EP2025484B1 - Method for producing a moulded part, in particular for the construction or furniture industry - Google Patents
Method for producing a moulded part, in particular for the construction or furniture industry Download PDFInfo
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- EP2025484B1 EP2025484B1 EP08162334A EP08162334A EP2025484B1 EP 2025484 B1 EP2025484 B1 EP 2025484B1 EP 08162334 A EP08162334 A EP 08162334A EP 08162334 A EP08162334 A EP 08162334A EP 2025484 B1 EP2025484 B1 EP 2025484B1
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- wood
- bonding agent
- temperature
- molding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
- B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
Definitions
- the present invention relates to a method for producing a shaped body or a component, in particular for the construction or furniture industry.
- fastening elements for connecting the wooden components are provided in the area of the connection point.
- fastening elements for connecting the wooden components are provided in the area of the connection point.
- nail plates or nail binder plates can be used for this purpose.
- Such nail plates usually have a support plate made of steel with attached nail elements.
- the DE 1 808 375 A1 discloses a method for producing a material, in which the raw materials, in particular wood chips, are glued with binders, preferably aminoplasts, their homologs and mixed resins in an aqueous system and hot pressed into sheets or moldings.
- binders preferably aminoplasts, their homologs and mixed resins in an aqueous system and hot pressed into sheets or moldings.
- the raw materials are dried down after gluing to a moisture content of less than 10% and then pressed.
- urea-formaldehyde resins in an aqueous solution are used as binders.
- the US 6,368,528 B1 discloses a method of forming a composite body wherein fiber material is mixed with a resin-based binder. Subsequently, this mixture is dried to a moisture content of about 6 to 14 wt .-% and formed into a mat. Then, the surface of the mat is coated with an aqueous solution comprising, among others, a humectant, a mold release agent, a set retarder and, optionally, a thermoplastic resin. Finally, the mat is processed under heat and pressure to form a shaped body.
- the binder it is an amino resin or a phenol-formaldehyde resin.
- the invention has for its object to provide measures by means of which universally applicable moldings or components for the construction and furniture industry can be formed, which preferably have improved properties in terms of fire protection and / or the source protection.
- a molded body or component and a molding compound intended for this purpose should be specified and manufactured for this purpose.
- the residual moisture contained in the still moist molding composition after mixing in a moisture content of about 2 wt .-% to about 20 wt .-% is meant that the matched to this moisture content binder in the molding material is not yet "activated” and is activated only at later temperatures at a temperature of about 50 ° C to about 250 ° C.
- the adhesive forces provided by the binder exert their effect and hold the batch-binder mixture together. It has been found that in order to activate the binder, a temperature in the said temperature range is suitable, since at this temperature, in particular with a copolymer-containing binder of this copolymer can be activated in a suitable manner.
- the process of drying to obtain the moisture content of from about 2% to about 20% by weight, and molding of the molding composition at a temperature of from about 50 ° C to about 250 ° C achieved the above synergistic effect.
- the temperature range to be selected for shaping, for example by means of pressing is selected according to the composition of the batch. For example, a higher temperature can be used for chipboard than for fiberboard.
- tests with particleboard have shown that a pressing temperature of about 200 ° C with a pressing time of 2 min. is suitable, provided that in this period the temperature in the core region of the molding body does not exceed about 150 ° C.
- a lower temperature of up to about 180 ° C. is possible with fiberboards, in particular with a mineral fiber base.
- the mixture is mixed with a water-containing and thus "wet" binder, whereby quasi a moist mass or a moist pulp is formed.
- the constituents of the batch that is to say the fibers, chips and / or the powder, are at least partially wetted with the binder. This can lead to an impregnation of at least part of the batch constituents.
- a swelling-inhibiting effect can be achieved. This is particularly advantageous in the case of wood chips, which swell strongly without such impregnation by the binder.
- a certain proportion of mineral fibers are provided for the mixture, since they do not absorb water.
- a particular source protection can be effected in particular by selecting the mineral fiber content.
- such mineral fibers also have a fire-retardant effect and are therefore also advantageous in terms of fire protection aspects.
- dry mass forms a kind of intermediate, which is then dried to obtain the molding material.
- This preferably granular, substantially dry molding material may also be referred to as dry mass.
- dry is understood to mean a certain residual moisture inherent in particular wood fibers. In a preferred embodiment, this residual moisture can be at least partially reduced at the wet wetted sites of the wet mass in the drying process.
- the binder contained in the molding composition is substantially water-insoluble, in particular because it has not yet been "activated" by means of temperature.
- the activation of the binder can then take place by the shaping process for shaping the shaped body from this molding composition, preferably by hot pressing.
- an at least fire-retardant and / or at least one swelling-inhibiting effect of the molding compound and thus of the finished molding can be achieved.
- This is preferably done, as already indicated above, by adding mineral fibers to the mixture. Such mineral fibers are less prone to swelling. Further, the binder impregnates the mineral fibers. Furthermore, by means of the mineral fibers at least a fire retardant effect can be achieved.
- the term "at least fire-retardant" in the definition of the shaped body and / or the component defined below is to be understood in the sense of the present invention that the shaped body or the component is formed from a building material, material, material or composition which is at least hardly inflammable within the meaning of class B1 of DIN 4102 Part 1.
- the molded body or the component and the fire protection technically higher requirements of class A, A1 or A2 meet, that is, for example, be formed from non-combustible material.
- Such a shaped body or the component preferably fulfills the requirements of the fire resistance class F30 or the higher requirements of the fire resistance classes F60 to F180.
- the molded body or the component can fulfill its function in case of fire for at least 30 minutes (class F30) or depending on the material used longer.
- a component is capable of carrying out at least 30 minutes to the extent that persons located therein can leave the building or be evacuated and more time is available for extinguisher search.
- the shaped body is molded from the molding compound at a temperature of about 80 ° C to about 220 ° C, preferably at a temperature of about 100 ° C to about 200 ° C.
- the molding composition after drying has a moisture content of about 5 wt .-% to about 12 wt .-%, preferably from about 7 wt .-% to 10 wt .-%, on.
- the shaped body is formed from the molding composition in such a way that the molding has a residual moisture content of approximately less than 10% by weight, preferably of approximately less than 5% by weight. This reduction of the moisture content can be achieved for example by hot pressing.
- the component acrylic is preferably in the form of acrylic resin, preferably as a modified acrylic resin.
- the binder Includes a modified acrylate-styrene copolymer emulsion. Such an emulsion is available under the trade name NeoCryl (for example NeoCryl XK series)
- the mixture comprises mineral fibers, wood fibers, wood flour and / or wood chips. It is also possible to add additives such as kaolin, graphite and / or mica.
- the blend comprises from about 25% to about 50% by weight wood fibers, from about 0% to about 25% by weight mineral fibers, and from about 50% to about 65% by weight. Binder.
- the blend may comprise about 50% to about 65% by weight wood chips, about 0% to about 10% by weight wood flour, and about 35% to about 50% binder by weight
- the blend may contain from about 35% to about 50% by weight mineral fibers, from about 0% to about 15% by weight graphite and / or mica, and from about 50% to about 65% by weight. -% binder.
- the use of the abovementioned constituents constitutes a cost-effective and easily manageable measure, since the associated raw materials are available in sufficient form, for example as residual or waste materials, and / or are produced for recycling in recycling processes.
- the associated raw materials are available in sufficient form, for example as residual or waste materials, and / or are produced for recycling in recycling processes.
- a wood-like structure of the molding can be achieved, resulting in versatile applications in the construction or furniture industry.
- the crushing is done for example by grinding or shredding.
- the crushing is preferably carried out after drying.
- batch components such as chips can be broken.
- the moisture from the chips can enter or leave these fractures.
- the molding compound is dried at a temperature of up to about 100 ° C, preferably at a temperature of up to about 50 ° C, for example by means of hot air.
- the shaped body is formed by extruding or pressing the molding material.
- the pressing or hot pressing for example, the above temperatures are used.
- the molding material is introduced into a pressing tool and pressed at a predetermined temperature over a predetermined period of time at a predetermined pressure.
- the molding compound is pressed at a pressure of about 20 to 50 bar.
- the molding compound is pressed at a temperature of about 100 ° C to about 200 ° C.
- a plate-shaped molded body is formed. It is advantageous if the molding compound is pressed for a period of at least one minute.
- a plate can serve as a fire protection board.
- any shape, as they are known in the construction or furniture industry, for the molding be provided.
- the shape may, for example, be directed to a component to be covered or covered, in particular a component in the sense of a fastening element.
- a molding composition for producing a shaped article according to claim 1 is characterized by a mixture of a mixture of fibers, chips and / or powder and a binder, wherein the molding composition after drying the mixture has a moisture content of about 2 wt .-% to about 20 wt .-% having.
- the mixture comprises or consists of mineral fibers and / or powder and a binder.
- the molding composition has a moisture content of about 5 wt .-% to about 12 wt .-%, preferably from about 7 wt .-% to about 10 wt .-%, on.
- a molded body is pressed onto a support body, so that the support body and the molded body are positively and / or materially connected to each other.
- the shaped body is pressed onto the supporting body such that at least one area of the shaped body is pressed into an opening of the supporting body.
- the shape of the shaped body can be adapted to the shape of the supporting body.
- the support body comprises a plurality of openings or recesses, in which case a positive connection can then be achieved at several points.
- a component in particular a perforated plate, inserted into a mold and the molded body introduced into the mold and pressed onto the support body such that the molded body is connected to the support body positively and / or cohesively as a support body.
- the molded body can be introduced into the mold in already substantially consolidated form or else in the form of the above-mentioned molding compound.
- the mold can be closed after inserting the support body or component and then filled the molding material in the closed mold into a corresponding cavity.
- the shaped body for example in the form of a plate, placed on the support body or the component and then the mold getting closed.
- the shaped body When introducing the shaped body, it is preferably provided that the shaped body has approximately 1.5 to 3 times the volume of the subsequent volume of the shaped body after completion of the pressing process.
- the molded body to be connected to the support body is produced according to one of claims 1 to 9.
- a component for fire protection of components comprises a support body and a molded body, wherein the support body and molded body by means of the above-mentioned method for producing a component in which a molded body is pressed onto a support body, so that the support body and the molded body positively / or cohesively connected to each other, are processed.
- the support body is a perforated plate and the molded body is a fire protection plate, which is positively and / or materially connected to the support plate.
- the support body is designed as a perforated plate.
- a plurality of holes, openings or openings is provided in the perforated plate.
- the above-described molding compound, the molded body and the component are preferably made of an at least fire-retardant and / or at least swelling-inhibiting material or such a material composition.
- the molding or the molding compound may consist of at least fire-retardant material, that is to say be at least flame retardant according to the class B1 of the standard DIN 4102 Part 1. Reference is made to the above statements.
- the molded body or the component meets the requirements of the fire resistance class F30, that is holds in case of fire stood for at least 30 minutes.
- the higher requirements of the fire resistance classes F60 to F180 can also be met.
- it is already of great advantage if a supporting structure or a building is at least 30 minutes to the extent that persons located therein leave the building or can be evacuated and more time for deletion attempts exists.
- the above-mentioned methods for producing a molded article and for producing a component may be combined with each other.
- the molded body can first be produced and then connected to the support body for further production of the component.
- Fig. 1 shows a wooden support structure, wherein a component 10 is provided for fire protection of the connection of components 12 in the form of five wooden components.
- This component 10 comprises the wooden components 12 on both sides.
- the component 10 comprises, as a supporting body 20, a perforated plate and, as a shaped body 50, a protective plate in the form of a fire protection plate.
- This perforated plate 20 comprises holes or openings 30 arranged adjacent to one another in a plurality of rows.
- the openings 30 can serve at least in partial regions of the perforated plate 20 for the passage of fastening elements 32 in order to protect the components 12 by means of the component 10.
- the support plate 20 comprises an inner side 22, an outer side 24 and a side surface 26.
- the outer side 24 faces the timber components 12 in the assembled state.
- the inside 22 is facing away from the wooden components 12.
- the side or end surface 26 extends circumferentially of the support plate 20 circumferentially.
- the protective plate 50 rests on the inside 22 of the support plate 20 and is positively connected to the support plate 20.
- the protective plate 50 is preferably formed from a structure comprising mineral fibers and binder and has a thickness of about 1 mm to about 20 mm, preferably from about 5 mm to about 12 mm.
- This protective plate 50 meets the requirements of building materials class B1 of DIN 4102 Part 1 requirements.
- the wooden support structure according to Fig. 1 in which several wooden components 12 are connected to each other by means of a nail binder plate, keep in case of fire for at least 30 minutes.
- a swelling-inhibiting effect whereby the protective plate 50 also causes swelling protection.
- the protective plate 50 in the region of a plurality or all openings 30 of the support plate 20 has a projection 52 which projects into the respective opening 30 for the positive connection of the protective plate 50 and the support plate 20.
- the respective projection 52 may have a height that is less than, greater than, or equal to the depth of the associated opening 30. In Fig. 4 the height of the projections is slightly smaller than the depth of the opening 30 or substantially corresponds to the depth of the opening 30th
- a mixture of fibers, chips and / or powder is mixed with a binder and processed by drying to a molding compound. After drying, the molding composition has a moisture content of about 2 wt .-% to about 20 wt .-%. From this "dried" molding compound, the molded body 50 is then molded at a temperature of about 50 ° C to about 250 ° C. In tests, good results were achieved at a temperature of about 80 ° C to about 220 ° C. The best results were obtained in experiments at temperatures of about 100 ° C to about 200 ° C.
- the temperature range to be selected for shaping, for example by means of pressing, is selected according to the composition of the batch. For example, a higher temperature can be used for chipboard than for fiberboard. For example, tests with particleboard have shown that a pressing temperature of about 200 ° C with a pressing time of 2 min. is suitable, provided that in this period, the temperature in the core region of the molding does not exceed about 150 ° C. On the other hand, a lower temperature of up to about 180 ° C. is possible with fiberboards, in particular with a mineral fiber base.
- the range of moisture content of the molding composition after drying is in the range of about 5% to about 12%, preferably in the range of about 7% to about 10%, by weight.
- the mixture comprises as constituents substantially from about 25% to about 50% by weight wood fibers and from about 0% to about 25% by weight mineral fibers.
- the blend comprises about 50% to about 65% by weight wood chips and about 0% to about 10% by weight wood flour.
- the mixture according to variant 3 comprises about 35 wt .-% to about 50 wt .-% mineral fibers and about 0 wt .-% to about 15 wt .-% graphite and / or mica.
- a composition comprising the constituents acrylic, copolymer and water is added to the respective mixture as binder.
- binder is a modified acylate-styrene copolymer emulsion (available under the trade name "NeoCryl XK series"), in particular with a weight fraction of acylate, styrene and copolymer of about 50 wt .-% to about 75 wt .-% and a weight fraction of water of from about 25% to about 50% by weight.
- Mixture and Binders are then mixed in a mixing device in the cold state until a moist mass or a slurry is obtained.
- This "wet" mass is then dried in the variants 1 and 3 at a temperature of up to about 50 ° C and then comminuted into particles having a maximum size or maximum length of about 1 mm. This crushing can be done by shredding or grinding.
- the molding compound now in the form of a dry powder or in the form of dry chips is introduced into a mold.
- about 1.5 to 2 times the volume of molding compound in comparison to the later obtained after the pressing process volume of the molding material
- the pressing operation is performed.
- the duration of the pressing process is selected such that the thickness of the subsequent shaped body 50 is estimated to be at least one minute.
- the molded body 50 can be removed from the mold.
- the cavity of the mold is designed accordingly, so that a plate-shaped molded body 50 is malleable.
- the molded body 50 produced is plate-shaped and represents the protective plate 50 shown in the figures.
- a pressing tool is provided. After opening the pressing tool, the perforated plate 20 is inserted into the pressing tool. Subsequently, the shaped body 50 is placed on the inner side 22 of the perforated plate 20. After closing the pressing tool, the protective plate 50 is pressed onto the perforated plate 20 over a predetermined period of time and with a predetermined pressing pressure in such a way that the perforated plate 20 and the protective plate 50 are connected to one another in a form-fitting and / or cohesive manner.
- the cohesive connection can be achieved on the one hand by a corresponding nature of the molding compound or the molding or by a subsequent application of an adhesive layer on the inside 22 or the protective plate 50.
- the form-fitting connection is achieved in that areas of the molded body 50 located in the region of the openings 30 during pressing are pressed into the respective opening or recess 30 of the support plate 20. In this way, the projections 52 are formed. Due to the thereby achieved positive connection between the perforated plate 20 and the protective plate 50 but can be dispensed with in principle an additional cohesive connection.
- the at least fire-retardant and / or at least swelling-inhibiting component 10 thus formed is thus protected in such a case on the fireproofed outside with the molded body 50 (protective plate), that this compound is maintained even in case of fire over a longer period.
- the molded body 50 protective plate
- Fig. 5 shows an enlarged view of the detail V from Fig. 2 .
- the protective plate 50 is pressed onto the perforated plate 20.
- the projections 52 extend into several or all openings 30. In this way, a positive connection of the perforated plate 20 and the protective plate 50 is achieved.
- assembled state according to Fig. 5 is located on the outside of the protective plate 50, the perforated plate 20. In case of fire prevents the protective plate 50 due to their good fire retardant effect and on the perforated plate 20 that high temperatures are registered in the components 12.
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- Life Sciences & Earth Sciences (AREA)
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Wood Science & Technology (AREA)
- Forests & Forestry (AREA)
- Dry Formation Of Fiberboard And The Like (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Treatments Of Macromolecular Shaped Articles (AREA)
- Snaps, Bayonet Connections, Set Pins, And Snap Rings (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
Description
Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung eines Formkörpers beziehungsweise eines Bauelementes, insbesondere für die Bau- oder Möbelindustrie.The present invention relates to a method for producing a shaped body or a component, in particular for the construction or furniture industry.
Um insbesondere im Holzbau auf einfache Weise mehrere Holzbauteile miteinander kraftschlüssig zu verbinden, werden im Bereich der Verbindungsstelle Befestigungselemente zur Verbindung der Holzbauteile vorgesehen. Beispielsweise können hierfür so genannte Nagelplatten beziehungsweise Nagelbinderplatten eingesetzt werden. Derartige Nagelplatten weisen üblicherweise eine aus Stahl bestehende Tragplatte mit daran angebrachten Nagelelementen auf.In order to connect a plurality of wooden components in a simple manner, in particular in timber construction, fastening elements for connecting the wooden components are provided in the area of the connection point. For example, so-called nail plates or nail binder plates can be used for this purpose. Such nail plates usually have a support plate made of steel with attached nail elements.
Insbesondere an den Außenseiten von Holzbauteilen angebrachte Nagelplatten haben den Nachteil, dass im Falle eines Brandes in vergleichsweise kurzer Zeit ein Totalversagen der Tragkonstruktion, wie beispielsweise einem Dachträger, eintritt. Dies liegt vor allem daran, dass bei einem Brand zunächst bei einer Temperatur bis etwa 250 °C die Hitze über die aus Stahlblech bestehende Nagelplatte und die Nagelelemente in das Holzbauteil eingeleitet wird und dort eine Verkohlung und anschließend eine Verkoksung der Holzbereiche um die einzelnen Nagelelemente herum bewirkt. Nach einem innerhalb weniger Minuten eintretenden Anstieg der Temperatur in einen Bereich von 600 °C bis 800 °C erweicht dann die aus Stahlblech bestehende Tragplatte der Nagelplatte, wodurch es zu einem plötzlichen Totalversagen der Tragplatte und somit der Holztragkonstruktion kommt.In particular, on the outer sides of wooden components attached nail plates have the disadvantage that in the case of a fire in a relatively short time a total failure of the support structure, such as a roof rack, occurs. This is mainly due to the fact that in a fire initially at a temperature up to about 250 ° C, the heat introduced via the existing steel sheet nail plate and the nail elements in the wood component and there causes charring and then coking of the wood areas around the individual nail elements around. After a rise in temperature within a few minutes in a range of 600 ° C to 800 ° C then softens the existing sheet steel support plate of the nail plate, which leads to a sudden total failure of the support plate and thus the wooden support structure.
Ferner haben herkömmliche Formkörper beziehungsweise Bauelemente wie beispielsweise in der Bau- oder Möbelindustrie eingesetzte Pressspanplatten den Nachteil, dass bei derartigen Platten ein Quellen auftritt. Dies liegt vor allem daran, dass kostengünstige Bindemittel beispielsweise auf Harnstoff-Formaldehyd-Basis eingesetzt werden, die jedoch leicht wasserlöslich sind, wodurch es dann zu einem Quellen kommt.Further, conventional moldings or components such as used in the construction or furniture industry pressboard have the disadvantage that in such plates swelling occurs. This is mainly due to the fact that inexpensive binders are used, for example, urea-formaldehyde-based, but which are slightly soluble in water, which then comes to a source.
Die
Die
Der Erfindung liegt die Aufgabe zugrunde, Maßnahmen bereit zu stellen, mit Hilfe derer universell einsetzbare Formkörper beziehungsweise Bauelemente für die Bau- und Möbelbranche ausgebildet werden können, die vorzugsweise verbesserte Eigenschaften hinsichtlich des Brandschutzes und/oder des Quellschutzes haben. Insbesondere soll hierzu ein Formkörper beziehungsweise Bauelement und eine dafür vorgesehene Formmasse angegeben und hergestellt werden.The invention has for its object to provide measures by means of which universally applicable moldings or components for the construction and furniture industry can be formed, which preferably have improved properties in terms of fire protection and / or the source protection. In particular, a molded body or component and a molding compound intended for this purpose should be specified and manufactured for this purpose.
Zur Lösung dieser Aufgabe wird ein Verfahren mit den Merkmalen des beigefügten Anspruchs 1 vorgeschlagen.To solve this problem, a method with the features of the appended
So ist die nach dem Vermischen in der noch feuchten Formmasse enthaltene Restfeuchte mit einem Feuchtegehalt von etwa 2 Gew.-% bis etwa 20 Gew.-% dazu gedacht, dass das auf diesen Feuchtegehalt abgestimmte Bindemittel in der Formmasse noch nicht "aktiviert" ist und erst beim späteren Formen bei einer Temperatur von etwa 50 °C bis etwa 250 °C aktiviert wird. Bei diesem Formen entfalten die durch das Bindemittel bereitgestellten Adhäsionskräfte ihre Wirkung und halten das Gemenge-Bindemittel-Gemisch zusammen. Es hat sich herausgestellt, dass, um das Bindemittel zu aktivieren, eine Temperatur in dem genannten Temperaturbereich geeignet ist, da bei dieser Temperatur insbesondere bei einem Copolymer enthaltenden Bindemittel dieses Copolymer in geeigneter Weise aktiviert werden kann. Somit wird durch die erfindungsgemäße Generierung der Bindemittelbestandteile, den Vorgang des Trocknens, um den Feuchtegehalt von etwa 2 Gew.-% bis etwa 20 Gew.-% zu erhalten, und die Formgebung der Formmasse bei einer Temperatur von etwa 50 °C bis etwa 250 °C der vorbeschriebene synergetische Effekt erzielt.Thus, the residual moisture contained in the still moist molding composition after mixing in a moisture content of about 2 wt .-% to about 20 wt .-% is meant that the matched to this moisture content binder in the molding material is not yet "activated" and is activated only at later temperatures at a temperature of about 50 ° C to about 250 ° C. In this molding, the adhesive forces provided by the binder exert their effect and hold the batch-binder mixture together. It has been found that in order to activate the binder, a temperature in the said temperature range is suitable, since at this temperature, in particular with a copolymer-containing binder of this copolymer can be activated in a suitable manner. Thus, by generating the binder ingredients of the present invention, the process of drying to obtain the moisture content of from about 2% to about 20% by weight, and molding of the molding composition at a temperature of from about 50 ° C to about 250 ° C achieved the above synergistic effect.
Bei Versuchen wurden gute Ergebnisse bei einer Temperatur von etwa 80 °C bis etwa 220 °C erreicht. Die besten Ergebnisse wurden bei Versuchen mit Temperaturen von etwa 100 °C bis etwa 200 °C erzielt. Der für die Formgebung, beispielsweise mittels Pressen, zu wählende Temperaturbereich wird je nach Zusammensetzung des Gemenges ausgewählt. So kann bei Spanplatten eine höhere Temperatur eingesetzt werden als bei Faserplatten. Beispielsweise haben Versuche mit Spanplatten gezeigt, dass eine Presstemperatur von etwa 200 °C bei einer Presszeit von 2 min. geeignet ist, sofern in dieser Zeitdauer die Temperatur im Kernbereich des Formkörpers etwa 150 °C nicht überschreitet. Hingegen ist bei Faserplatten, insbesondere auf Mineralfaserbasis, eine niedrigere Temperatur von bis zu etwa 180 °C möglich.In tests, good results were achieved at a temperature of about 80 ° C to about 220 ° C. The best results were obtained in experiments at temperatures of about 100 ° C to about 200 ° C. The temperature range to be selected for shaping, for example by means of pressing, is selected according to the composition of the batch. For example, a higher temperature can be used for chipboard than for fiberboard. For example, tests with particleboard have shown that a pressing temperature of about 200 ° C with a pressing time of 2 min. is suitable, provided that in this period the temperature in the core region of the molding body does not exceed about 150 ° C. On the other hand, a lower temperature of up to about 180 ° C. is possible with fiberboards, in particular with a mineral fiber base.
Je nachdem welche der vorgenannten Temperaturbereiche bzw. Temperaturen eingesetzt wird, werden nach dem Trocknen unterschiedliche Feuchtegehalte für die Formmasse beziehungsweise nach dem Formen unterschiedliche Restfeuchtegehalte für den Formkörper erreicht.Depending on which of the aforementioned temperature ranges or temperatures is used, after drying different moisture contents achieved for the molding material or after molding different residual moisture contents for the molding.
In bevorzugter Ausgestaltung wird das Gemenge mit einem Wasser enthaltenden und somit "feuchten" Bindemittel vermischt, wodurch quasi eine feuchte Masse beziehungsweise ein feuchter Brei entsteht. Bei dem Mischvorgang werden die Bestandteile des Gemenges, dass heisst die Fasern, Späne und/oder das Pulver, mit dem Bindemittel zumindest teilweise benetzt. Dies kann zu einer Imprägnierung zumindest eines Teils der Gemengebestandteile führen. Hierdurch kann im Hinblick auf den fertigen Formkörper eine quellhemmende Wirkung erzielt werden. Dies ist insbesondere bei Holzspänen von Vorteil, die ohne eine solche Imprägnierung durch das Bindemittel stark quellen.In a preferred embodiment, the mixture is mixed with a water-containing and thus "wet" binder, whereby quasi a moist mass or a moist pulp is formed. In the mixing process, the constituents of the batch, that is to say the fibers, chips and / or the powder, are at least partially wetted with the binder. This can lead to an impregnation of at least part of the batch constituents. As a result, with regard to the finished molded body, a swelling-inhibiting effect can be achieved. This is particularly advantageous in the case of wood chips, which swell strongly without such impregnation by the binder.
Um einen noch höheren Quellschutz für den fertigen Formkörper zu erreichen, kann in bevorzugter Ausgestaltung ein bestimmter Anteil von Mineralfasern für das Gemenge vorgesehen werden, da diese kein Wasser aufnehmen. Mit anderen Worten kann insbesondere durch Wahl des Mineralfaseranteils ein bestimmter Quellschutz bewirkt werden. Hinzu kommt, dass derartige Mineralfasern auch eine feuerhemmende Wirkung haben und daher auch im Hinblick auf Brandschutzaspekte vorteilhaft sind.In order to achieve an even higher swelling protection for the finished molded body, in a preferred embodiment, a certain proportion of mineral fibers are provided for the mixture, since they do not absorb water. In other words, a particular source protection can be effected in particular by selecting the mineral fiber content. In addition, such mineral fibers also have a fire-retardant effect and are therefore also advantageous in terms of fire protection aspects.
Die oben genannte "feuchte Masse" bildet eine Art Zwischenprodukt, welches dann getrocknet wird, um die Formmasse zu erhalten. Diese vorzugsweise granulatartige, weitgehend trockene Formmasse kann auch als Trockenmasse bezeichnet werden. Vorzugsweise wird unter dem Begriff "trocken" eine gewisse insbesondere Holzfasern immanente Restfeuchte verstanden. In bevorzugter Ausgestaltung kann diese Restfeuchte an den nicht mit Bindemittel benetzten Stellen der feuchten Masse bei dem Trockenvorgang zumindest teilweise reduziert werden.The above-mentioned "wet mass" forms a kind of intermediate, which is then dried to obtain the molding material. This preferably granular, substantially dry molding material may also be referred to as dry mass. Preferably, the term "dry" is understood to mean a certain residual moisture inherent in particular wood fibers. In a preferred embodiment, this residual moisture can be at least partially reduced at the wet wetted sites of the wet mass in the drying process.
In dem Zustand nach dem Trocknen der Mischung aus Gemenge und Bindemittel, das heisst bei Vorliegen der Formmasse, ist das in der Formmasse enthaltene Bindemittel im Wesentlichen wasserunlöslich, insbesondere deshalb weil es noch nicht mittels Temperatur "aktiviert" worden ist. Die Aktivierung des Bindemittels kann dann durch den Formgebungsprozess zur Formung des Formkörpers aus dieser Formmasse, vorzugsweise durch Heißpressen, erfolgen.In the state after drying the mixture of mixture and binder, that is in the presence of the molding composition, the binder contained in the molding composition is substantially water-insoluble, in particular because it has not yet been "activated" by means of temperature. The activation of the binder can then take place by the shaping process for shaping the shaped body from this molding composition, preferably by hot pressing.
In bevorzugter Ausgestaltung kann eine wenigstens feuerhemmende und/oder wenigstens eine quellhemmende Wirkung der Formmasse und somit des fertigen Formkörpers erzielt werden. Vorzugsweise erfolgt dies, wie bereits oben angedeutet, dadurch, dass dem Gemenge Mineralfasern beigefügt werden. Derartige Mineralfasern sind wenig quellanfällig. Ferner imprägniert das Bindemittel die Mineralfasern. Weiterhin kann mittels der Mineralfasern eine wenigstens feuerhemmende Wirkung erzielt werden.In a preferred embodiment, an at least fire-retardant and / or at least one swelling-inhibiting effect of the molding compound and thus of the finished molding can be achieved. This is preferably done, as already indicated above, by adding mineral fibers to the mixture. Such mineral fibers are less prone to swelling. Further, the binder impregnates the mineral fibers. Furthermore, by means of the mineral fibers at least a fire retardant effect can be achieved.
Unter der den Formkörper und/oder das weiter unten definierte Bauelement betreffenden Definition "wenigstens feuerhemmend" soll im Sinne der vorliegenden Erfindung verstanden werden, dass der Formkörper beziehungsweise das Bauelement aus einem Baustoff, Werkstoff, Material beziehungsweise einer Zusammensetzung gebildet ist, der zumindest schwer entflammbar im Sinne der Klasse B1 der Norm DIN 4102 Teil 1 ist. Gegebenenfalls kann der Formkörper beziehungsweise das Bauelement auch die brandschutztechnisch höheren Anforderungen der Klasse A, A1 oder A2 erfüllen, das heisst beispielsweise auch aus nicht brennbarem Material gebildet sein. Vorzugsweise erfüllt eine derartiger Formkörper beziehungsweise das Bauelement die Anforderungen der Feuerwiderstandsklasse F30 oder die höheren Anforderungen der Feuerwiderstandsklassen F60 bis F180. Auf diese Weise kann der Formkörper beziehungsweise das Bauelement seine Funktion im Brandfall für mindestens 30 Minuten (Klasse F30) oder je nach verwendetem Material auch länger erfüllen. In der Regel ist es aber bereits von großem Vorteil, wenn bei einem Brand insbesondere ein Bauelement wenigstens 30 Minuten insoweit tragfähig ist, dass darin befindliche Personen das Bauwerk verlassen beziehungsweise evakuiert werden können und mehr Zeit für Löschver, suche besteht.The term "at least fire-retardant" in the definition of the shaped body and / or the component defined below is to be understood in the sense of the present invention that the shaped body or the component is formed from a building material, material, material or composition which is at least hardly inflammable within the meaning of class B1 of DIN 4102
Bevorzugle Weiterbildungen des erfindungsgemäßen Verfahrens sind Gegenstand der abhängigen Ansprüche 2 bis 9.Preferred developments of the method according to the invention are the subject of the dependent claims 2 to 9.
Bei einer bevorzugten Weiterbildung des erfindungsgemäßen Verfahrens wird der Formkörper bei einer Temperatur von etwa 80°C bis etwa 220 °C, vorzugsweise bei einer Temperatur von etwa 100 °C bis etwa 200 °C, aus der Formmasse geformt.In a preferred embodiment of the method according to the invention, the shaped body is molded from the molding compound at a temperature of about 80 ° C to about 220 ° C, preferably at a temperature of about 100 ° C to about 200 ° C.
Bei einer weiteren bevorzugten Weiterbildung des Verfahrens weist die Formmasse nach dem Trocknen einen Feuchtegehalt von etwa 5 Gew.-% bis etwa 12 Gew.-%, vorzugsweise von etwa 7 Gew.-% bis 10 Gew.-%, auf.In a further preferred embodiment of the method, the molding composition after drying has a moisture content of about 5 wt .-% to about 12 wt .-%, preferably from about 7 wt .-% to 10 wt .-%, on.
Weiter ist vorgesehen, dass der Formkörper derart aus der Formmasse geformt wird, dass der Formkörper eine Restfeuchte von etwa kleiner als 10 Gew.-%, vorzugsweise von etwa kleiner als 5 Gew.-%, aufweist. Diese Reduzierung des Feuchtegehalts kann beispielsweise durch Heißpressen erreicht werden.It is further provided that the shaped body is formed from the molding composition in such a way that the molding has a residual moisture content of approximately less than 10% by weight, preferably of approximately less than 5% by weight. This reduction of the moisture content can be achieved for example by hot pressing.
Weiter vorteilhaft ist ein Bindemittel mit einem Gewichtsanteil an Acryl, Styrol und/oder Copolymer von etwa 50 bis 75 Gew.-% und einem Gewichtsanteil von Wasser von etwa 25 Gew.-% bis etwa 50 Gew.-%. Der Bestandteil Acryl liegt vorzugsweise in Form von Acrylharz, vorzugsweise als modifiziertes Acrylharz, vor. Das Bindemittel Umfasst eine modifizierte Acrylat-Styrol-Copolymer-Emulsion. Eine derartige Emulsion ist unter dem Handelsnamen NeoCryl (beispielsweise NeoCryl XK-Serie) erhältlichFurther advantageous is a binder with a weight fraction of acrylic, styrene and / or copolymer of about 50 to 75% by weight and a weight proportion of water of from about 25% to about 50% by weight. The component acrylic is preferably in the form of acrylic resin, preferably as a modified acrylic resin. The binder Includes a modified acrylate-styrene copolymer emulsion. Such an emulsion is available under the trade name NeoCryl (for example NeoCryl XK series)
Bei einer weiteren bevorzugten Ausgestaltung umfasst das Gemenge Mineralfasern, Holzfasern, Holzmehl und/oder Holzspäne. Es können auch Zusätze wie Kaolin, Graphit und/oder Glimmer beigemengt werden.In a further preferred embodiment, the mixture comprises mineral fibers, wood fibers, wood flour and / or wood chips. It is also possible to add additives such as kaolin, graphite and / or mica.
In einem bevorzugten Anwendungsfall umfasst das Gemenge etwa 25 Gew.-% bis etwa 50 Gew.-% Holzfasern, etwa 0 Gew.-% bis etwa 25 Gew.-% Mineralfasern und etwa 50 Gew.-% bis etwa 65 Gew.-% Bindemittel. Alternativ hierzu kann das Gemenge etwa 50 Gew.-% bis etwa 65 Gew.-% Holzspäne, etwa 0 Gew.-% bis etwa 10 Gew.-% Holzmehl und etwa 35 Gew.-% bis etwa 50 Gew.-% Bindemittel umfassen. Ebenso alternativ kann das Gemenge etwa 35 Gew.-% bis etwa 50 Gew.-% Mineralfasern, etwa 0 Gew.-% bis etwa 15 Gew.-% Graphit und/oder Glimmer und etwa 50 Gew.-% bis etwa 65 Gew.-% Bindemittel umfassen. Die Verwendung vorgenannter Bestandteile stellt eine kostengünstige und einfach handhabbare Maßnahme dar, da die zugehörigen Rohstoffe in ausreichender Form beispielsweise als Rest- oder Abfallstoffe zur Verfügung stehen und/oder bei Recyclingprozessen zur Wiederverwertung anfallen. So kann beispielsweise bei einer Mischung von etwa 50 Gew.-% Mineralfasern und etwa 50 Gew.-% Holzfasern oder Holzspänen eine holzartige Struktur des Formkörpers erreicht werden, wodurch sich vielseitige Anwendungen in der Bau- oder Möbelindustrie ergeben.In a preferred application, the blend comprises from about 25% to about 50% by weight wood fibers, from about 0% to about 25% by weight mineral fibers, and from about 50% to about 65% by weight. Binder. Alternatively, the blend may comprise about 50% to about 65% by weight wood chips, about 0% to about 10% by weight wood flour, and about 35% to about 50% binder by weight , Also alternatively, the blend may contain from about 35% to about 50% by weight mineral fibers, from about 0% to about 15% by weight graphite and / or mica, and from about 50% to about 65% by weight. -% binder. The use of the abovementioned constituents constitutes a cost-effective and easily manageable measure, since the associated raw materials are available in sufficient form, for example as residual or waste materials, and / or are produced for recycling in recycling processes. For example, in a mixture of about 50 wt .-% of mineral fibers and about 50 wt .-% wood fibers or wood shavings a wood-like structure of the molding can be achieved, resulting in versatile applications in the construction or furniture industry.
Das Zerkleinern erfolgt beispielsweise durch Mahlen oder Schreddern. Das Zerkleinern erfolgt vorzugsweise nach dem Trocknen. So können insbesondere Gemengebestandteile wie Späne gebrochen werden. An diesen Bruchstellen kann die Feuchtigkeit aus den Spänen ein- oder austreten.The crushing is done for example by grinding or shredding. The crushing is preferably carried out after drying. In particular, batch components such as chips can be broken. The moisture from the chips can enter or leave these fractures.
Weiterhin kann vorgesehen werden, dass die Formmasse bei einer Temperatur von bis zu etwa 100 °C, vorzugsweise bei einer Temperatur von bis zu etwa 50° C, getrocknet wird, beispielsweise mittels heißer Luft.Furthermore, it can be provided that the molding compound is dried at a temperature of up to about 100 ° C, preferably at a temperature of up to about 50 ° C, for example by means of hot air.
Hinsichtlich der Formgebung kann vorgesehen werden, dass der Formkörper durch Extrudieren oder Pressen der Formmasse geformt wird. Bei dem Pressen beziehungsweise Heißpressen werden beispielsweise oben genannte Temperaturen eingesetzt.With regard to the shaping can be provided that the shaped body is formed by extruding or pressing the molding material. In the pressing or hot pressing, for example, the above temperatures are used.
In bevorzugter Ausgestaltung wird die Formmasse in ein Presswerkzeug eingefüllt und bei einer vorbestimmten Temperatur über eine vorbestimmte Zeitdauer mit einem vorbestimmten Druck gepresst. Vorteilhafterweise wird die Formmasse bei einem Druck von etwa 20 bis 50 bar gepresst. Vorzugsweise wird die Formmasse bei einer Temperatur von etwa 100 °C bis etwa 200 °C gepresst.In a preferred embodiment, the molding material is introduced into a pressing tool and pressed at a predetermined temperature over a predetermined period of time at a predetermined pressure. Advantageously, the molding compound is pressed at a pressure of about 20 to 50 bar. Preferably, the molding compound is pressed at a temperature of about 100 ° C to about 200 ° C.
In bevorzugter Anwendung des Verfahrens wird ein plattenförmiger Formkörper geformt. Hierbei ist es von Vorteil, wenn die Formmasse über eine Zeitdauer von mindestens einer Minute gepresst wird. Eine derartige Platte kann als Brandschutzplatte dienen. Grundsätzlich kann aber jede beliebige Form, wie sie in der Bau- oder Möbelindustrie bekannt sind, für den Formkörper vorgesehen werden. Die Form kann sich beispielsweise nach einem zu verkleidenden oder abzudeckenden Bauelement, insbesondere Bauelement im Sinne eines Befestigungselementes, richten.In preferred application of the method, a plate-shaped molded body is formed. It is advantageous if the molding compound is pressed for a period of at least one minute. Such a plate can serve as a fire protection board. In principle, however, any shape, as they are known in the construction or furniture industry, for the molding be provided. The shape may, for example, be directed to a component to be covered or covered, in particular a component in the sense of a fastening element.
Eine Formmasse zur Herstellung eines Formkörpers nach Anspruch 1 ist gekennzeichnet durch eine Mischung aus einem Gemenge aus Fasern, Spänen und/oder Pulver und einem Bindemittel, wobei die Formmasse nach einem Trocknen der Mischung einen Feuchtegehalt von etwa 2 Gew.-% bis etwa 20 Gew.-% aufweist.A molding composition for producing a shaped article according to
Vorteilhafterweise umfasst oder besteht das Gemenge aus Mineralfasern und/oder Pulver und einem Bindemittel.Advantageously, the mixture comprises or consists of mineral fibers and / or powder and a binder.
In bevorzugter Ausgestaltung weist die Formmasse einen Feuchtegehalt von etwa 5 Gew.-% bis etwa 12 Gew.-%, vorzugsweise von etwa 7 Gew.-% bis etwa 10 Gew.-%, auf.In a preferred embodiment, the molding composition has a moisture content of about 5 wt .-% to about 12 wt .-%, preferably from about 7 wt .-% to about 10 wt .-%, on.
Hinsichtlich des Gemenges, des Bindemittels und deren Vermengung, auch in verschiedenen Kombinationen, wird auf obige Ausführungen verwiesen.With regard to the mixture, the binder and their mixing, also in various combinations, reference is made to the above statements.
Bei einem Verfahren zur Herstellung eines Bauelements, insbesondere für den Brandschutz bei der Verbindung von Bauteilen wird ein Formkörper auf einen Tragkörper gepresst , so dass der Tragkörper und der Formkörper formschlüssig und/oder stoffschlüssig miteinander verbunden werden.In a method for producing a component, in particular for fire protection in the connection of components, a molded body is pressed onto a support body, so that the support body and the molded body are positively and / or materially connected to each other.
Mit diesem Verfahren kann beispielsweise erreicht werden, dass mit der Aufpressung des Formkörpers auf den Tragkörper zugleich eine wenigstens teilweise Formgebung des Formkörpers erfolgt, so dass eine weitere Reduzierung der Verfahrensschritte erreicht wird. Zudem kann hierbei vorzugsweise ein und dasselbe Werkzeug zur Verpressung und Formgebung eingesetzt werden. Somit kann auch die Anzahl der erforderlichen Werkzeuge weiter reduziert werden.With this method, it can be achieved, for example, that at the same time an at least partial shaping of the shaped body takes place with the pressing on of the shaped body onto the supporting body, so that a further reduction of the method steps is achieved. In addition, preferably one and the same tool for pressing and shaping can be used here. Thus, the number of required tools can be further reduced.
In bevorzugter Ausgestaltung wird der Formkörper derart auf den Tragkörper gepresst, dass wenigstens ein Bereich des Formkörpers in eine Öffnung des Tragkörpers hingedrückt wird. So kann zum einen die Form des Formkörpers an die Form des Tragkörpers angepasst werden. Zum anderen kann in einer Weiterbildung des Verfahrens vorgesehen sein, dass der Bereich des Formkörpers so weit in die Öffnung des Tragkörpers hineingedrückt wird, so dass im Bereich der Öffnung die formschlüssige Verbindung von Tragkörper und Formkörper entsteht. Vorzugsweise umfasst der Tragkörper eine Vielzahl von Öffnungen oder Ausnehmungen, wobei dann an mehreren Stellen eine formschlüssige Verbindung erreicht werden kann.In a preferred embodiment, the shaped body is pressed onto the supporting body such that at least one area of the shaped body is pressed into an opening of the supporting body. Thus, on the one hand, the shape of the shaped body can be adapted to the shape of the supporting body. On the other hand, it can be provided in a further development of the method that the region of the shaped body is pushed so far into the opening of the support body, so that in the region of the opening, the positive connection of support body and molded body is formed. Preferably, the support body comprises a plurality of openings or recesses, in which case a positive connection can then be achieved at several points.
Bei einer besonders bevorzugten Ausgestaltung des Verfahrens wird als Tragkörper ein Bauelement, insbesondere eine Lochplatte, in ein Formwerkzeug eingelegt und der Formkörper in das Formwerkzeug eingebracht und derart auf den Tragkörper gepresst, dass der Formkörper mit dem Tragkörper formschlüssig und/oder stoffschlüssig verbunden wird. Hierbei kann der Formkörper in bereits weitgehend gefestigter Form oder aber in Form der oben erwähnten Formmasse in das Formwerkzeug eingebracht werden. Beispielsweise kann das Formwerkzeug nach Einlegen des Tragkörpers oder Bauelementes geschlossen und dann die Formmasse in das geschlossene Formwerkzeug in einen entsprechenden Hohlraum eingefüllt werden. Alternativ kann der Formkörper, beispielsweise in Form einer Platte, auf den Tragkörper oder das Bauelement aufgelegt und anschließend das Formwerkzeug geschlossen werden. Bei dem Einbringen des Formkörpers ist vorzugsweise vorgesehen, dass der Formkörper etwa das 1,5- bis 3-fache Volumen des späteren Volumens des Formkörpers nach Abschluss des Pressvorganges hat. Vorzugsweise ist der mit dem Tragkörper zu verbindende Formkörper nach einem der Ansprüche 1 bis 9 hergestellt.In a particularly preferred embodiment of the method, a component, in particular a perforated plate, inserted into a mold and the molded body introduced into the mold and pressed onto the support body such that the molded body is connected to the support body positively and / or cohesively as a support body. In this case, the molded body can be introduced into the mold in already substantially consolidated form or else in the form of the above-mentioned molding compound. For example, the mold can be closed after inserting the support body or component and then filled the molding material in the closed mold into a corresponding cavity. Alternatively, the shaped body, for example in the form of a plate, placed on the support body or the component and then the mold getting closed. When introducing the shaped body, it is preferably provided that the shaped body has approximately 1.5 to 3 times the volume of the subsequent volume of the shaped body after completion of the pressing process. Preferably, the molded body to be connected to the support body is produced according to one of
Ein Bauelement zum Brandschutz von Bauteilen, insbesondere von Holzbauteilen, umfasst einen Tragkörper und einen Formkörper, wobei Tragkörper und Formkörper mittels oben genannten Verfahrens zur Herstellung eines Bauelements, bei dem ein Formkörper auf einen Tragkörper gepresst wird, so dass der Tragkörper und der Formkörper formschlüssig und/oder stoffschlüssig miteinander verbunden werden, verarbeitet werden. In bevorzugter Ausgestaltung ist der Tragkörper eine Lochplatte und der Formkörper eine Brandschutzplatte, die formschlüssig und/oder stoffschlüssig mit der Tragplatte verbunden ist.A component for fire protection of components, in particular of wooden components, comprises a support body and a molded body, wherein the support body and molded body by means of the above-mentioned method for producing a component in which a molded body is pressed onto a support body, so that the support body and the molded body positively / or cohesively connected to each other, are processed. In a preferred embodiment, the support body is a perforated plate and the molded body is a fire protection plate, which is positively and / or materially connected to the support plate.
Vorzugsweise ist der Tragkörper als Lochplatte ausgeführt. Hierbei ist in der Lochplatte eine Vielzahl von Löchern, Öffnungen beziehungsweise Durchbrechungen vorgesehen.Preferably, the support body is designed as a perforated plate. Here, a plurality of holes, openings or openings is provided in the perforated plate.
Die oben erläuterte Formmasse, der Formkörper und das Bauelement bestehen vorzugsweise aus einem wenigstens feuerhemmenden und/oder wenigstens quellhemmenden Material oder einer solchen Materialzusammensetzung. Der Formkörper beziehungsweise die Formmasse kann aus wenigstens feuerhemmenden Material bestehen, dass heisst zumindest schwer entflammbar entsprechend der Klasse B1 der Norm DIN 4102 Teil 1 sein. Auf obige Ausführungen wird verwiesen.The above-described molding compound, the molded body and the component are preferably made of an at least fire-retardant and / or at least swelling-inhibiting material or such a material composition. The molding or the molding compound may consist of at least fire-retardant material, that is to say be at least flame retardant according to the class B1 of the standard DIN 4102
Beispielsweise erfüllt der Formkörper beziehungsweise das Bauelement die Anforderungen der Feuerwiderstandsklasse F30, dass heisst hält im Brandfall für mindestens 30 Minuten stand. Je nach für die Formmasse verwendetem Material können auch die höheren Anforderungen der Feuerwiderstandsklassen F60 bis F180 erfüllt werden. In der Regel ist es aber bereits von großem Vorteil, wenn eine Tragkonstruktion oder ein Bauwerk wenigstens 30 Minuten insoweit tragfähig ist, dass darin befindliche Personen das Bauwerk verlassen beziehungsweise evakuiert werden können und mehr Zeit für Löschversuche besteht.For example, the molded body or the component meets the requirements of the fire resistance class F30, that is holds in case of fire stood for at least 30 minutes. Depending on the material used for the molding compound, the higher requirements of the fire resistance classes F60 to F180 can also be met. In general, however, it is already of great advantage if a supporting structure or a building is at least 30 minutes to the extent that persons located therein leave the building or can be evacuated and more time for deletion attempts exists.
Die oben genannten Verfahren zur Herstellung eines Formkörpers und zur Herstellung eines Bauelementes können miteinander kombiniert werden. So kann beispielsweise zunächst der Formkörper hergestellt und dieser sodann zur weiteren Herstellung des Bauelementes mit dem Tragkörper verbunden werden.The above-mentioned methods for producing a molded article and for producing a component may be combined with each other. Thus, for example, the molded body can first be produced and then connected to the support body for further production of the component.
Nachfolgend wird die Erfindung unter Bezugnahme auf mehrere Ausführungsbeispiele und die Zeichnungen weiter erläutert. Dabei zeigen schematisch:
- Fig. 1
- eine Holztragkonstruktion mit einem Bauelement;
- Fig. 2
- einen Schnitt durch die Holztragkonstruktion entlang der Linie II-II in
Fig. 1 ; - Fig. 3
- eine perspektivische Darstellung des Bauelementes gemäß
Fig. 1 , - Fig. 4
- einen Querschnitt durch das Bauelement
gemäß den Figuren 1 bis 3 , und - Fig. 5
- eine vergrößerte Ansicht des Details V aus
Fig. 2 .
- Fig. 1
- a wooden support structure with a structural element;
- Fig. 2
- a section through the timber support structure along the line II-II in
Fig. 1 ; - Fig. 3
- a perspective view of the device according to
Fig. 1 . - Fig. 4
- a cross section through the device according to the
FIGS. 1 to 3 , and - Fig. 5
- an enlarged view of the detail V off
Fig. 2 ,
Das Bauelement 10 umfasst als einen Tragkörper 20 eine Lochplatte und als Formkörper 50 eine Schutzplatte in Form einer Brandschutzplatte. Diese Lochplatte 20 umfasst in mehreren Reihen benachbart zueinander angeordnete Löcher beziehungsweise Öffnungen 30. Die Öffnungen 30 können zumindest in Teilbereichen der Lochplatte 20 zur Hindurchführung von Befestigungselementen 32 dienen, um mittels des Bauelements 10 die Bauteile 12 zu schützen.The
Ferner umfasst die Tragplatte 20 eine Innenseite 22, eine Außenseite 24 und eine Seitenfläche 26. Die Außenseite 24 ist im montierten Zustand den Holzbauteilen 12 zugewandt. Die Innenseite 22 ist den Holzbauteilen 12 abgewandt. Die Seiten- oder Stirnfläche 26 verläuft in Umfangsrichtung der Tragplatte 20 umlaufend.Furthermore, the
Zwischen den Öffnungen 30 bilden verbleibende Plattenbereiche 28 der Tragplatte quasi Stege oder Streifen, die im eingebauten Zustand zur Formstabilität des Bauelements 10 dienen.Between the
Wie sich aus den
Wie sich insbesondere der
Um den Formkörper, insbesondere die Schutzplatte 50, herzustellen, wird ein Gemenge aus Fasern, Spänen und/oder Pulver mit einem Bindemittel vermischt und durch Trocknen zu einer Formmasse verarbeitet. Nach dem Trocknen weist die Formmasse einen Feuchtegehalt von etwa 2 Gew.-% bis etwa 20 Gew.-% auf. Aus dieser "getrockneten" Formmasse wird dann der Formkörper 50 bei einer Temperatur von etwa 50 °C bis etwa 250 °C geformt. Bei Versuchen wurden gute Ergebnisse bei einer Temperatur von etwa 80 °C bis etwa 220 °C erreicht. Die besten Ergebnisse wurden bei Versuchen mit Temperaturen von etwa 100 °C bis etwa 200 °C erzielt.In order to produce the shaped body, in particular the
Der für die Formgebung, beispielsweise mittels Pressen, zu wählende Temperaturbereich wird je nach Zusammensetzung des Gemenges ausgewählt. So kann bei Spanplatten eine höhere Temperatur eingesetzt werden als bei Faserplatten. Beispielsweise haben Versuche mit Spanplatten gezeigt, dass eine Presstemperatur von etwa 200 °C bei einer Presszeit von 2 min. geeignet ist, sofern in dieser Zeitdauer die Temperatur im Kernbereich des Formkörpers etwa 150 °C nicht überschreitet. Hingegen ist bei Faserplatten, insbesondere auf Mineralfaserbasis, eine niedrigere Temperatur von bis zu etwa 180 °C möglich.The temperature range to be selected for shaping, for example by means of pressing, is selected according to the composition of the batch. For example, a higher temperature can be used for chipboard than for fiberboard. For example, tests with particleboard have shown that a pressing temperature of about 200 ° C with a pressing time of 2 min. is suitable, provided that in this period, the temperature in the core region of the molding does not exceed about 150 ° C. On the other hand, a lower temperature of up to about 180 ° C. is possible with fiberboards, in particular with a mineral fiber base.
Je nachdem welche der vorgenannten Temperaturbereiche bzw. Temperaturen eingesetzt wird, werden nach dem Trocknen unterschiedliche Feuchtegehalte für die Formmasse beziehungsweise nach dem Formen unterschiedliche Restfeuchtegehalte für den Formkörper 50 erreicht.Depending on which of the abovementioned temperature ranges or temperatures is used, different moisture contents for the molding compound or, after molding, different residual moisture contents for the
Insbesondere liegt der Bereich des Feuchtegehaltes der Formmasse nach dem Trocknen im Bereich von etwa 5 Gew.-% bis etwa 12 Gew.-%, vorzugsweise im Bereich von etwa 7 Gew.-% bis etwa 10 Gew.-%.In particular, the range of moisture content of the molding composition after drying is in the range of about 5% to about 12%, preferably in the range of about 7% to about 10%, by weight.
Um eine geeignete Formmasse zu erhalten, werden im Folgenden drei Varianten erläutert:In order to obtain a suitable molding composition, three variants are explained below:
Bei der ersten Variante umfasst das Gemenge als Bestandteile im Wesentlichen etwa 25 Gew.-% bis etwa 50 Gew.-% Holzfasern und etwa 0 Gew.-% bis etwa 25 Gew.-% Mineralfasern. Bei einer zweiten Variante umfasst das Gemenge etwa 50 Gew.-% bis etwa 65 Gew.-% Holzspäne und etwa 0 Gew.-% bis etwa 10 Gew.-% Holzmehl. Das Gemenge gemäß Variante 3 umfasst etwa 35 Gew.-% bis etwa 50 Gew.-% Mineralfasern und etwa 0 Gew.-% bis etwa 15 Gew.-% Graphit und/oder Glimmer.In the first variant, the mixture comprises as constituents substantially from about 25% to about 50% by weight wood fibers and from about 0% to about 25% by weight mineral fibers. In a second variant, the blend comprises about 50% to about 65% by weight wood chips and about 0% to about 10% by weight wood flour. The mixture according to variant 3 comprises about 35 wt .-% to about 50 wt .-% mineral fibers and about 0 wt .-% to about 15 wt .-% graphite and / or mica.
Bei allen drei vorgenannten Varianten wird dem jeweiligen Gemenge als Bindemittel eine Zusammensetzung mit den Bestandteilen Acryl, Copolymer und Wasser beigemengt. Als Bindemittel wird eine modifizierte Acylat-Styrol-Copolymer-Emulsion (erhältlich unter dem Handelsnamen "NeoCryl XK-Serie"), insbesondere mit einem Gewichtsanteil an Acylat, Styrol und Copolymer von etwa 50 Gew.-% bis etwa 75 Gew.-% und einem Gewichtsanteil von Wasser von etwa 25 Gew.-% bis etwa 50 Gew.-%, verwendet werden. Gemenge und Bindemittel werden sodann in einer Mischvorrichtung im kalten Zustand vermischt bis eine feuchte Masse beziehungsweise ein Brei erhalten wird.In all three variants mentioned above, a composition comprising the constituents acrylic, copolymer and water is added to the respective mixture as binder. As binder is a modified acylate-styrene copolymer emulsion (available under the trade name "NeoCryl XK series"), in particular with a weight fraction of acylate, styrene and copolymer of about 50 wt .-% to about 75 wt .-% and a weight fraction of water of from about 25% to about 50% by weight. Mixture and Binders are then mixed in a mixing device in the cold state until a moist mass or a slurry is obtained.
Diese "feuchte" Masse wird bei den Varianten 1 und 3 anschließend bei einer Temperatur von bis zu etwa 50° C getrocknet und anschließend in Partikel mit einer Maximalgröße bzw. Maximallänge von etwa 1 mm zerkleinert. Dieses Zerkleinern kann durch Schreddern oder Mahlen erfolgen.This "wet" mass is then dried in the
Nach dieser Behandlung wird die nun in Form eines trockenen Pulvers oder in Form von trockenen Spänen vorliegende Formmasse in ein Formwerkzeug eingebracht. Hierbei kann etwa das 1,5- bis 2-fache Volumen an Formmasse (im Vergleich zum späteren nach dem Pressvorgang erhaltenen Volumen der Formmasse) eingebracht werden. Nach Schließen des Formwerkzeuges wird bei allen Varianten mit einem Pressdruck von etwa 20 bis 50 bar und einer Temperatur von im Bereich von etwa 50 °C bis etwa 250 °C, insbesondere bei einer Temperatur in den oben genannten Bereichen, der Pressvorgang durchgeführt. Die zeitliche Dauer des Pressvorganges ist derart gewählt, dass die Dicke des späteren Formkörpers 50 eine Pressdauer von mindestens einer Minute veranschlagt wird. Nach Abschluss des Pressvorganges und einem zumindest teilweise Abkühlen bis auf etwa maximal 80° C kann der Formkörper 50 aus dem Formwerkzeug entnommen werden.After this treatment, the molding compound now in the form of a dry powder or in the form of dry chips is introduced into a mold. In this case, about 1.5 to 2 times the volume of molding compound (in comparison to the later obtained after the pressing process volume of the molding material) can be introduced. After closing the mold, in all variants with a pressure of about 20 to 50 bar and a temperature of in the range of about 50 ° C to about 250 ° C, in particular at a temperature in the above ranges, the pressing operation is performed. The duration of the pressing process is selected such that the thickness of the subsequent shaped
In bevorzugter Ausgestaltung ist der Hohlraum des Formwerkzeuges entsprechend ausgebildet, so dass ein plattenförmiger Formkörper 50 formbar ist.In a preferred embodiment, the cavity of the mold is designed accordingly, so that a plate-shaped molded
Nachfolgend wird auf Basis des mittels des oben erläuterten Verfahrens hergestellten Formkörpers 50 ein Verfahren zur Herstellung des Bauelementes 10 erläutert. Diese beiden Verfahren können auch zu einem gemeinsamen Verfahren kombiniert werden.Hereinafter, on the basis of the molded
Der hergestellte Formkörper 50 ist plattenartig geformt und stellt die in den Figuren gezeigte Schutzplatte 50 dar. Um nun die gewünschte Verbindung zwischen dem Tragkörper 20 in Form der Tragplatte und dem Formkörper 50 (Schutzplatte) erreichen zu können, wird ein Presswerkzeug bereit gestellt. Nach Öffnen des Presswerkzeuges wird die Lochplatte 20 in das Presswerkzeug eingelegt. Anschließend wird der Formkörper 50 auf die Innenseite 22 der Lochplatte 20 aufgelegt. Nach Schließen des Presswerkzeuges wird über eine vorbestimmte Zeitdauer und mit einem vorbestimmten Pressdruck die Schutzplatte 50 derart auf die Lochplatte 20 aufgepresst, dass Lochplatte 20 und Schutzplatte 50 formschlüssig und/oder stoffschlüssig miteinander verbunden sind.The molded
Die stoffschlüssige Verbindung kann einerseits durch eine entsprechende Beschaffenheit der Formmasse oder des Formkörpers oder durch eine nachträgliche Aufbringung einer Klebeschicht auf die Innenseite 22 oder die Schutzplatte 50 erreicht werden.The cohesive connection can be achieved on the one hand by a corresponding nature of the molding compound or the molding or by a subsequent application of an adhesive layer on the inside 22 or the
Die formschlüssige Verbindung wird dadurch erreicht, dass während des Pressens im Bereich der Öffnungen 30 befindliche Bereiche des Formkörpers 50 in die jeweilige Öffnung bzw. Ausnehmung 30 der Tragplatte 20 hineingedrückt werden. Auf diese Weise werden die Vorsprünge 52 ausgebildet. Aufgrund der dadurch erreichten formschlüssigen Verbindung zwischen Lochplatte 20 und Schutzplatte 50 kann aber grundsätzlich auf eine zusätzliche stoffschlüssige Verbindung verzichtet werden.The form-fitting connection is achieved in that areas of the molded
Das derart gebildete wenigstens feuerhemmende und/oder wenigstens quellhemmende Bauelement 10 ist somit im Brandfall auf der feuerbeaufschlagten Außenseite mit dem Formkörper 50 (Schutzplatte) derart geschützt, dass diese Verbindung auch im Brandfall über einen längeren Zeitraum erhalten bleibt. So kann im Brandfall wertvolle Zeit für das Verlassen oder Evakuieren eines Gebäudes sowie für die Löscharbeiten gewonnen werden.The at least fire-retardant and / or at least swelling-inhibiting
Die Schutzplatte 50 ist auf die Lochplatte 20 aufgepresst. Dabei erstrecken sich die Vorsprünge 52 in mehrere oder alle Öffnungen 30. Auf diese Weise wird eine formschlüssige Verbindung von Lochplatte 20 und Schutzplatte 50 erreicht. Im montierten Zustand gemäß
- 1010
- Bauelementmodule
- 1212
- Bauteilcomponent
- 2020
- Tragkörpersupporting body
- 2222
- Innenseiteinside
- 2424
- Aussenseiteoutside
- 2626
- Seitenflächeside surface
- 2828
- Plattenbereichplate area
- 3030
- Öffnungopening
- 3232
- Befestigungselementfastener
- 4040
- NagelbinderplatteTruss plate
- 5050
- Formkörpermoldings
- 5252
- Vorsprunghead Start
Claims (9)
- Method for producing a moulded part (50), in particular for the construction or furniture industry,
wherein a mixture comprising mineral fibres and/or wood fibres is combined with a bonding agent comprising a modified styrene-acrylic copolymer emulsion and
is dried to produce a moulding compound, whereby, after drying, the moulding compound has a moisture content from approximately 2 wt.% to approximately 20 wt.%,
the moulding compound is reduced
and the moulded part (50) is formed from the moulding compound at a temperature from about 50°C to approximately 250°C so that the moulded part has a residual moisture content of somewhat less than 10 wt.%. - Method according to claim 1, characterised in that the moulding part (50) is formed from the moulding compound at a temperature from approximately 80°C to approximately 220°C, preferably at a temperature from approximately 100°C to approximately 200°C.
- Method according to claim 1 or 2 characterised in that the moulding compound is dried so that, after drying, the moulded compound has a moisture content of approximately 5 wt.% to approximately 12 wt.%, preferably of approximately 7 wt. % to 10 wt. %.
- Method according to one of the claims 1 to 3 characterised in that the moulded part is moulded so that the moulded part has a residual moisture content of somewhat less than 5 wt.%.
- Method according to one of the claims 1 to 4 characterised in that the mixture comprises wood flour and/or wood chips
- Method according to one of the claims 1 to 5 characterised in that, prior to drying, the moulding compound comprises one of the following compositions:(a) from approximately 25 wt.% to 50 wt.% of wood fibres, from approximately 0 wt.% to 25 wt.% of mineral fibres and from approximately 50 wt.% to 65 wt.% of bonding agent;(b) from approximately 50 wt.% to 65 wt.% of wood chips, from approximately 0 wt.% to 10 wt.% of wood flour and from approximately 35 wt.% to 50 wt.% of bonding agent, or(c) from approximately 35 wt.% to 50 wt.% of mineral fibres, from approximately 0 wt.% to 15 wt.% of graphite and/or glimmer and from approximately 50 wt.% to 65 wt.% of bonding agent.
- Method according to one of the claims 1 to 6 characterised in that drying takes place at a temperature of up to 100°C, preferably at a temperature of up to 50°C.
- Method according to one of claims 1 to 7 characterised in that the moulding compound is filled into a pressing tool and is pressed at a predetermined temperature for a prescribed period of time and at a predefined pressure, in particular at a pressure of about 20 to 50 bar.
- Method according to one of the claims 1 to 8 characterised in that the moulding compound is pressurised for a period of at least one minute.
Priority Applications (1)
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PL08162334T PL2025484T3 (en) | 2007-08-14 | 2008-08-13 | Method for producing a moulded part, in particular for the construction or furniture industry |
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DE102007038408A DE102007038408B4 (en) | 2007-08-14 | 2007-08-14 | Process for producing a shaped body, in particular for the construction or furniture industry, and molding compound for producing a shaped body |
Publications (2)
Publication Number | Publication Date |
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EP2025484A1 EP2025484A1 (en) | 2009-02-18 |
EP2025484B1 true EP2025484B1 (en) | 2011-02-02 |
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EP08162334A Not-in-force EP2025484B1 (en) | 2007-08-14 | 2008-08-13 | Method for producing a moulded part, in particular for the construction or furniture industry |
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EP (1) | EP2025484B1 (en) |
AT (1) | ATE497432T1 (en) |
DE (2) | DE102007038408B4 (en) |
PL (1) | PL2025484T3 (en) |
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US11235565B2 (en) | 2008-04-07 | 2022-02-01 | Valinge Innovation Ab | Wood fibre based panels with a thin surface layer |
US8419877B2 (en) | 2008-04-07 | 2013-04-16 | Ceraloc Innovation Belgium Bvba | Wood fibre based panels with a thin surface layer |
DE102009021555B4 (en) * | 2009-05-15 | 2011-06-22 | AGM Mader GmbH, 85221 | Process for the preparation of a binder and use of such a binder for the production of a shaped body |
US8784587B2 (en) | 2010-01-15 | 2014-07-22 | Valinge Innovation Ab | Fibre based panels with a decorative wear resistance surface |
WO2011087424A1 (en) | 2010-01-15 | 2011-07-21 | Ceraloc Innovation Belgium Bvba | Heat and pressure generated design |
EP2523808A4 (en) | 2010-01-15 | 2017-01-04 | Välinge Innovation AB | Fibre based panels with a decorative wear resistance surface |
UA106783C2 (en) | 2010-01-15 | 2014-10-10 | Велінге Інновейшн Аб | Method to produce wear resistant surface layer (options) and flooring produced this way |
AT509429B1 (en) * | 2010-01-20 | 2016-09-15 | Erema | METHOD FOR PRODUCING A POLYMERIC MATERIAL FILLED WITH LONGER FIBERS |
US10899166B2 (en) | 2010-04-13 | 2021-01-26 | Valinge Innovation Ab | Digitally injected designs in powder surfaces |
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CN102528886B (en) * | 2010-12-13 | 2014-03-26 | 中国建筑材料科学研究总院 | Composite shaving board with electromagnetic wave absorbing function and manufacturing method of composite shaving board |
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ES2805332T3 (en) | 2011-04-12 | 2021-02-11 | Vaelinge Innovation Ab | Manufacturing method of a building panel |
RU2591466C2 (en) | 2011-04-12 | 2016-07-20 | Велинге Инновейшн Аб | Balancing layer on powder base |
EP3722104B1 (en) | 2011-04-12 | 2024-07-03 | Välinge Innovation AB | Method of manufacturing a layer |
EP3960956A1 (en) | 2011-08-26 | 2022-03-02 | Ceraloc Innovation AB | Floor panel |
US8920876B2 (en) | 2012-03-19 | 2014-12-30 | Valinge Innovation Ab | Method for producing a building panel |
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US9181698B2 (en) | 2013-01-11 | 2015-11-10 | Valinge Innovation Ab | Method of producing a building panel and a building panel |
US20140199495A1 (en) | 2013-01-11 | 2014-07-17 | Floor Iptech Ab | Digital printing and embossing |
UA118967C2 (en) | 2013-07-02 | 2019-04-10 | Велінге Інновейшн Аб | A method of manufacturing a building panel and a building panel |
WO2015057153A1 (en) | 2013-10-18 | 2015-04-23 | Välinge Innovation AB | A method of manufacturing a building panel |
DE102013113109A1 (en) | 2013-11-27 | 2015-06-11 | Guido Schulte | floorboard |
DE102013113125A1 (en) | 2013-11-27 | 2015-05-28 | Guido Schulte | Floor, wall or ceiling panel and method of making the same |
DE102013113130B4 (en) | 2013-11-27 | 2022-01-27 | Välinge Innovation AB | Method of manufacturing a floorboard |
HRP20220122T1 (en) | 2014-01-10 | 2022-04-15 | Välinge Innovation AB | A method of producing a veneered element |
CN106103096B (en) | 2014-03-31 | 2018-08-24 | 塞拉洛克创新股份有限公司 | Composite plate and panelling |
JP6567555B2 (en) | 2014-05-12 | 2019-08-28 | ベーリンゲ、イノベイション、アクチボラグVaelinge Innovation Ab | Single plate element manufacturing method and single plate element |
WO2016204681A1 (en) | 2015-06-16 | 2016-12-22 | Välinge Innovation AB | A method of forming a building panel or surface element and such a building panel and surface element |
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EP3908459A4 (en) | 2019-01-09 | 2022-10-05 | Välinge Innovation AB | A method to produce a veneer element and a veneer element |
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AT410943B (en) * | 2001-10-23 | 2003-08-25 | Markus Dipl Ing Rettenbacher | FORM BODIES OF NATURAL FIBERS AND PLASTIC, ITS MANUFACTURE IN THE PRESENCE OF MOISTURE AND ITS USE |
DE10247711A1 (en) * | 2002-03-08 | 2003-09-25 | Helmut Hiendl | Process for making a thermoplastic natural fiber product |
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PL2025484T3 (en) | 2011-07-29 |
DE102007038408A1 (en) | 2009-02-26 |
DE102007038408B4 (en) | 2011-04-21 |
DE502008002517D1 (en) | 2011-03-17 |
ATE497432T1 (en) | 2011-02-15 |
EP2025484A1 (en) | 2009-02-18 |
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