for the production of construction panels, the composite Have profiling by using shapes that have surfaces with multiple profiling, in particular, when the panels have to be manufactured with exact thickness and good surface quality. As an example is shown below describes the way in which a cement roof

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Bricks of the so-called "overlap" (overtile) type with glass fibers can be made reinforced according to the invention. Such a roof tile should not only have a good surface finish have on both sides, but the curvature, so the profile of the roof tile and its thickness must be more precise within There are limits.

A first mold half, which is made of sheet steel and has a thickness of 1.5 mm, and a second mold half, which is made of Vacuum-drawn synthetic resin is made and has a thickness of about 1 mm, are placed on a conveyor belt that is attached to a Number of spray devices passes by at a speed of about 0.1 m per second. Each of the forms has a Form profile that corresponds to the desired profile of the top and bottom of the roof tile. A thin layer of a substance both molds were sprayed to retard the setting of a cement mix.

A mixture of setting cement, which contains glass fibers, was applied to the mold halves to a thickness of about 2 mm Using a spray nozzle that is sprayed perpendicular to the conveyor belt at a speed of about 1 m / sec. reversed. The spray pattern was roughly elliptical and had the same direction as the conveyor belt to minimize loss at the corners of the mold that extended parallel to the conveyor belt. Every point on the mold surface was

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about 6 χ covered by the spray pattern and the required thickness the layer was controlled by controlling the amount of material sprayed per unit time. A cement mix, which contained a much smaller amount of glass fibers than the aforementioned cement mixture was in a strength of about 1.5 mm sprayed onto the first layer in "both mold halves from a spray device which was arranged downstream of the first-mentioned spray device.

After completion of the spraying process, the molds were brought to a station on the conveyor belt, which was equipped with mechanical equipment was provided, which, by means of gripping devices, lifted the mold halves 90 ° against each other and pressed the mold halves against each other, with the sprayed-on layers in between, bi, s the distance between the mold halves equal to the desired thickness of the roof tile of about 7 mm was reached.

The gripping device that held the second mold half, i.e. the Mold half, which consists of vacuum-drawn plastic, is set up so that this mold half is formed from sheet steel Half was moved to form a small angle between the two mold surfaces of the mold halves prevent the formation of air pockets and pores in the roof tile. When the lower edges of the mold halves touched and the pressing process began, a thin one became relatively more viscous Cement glue in a small amount between the sprayed

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Layers poured until "both layers touched."

The final press position was maintained for 5 seconds. After that it was the pressure was released and the two mold halves with the pressed, laminar material composition were in shape of a package and placed in a horizontal position on other packages received in the same way. After the setting and curing time of about 24 hours, the roof tile was removed from the two mold halves. The thin layer of the Delay agent between two mold surfaces and the outer surface of the cement product facilitated the detachment of the cement product from the mold halves and thus guaranteed that the high surface quality was not impaired when the product was released from the mold halves.

A statistical monitoring of the thickness of 20 corrugated cement roof tiles, which were reinforced with glass fibers and were produced in the manner described above, showed an average Roof tile thickness of 7.0 + 0.5 mm and a mean deviation for each individual tile of 0.11 mm. The number of roof tiles, which were prepared by spray drying in the usual manner with the same thickness gave an average thickness of 2.2 + 0.8 mm and a mean maximum deviation for each single brick of 1.2 mm.

The flexural strength of test rods sawn from roof tiles

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manufactured according to the invention was found to be greater than that yielded test bars produced by Bricks were taken that were made in the usual way:

32.1 + 1.0 MPa or 26.7 + 2.2 ICPa

The surface quality on the top and bottom of the bricks made by spraying and pressing according to the invention, was significantly above the surface quality of the sides of bricks made according to conventional methods, but not were pressed.

The bricks made according to the invention also have a better aesthetic appearance than bricks that made in the usual way, moreover, withstand much better cheers and surrender, as a result of the large ones Surface quality on the top and bottom of the brick a good seal in the overlapping zones of the brick, though these are applied to the roof.

A high degree of precision of the dimensions of the roof tile according to the invention is a prerequisite for its realization an improved sealing of the roof.

The invention is explained in more detail below with reference to the drawing. In this show:

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Pig. 1 is a perspective view of two forms ~

halves for making bricks from glass fiber reinforced Concrete, the form being composed of positive and negative halves;

2 shows the mold halves after a preliminary layer has been applied;

Pig 3 the same mold halves after applying a mixture of fiber and cement;

Pig. 4 the positive and negative half of the pom the joining;

Pig. 5 the finished brick after removal from the mold and

Figure 6 shows a number of bricks stacked on top of one another for curing.

The production of bricks from reinforced concrete includes the process step in which two Pormhälften 1 and 2 on one Conveyor belt are placed. The left of the two halves of the shape is a positive molding and the right one is a negative shape.

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part. Both mold surfaces are wavy. As can be seen from the right half of FIG. 1, the "two mold halves each covered with a vacuum-drawn, likewise corrugated film 3 made of thermoplastic plastic "to serve as protection and to prevent the water in the brick from evaporating as it is removed from the mold after it has hardened. After this Applying the plastic film, the mold halves are moved by the conveyor belt to a station (Fig. 2) in which a Yorschicht 4 is applied to the surface of the thermoplastic film. A watery one is used for this gate layer Mixture of sand and Portland cement used, which can also contain the desired color pigments and additives. the Precoat is applied by spraying a thin layer of the aqueous mixture in a gaseous form Medium floats that emerges from a spray nozzle, which is arranged above the conveyor belt.

The composition of the mixture for the Yor layer is the following:

Portland cement 1 part
Sand 0.50 parts

Water 0.35 parts

The term "part" means "parts by weight".

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The mold halves, which are provided with a pre-layer, then move to a station (Fig. 3), in which a layer 5 a Starting mixture for the reinforcement compound of the brick is applied. The composition of this mixture is as follows:

Portland cement 1 part

Sand 0.50 parts

Water 0.35 parts

Fibers 0.1 part

The fiber material used is alkali-resistant glass fibers in the form of strands with a diameter of 12 μm, each Strand contains 200 fibers. This fiber material has been cut into short fiber parts, each with a length between 25 and 50 mm. The reinforcing mass has been produced by a stream of a gaseous medium in which the fibers are contained were, in an aqueous mixture of Portiand cement and sand was blown, thereby producing a slurry of fibers in the aqueous solution. This slip is on applied the pre-layers that had previously been applied to the corrugated surface of the molded parts. As shown in Fig. 4 as can be seen, the two mold halves are then united. The air present between the two halves is created by applying a low pressure on the upper molding. As a result of this pressing operation, the layers are each of the halves combined together to make the desired brick

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6 to form. The mold is then opened and the brick 6 together with the thermoplastic corrugated foils resting on both sides of the brick to prevent that Water can evaporate from the brick. The bricks are then stacked and left for about 24 hours. During this Time period, the Portland cement sets, which serves as a binder for the sand particles in the concrete, so that a The result is brick that is formed from fiber-reinforced concrete. after the setting has taken place, the thermoplastic Slides 3 slightly from the two surfaces of the latch 6, preferably can be removed by a suction device. The bricks can then be stacked again and stored in a damp place be stored for a further three weeks for the rest of the setting (Fig. 6). The edges of each brick can be trimmed and the corners are cut off. The bricks can then be sprayed with a water-soluble acrylic paint, if not Color pigments or granulates are already contained in the brick.

It is also possible to proceed in such a way that two layers, i.e. a Yor layer and the main layer, are on top of a preformed layer Plate made of thermoplastic material is applied without this being carried by a mold half. The plates with Applied layers are then combined and placed in a mold. The mold halves are made in this way just for used the pressing process, whereby the accuracy of the end

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measurement is achieved. This modified method assumes that the corrugated sheets are made of thermoplastic sufficient strength and stiffness to adhere to "when sprayed on." of layers not to be flattened. It is clear that instead of the thermoplastic panels, too any other deformable material such as steel can be used.

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Claims (10)

Claims 1.] Method of making objects that two profiled Surfaces are made of setting material, with a small amount of this material per half of the porcelain applied, which has a surface that corresponds to one of the profiled surfaces of the article, and in the porm half is left to set, thereby marked that also on a mold half, which has a surface corresponding to the second profiled surface of the object, a lot of this applied setting material and then, as long as the material in the Pormhälften is still deformable, this to A shape can be assembled in which the quantities of the deformable Material are pressed against each other to form the desired object and the object afterwards is removed from the mold. 2. The method according to claim 1, characterized in that that a second setting material on the first setting material on or in the corresponding Porm half is applied that optionally a third setting material on the second in the corresponding Porm halves is applied, etc., before the pressing operation is carried out. - 21 - 70982B / 0926 or, g, nal, nspected 265701Q 3. The method according to claim 1 or 2, characterized in that that the additional material is applied between the material that is in the two lOrmhälften has been introduced, the material in the mold halves are introduced before the start of the pressing process or in connection with the beginning of the pressing process will. 4. The method according to claim 3, characterized eich η et that the additional material is an aqueous adhesive, a plastic binder, a rigid construction plate or the like. 5 · The method according to claim 3, characterized in that the additional material a light, porous core in the pressed and hardened product. 6. The method according to any one of claims 1 to 5, characterized in that the setting material or the setting materials that are applied to the lOrmhälften are reinforced, in particular by glass fibers. 7. The method according to any one of claims 1 to 6, characterized - 22 - 709825/0926 -at- 265701Q • J ' characterized in that the mold halves in front of or after the start of the pressing process with the formation of a slight Angles against each other v / ground. S. The method according to any one of claims 1 to 6, characterized characterized in that after the introduction of hardenable material into the mold halves, they are removed from the horizontal position moved out into a vertical position and pressed against each other in this position, after which the mold halves with the pressed material on them are rotated back into a horizontal position, in which the setting or curing takes place. 9. The method according to any one of claims 1 to 6, characterized in that at least one of the Mold halves is flexible and preferably into a parabolic shape prior to moving the mold halves together is curved that the curved mold halves are gradually flattened during the Pi'essvorganges and then when the pressing process is complete, are completely flattened. 10. The method according to any one of claims 1 to 9, characterized in that one or both mold halves a single or double profiled upper mold - 23 70982 5/0326 have surface even after the completion of the pressing process. 709825/0926