Method for producing plastic drainage panel and plastic drainage panel

Abstract

The invention discloses a method for manufacturing a plastic drainage plate and the plastic drainage plate. For manufacturing purposes, a plate-like body (2) having a first surface (5) and a second surface (6) is provided, the second surface (6) being spaced apart from the first surface (5) by a substrate thickness. A groove (7) is introduced into the first surface (5) of the body (2) and a mating groove (8) is introduced into the second surface (6) of the body (2). The mating groove (8) and the groove (7) intersect one another at an intersection point (9). A through hole (10) located between the groove (7) and the mating groove (8) is formed at the intersection point (9).

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This patent application claims the priority of German patent application DE102018211667.9, the content of which is incorporated herein by reference. Technical Field

[0003] The present invention relates to a method for manufacturing a plastic drain board. In addition, the present invention relates to a plastic drain board. Background Art

[0004] Plastic drains can also be called geosynthetic drains (GDS). They are used in mining, landfill construction, tunnel construction, road construction or other geotechnical applications. In this respect, it is desirable to ensure a sufficiently high drainage capacity with the aid of plastic drains. Geonets (GNT) are often used as plastic drains, especially in cases where pressure loads are high. Geonets are produced in devices designed specifically for this purpose. US2009 / 0041544A1 discloses geonets and methods for their manufacture.

[0005] DE2400941C2 discloses a method for producing a plastic mesh. After grooves are introduced into both surfaces of the plastic film, the plastic film is stretched and / or extended to several times its length, for example seven times its length. The dimensions of the resulting plastic mesh are not suitable for plastic drain boards, in particular, for example, a maximum film thickness of 0.38 mm. In addition, due to the stretching, the plastic mesh is deformed by a multiple of its length, so that a flow path cannot be formed along the plastic mesh. The plastic mesh that can be produced according to the method in DE2400941C2 cannot be used as a plastic drain board. Summary of the invention

[0006] The object of the present invention is to propose an improved method for producing plastic drain panels. The method should be flexible and capable of producing plastic drain panels that can withstand high pressure loads.

[0007] The object is achieved by a method having the steps specified in claim 1. A plate-like body is provided, which has a first surface and a second surface, the second surface being spaced apart from the first surface by the substrate thickness of the body. A groove is introduced into the first surface of the body, and a matching groove is introduced into the second surface of the body. The matching groove and the groove intersect each other at an intersection. For the purpose of manufacturing the plastic drain board, a through hole located between the groove and the matching groove is formed in the region of the intersection.

[0008] According to the present invention, it has been recognized that manufacturing the plastic drain panel from a plate-like body increases the stability of the plastic drain panel. The plastic drain panel is manufactured in one piece. The pressure load is borne and absorbed into the plastic drain panel produced in this way via solid support points. Stability failures that can occur in geonets, for example due to the folding or unfolding of separately manufactured wires, are avoided in the plastic drain panel manufactured in this way. The plastic drain panel has high stability, in particular high compressive strength, high shear strength, high contact shear strength and high dimensional stability. Even in the case of high pressure loads, sufficient drainage capacity can be ensured throughout the service life of the plastic drain panel.

[0009] Perpendicular to the substrate thickness, the provided plate-like body has a longitudinal direction and a transverse direction. The longitudinal direction and the transverse direction cross the plane of the plate. The longitudinal direction is also referred to as the production direction (longitudinal direction (MD)). The transverse direction is correspondingly referred to as transverse to the production direction (cross-machine direction (CMD)). In the plate-like body, the length of the body, i.e. its extension in the longitudinal direction, and the width of the body, i.e. its extension in the transverse direction, are significantly greater than the substrate thickness. The body has a planar form. The width of the body and the substrate thickness can vary over the length of the body. However, preferably, the width and / or the substrate thickness are constant. In the case of a constant substrate thickness, the first surface and the second surface are parallel to each other and extend parallel to the plane of the plate.

[0010] The through holes form perforations in the body. In this way, the water permeability of the plastic drain board perpendicular to the board plane is ensured. Water can flow into the grooves and matching grooves in the board plane and penetrate the plastic drain board via the through holes perpendicular to the board plane.

[0011] The grooves and / or matching grooves can be introduced in a variety of ways, for example by removing material of the main body in the area of ​​the grooves and / or matching grooves to be introduced. The grooves and / or matching grooves are preferably formed in the main body. The grooves and / or matching grooves can be formed substantially without removing material. The grooves and / or matching grooves can be formed together with the main body or after the main body is provided. For example, the grooves and / or matching grooves are embossed into the surface of the plate-like main body by means of embossing rollers, in particular one or more smoothing calenders.

[0012] By introducing grooves and matching grooves and forming through holes, the plastic drain board can be manufactured integrally from the main body. Therefore, the size of the finished plastic drain board substantially corresponds to the above-mentioned initial size of the main body provided. However, due to the introduction of grooves and / or matching grooves, the thickness of the main body perpendicular to the plane of the board will change. When the grooves and / or matching grooves are formed without material removal, especially in the case of embossing, the material of the main body originally located in the area of ​​the grooves and / or matching grooves is displaced. Due to this material displacement, the thickness of the main body is increased compared to providing the main body with the substrate thickness, and therefore the thickness of the plastic drain board is increased. In order to clearly distinguish the thickness that may vary, the term "substrate thickness" is used to refer to the thickness of the main body provided before the introduction of grooves and / or matching grooves. In contrast, the term "plate thickness" refers to the thickness of the main body after the grooves and matching grooves are formed. Therefore, the term "plate thickness" refers to the thickness of the main body of the finished plastic drain board.

[0013] The board thickness may be, for example, between 4 mm and 20 mm, in particular between 4 mm and 10 mm. If the grooves and / or the matching grooves are formed, in particular embossed, the body must have a correspondingly lower substrate thickness, for example between 2 mm and 10 mm, in particular between 2 mm and 5 mm. In some cases, the formation of the grooves and / or the matching grooves may result in a doubling, in particular a tripling, of the substrate thickness due to material displacement. If, on the other hand, the grooves and / or the matching grooves are introduced into the body by material removal, the board thickness of the body of the finished plastic drain substantially corresponds to the substrate thickness.

[0014] The width of the plastic drain board corresponds essentially to the width of the provided body. In some embodiments of the method, the width of the plastic drain board can be varied in a targeted manner relative to the initially provided body. Thus, the body can be pulled out longitudinally in the production direction, for example, so that the width of the plastic drain board is reduced. This is also referred to as stretching of the body. Stretching can be carried out in particular by means of a pull-out speed of a smoothing calender that is increased relative to the conveying speed of the body. Alternatively, the body can also be grasped at the longitudinal edges extending parallel to the longitudinal direction and pulled out transversely, thereby increasing the width of the plastic drain board. This operation is also referred to as expansion. Therefore, the width of the plastic drain board can be influenced in a targeted manner and adapted to the respective use case.

[0015] The first surface and the grooves introduced therein constitute the first functional layer of the plastic drain board. The second surface and the matching grooves introduced therein constitute the second functional layer of the plastic drain board. The functional layer allows water to be discharged along the board plane of the body via the grooves and / or the matching grooves. The functional layers of the plastic drain board are fluidly connected to each other via through holes.

[0016] The method can be flexibly adapted to the requirements of the plastic drain board to be manufactured. In particular, the method provides a great degree of design freedom for the arrangement, structure and cross section of the grooves and the matching grooves. In this way, the water mobility of the grooves and / or the matching grooves can be flexibly influenced and optimized in a manner specific to the application. For example, the cross section of the groove can be rectangular, with or without corner reinforcements (arch axils), tunnel-shaped or trapezoidal. The cross sections of the grooves and the matching grooves can be the same or different. In addition, the grooves and / or the matching grooves can be introduced into the corresponding surfaces of the body with different widths and spacings. For example, grooves that are wider than their respective spacings can be manufactured in order to ensure high water mobility and a low weight per unit area of ​​the plastic drain board.

[0017] The groove and the matching groove intersect each other. In other words, the groove extends in the plate plane at a limited angle to the matching groove. By way of example, the angle may be between 20° and 160°, in particular between 45° and 135°, in particular between 80° and 100°, preferably about 90°. At the intersection, the groove and the matching groove overlap in the direction of the plate plane of the body.

[0018] However, providing an intersection does not mean that the groove and the matching groove also have an overlap at the intersection perpendicular to the plate plane, that is to say in the direction of the plate thickness, i.e. the sum of the depths of the groove and the matching groove is greater than the plate thickness of the body. In practice, the depth of the groove and / or the matching groove, i.e. its dimension perpendicular to the plate plane, can also have a flexible construction. For example, each groove and / or matching groove can have a depth between 10% and 90% of the plate thickness. The depth of the groove and / or matching groove can be selected to be constant. Alternatively, the depth of the groove and / or matching groove can be periodically alternating. For example, each second groove and each third matching groove can have a depth of 50% of the plate thickness, respectively, while the remaining grooves and / or matching grooves can have a smaller depth.

[0019] In addition to forming intersections, the grooves and / or mating grooves may extend in any desired direction in the plane of the plate. The grooves preferably extend parallel to each other. The mating grooves also preferably extend parallel to each other.

[0020] The method according to claim 2 is flexible and economical. The body can be extruded with a variable, adjustable substrate thickness. Extrusion of the body also has the advantage that the body and thus the plastic drain board can be manufactured in any desired length. For example, plastic drain boards with a length of more than 10 m, in particular more than 50 m, in particular more than 100 m, in particular more than 200 m can be manufactured.

[0021] The preferred use of a slot die extruder allows the manufacture of wider plastic drain panels, for example with a width between 2 m and 8 m. The width of the plastic drain panel is in particular at least 4 m, in particular at least 6 m, in particular at most 8 m. The width of the plastic drain panel is limited only by the width of the slot die extruder. In addition, the width of the extruded plastic drain panel can be specifically changed by more manufacturing steps. Therefore, the width of the plastic drain panel can be reduced by, for example, stretching the body by a smoothing calender. Alternatively, it is also possible to extend the body to increase the width.

[0022] Extrusion also allows the body to be provided with a consistent quality. In particular, extrusion offers the possibility of increasing the flexibility of the choice of material for the body. A wide variety of plastics and plastic mixtures can thus be used. A variety of materials can also be bonded to the body by coextrusion.

[0023] The extrusion of the main body also has the advantage that other components of the plastic drain plate can be provided together with the main body. Particularly preferably, the main body is provided together with the reinforcement structure. For this purpose, a continuous yarn can be provided and introduced into the main body during extrusion. In this way, the continuous yarn can be embedded in the main body in the longitudinal direction over the entire length of the main body. The continuous yarn allows uniaxial reinforcement of the main body. The yarn that can be used for this purpose is particularly a multifilament yarn, for example a multifilament yarn consisting of polyethylene terephthalate (PET) or polyvinyl alcohol (PVAL). Alternatively, other yarns, such as glass fibers, basalt fibers and / or steel fibers can also be embedded in the main body during the extrusion process.

[0024] The method according to claim 3 is flexible in the choice of materials. Polyethylene (PE), polypropylene (PP), polyamide (PA), polystyrene (PS), acrylonitrile butadiene styrene copolymer (ABS), wood plastic composites (WPC), biopolymers, polyvinyl chloride (PVC) and / or polyethylene terephthalate (PET) have proven to be particularly suitable for the production of plastic drain panels. These materials are recyclable, resistant to aging, weathering and chemical corrosion, and have low creep properties. In addition, all of these materials are suitable for extrusion. Polyethylene is particularly preferably used, in particular in the form of PE-LLD, PE 80, PE 100, PE 100-RC, PE-EL, PE-MD and / or PE-HD. In addition, the method can also process all of the above-mentioned materials as new materials and recycled materials (rework materials), materials recovered from waste (post-industrial materials) and / or recyclates (post-consumer materials (PCM)). This enables plastic drain panels to be manufactured in an economical and resource-saving manner.

[0025] Suitable materials or suitable mixtures of these materials can be selected according to the requirements for the plastic drain board. In addition, fillers, in particular inert fillers, can be added to the materials used. Examples of suitable fillers are rock flour, wood flour, biopolymers and / or short fibers.

[0026] When using these preferred materials, the plastic drainage board can have a weight between 1500g / m 2 and 18000g / m 2 . This has the advantage that the plastic drain panels are light in relation to their size and can be easily transported. The weight per unit area is determined in accordance with DIN EN ISO 9864.

[0027] The method according to claim 4 is efficient and easy to implement. For example, the grooves can be embossed in the longitudinal direction or perpendicular thereto via a suitable embossing roller of a smoothing calender. In the case where the main body is extruded, the longitudinal direction corresponds to the machine direction (MD). In this case, it is particularly preferred to form the grooves on the first surface of the main body parallel to the longitudinal direction, because the grooves then cover the entire length of the plastic drain board. The grooves can be formed directly during the extrusion of the main body, because the extruder has a correspondingly formed distribution groove or extruder groove. The grooves can then be formed while the main body is provided.

[0028] The mating groove is preferably formed parallel to the second surface of the body in the transverse direction.The groove and the mating groove particularly preferably extend perpendicularly relative to each other, ie at an angle of approximately 90°.

[0029] The method according to claim 5 is efficient. In particular, a groove is formed, in particular embossed, with a depth d1 in a direction perpendicular to the first surface, and a matching groove is formed, in particular embossed, with a depth d2 in a direction perpendicular to the second surface. When the depth d1 of the groove and the depth d2 of the matching groove together are greater than or equal to the plate thickness of the body, a through hole can be formed only by introducing, in particular forming the groove and the matching groove. Advantageously, after being introduced, the groove and the matching groove have the depth d1 and / or d2 required for forming the through hole. No further method steps are required for forming the through hole. In addition, the plastic drain board manufactured in this way has the advantage of high drainage capacity. The sum of d1 and d2 is particularly preferably greater than the plate thickness of the body. In this case, the plastic drain board has high stability as well as high drainage capacity.

[0030] The method according to claim 6 ensures a high water permeability perpendicular to the plane of the plate. The pneumatic, hydraulic and / or mechanical introduction of the through-holes ensures that the body is perforated regardless of the depth d1 of the groove and the depth d2 of the mating groove. The through-holes can be introduced, for example, by compressed air, water jets and / or by piercing and / or punching holes in the material of the body, which remain in the region of the intersection of the groove and the mating groove. The use of compressed air has proven to be particularly suitable, in particular when only a thin layer of water-impermeable material is present after the introduction, in particular the formation, of the groove and / or the mating groove.

[0031] The method according to claim 7 allows the produced plastic drain panels to have a particularly high contact shear strength. The surface profile is preferably formed on both surfaces in the region between the grooves and / or the mating grooves. When the grooves and / or the mating grooves are embossed into the surface of the body, the surface profile can be embossed particularly easily using an embossing roller with grooves and / or mating grooves of a corresponding profile. Optionally, an embossing roller forming a specific profile for embossing the surface profile can also be provided.

[0032] The surface profile is in particular a micro-profile. The micro-profile may have a height between 0.1 mm and 1.1 mm. The height of the micro-profile may be measured as a so-called roughness height according to ASTM D7466. The micro-profile may have any desired shape. So-called peaks and / or straight elevations have proven to be particularly suitable.

[0033] The method according to claim 8 ensures the production of plastic drain panels that can be stored and transported particularly easily. Due to the grooves, the plastic drain panels can be rolled into rolls particularly easily, in particular rolls with a small diameter. The stowage space required for storage and transportation is reduced.

[0034] Grooving can be performed without removing material, for example by means of an incision cut into the body. The notch particularly preferably occurs in the area between the grooves and / or the matching grooves. Grooving parallel to or perpendicular to the longitudinal direction is particularly suitable. For example, the grooves extend parallel to the grooves and / or the matching grooves on the respective other surface. Grooving particularly preferably extends parallel to the transverse direction of the plastic drain board on one of the two surfaces, one of which is located on the outside of the winding when the plastic drain board is wound. The section modulus of the cross section along the winding direction is reduced by means of the grooves. Therefore, the bending moment to be applied is smaller and the plastic drain board can be wound up with a smaller winding radius. Due to the grooves in the transverse direction, the plastic drain board is more flexible in the longitudinal direction.

[0035] In addition to the grooves and the matching grooves, the grooves are in particular introduced into the body. Optionally, the grooves can be used to introduce the grooves and / or the matching grooves. For example, the second surface can be grooved for introducing the matching grooves. In order to form the matching grooves, the grooved body is stretched in particular in a direction perpendicular to the grooves. This stretching makes it possible to open the notched opening and form the matching grooves. The through hole between the groove and the open matching groove is also preferably formed by stretching. The grooves preferably extend in the transverse direction of the body. The stretching is carried out in particular in the longitudinal direction, for example by means of an increased pull-out speed of a downstream smoothing calender.

[0036] In a preferred variant, the grooves are introduced, in particular formed, in particular embossed, with a depth d1 in the longitudinal direction of the body. The second surface can be grooved in the transverse direction. The grooves preferably have a depth d2, which corresponds at least to the difference between the sheet thickness of the body and the depth d1 of the grooves. As a result of the grooves and the subsequent slight stretching, openings can be easily formed in a sheet material that is previously provided with grooves in the longitudinal direction. In particular, the plastic drain is permeable at the through holes formed by the stretching and perpendicular to the plane of the plastic drain. Due to the matching grooves of the openings, permeability is preferably generated in the plane of the second surface in the transverse direction.

[0037] The method according to claim 9 allows the manufacture of plastic drain panels with particularly high water fluidity. A corresponding average surface roughness in the region of the grooves and / or mating grooves makes it possible to produce a continuous flow channel. The grooves and / or mating grooves in the micro range, in particular, do not have any unevenness, such as notches. The region with the corresponding average surface roughness has a substantially smooth surface. An advantageous surface roughness of the grooves and / or mating grooves can be achieved, for example, by using a corresponding embossing roller, i.e. an embossing roller with this surface roughness, in order to emboss the grooves and / or mating grooves into the corresponding surface of the mating groove of the main body.

[0038] The method according to claim 10 broadens the application range of the plastic drainage board to be produced. The plastic drainage board can be used as a geocomposite. Preferably, a corresponding cover layer is applied to both surfaces of the main body. Geotextiles, in particular PP nonwovens, PET nonwovens and / or PE nonwovens in the form of filter layers, have proven to be particularly suitable as cover layers. The cover layer can be bonded to the corresponding surface of the main body by heat bonding or by means of an adhesive, in particular a hot melt adhesive.

[0039] Another object of the present invention is to provide an improved plastic drain board. The provided plastic drain board is particularly intended to have high stability and high drainage capacity.

[0040] Said object is achieved by a plastic drain board according to claim 11. The advantages of the plastic drain board become apparent from the above-described method for manufacturing it.

[0041] The object is also achieved by a plastic drain board having the features mentioned in claim 12. The plastic drain board has a plate-like body having a first surface and a second surface, the second surface being spaced apart from the first surface by the plate thickness of the body. In addition, the plastic drain board comprises a groove introduced into the first surface of the body and a matching groove introduced into the second surface of the body, wherein the matching groove and the groove intersect each other at an intersection. The groove and / or the matching groove are preferably formed into, in particular embossed into, the respective surface. In addition, a through hole between the groove and the matching groove is present at the intersection. Due to the one-piece plate-like body, the plastic drain board has a high stability, as has been described above with respect to the method. The plastic drain board can be manufactured easily and economically. It has a flexible structure, in particular a variable, freely selectable plate thickness that is constant in width. The form, depth and / or arrangement of the groove and / or the matching groove can also be freely selected.

[0042] The plastic drain board according to claim 13 has a high stability and a high and adaptable drainage capacity. The cross-sectional form of the grooves and / or the matching grooves enables a targeted distribution of the compressive and / or shearing forces acting on the plastic drain board. In addition, the water flowability of the grooves and / or the matching grooves can be adjusted by means of their cross-sectional form.

[0043] The plastic drain board of claim 14 is suitable for large-area applications. The plastic drain board preferably has a width of more than 4 m, in particular more than 6 m, in particular at most 8 m.

[0044] The plastic drain plate according to claim 15 has a particularly high drainage capacity. The low average surface roughness in the region of the grooves and / or mating grooves has the effect that no inhomogeneities in the grooves and / or mating grooves exist in the micrometer range. In this way, a continuous flow path is ensured.

[0045] The plastic drain sheet according to claim 16 has a high contact shear strength. The surface profile is in particular in the form of a micro-profile. The height of the micro-profile can be measured, for example, according to ASTM D7466 as a so-called roughness height. The micro-profile preferably has a height between 0.1 mm and 1.1 mm. The micro-profile can particularly preferably have so-called peaks and / or straight elevations.

[0046] The plastic drain board according to claim 17 has low weight and high internal shear strength. Therefore, the plastic drain board is particularly easy to transport and simple to install.

[0047] The plastic drain board according to claim 18 can be used flexibly and is strong. Suitable materials and / or suitable material mixtures (optionally with mixed fillers) can be selected as required. The plastic drain board is resistant to chemical corrosion, aging and weathering. In addition, the plastic drain board is recyclable.

[0048] The plastic drain board is particularly preferably made of recycled materials (rework materials), materials recovered from waste (post-industrial materials) and / or recyclates (post-consumer materials). Plastic drain boards composed of these types of materials are cost-effective and save resources.

[0049] The plastic drain board according to claim 19 has a wide range of applications. By selecting a suitable covering layer, the properties of the plastic drain board can be adapted even more effectively to the respective case of use. Suitable covering layers are in particular geotextiles, particularly preferably PP nonwovens, PET nonwovens and / or PE nonwovens, which have been bonded, for example, thermally or by means of an adhesive, in particular a hot melt adhesive, to the main body. The plastic drain board particularly preferably has a corresponding covering layer on each surface of the main body.

[0050] The plastic drain board according to claim 20 is particularly stable and has a wide range of applications. The reinforcement structure enables the plastic drain board to absorb particularly large forces without impairing the water mobility of the plastic drain board. In addition, the plastic drain board can be used for reinforcement purposes without external reinforcement elements such as geogrids.

[0051] At least one reinforcement structure preferably extends in the longitudinal direction over the entire length of the body and thus over the entire length of the plastic drain board. Particularly preferably, a respective reinforcement structure is arranged between two grooves extending in the longitudinal direction. In this way, a particularly stable uniaxial reinforcement of the plastic drain board is achieved. In principle, the entire volume of the body between the longitudinal grooves can be used for the reinforcement structure.

[0052] The reinforcement structure may comprise yarns, in particular plastic yarns, preferably multifilament yarns, for example made of polyethylene terephthalate (PET) and / or polyvinyl alcohol (PVAL). Alternatively and / or additionally, at least one reinforcement structure may also comprise glass fibers, basalt fibers and / or steel fibers.

[0053] The reinforcing structure is preferably completely embedded in the material of the main body. As a result, the reinforcing structure is protected from environmental influences.

[0054] In order to produce the at least one reinforcing structure, a continuous yarn consisting of the material forming the reinforcing structure can be provided and embedded in the molding compound forming the main body. This is particularly preferably carried out during the extrusion of the main body. In this respect, the yarn can be easily introduced into the extruded main body at a suitable location. The at least one reinforcing structure and the main body are produced in one piece. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Other features, advantages and details of the present invention will become apparent from the following exemplary embodiments and the related drawings, in which:

[0056] Figure 1 A perspective view of a plastic drain board is shown.

[0057] Figure 2 Shown along the cutting edge II-II through the Figure 1 Longitudinal section of the plastic drainage board,

[0058] Figure 3 Shown along the cutting edge III-III through the Figure 1 The cross section of the plastic drainage board,

[0059] Figure 4 A schematic process sequence for manufacturing a plastic drain board is shown,

[0060] Figure 5 A schematic diagram of a manufacturing device for manufacturing plastic drainage boards is shown,

[0061] Figure 6 A schematic diagram of another manufacturing equipment for manufacturing plastic drainage board is shown,

[0062] Figure 7 A schematic diagram showing alternative cross-sections of the grooves of the plastic drain board, and

[0063] Figure 8 A cross section through another exemplary embodiment of a plastic drain board is shown. DETAILED DESCRIPTION

[0064] Figures 1 to 3 An exemplary embodiment of a plastic drain board is shown. The plastic drain board 1 has a plate-like body 2. The plate-like body 2 extends in a longitudinal direction 3 and a transverse direction 4 extending perpendicularly thereto. Figure 1 Only a portion of the plastic drain board 1 is shown. The plastic drain board 1 extends in the longitudinal direction 3 over Figure 1 The part shown in . Figure 2 A longitudinal section through the plastic drainage board 1 along the cutting edge II-II in the longitudinal direction 3 is shown. Figure 3 A cross section through the plastic drain board 1 along the cutting edge III-III in the transverse direction 4 is shown.

[0065] The plastic drain board 1 has a length in the longitudinal direction 3 and a width B in the transverse direction 4. The longitudinal direction 3 and the transverse direction 4 span the board plane. Perpendicular to the board plane, i.e. in a direction perpendicular to the longitudinal direction 3 and the transverse direction 4, the body 2 of the plastic drain board 1 has a constant board thickness d. The length and width B are several times greater than the board thickness d. The width B of the plastic drain board 1 is 2m. A larger width B of up to 8m or more is also possible. In principle, the length is not limited and can exceed the width B. For example, the length can exceed 10m, in particular exceed 50m, in particular exceed 100m, in particular exceed 200m. The board thickness d is typically between 4mm and 10mm.

[0066] The main body 2 has a structure Figures 1 to 3 The main body 2 further comprises a first surface 5 on the bottom side of the plastic drain board 1. In addition, the main body 2 has a second surface 6 which is spaced apart from the first surface 5 by a plate thickness d and is shown in the figure as the top side of the plastic drain board 1. Grooves 7 are formed in the first surface 5. The grooves 7 extend parallel to each other in the longitudinal direction 3 of the plastic drain board. Matching grooves 8 extending parallel to each other in the transverse direction 4 are formed in the second surface 6 of the main body 2. Therefore, the grooves 7 and the matching grooves 8 extend perpendicularly to each other and intersect each other at an intersection 9. A through hole 10 located between the grooves 7 and the matching grooves 8 is formed in the region of the intersection 9.

[0067] The grooves 7 and the matching grooves 8 constitute the flow path of the water discharged through the plastic drain board 1. The through holes 10 ensure the water permeability of the plastic drain board 1 perpendicular to its board plane. The structure of the plastic drain board 1 as a plate-like body 2 in which the grooves 7 and the matching grooves 8 have been formed ensures good water flowability as well as high stability, in particular high compressive strength, high internal shear strength, high contact shear strength and high dimensional stability. The plastic drain board has a high drainage capacity throughout its service life.

[0068] The grooves 7 and the mating grooves 8 have a cross section Q. The cross section Q is rectangular in each case. The grooves 7 have a regular spacing B2 and a width B1 in the transverse direction 4. The mating grooves 8 have a width L1 and a regular spacing L2 in the longitudinal direction 3. The spacings B2 and L2 may be between 2 mm and 16 mm, in particular between 3 mm and 10 mm. The widths B1 and L1 are, for example, between 2 mm and 12 mm, in particular between 3 mm and 10 mm.

[0069] The rectangular cross section Q of the groove 7 and the mating groove 8 ensures a high drainage capacity. At the same time, the body 2 has a high stability.

[0070] The groove 7 is formed in the first surface 5 with a depth d1 perpendicular to the plate plane of the body 2. The mating groove 8 is formed in the second surface 6 with a depth d2 perpendicular to the plate plane.

[0071] The depths d1 and d2 are dimensioned such that their sum equals the plate thickness d: d1 + d2 = d. This has the effect that the groove 7 overlaps the mating groove 8 in the region of the intersection 9 perpendicular to the plate plane, so that a through hole 10 is obtained.

[0072] To further improve the water mobility of the grooves 7 and mating grooves 8, the edge faces formed by the body 2 have an average surface roughness of between 0.2 μm and 0.7 μm according to DIN 4768 Part 1. This ensures a continuous flow path in the grooves 7 and mating grooves 8. Inhomogeneities in the microscopic range are avoided.

[0073] In the region between the grooves 7 and / or the matching grooves 8, the first surface 5 and the second surface 6 have a surface profile in the form of a micro-profile 11. The micro-profile 11 has so-called peaks and / or straight elevations with a height between 0.1 mm and 1.1 mm. The height of the micro-profile 11 is measured as the surface roughness height according to ASTM D7466. The effect of the micro-profile 11 is to increase the contact shear strength of the plastic drain board 1.

[0074] The body 2 of the plastic drain board 1 comprises polyethylene (PE). PE-LLD, PE 80, PE 100, PE 100-RC, PE-EL, PE-MD or PE-HD are particularly suitable. Alternative materials for the body 2 of the plastic drain board 1 are polypropylene (PP), polyamide (PA), polystyrene (PS), acrylonitrile butadiene styrene copolymer (ABS), wood plastic composite (WPC), biopolymers, polyvinyl chloride (PVC) and / or polyethylene terephthalate (PET). In some exemplary embodiments, the body 2 is made of recycled materials (rework materials), materials recovered from waste (post-industrial materials) and / or recyclates (post-consumer materials). In other exemplary embodiments, fillers, in particular inert fillers, are also mixed with the body 2. Examples thereof are rock powder, wood powder, biopolymers and short fibers. The mixing of fillers better adapts the material properties of the body 2 of the plastic drain board 1 to the requirements to be met.

[0075] The plastic drainage board 1 has a thickness between 1500g / m 2 and 18000g / m 2 The weight per unit area of ​​the plastic drain board 1 is determined in accordance with DIN EN ISO 9864. The plastic drain board 1 is light in relation to its size and is therefore easy to transport.

[0076] Since the first surface 5 is notched, the transportability is further improved. The notches 12 extend parallel to each other in the transverse direction 4. The notches 12 extend parallel to the mating grooves 8. The notches 12 are cutouts in the body 2.

[0077] The notch 12 has a depth d3 perpendicular to the board plane, which is less than the board thickness d minus the depth d2 of the matching groove 8: d-d2>d3. The main body 2 improves the curling of the plastic drainage board on the transport roller by means of the notch 12.

[0078] Plastic drainage board 1 can be Figures 1 to 3 In addition, the plastic drainage board 1 can be supplemented by a covering layer on the surface 5, 6. A suitable covering layer is a geotextile, in particular composed of a PP nonwoven material, which is thermally bonded to the plastic drainage board 1.

[0079] The following will refer to Figures 4 to 6 The manufacture of the plastic drain board 1 is described. Figure 4 A schematic method sequence of a suitable manufacturing method 13 is shown. The manufacturing method 13 is divided into functional manufacturing steps. Therefore, the individual manufacturing steps do not constitute a strict time sequence. Instead, the order of the manufacturing steps over time is determined by the manufacturing equipment used to implement the manufacturing method 13.

[0080] Figure 5 Schematically shown is an exemplary embodiment of a production apparatus 14 which can be used to implement the production method 13. The production apparatus 14 essentially comprises a slot die extruder 15 and two smoothing calenders 17, 18 following each other in the machine direction.

[0081] In the preparation step 19, the plate-like body 2 is extruded using a slot die extruder 15. Therefore, the width B of the body 2 and thus the width B of the plastic drain board 1 is determined by the width of the slot die extruder 15. The body 2 and the plastic drain board 1 can be made in any desired length using the slot die extruder 15, in particular can be made continuously. The slot die extruder 15 therefore also predefines the longitudinal direction 3 corresponding to the machine direction 16, and the transverse direction 4 of the plastic drain board 1. Using the slot die extruder 15, all materials that can be used for the body 2 as described above can be processed individually or in combination in a coextrusion method.

[0082] In a preparatory step 19 , the plate-like body 2 is extruded with the substrate thickness.

[0083] In the groove forming step 20, the groove 7 is formed in the first surface 5 of the main body 2. For this purpose, the first smoothing calender 17 has a groove embossing roller 21 having a groove tool 22 adapted to the cross section Q of the groove 7. The groove 7 is embossed into the main body 2 using the groove tool 22 of the groove embossing roller 21. The groove tool 22 has an average surface roughness corresponding to the average surface roughness of the edge face of the groove 7.

[0084] In the matching groove forming step 23, the matching groove 8 is formed in the second surface 6 of the main body 2. In the manufacturing device 14, this is performed using a matching groove embossing roller 24 of the second smoothing calender 18. The matching groove embossing roller 24 has a matching groove tool 25, whose cross section corresponds to the cross section Q of the matching groove 8. The matching groove tool 25 has an average surface roughness corresponding to the average surface roughness of the matching groove 8.

[0085] During the imprinting of the grooves 7 and the complementary grooves 8 in the groove forming step 20 and the complementary groove forming step 23, respectively, the material of the body 2, which was originally located in the region of the grooves 7 and the complementary grooves 8, respectively, is displaced. Due to this material displacement, the thickness of the body 2 increases beyond the substrate thickness with which the body 2 was extruded in the preparation step 19. After the grooves 7 and the complementary grooves 8 have been imprinted, the body 2 has a plate thickness d, as described above with reference to Figures 1 to 3 as described.

[0086] The micro-contours 11 are produced in an embossing step 26. In the manufacturing device 14, the embossing step is carried out using a profile embossing roller 27. To this end, the profile embossing roller 27 has a surface profile 28 corresponding to the micro-contours 11. The micro-contours 11 of the second surface 6 are produced using the profile embossing roller 27 as part of the first smoothing calender 17. The micro-contours 11 of the first surface 5 are produced using the profile embossing roller 27 as part of the second smoothing calender 18.

[0087] As long as the material forming the body 2 is still hot and accordingly mouldable, the groove forming step 20, the matching groove forming step 23 and the profiling step 26 can be carried out. Further manufacturing steps may also be performed after the material has cooled.

[0088] For the case where the through hole 10 is not formed solely by embossing the groove 7 and the matching groove 8 in the groove forming step 20 and the matching groove forming step 23, respectively, the manufacturing method 13 can include an optional punching step 29. The material residues remaining in the region of the intersection 9 can then be cut off and / or removed in the punching step 29. This can be done mechanically, for example by means of holes or perforations, or pneumatically by compressed air. Alternatively, the through hole 10 can also be introduced hydraulically by water jets. A correspondingly designed punching device 30 is adjacent to the smoothing calenders 17, 18 in the manufacturing device 14 in the machine direction 16.

[0089] In a notching step 31, the first surface 5 of the body 2 is notched. The notches 12 are introduced using a notching device 32. As an alternative to providing an additional notching device 32, a corresponding notching tool can also be provided at the profile embossing roller 27.

[0090] The above-described manufacturing steps are followed by an optional supplementary step 33. In supplementary step 33, a cover layer, for example in the form of a PP nonwoven, can be applied to the surfaces 5, 6 of the body 2. For the sake of clarity, a laminating device that can be used for supplementary step 33 is not shown in the case of the manufacturing device 14.

[0091] In addition to the manufacturing equipment 14, other manufacturing equipment for implementing the manufacturing method 13 can also be used. In other exemplary embodiments not shown of the manufacturing equipment for the plastic drainage board 1, the embossing rollers can be arranged differently. For example, a groove embossing roller and a matching groove embossing roller can be combined in a first smoothing calender. Then two profile embossing rollers can be stacked in a second downstream smoothing calender. In other exemplary embodiments not shown, the groove embossing roller and the matching groove embossing roller include a surface profile between the corresponding (matching) grooving tools in each case. These groove embossing rollers and matching groove embossing rollers are combined into a single smoothing calender in each case, which ensures the embossing of the grooves 7, the matching grooves 8 and the micro-contours 11. Accordingly, the second smoothing calender is unnecessary.

[0092] Figure 6 Another exemplary embodiment of a manufacturing device 14a for manufacturing a plastic drainage board 1 is shown. Figure 5 Components described in the manufacturing apparatus 14 have the same reference numerals. Structurally different but functionally similar parts are given the same reference numerals with an a.

[0093] In the illustration of the manufacturing device 14a, the first surface 5 of the plastic drainage board 1 to be manufactured points upward, while the second surface 6 faces downward. The manufacturing device 14a has a slot die extruder 15a. The slot die extruder 15a has an extruder slot 34 with a protrusion 35. The form of a single protrusion 35 corresponds to the cross-section Q of the groove 7 in the first surface 5. During the extrusion of the body 2 using the slot die extruder 15a, the groove 7 is formed in the first surface 5 of the body 2. In this case, the groove forming step 20 is carried out simultaneously with the preparation step 19. Subsequent embossing of the groove 7 in the body 2 is unnecessary. Therefore, the manufacturing device 14a does not have a first smoothing calender 17.

[0094] The single smoothing calender 18a of the manufacturing device 14a has a profile embossing roller 27 and a matching groove embossing roller 24a. The profile embossing roller 27 is used to produce micro-contours 11 on the first surface 5 in the area between the grooves 7. The matching groove embossing roller 24a includes a matching groove tool 25, with the help of which the matching grooves 8 are embossed into the second surface 6 of the body 2. Between the matching groove tools 25, the matching groove embossing roller 24a has a surface profile 28, with the help of which the micro-contours 11 are produced on the second surface 6 in the area between the matching grooves 8.

[0095] Other components of the manufacturing device 14a, such as the punching device or the slotting device, are similar to the corresponding components of the manufacturing device 14. For the sake of clarity, Figure 6 These components and the optionally provided lamination equipment are not shown.

[0096] The manufacturing method 13 described here makes it possible to manufacture the plastic drain board 1 with a defined and uniform quality. In addition, the properties of the plastic drain board 1 can be flexibly adapted to the respective requirements. For example, the material used can be changed. The cross section Q, the depth d1, d2 and the spacing B2, L2 between the grooves 7 and / or the matching grooves 8 can be freely selected in a similar manner.

[0097] In the above-mentioned manufacturing method 13, the width B of the plastic drain board 1 substantially corresponds to the width of the extruded body 2. However, in other embodiments of the method, the width B of the plastic drain board 1 can also be changed in a targeted manner. In an exemplary embodiment of the manufacturing method, the extruded body 2 can be gripped at its longitudinal edge extending in the longitudinal direction 3 and pulled out transversely in the transverse direction 4. Therefore, the width B of the body 2 and, therefore, the width of the plastic drain board 1 can be increased. The plastic drain board 1 can in particular have a width B that exceeds the width of the slot die extruder used to extrude the body 2.

[0098] In another exemplary embodiment of the manufacturing method, the plastic drain sheet 1 is stretched in the machine direction 16, i.e. in the longitudinal direction 3. This can be done, for example, in the following way: the smoothing calender downstream of the extruder has a pull-out speed that is increased relative to the conveying speed of the body. The pull-out speed is determined by the surface of the embossing roller of the smoothing calender and / or the speed at which the embossing tool moves along the circumference of the embossing roller. The conveying speed corresponds to the extrusion speed of the extruded body 2. The increased pull-out speed causes the plastic drain sheet 1 to be stretched in the machine direction 16. As a result, the width B of the plastic drain sheet 1 is reduced in favor of its length.

[0099] Other exemplary embodiments of the manufacturing method for manufacturing a plastic drain board 1 differ in the method of introducing the matching groove 8 into the second surface 6. In the exemplary embodiment, the groove 7 is first embossed into the first surface 5 with a depth d1. Thereafter, the second surface 6 is grooved. The groove preferably extends in the transverse direction 4. The groove has a depth d2, which corresponds at least to the difference between the plate thickness d and the depth d1 of the groove 7: d2 ≥ d-d1. After the introduction of the grooves, the body 2 is stretched in the machine direction 16, i.e. in the longitudinal direction 3. Due to the increased pull-out speed of the downstream smoothing calender, stretching is performed in sequence. As a result of the stretching, the grooves are opened and the matching grooves 8 are formed. At the same time, the through hole 10 between the groove 7 and the matching groove 8 is opened.

[0100] Figure 7 Alternative cross-sectional forms of the groove 7 are shown. In addition to the groove 7 with a rectangular cross section Q as described above, a groove with a rectangular cross section Q3 with corner reinforcements, called haunches, can also be provided. Other possible cross sections have a tunnel form (Q2), a flat trapezoidal form (Q4), a steep trapezoidal form (Q5) or an undercut trapezoidal form (Q6). Of course, corresponding cross-sectional forms can also be provided for the matching groove 8.

[0101] from Figure 7 It can also be clearly seen that a groove 36 extending in the longitudinal direction 3 can also be provided on the second surface 6. The depth d4 of the groove 36 is less than the plate thickness d minus the depth d1 of the groove 7: d−d1>d4.

[0102] In other exemplary embodiments not shown, the grooves 7 and the mating grooves 8 have a modified arrangement. For example, the mating grooves 8 may not extend perpendicularly to the longitudinal direction 3, that is to say in the transverse direction 4, but rather extend obliquely relative to the longitudinal direction 3. Typically, the grooves 7 and the mating grooves 8 may enclose an angle between 20° and 160°.

[0103] In a further exemplary embodiment, the sum of the depth d1 of the groove 7 and the depth d2 of the matching groove 8 is not equal to the plate thickness d. Typically, the depths d1, d2 may each be between 10% and 90% of the plate thickness d. In the case where the sum of the depths d1 and d2 is less than the thin plate thickness d, a through hole 10 in the region of the intersection 9 must be introduced by a punching step 29, for example by piercing the remaining material using a mandrel.

[0104] Figure 8 A cross section through another exemplary embodiment of a plastic drain board 100 is shown. Figures 1 to 7 The components of the plastic drainage board 1 described above have the same reference numerals.

[0105] The plastic drain board 100 differs from the plastic drain board 1 in that a reinforcement structure 37 is embedded in the body 2 between the grooves 7 extending in the longitudinal direction 3. The reinforcement structure 37 is embedded in the body 2 of the plastic drain board 100 around the entire periphery. The reinforcement structure 37 extends over the entire length of the plastic drain board 100 in the longitudinal direction 3. As a result, a uniaxial reinforcement of the plastic drain board 100 is achieved. The plastic drain board 100 can withstand considerable forces in the longitudinal direction 3. As a result, the functionality and possible uses of the plastic drain board 100 are increased. The plastic drain board 100 can be used as a reinforcement, without the need for additional external reinforcements, such as geonets, for this purpose.

[0106] The reinforcing structure 37 comprises plastic yarns in the form of multifilaments composed of polyethylene terephthalate (PET) and / or polyvinyl alcohol (PVAL). In other exemplary embodiments, the reinforcing structure 37 comprises yarns composed of glass fibers, basalt fibers and / or steel fibers.

[0107] In another exemplary embodiment of the plastic drainage board 100 , a plurality of reinforcement structures 37 are respectively embedded between two longitudinal grooves 7 .

[0108] The reinforcing structure 37 of the plastic drain board 100 in the above manufacturing method can be introduced into the body 2. For this purpose, when the body 2 is extruded in the preparation step 19, a continuous yarn of the material forming the reinforcing structure 37 is provided and inserted and embedded in the molding compound of the body 2.

Claims

1. A method for manufacturing a plastic drain board, comprising the following steps: - providing a plate-like body (2) having a first surface (5) and a second surface (6), the second surface (6) being spaced apart from the first surface (5) by a substrate thickness of the body (2), - introducing a groove (7) in the first surface (5) of said body (2), - introducing a matching groove (8) in said second surface (6) of said body (2), wherein said matching groove (8) and said groove (7) intersect each other at an intersection point (9), and - forming a through hole (10) between the groove (7) and the mating groove (8) in the area of ​​the intersection (9) to complete the plastic drain board (1; 100).

2. The method according to claim 1, characterized in that The body (2) is extruded, in particular by means of a slot die extruder (15; 15a).

3. The method according to any one of the preceding claims, characterized in that The main body (2) comprises at least one of the following materials: polyethylene (PE), polypropylene (PP), polyamide (PA), polystyrene (PS), acrylonitrile butadiene styrene copolymer (ABS), wood plastic composite (WPC), biopolymer, polyvinyl chloride (PVC) and polyethylene terephthalate (PET).

4. The method according to one of the preceding claims, characterized in that The groove (7) is introduced, in particular formed, in the first surface (5) of the body (2) in such a way that it extends in the longitudinal direction (3) of the body (2) or perpendicularly to the longitudinal direction (3).

5. The method according to one of the preceding claims, characterized in that The groove (7) is introduced with a depth d1 in a direction perpendicular to the first surface (5), and the matching groove (8) is introduced with a depth d2 in a direction perpendicular to the second surface (6), wherein the sum of d1 and d2 is greater than or equal to the plate thickness (d) of the main body (2).

6. The method according to one of the preceding claims, characterized in that The through hole (10) is introduced pneumatically, hydraulically and / or mechanically.

7. The method according to one of the preceding claims, characterized in that A surface profile (11) is formed on at least one of the surfaces (5, 6) of the body (2) in the region between the grooves (7) and / or the mating grooves (8).

8. The method according to one of the preceding claims, characterized in that At least one of the surfaces (5, 6) of the body (2) is grooved.

9. The method according to one of the preceding claims, characterized in that The groove (7) and / or the mating groove (8) are formed with an average surface roughness between 0.2 μ. and 0.7 μ. according to DIN 4768 Part 1.

10. The method according to one of the preceding claims, characterized in that A covering layer is applied to at least one of the surfaces (5, 6) of the body (2).

11. A plastic drain board manufactured according to one of claims 1 to 10.

12. A plastic drainage board, comprising: a plate-like body (2) having a first surface (5) and a second surface (6), the second surface (6) being spaced apart from the first surface (5) by the substrate thickness of the body (2), - a groove (7) introduced into the first surface (5) of the body (2), - a mating groove (8) introduced into the second surface (6) of the body (2), wherein the mating groove (8) and the groove (7) intersect each other at an intersection point (9), and A through hole (10) located between the groove (7) and the mating groove (8) in the region of the intersection (9).

13. The plastic drainage board according to claim 12, characterized in that: The groove (7) and / or the matching groove (8) has a tunnel-shaped, rectangular or trapezoidal cross section (Q).

14. The plastic drainage board according to claim 12 or 13, characterized in that: The body (2) has a width (B) between 2m and 8m.

15. The plastic drainage board according to one of claims 12 to 14, characterized in that At least in the region of the groove (7) and / or the mating groove (8), the surface has an average surface roughness in accordance with DIN 4768 Part 1 of between 0.2 and 0.

7.

16. The plastic drainage board according to one of claims 12 to 15, characterized in that In the region between the grooves (7) and / or the mating grooves (8), a surface contour (11) is present on at least one of the surfaces (5, 6) of the body (2).

17. The plastic drainage board according to one of claims 12 to 16, characterized in that With a density between 1500g / m 2 and 18000g / m 2 The weight per unit area is between .

18. The plastic drainage board according to one of claims 12 to 17, characterized in that The main body (2) comprises at least one of the following materials: polyethylene (PE), polypropylene (PP), polyamide (PA), polystyrene (PS), acrylonitrile butadiene styrene copolymer (ABS), wood plastic composite (WPC), biopolymer, polyvinyl chloride (PVC) and polyethylene terephthalate (PET).

19. The plastic drainage board according to one of claims 12 to 18, characterized in that It comprises a covering layer located on at least one of the surfaces (5, 6) of the body (2).

20. The plastic drainage board according to one of claims 12 to 19, characterized in that It comprises at least one reinforcement structure (37) embedded in the body (2).

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