DE2711198A1 - METHOD AND MOLDING TOOL FOR MANUFACTURING POINT-LOADABLE POLYGON-SHAPED BUILDING PANEL, IN PARTICULAR DOUBLE BOTTOM PANEL AND A CORE FOR USE IN THE MANUFACTURING OF THE BUILDING PANEL - Google Patents

Description

Method and mold for the production of a point loadable polygon

colored building board, in particular double floor board and core for use in the manufacture of the building board The invention relates to a method and a molding tool for the production of a point loadable polygon-shaped building board, in particular raised floor panel for exclusive support on the polygon corners, the at least one core made of relatively pressure-resistant lightweight material and two parallel ones Has outer layers which at least on the narrow sides of the building board through Webs are connected and consist of a tensile and / or pressure-resistant material, and in which the core is in a mold with an injectable, pourable or pourable, Curable material is coated, which cures in the mold to the To form tensile and / or pressure-resistant outer layers and webs of the building board.

It is known to use building boards for a wide variety of purposes to produce that cores with plastics of various kinds in a mold are overmolded, which after hardening are tensile and pressure-resistant within certain limits Form outer layers and bar-shaped framing of the building board. Such building panels however, are not suitable for relatively high loads, especially point loads, such as they can occur e.g. with raised access floor panels. Furthermore, these are jackets or coating materials also easily flammable, which is a nondescript for building panels Represents deficiency.

The building panels, which are still manufactured using conventional methods made of heavy concrete with steel reinforcement in the manner of roof and ceiling panels also not suitable for the above purposes, in particular because of the relative high Weight and the difficulty that comes with being exclusive Support of such a building board at the polygon corners result.

On the other hand, it is also known to use concrete with fibers - in particular Asbestos fibers or glass fibers - to be used for the production of building panels. It is to this day, however, it has not been a simple and at the same time economical process for processing from fiber concrete to building panels of the type described above become known.

The invention is therefore based on the object of an economical Process for the production of a polygonal building board with point loads, in particular Raised floor slab indicating the processing of fiber concrete and in particular Glass fiber reinforced concrete allows to obtain a construction panel + which is exclusively at the polygon corners can be supported on supports, but on practically everyone can accommodate a high point load at any point, which also has a composite effect between the two outer layers at least via webs on the narrow sides of the Building plate is present and in which also the narrow sides and at least one of the two outer surfaces a perfect, dense and smooth or even surface have and has a minimal weight and is practically non-combustible.

According to the invention, this object is achieved by a method, which is characterized by the following steps: a) pouring concrete for the first outer layer and at least some of the webs in the mold with easy overdosed amount and leveling the same to a first layer as well as under alignment the fibers substantially parallel to the plate surface; b) controlled pressing of the prefabricated core in the plastic surface of the concrete of the first layer; c) Pressing fibrous flow concrete into cavities in the area of the perimeter of the Core and possibly the remaining part of the core with displacement of the air, in such a way, that after setting, a cramped connection of this forming the webs Material with the first outer layer according to item a is obtained; d) Pour in more concrete for the second outer layer and, if necessary, for filling the remaining part of the cavities in the area of the periphery of the core and optionally the remaining part of the core, again displacing the air, leveling it to a second layer and with the fibers aligned essentially parallel to the plane of the plate, this second layer being connected to the material forming the webs will.

The real problem is having two outer layers of concrete With the help of fiber-reinforced concrete technology in a simple, economical way that the finished building board is supported exclusively at its polygon corners on supports and nevertheless subjected to a high point load at practically any point can be. This problem is solved by using a pre-built Kemes and the pressing of flow concrete containing fibers into cavities in the area of the Perimeter of the core arranged between the cover layers and optionally the Remaining part of the core with displacement of the air, the fibrous flow concrete its composition can be easily adapted to the respective circumstances. Aligning the fibers essentially parallel to both the plate surface in the first as well as the second outer layer, e.g. can also be done manually. The controlled pressing in of the prefabricated Kems in the plastic surface of the fiber concrete the first concrete lye becomes theirs Thickness and also compression predetermined, while at the same time depending on the The underlay used has a high-quality, perfectly smooth or flat outside obtained e.g.

in the case of a raised floor panel, the walking side (correspondingly for roofs the weather side).

One of the many advantages of the method according to the invention is furthermore the possibility with relatively low investment funds at the same time Use of workers without specialist training to set up very efficient production and to be able to operate. This is particularly important for the application of the method in so-called developing countries. At the same time, however, the process also offers the Possibility according to the catalog of requirements listed above to the building board without revealing the fundamental structure the Building board both the static and the other functional services and Properties largely with a once set up manufacturing plant vary. For example, the span and / or load-bearing capacity of the building board by varying the thickness of the two outer layers and the webs as well as the core to be changed. Even with a given total thickness of the building board, the load-bearing capacity and / or the span by changing the layer stork and / or the layer composition can be changed, and this can be done without affecting the external differences appear visibly. Depending on the core material used, this can Variability also extended to the sound and / or thermal insulation of the finished building board be what a particular when using such building panels as roof elements Role play. For these purposes, known core materials, such as Find Polistyralschaum or mineral fibers use. Unless a slightly higher one Volume weight is bearable and at the same time great compressive strength is required lightweight concrete or wood wool panels are preferred as the core material. As fibers glass fibers, asbestos fibers, but also metal fibers can be used for concrete reinforcement be used. The fiber content and the dimensions of the fibers can optionally be varied so that the first outer layer predominantly in the cured state pressure-resistant, the second outer layer and the bars in the hardened state on the other hand are predominantly tensile strength. Due to the layered processing of the fiber concrete it is also possible to vary the composition of the concrete itself. This is important e.g. in connection with the surface hardness of the walking side a raised access floor panel to prevent damage to the Exclude surface or permanent deformation.

The method according to the invention also offers the possibility of except the prefabricated core also e.g. a top layer of the building board as a prefabricated part, e.g. to be introduced into the molding tool in the form of a tile covering or a floor covering and to be attached to one of the fiber-reinforced concrete outer layers. For the introduction of the Fiber concrete for the outer layers as well as for the fiber-containing flow concrete for training the webs can at least on the narrow sides of the building board in the form of a frame different, appropriately adapted feeds used for the fiber concrete will.

According to a further embodiment of the invention, these are to be filled out the cavities in the area of the circumference of the core and, if applicable, the remaining part The core used flowing concrete fibers added, the length of which is at least somewhat smaller than the clear width of the cavities to be filled, so that they easily move into the corresponding cavities together with the flowing concrete Let it be pressed in and consequently do not hinder the pressing in of the flowing concrete. on In this way it is also possible to use, for example, relatively stiff glass fibers.

Instead of individual fibers distributed in the concrete, at least the fibers forming the main tensile reinforcement in the building board are arranged in the plane the tensile forces occurring when the building board is loaded in the form of a fiber fleece or fabric are introduced into the molding tool, these nonwovens or fabrics can be interspersed with concrete at the same time or subsequently.

Appropriately, the hardening of the fiber concrete takes place when the Mold, so that undesired water evaporation during the setting process and thus a disruptive loss is prevented.

If, according to a further embodiment of the invention, the building panels can be produced cyclically one above the other in what is known as a batch process the work area required for the production of the building panels is kept relatively small which is also in view of the relatively long setting time of the fiber-reinforced concrete Meaning is.

An expedient simple molding tool for carrying out the invention The stacking method consists of a base plate with high quality Work surface, a frame placed on the base plate in a sealed manner, its Inside dimensions correspond to the outside dimensions of the building panels, and one on this frame is sealed on top plate with at least one high quality Work surface that forms the base plate for the next molding tool, etc. The high-quality work surface of the first base plate enables the formation of a perfectly smooth or even outer surface on the building board that does not require any post-processing more needs. The same effect is analogously with the work surface of the cover plate achieved when the next building board is made.

Another embodiment of the molding tool is characterized by one base plate with a high-quality work surface, one sealed to the base plate attached frame, the outer dimensions of which correspond to those of the building board and which forms part of the finished building panel, and one is sealed onto this frame attached cover plate with at least one high-quality work surface that the Forms the base plate for the next molding tool, etc.

In this variant, the frame consists of a lost part, that limits the outer circumference of the respective building board and is made of e.g. steel, light metal, There is plastic or precast concrete as well as a molded concrete part, which also the anchoring with the prefabricated core and the two outer layers the building board causes the fibrous flow concrete in the corresponding Cavities in the area of the core is pressed.

Further advantageous refinements of the molding tool can be found in FIGS Claims 8, 9 and 10 emerge. The movable frame elements make the The advantage achieved is that the webs forming a frame on the narrow sides of the building board can be made from excess concrete of the first outer layer.

If in the production of a building board according to the initially explained Procedure a core is used, which is arranged with at regular intervals, in each case aligned and at least uniform in the respective alignment, breakthroughs extending perpendicular to the plane of the plate are provided, so that in their Filling with flow concrete containing fibers in connection with the two fiber concrete outer layers The building board in which a system of Vierendeel beams is created is reached a building board that not only complies with the catalog of requirements set out at the beginning corresponds, but has an even lower weight and without noticeable impairment their strength can also be cut out or cut off, e.g. in the edge area, Such cutouts, e.g. in the case of raised floor panels, accommodate sockets or the like can.

In the case of larger building boards, a core is expediently used which consists of consists of several segments that are mutually and possibly also with respect to the molding tool are arranged so that between the segments and possibly also opposite the Forming tool there are narrow elongated cavities that are parallel to the edge and / or diagonally run between the support corners of the building board or radiate. The this Flow concrete, which fills cavities, in particular contains fibers, forms in the hardened State of frame-shaped and / or diagonal or radial webs that in connection with the two outer layers on dXe building board vertically or almost loads acting vertically on the corresponding polygon corners Derive supports.

Without practically reducing the load-bearing capacity of the building board, A further weight saving achieved in that the narrow elongated Cavities between the segments of the core and possibly also opposite the molding tool are interrupted at regular intervals so that after filling in with fibrous Flow concrete webs are created according to the Vierendeel principle. These webs therefore complement the system of Vierendeel trolleys obtained using a core according to claim 11 arises. It is repeated that these measures are practically unaffected the strength of a high-strength, point loadable building board is relatively lower Weight lead.

The invention will then be described with reference to the drawings of exemplary embodiments explains it show: FIG. 1 a perspective view of one according to the invention Process produced raised access floor panel, partially cut open and attached to the Corners supported on footrests; FIG. 2 is a sectional view of that shown in FIG Raised floor panel along the line 11 - II in FIG. 1; Figure 3 is an oblique view one that can be used to manufacture the raised access floor panel according to FIGS Kems; FIG. 4 shows a plan view of a molding tool in which core segments are partially are inserted which, when assembled, form the core shown in FIG. 3; figure 5 shows a sectional view along the line V - V in FIG. 4; Figure 6 is an enlarged Partial sectional view in the edge area of the arrangement according to FIG. 4, but with fiber concrete or flow concrete containing fibers has already been introduced into the mold; figure 7 a - g different phases in the production of a raised access floor panel according to the Method according to the invention with a molding tool according to FIGS. 4 and 5, however extended to a so-called batch mode; Figure 8 a - h different phases in the production of a raised access floor panel according to a modified method of Invention using a "lost frame" which is then part of the finished building panel forms, Figure 9 is a partial sectional view of a raised access floor panel in the edge area with a fiber fleece or fabric in the lower outer layer and in part of the edge webs, in connection with a load diagram; FIG. 10 shows a partial section, similar to FIG. 9, of a raised access floor panel, the Outer layers, webs and nozzles consist of different fiber concrete; figure 11 shows a mold for carrying out the method according to the invention with movable ones Frame elements; FIG. 12 two sectional views of one according to the method according to the invention manufactured curved building panel; As an exemplary embodiment for explanation of the method according to the invention in Figures 1 and 2 represents the building board represents a raised floor panel 10 which is supported on footrest 12 at its corners.

The raised floor panel 10 contains a core 1 1 made of relatively pressure-resistant, light material, e.g. plastic foam, which on its peripheral edges or narrow sides a series of equally spaced, uniform projections 13 as well as numerous has narrow elongated cavities 14 diagonally between the support corners the raised floor panel and run in a cross shape. These narrow elongated ones Cavities are only through connecting pieces arranged at regular intervals 15th interrupted, which are formed identically. In addition, the core 11 has a plurality of openings with the same diameter running perpendicular to the plane of the plate which are arranged in a grid. The core shown in Figure 3 is in one piece formed, the one shown in Figures 4 and 5 consists of four core segments 11 a, 11 b, 11 c and 11 d together, but otherwise corresponds to the core according to FIG 3. The projections 15 a complement each other when assembling the core segments and meet when filling the cavities 14 with fiber concrete, as will be explained, the function of the connecting pieces 15.

In the production of the double floor panel 10, the one-piece act Core 11 or the four core segments 11 a - 11 d together with a frame 17, the placed on a base plate 18 with a high-quality work surface 19 in a sealed manner is and together with this forms a molding tool. The inside dimensions of the frame 17 correspond exactly to the external dimensions of the raised access floor panel to be produced 10. Figure 4 shows that the projections 13 are full on the inside of the frame 17 rest, whereby in connection with the frame 17 further narrow elongated Cavities 140 are formed. It should be noted, however, that to create the cavities 140 the projections 13 also drop out or by a few removable spacers can be replaced. If, as will be explained in detail below, the Breakthroughs 16 and the cavities 14 and 140 filled with flow concrete containing fibers are, supports 20 or diagonally and radially extending webs arise 21 as well as webs 22 running parallel to the edge, which in combination with the outer layers 23 and 24 are made of fiber-reinforced concrete and together with them are a system of Vierendeel trolleys form.

The method according to the invention is first described below with reference to FIG Figure 7 explains. In a first step "a" is inserted into the cavity of the Frame 17 and the base plate 18 with the high-quality work surface 19 are limited is, fiber concrete for the first outer layer 23 and at least some of the webs and supports poured in a correspondingly overdosed amount and then by means of common tools with alignment of the fibers essentially parallel to the plane of the plate leveled. In the following phase "b", the prefabricated core 11 is transformed into the plastic Surface of the fiber concrete of the first layer or lower outer layer 23 is controlled pressed in so that the desired thickness and compression the outer layer 23 is obtained0 Excess flow concrete can get into the cavities 14, 16 and 140 escape, as Figure 7d clearly shows. In the following step "c" becomes more fibrous Flow concrete into the cavities 14, 140 and openings 16 with displacement of the air pressed in such a way that after the setting of this flow concrete a non-positive Connection of the supports 20 and webs 21, 22 with the lower outer layer 23 is obtained will. This means that the fibrous flow concrete in the breakthroughs and cavities is filled while the fiber concrete in the lower outer layer 23 is still is in the plastic state. In the then following step "d" is further Fiber concrete poured into the mold for the second outer layer 24 and in the next following phase "e" with alignment of the fibers essentially parallel leveled to the slab surface, with excess fiber concrete being stripped off at the same time will. At the same time, the second outer layer 24 is attached to the fiber-containing flow concrete connected, which forms the supports 20 and webs 21, 22 in the cured state. In the next step "f", a cover plate 25 is placed on the frame 17 in a sealed manner, which has two high-quality work surfaces 26, 27 in the exemplary embodiment. Included the upper outer layer 24 is smoothed and compacted, so that the raised access floor panel has two perfectly smooth, highly compressed outer sides. However, it is enough also off when the outer layer lying at the bottom in FIG. 7 passes through the work surface 19 of the base plate 18 is perfectly smoothed and consequently the cover plate 25 correspondingly only has a high-quality work surface 27. In this case then the outer layer 23 form the walking side of the raised access floor panel.

In the next following step "g", a further frame 17 is sealed placed on the cover plate 25 and the process steps "a" - "f" are repeated.

In this way, numerous building panels can be saved in one space Batch work can be produced, with the hardening of the fiber concrete of the individual Raised floor panels in the closed molds takes place, if necessary to accelerate the setting process by supplying heat.

The manufacturing method indicated in FIG. 8 corresponds to that above described with reference to Figure 7, in all phases, and there are therefore the same reference numerals are also used in FIG. However, in this case it will a frame 170 is used, the external dimensions of which correspond to those of the raised floor panel 10 and correspond to a lost part or part of the finished building board forms.

This frame 170 can be made of metal, plastic, prefabricated concrete for this purpose etc. exist. The in the rendparellelen cavities 140 between the core 11 and the Frame 170 indented fibrous flowing concrete creates the connection in this case between the frame 170 and the core 11 or the outer layers 23 and 24 of the double floor panel 10. Such a headpiece 170 is particularly suitable for building panels for ceilings and roofs in connection with space frame constructions; he can also for the Force transmission in the plate plane from one node to another can be used.

FIG. 9 shows part of a process according to the invention produced raised floor panel 10 a shown, which is a point load, for example is exposed by castors 28 (for example in the case of heavy office machines). Those Parts of the fiber concrete that are exposed to tensile forces, i.e. the lower outer layer 23 and the webs 22 running parallel to the edge are here additionally made of nonwovens or fabric 29 reinforced. As a result, the proportion of fibers in the fiber concrete can be relative can be kept small.

In the double floor panel 10 b according to Figure 10 is for training the lower outer layer 23, the nozzle 20 and webs 22 a fiber concrete with a higher Fiber content used as for the outer layer 24 and the upper part of the webs and supports to have practically the same strength properties as the embodiment according to Figure 9 to achieve.

FIG. 11 shows, in an oblique view, a molding tool for executing the Method according to the invention, a base plate 180 with stationary guide pieces 30 for frame elements 31 arranged so as to be movable transversely. The base plate 180, similar to the base plate 18, is provided with a high-quality work surface 190 and dimensioned so that when the frame elements 31 are completely moved outwards first layer of fiber concrete can be introduced, the volume of which is for the outer layer 23 and the edge-side webs 22 of the building board is sufficient.

After pouring in the fiber concrete for the first outer layer and the webs 22 parallel to the edge, leveling the same with alignment of the fibers essentially parallel to the plane of the plate and after controlled pressing of the prefabricated core into the plastic surface of the fiber concrete of this duck layer the frame elements 31 are moved transversely axially inward until they are not shown attacks meet, the fiber concrete in the edge area to form the webs 22 upwards pressed and the fibers are bent accordingly upwards, and at the same time flawlessly smooth, highly compressed narrow sides of the building board can be achieved. The further course of the procedure corresponds to what was explained with reference to FIGS. 7 and 8. The leaders 30 are provided with bores 32 which receive centering pins (not shown), so that the base plates 180 can be stacked on top of each other, like the Base plates 18 and frame 17 of the procedure according to FIG. 7.

Practically the same procedure can be used with a molding tool achieve (not shown) which has frame elements hinged to the base plate, from a position parallel to the base plate in a position perpendicular to this and reversed are foldable. Here elastic, Foldable bridging elements used when folding up the frame elements fold themselves outwards.

Figure 12 shows a building board 10c with a curved shape (for example for roofs) which can also be produced by the method according to the invention. The molding tool required for this must have a correspondingly curved base plate and have an adapted curved frame, likewise the core 11 must correspondingly be preformed arcuately. The example shows that the inventive method consequently is not limited to the production of flat building panels.

As it is possible with the aid of the method according to the invention, the static properties to vary, so can in principle retention of the process steps by using different concrete mixes also the property the finished plate and its economic efficiency can be designed in different ways. For example, it is possible with a plate according to FIG. 9 or 10 only on the On the other hand, to work with tensile stressed underside and in the edge area with fiber concrete on the top with a fiber-free tile concrete of traditional composition, which by executing in the first layer after process step "a" a high quality, maintains a smooth, dense and hard surface.

Claims (13)

Claim 1. Process for the production of a point loadable polygonal building board, inshes. Do @ pelbodenplatte for exclusive Auflaqerunn at the polygon corners, the at least one core airs relatively pressure-resistant lightweight Has material and two parallel outer layers, at least on the narrow sides the building board are connected by webs and made of a tensile and / or pressure-resistant Meter, and that means that the core is in a mold with a soritz-, pourable, curable material is bascoated in the mold hardens around the tensile and / or pressure-resistant outer layers and webs of the building board to form, characterized by the following process step a) pouring Fiber concrete for the first outer layer and at least some of the webs in the Molding tool in a slightly overdosed amount and leveling the same to a first Position and alignment of the fibers essentially parallel to the plane of the plate; b) Controlled pressing of the prefabricated core into the plastic surface the fiber concrete of the first layer; c) Pressing flow concrete containing flesh into cavities in the area of the circumference of the core and optionally the remaining part of the core while displacing the air in such a way that a force-locking connection after setting this material forming the webs with the first outer layer according to item a is obtained; d) Covering in further fiber concrete for the second outer layer and qeq also to fill in the remaining part of the cavities in the area of the circumference of the core and possibly the remaining part of the core, again with displacement the air, leveling it into a second layer and aligning the fibers essentially parallel to the plane of the plate, where this second layer adjoins the webs forming material is attached. 2. Ilartahren nerh claim 1, characterized in that the for Filling the cavities in the area of the periphery of the core and, if necessary, of the remaining part of the core used flow concrete fibers are added, their length dimensioned at least slightly smaller than the clear width of the cavities to be filled will. Method according to Claim 1 or 2, characterized in that at least the fibers forming the tensile reinforcement in the building panel are arranged in the area of the tensile forces occurring when the building board is loaded in the form of a fiber fleece or -Tissue can be introduced into the molding tool. 4. Process according to claims 1-3, characterized in that the hardening of the fiber concrete takes place with the mold tool closed. 5. Process according to claims 1-4, characterized in that the building boards are manufactured in cycles, one above the other, in a so-called stacking method will. 6 @ Form @ tool for executing the procedure according to the claims 1 - 5, characterized by a base plate (1i) with a raised work surface (19), a frame (17) placed on the base plate in a sealed manner, the internal dimensions of which correspond to the outer dimensions of the building board (10), and one on this frame (17) sealed cover plate (25) with at least one high quality Work surface that forms the base plate for the next forming tool, etc. 7. Mold for performing the method according to the claims 1 - 5, characterized by a base plate (ins) with a high-quality work surface (19), a frame (170) placed on the base plate (18) in a sealed manner, the External dimensions correspond to those of the building board (10) and a part of the Finished building board forms, and one placed on this frame (17w) in a sealed manner Cover plate (25) with at least one high-quality work surface, which the base plate @ for the next molding tool, etc. 8. Formmerkzeun according to claim 6, characterized in that the Rahman sealed on the base mat (180) from individual beweplich Appropriate room elements (31) lifts, each one on top of the other and apart are manageable. 9. shape memorial fence according to claim 8, characterized in that the Frame elements on the base plate appelenken so that they are parallel from a lane to the base plate in a position perpendicular to this and vice versa can be folded, and that between the @ ends of the frame elements elastic, foldable Überhrückun @ selemente are seen in front of @ es. 10. Formwerkzeun according to claim 8, characterized in that the Frame element (31) in the Plattenehene @@ weils querachsial @en each other and apart movable and mix their ends guide and filler pieces (30) fixed to @ e @ rdnet are. 11. Core for use in the production of a Rau @ latte after Method dar claims 1 - 5, characterized in that the core (11) with in arranged at regular intervals, each flown out and at least in the respective alignment of uniform perforations running perpendicular to the plane of the plate (14, 16) is provided so that when it is filled in with faserhaltinem flowing hetone is Prevention of the fiber bed @ n outside layers (23, 24) of the construction lath (10) in this a system of four-end members is created. 12. Core according to claim 11, characterized in that larger @aunlatten the core consists of several sagments (11a - d), the mutual and @ en @ are also arranged with respect to the molding tool (17, 18) so that between the segments and possibly also narrow with respect to the molding tool elongated cavities (14, 140) are pre-banded, the rando-parallel and / or diaqonal between the Auflangeecken the building plate (10) or strahlenförmi @ run. 13. Core according to claim 12, characterized in that the narrow elongated cavities (14, 140) between the segments (11a-d) of the core and optionally also with respect to the molding tool (17, 18) at regular intervals are interrupted in this way, after they have been filled with fibrous flow concrete, webs should be used (21, 22) arise according to the Vierendeel principle.