LV15083B - Technique and equipment for manufacturing limited composite slabs with a central corrugated layer on a wood base - Google Patents

Abstract

Invention relates to industry of building and mechanical engineering, especially to manufacturing technology of multilayer ribbed plates that consist mainly of sheet materials. The provided method of ribbed plates production consists of the following technological phases: A) during the process of forming the package of constructive elements consecutively at least three sheets of layered composite are placed in special equipment (fig.2) on a spring supported framed plate, and at whole width between these plates on the certain lanes the wood slips are placed, optionally with applied glue layers on contacting surfaces, and the thickness of said slips is chosen equal to the height of formed goffer; B) in phase A obtained package at whole width is subjected to pressure simultaneously with thermal effect, as a result the outer layered composite sheets are being curved and in several lanes at whole width at increased temperature are bonded with central layered composite sheet to achieve two sided layered large size goffered pre-product that is strengthened with ribs which are formed by said slips at several zones; C) in phases A and B produced large size goffered pre-product after gluing, unloading and removing of press is sawn in goffered strips which width is equal to the required height of ribs to form hollow ribs on plywood composite base.

Description

Description of the Invention

BACKGROUND OF THE INVENTION The present invention relates to the construction and mechanical engineering industry, in particular to technology for the production of sandwich composite materials in the form of multilayer ribbed panels, mainly derived from structural sheet materials with a specific orientation and composite structure, laminated to a plurality of layers. the final product contains sheets with cellular ribs. The proposed ribbed fabrication technique can be used to produce tiles for building and civil engineering, mechanical and transport applications requiring materials with increased specific load-bearing capacity (mass per unit load) in bending and compression as well as combinations thereof, while providing improved slab thermal properties . The invention was created with support from the National Research Program "Innovative Materials and Smart Technologies for Environmental Safety (IMATEH)".

Analysis of prior art

There is a known process (patent LV14519) [1] for the production of wood-based cell-type material with a ribbed internal structure. An essential structural feature of the invention is the laminate wood material (SKM) inner layer with ribs of any configuration or ribs filled with heat and / or sound insulation, which can be of both regular and irregular shapes, such as natural wood, but is important. that said SKM ribs are formed as a lattice structure by interconnecting, at selected node points, SKM elements of this or other shape which are oriented perpendicularly or at a given angle to the surface of the outer layers and are made by sawing the SKM ribs in the elements

In patent LV14519, cell-type ribbed cells are manufactured as follows:

a) making the necessary number of identical corrugated blanks from SKM, which are paired in order to produce a cellular internal structure of the cell on both sides, aligning the waveguides of the opposite corrugated blanks and the locations of the slots on opposite surfaces of the auxiliary plate; a small number of said corrugated SKM blanks are glued to the auxiliary plate only on one side to cover the cellular plastic around the perimeter by placing a smooth surface on the outside;

b) The corrugated blanks produced in step a) are sawn in a plurality of bands by moving the cutting tool in the first direction, i. i.e., perpendicular to the corrugated wave backs, and the resulting bands for producing the structural elements necessary for the cellular plastic structure are sawn in a second direction perpendicular to said first direction by guiding the cutting tool through selectively selected corrugated wave recesses; all wells if the dimensions of the cellular plastic to be formed are longer than the dimensions of the obtained cellular plastic elements in the first cutting direction by length and / or width;

c) forming a cellular plastic structure in which the ribs from above form a lattice structure of constant height equal to the size of the elements produced in step b) in the second cutting direction; gauge cell plastic along its length and width, coaxially arranged according to the pre-selected cell plastic configuration and, where appropriate, secured along its length with glue, e.g. analogous to bevel glued joints or tangential overlaps, the outer covering contour surface is preferably formed from the cellular plastic elements obtained in step b) by sawing the corrugated SKM blanks which in step a) were glued to one side only and facing their flat surface to the outside.

A method of making ribbed composite boards is also known (patent LV14979), the essence of which is as follows:

(a) The load-bearing material plate (s) is (are) glued to the foam or similar. sheets of material, hereinafter referred to as "filler", on one or both sides, the type of filling being selected depending on the requirements of the ribbed board (thermal or acoustic insulation properties, humidity control, etc.);

(b) the bonded structure referred to in (a) is cut into strips of a width equal to the projected distance between the cover layers of the slab;

c) orienting said strips in such a way that their rib plane is perpendicular to the facing layers of the panel cladding and that the strips are glued together or otherwise bonded together to form a single whole, as well as an adhesive bond: multilayer ribbed composite board.

The wood-based composite board, manufactured in accordance with the techniques defined in patents LV14159 and LV14979, using a cellular-type ribbed cellular material (SKM) based panel to reinforce it, can be used in lightweight enclosures (self-supporting wall elements, office work area separation panels, etc.) , as well as in load-bearing structures such as floor, wall, ceiling slab construction, ship, trailer and wagon construction including furniture industry etc. All layers of laminated composite panels are glued together and form an integral structure, in which the distribution of the amount of wood fibers in the individual layers and layers in a given direction ensures the load-bearing capacity of the board, whereby rib structure provides effective control of material strength under various actions , torsion, humidity and temperature, and a combination of these. Depending on the type of action, the configuration of the SKM ribs plays a decisive role in the operating process and therefore, for a particular application, designers should look for the shape and construction of the middle panel slabs determined by the SKM wood bundle structure and wood fiber orientation in individual SKM layers.

Both of these patents:

(i) depending on the circumstances, said ribbing strips are assembled in groups, each consisting of a predetermined number of strips, and leaving a gap of a certain width between the groups in the ribbon forming process, e.g. system, or even leave it blank. According to the invention, the following materials or combinations thereof are used as load-bearing layers in accordance with the invention: plywood; OSB boards, different density fiber boards of organic and inorganic materials and reinforced plastics of different materials, with the load-bearing layer on one or both sides being offered with different density foams made of different polymeric material modifications, whereas the said outer coating layer The following materials, selected from the group consisting of: wood, wood material, laminated wood, veneer, plywood, particle or resin glued wood, metal, textile and fiber materials, cardboard, paper, plastics, fiber-reinforced plastics, mineral-based building materials, stone, artificial stone and composite materials made of two or more materials;

(ii) The following options, which are generally known, are traditionally offered in addition to the wood-based composite panels offered:

- the sheets are treated with flame retardants or antiseptics, if necessary, prior to gluing,

- a spacer frame structure, which performs the function of a wall frame / skeleton and can be optionally fitted with tilts, can be used for additional ribs,

- different adhesives are used to adhere said strips to the cladding boards and / or filler-forming foam sheet elements, where necessary;

- other ribbed materials, such as soft fiber fibreboards, are used to separate the ribs, if necessary, in addition to the foam sheets;

(iii) optionally performing at least one of the following:

- the strips are treated with flame retardants or antiseptics, if necessary, before bonding,

- and / or a spacer frame structure is used to create additional ribs, which performs the function of a skeleton / skeleton and can optionally be fitted with tilts,

- and / or different adhesives are used to glue the said strips to the cladding boards and / or the filler-forming foam elements, if necessary;

- and / or other sheet materials, such as soft wood fiber boards, are used for rib finishing, where appropriate.

The essence of the method of the invention

The object of the present invention is:

- using a corrugated blanks method based on layered wood materials (SKM) and a special machine as defined in claim 3, to provide a layered composite material board structure as defined in claims 7 and 8, sequentially arranged as defined in claim 4. to claim 6, at least two (preferably at least three) SKM sheets in spaced bands and spacers spacers / spacers which may optionally, but are not necessarily, coated with a layer of adhesive on SKM sheets and having the same thickness with a corrugated wave height of. Thus, the process of manufacturing laminated composite panels succeeds in increasing the useful yield of the panel materials and reducing the weight of the panels, while at the same time ensuring their high physical and mechanical properties and reducing the thickness of the panels from moisture.

The essence of the invention is as follows:

A) A large double-sided corrugated plate (workpiece for subsequent operations) is produced sequentially on the basis of SKM, using a special machine, which in cross-section is shown in Fig.2.1 and Fig.2.2, but in axonometry in Fig.2.3 , wherein said corrugated blanks are made of SKM sheets (layers), the topological structure of which is selected according to the angle of mutual orientation of the wood fibers in the adjacent SKM layers, the number and thickness of the layers and the method of fixing them. The package of structural elements of said corrugated preform is preformed as a package of structurally balanced layers relative to the median plane. After pressing, the ribbed blank is sawn widthwise into strips, which can be optionally treated with antiseptics and / or fire retardants to prevent burns, rot and insect damage, as well as, if necessary, between the ribs. can be filled with any type of foam type material, such as pellets, and covered with suitable sheet material as additional cover layers;

B) The resulting corrugated strips are glued as integral composite elements throughout the free contact surface area to the pre-fabricated composite top and bottom layers, each of which may be any required composite composite material, preferably structurally balanced on the wood

etc. bases of suitable materials, whereby all or part of the structure of the slab may also be treated with antiseptics and / or flame retardants against burning, decay and insect damage, and, if necessary, again covered with metal, plastic, etc. suitable sheet material as additional overlay. The cellular structure of the created composite plate with hollow corrugated ribs forms an integral composite plate structure and provides the possibility to regulate the specific strength of the material at various loads - compression, bending, shear, torsion as well as the combination of these loads. The characteristics of all these corrugated ribs can be adjusted based on the geometric and deformation properties of the SKM layers used to form them (thickness, relative tensile strength and layer placement / orientation), as well as taking into account the normative properties of laminate composite boards ( for this or another application, since the structural elements obtained during the fabrication of said rib blanks are respectively aligned with each other and positioned adjacent to each other in the desired direction (s) of coordinate axis (s) and optionally, but not necessarily, in separate zones. bonded together in a continuous ribbed construction over length and / or width.

A list of drawings explaining the invention

The proposed method of making corrugated blanks on the basis of wood materials, when said spacer strips are glued in separate zones together with said wood-based plywood sheets (layers) to form a ribbed continuous structure of length and / or width, is characterized by the following operations: In the process of constructing a package of structural elements, three sheets are successively represented in Fig. 1, whereby:

- Fig. 1.1 shows that in the special machine shown in Fig. 2, a plywood sheet 1 with a layer of glue applied across the width of two strips is inserted into the press support plate;

- Fig. 1.2 shows that strips 3 having a thickness equal to the height of the cavities to be formed and having a layer of glue applied at the top edge are placed in the special guides of the machine over the plywood sheet 1;

- Fig. 1.3 shows that above the slats 3 the plywood sheet 4 forming the straight central part of the SKM is placed in the machine;

Fig. 1.4 shows that, above said SKM plywood sheet 4, there is re-inserted into the special guides of the machine strips 5 having the thickness of the cavity formed on the other side and having an adhesive layer applied at the bottom;

Fig. 1.5 shows that the next plywood sheet 6 is placed on the upper layer 5 with a layer of glue applied to it in certain stripes;

- Fig. 1.6 shows that, after applying force, the outer plywood sheets 1 and 6 are curved and glued together with the central plywood sheet 4 at elevated temperature along the width of the pre-formed structural element packet in parallel to the thermal action. double-sided (corrugated) large-format SKM blank, reinforced at some points by ribs formed by said strips 3 and 5;

Fig. 1.7 shows the resulting double-curved, ribbed large-format SKM blade after gluing, releasing and unloading the pre-formed structural element package 1, 3, 4, 5 and 6;

Fig. 1.8 shows that the SKM large format blank shown in Fig. 1.7 is sawn widthwise into corrugated strips the width of which is equal to the required height of the ribs so that these strips are restructured in the form of a ribbed composite blank shown in Fig. 4.1 or Fig. 4.2 and Fig. 4.3, after having been trimmed with finishing boards 17 and 19 from above and below and, if necessary, from both ends and sides, to produce ribbed composite panels as defined in claims 7 and 8.

The special equipment used for the implementation of the technique is shown in cross-section in Fig. 2.1 and Fig. 2.2, and in axonometry in Fig. 2.3, in one of these operating positions, where:

- the device mentioned in fig.2.1 is schematically shown in the working condition, when a pre-formed set of structural elements is shown on the fixed frame 7 of the apparatus above the rigid slabs shown in fig. 1.5, and the clamping frame formed by the clamping elements 8 which are heated, are raised in an elevated position above said package of structural elements and the ends of moldings having a thickness equal to the height of the corrugation to be formed are inserted in the vertical guides 13;

- the apparatus of Fig.2.2 is shown in a second operating position when the assembly of structural members positioned in the frame of the apparatus between the rigid supports and the press members is actuated by the hydraulic cylinders on the press frame simultaneously with temperature and force perpendicular to the plane of said package; as a result, the outer package sheets are curved and compressed in separate strips and glued at elevated temperature together with the middle straight plywood sheet, resulting in a bilaterally curved ribbed large-format SKM blank as shown in Fig. 1.6;

Fig. 2.3 in addition to Fig. 2.1 and Fig. 2.2 shows a device for implementing the technique in axonometry, which corresponds to the embodiment depicted in Fig. 2.1, when the pressure frame is in the raised position above the package of structural elements;

Figure 3.1 relates to an embodiment of the invention in which the corrugated cavity moldings have been removed, i.e., during the process of forming the corrugated preforms, the glue between the spacer strips and the said plywood sheets was not used;

Fig. 3.2 relates to an embodiment of the invention in which the corrugated cavities are formed only of two plywood sheets 1 and 6 forming the corrugated wave, using spacer strips 3A and 5A glued to the corrugated workpiece, but without using the central plywood sheet 4, it is also possible in principle;

- fig. 3.3 relates to an embodiment of the invention in which the corrugated cavities are formed only of the corrugated weave plywood sheets 1 and 6 and the cavity strips 3A and 5A are removed;

Fig. 4.1, Fig. 4.2 and Fig. 4.3 show some structural variants of ribbed composite board preforms obtained using rib corrugated preform strips as defined in the "Exemplification of the Invention" section, respectively re-structured, e.g. , glued and trimmed with finishing boards 17 and 19 from the top and bottom and, if necessary, from both ends and sides, whereby tinting in Figure 4.2 indicates that, for example, foam granules are embedded in the rib rib cavities.

In Fig. 1, Fig. 2 and Fig. 3 the following designations are used: 1 - SKM sheet for forming a single layer of corrugated workpiece (abbreviated "corrugation") with a layer of glue optionally applied in separate columns 2; 3 - moldings with thickness equal to the maximum height of the corrugation to be formed, with an adhesive optionally applied to the upper edge; 4 sheet forming the central rectangular part of the blank; 5 - moldings of thickness equal to the maximum height of the corrugation to be formed, with an adhesive optionally applied to the lower edge; 6 - SKM sheet for forming a single waffle layer with an adhesive layer optionally applied in separate columns on its underside; 7 - Rigid supports for heating said package of structural elements which are heated; 8 - machine pressing elements for compressing said package of structural elements, which are heated; 9 - Machine bearing vertical frame; 10 - Hydraulic cylinders for the compression force required to form a corrugation to deform the package of structural members; 11 machine pressure frame; 12 - rigid horizontal frame of the machine, in which the following structural elements are fixed: 13 - spacer rail guides, 14 plate with longitudinal cut-outs facing the pressing elements, the plate being supported by springs 15 to keep it in the uncompressed position on the heating elements, 15 - springs for holding the plate above the heating elements, 16 - central pressing elements of the equipment (upper and lower), which are supported by springs; 17 - lower composite panel blanking sheet; 18 - filling of foam pellets in the interstellar space; 19 - Upper composite panel blanking sheet.

Examples of realization of the invention

Example 1 specifies one liter. Embodiment illustrates an embodiment of the invention in which the waveguide sheets 1 and 6 are 4 mm thick and the straight center 4 sheet 6.5 mm thick is made of plywood. For corrugated wave sheets 1 and 6, the direction of the outer layers of fibers is perpendicular to the longitudinal axis of the slab, while in sheets 4 the direction of the outer layers of fibers is equal to the longitudinal axis. The spacers 3 and 5 have a height equal to the height of the cavities to be formed, 44 mm, and are formed with an aspect ratio (height to width) of 1/2. The length of the sheet 4 forming the straight central part of the corrugated workpiece is equal to the length of the ribbed workpiece to be formed 1.5 m. The height of the ribbed cavity created is equal to the heights of strips 3 and 5, respectively 44 mm. The corrugated wave number is 4, the horizontal distances between the pressing elements 7 and 8, the slats ЗА and 5A and the guides 11 are equal to a wavelength of 375 mm. The waveguide sheets 1 and 6 are selected 64 mm (i.e., 32 mm at each end to the right and left) longer than the central part of the rib 4, so that after the hollow rib is produced, the sheets 4 and the wave sheets 1 and 6 may cross. The adhesive layer, if used, should preferably be applied in strips of 20 mm and a pressure of 5 kg / cm ² should be applied to the adhesive surfaces. Heated pressure members 7 and 8 must optimally maintain a temperature of 100 ° C at the bonding points of the sheets.

Example 2 is a fig. a variant of the corrugated blank shown in the case where the strips 3B and 5B were not glued (in other words, the adhesive was not used to bond them to the aforementioned structural composite sheets 1, 4 and 6) and were removed after forming the corrugated blank. The other directions are similar to

In Example 1.

Example 3 is Figure 3.2. a variant of the preform shown in the case where, for one reason or another, the central part sheet 4 was not used for forming the package of structural elements of the preform and therefore the strips 3A and 5A were each selected 3.25 mm thick, i.e. their height was increased by half the thickness of the sheet forming the central part of the package. The other indications are analogous to the corrugated blank shown in Example 2, which is shown in Fig. 1.

Example 4 is 3.3. fig. a variant of the blank shown in the case where the central part sheet 4 was not used for forming the package of structural elements of said blank. Therefore, strips 3B and 5B were taken 3.25 mm higher, i. the sheets forming half the straight part of the rib and were removed after gluing the corrugated workpiece. The other references are analogous to Example 1 or 2.

Example 5 is Figure 4l, Figure 4.2. and Figures 4.3. some of the structural variants of the ribbed composite board preforms 17 shown in claims 7 and 8, using the corrugated preform strips of the invention (see claims 1 and 2), respectively restructuring, joining, e.g. gluing, and trimmed with trim panels 17 and 19 from above and below and, if necessary, from both ends and sides, with tinting as shown in Figure 4.2. points out that, for example, foam granules are filled in the interstitial cavities 18.

Claims (8)

Claims 1. A method of making corrugated blanks (hereinafter referred to as corrugations) on the basis of layered wood materials (SKM), wherein the topological structure of the SKM is selected based on the angular orientation of the wood fibers in adjacent SKM layers and their number and thickness. that contains the following steps: A) At least three SKM sheets are placed sequentially on the slab, spring-based slabs in a special machine, forming spaced sections with spaced strips spaced between them, optionally covered with a layer of glue equal to the thickness of the molding wave height, B) The width of the structural element assembly obtained in step A is subjected to thermal extrusion at the same time as a result of which the outer SKM sheets are curved and compressed (optionally glued) in several bands at elevated temperature along the central SKM sheet to obtain a double curved a large-size corrugated workpiece reinforced in certain areas by ribs formed by said moldings; C) The large-size ribbed corrugated blank obtained in steps A and В is, after unloading and release from the press, sawn into corrugated strips of a width equal to the necessary rib height to form hollow ribbed panels based on SKM. A method of manufacturing corrugated blanks according to claim 1, characterized in that said steps А, В and C, when said spacer strips are glued together in the separate zones with said wood-based plywood sheets (layers), are successively performed. performing the following steps to obtain a ribbed continuous structure in length and / or width: 1.1) in a special machine, place the SKM sheet on a lattice-based, spring-based plate, optionally with a layer of glue applied in defined widths; 1.2) above the SKM sheet referred to in the previous step, there is a special guide for the machine, with strips of a thickness equal to the wavelength of the mold to be formed, with a layer of glue applied at the top; 1.3) the SKM sheet forming the central part of the workpiece is placed above the rails mentioned in the previous step; 1.4) above the previous step, re-insert strips of thickness equal to the wavelength of the corrugation to be formed on the reverse side of the SKM sheet into the special guides of the machine; 1.5) place the next SKM sheet with the adhesive layer applied to it on the upper layer of the wooden strips mentioned in the previous step; 1.6) after applying the force in the bands mentioned in the previous step along the width of the pre-fabricated structural package simultaneously with the thermal effect, the outer SKM sheets are folded and bonded (optionally glued) in several bands at elevated temperature to obtain double-curved corrugated large format SKM which, in certain zones, are reinforced by ribs formed by said moldings; 1.7) the double-curved, corrugated large-format SKM blank obtained in the previous step is relieved and pressed out after gluing; 1.8) The workpiece referred to in the previous step is sawn widthwise into corrugated strips the width of which is equal to the required height of the ribs to form hollow ribbed SKM boards. The device (Fig. 2) for carrying out the method according to claim 1 or 2, wherein the device comprises: rigid supports (7) for heating said package of structural elements, which are heated; apparatus for pressing said elements (8) for compressing said package of structural elements, which are heated; a vertical bearing frame (9) for the machine; hydrocylinders (10) for obtaining the pressing force required to form a corrugation to deform the package of structural elements; a press frame (11) for the machine; a rigid horizontal frame (12) of the apparatus, the following structural elements being fixed in said frame (12): guides (13) for spacers; a plate (14) having longitudinal cut-outs facing the pressing elements, wherein the plate is supported by springs (15) for holding the plate (14) above the heating elements; the middle press members (16) of the machine (upper and lower) supported by springs. Use of corrugated preforms based on layered wood materials (SKMs) according to claim 1 or 2 for the production of wood based composite laminates by gluing the obtained corrugated strips as integral composite elements over the entire free surface area to the prefabricated composite topsheet, each of which may be a composite material of any required structure, preferably structurally balanced on the wood etc. bases of suitable materials, optionally all or part of the structure of the slab is treated with antiseptics and / or flame retardants against burns, rot and insect damage and, if necessary, further covered with layers of metal, plastic or other suitable sheet material. The use according to claim 4, wherein both the structure of the two outer layers and the formed corrugated cellular plastic structure with hollow corrugated ribs which are glued together and form an integral composite panel construction are chosen to provide the maximum effective control of the material specificity. strength under various types of loading - compression, bending, shear, torsion, as well as the combination of these types of loading. The use according to claim 4 or 5, wherein the characteristics of the corrugated ribs are selected based on the geometrical and deformation properties (thickness, relative bulk density and layer placement / orientation) of the SKM layers used to form it, taking into account the normative characteristics of building panels. (mainly strength, shape stability in service, thermal insulation and sound insulation) for this or other application. 7. Composite wood-based composite board, characterized in that it contains: (i) a central layer formed by corrugated strips of plywood or laminated fibrous material, in particular strips of porous fibrous material according to claim 1 or 2, structured by interconnecting them in blocks. and corrugated wave contact areas, such as by gluing, the number and dimensions of the resulting corrugated blanks being aligned with the dimensions of the subsequent layer layers used for the finishing of said central layer, (ii) at least two outer layers fully applied to the two largest sides; using at least one thermosetting binder, wherein: the flat structure of the cover layers may comprise wood fibers and synthetic formaldehyde-free polymers and optionally may comprise thermoplastic fibers or mixtures thereof with wood fibers; each of said outer coatings preferably being a multilayer material based on wood, optionally a single layer plank or particle board, in particular particle board and oriented strand board, hard (high density) fibreboard and / or medium density fibreboard (iii) Optional layers required to be covered in the lateral and / or end areas of said corrugated blank. 8. Ъ ^ <^ np ^ oī ^ t ^ eJ ^ lā ^ ņ ^ u ssshangā ur 7. a method of making a pre-formed wood s bzzss comprising the following steps: (a) providing flat exterior oegolaf wood-based materials, (b) interconnecting blocks of corrugated blanks obtained according to claim 1 or 2 with glue in the corrugated wave peak areas, (c) corrugating obtained in step (b); interconnecting the blocks with an adhesive, adjusting the resulting corrugated structure in a dimenion ion to the gauge dimensions of the cover layers selected in step (a), laminating the corrugated structure obtained in step (c) simultaneously or sequentially on one side and then on the other. a) said outer blankets on a wood-based basis and subjected to pressure and heat such that the binder hardens at least partially, (e) final structuring of the slab surface obtained in step (d), optionally employing at least one functional finishing agent; layer of material and drying.