Holding, drainage and cultivation plate, method for producing same and production equipment system

Abstract

The holding, drainage and cultivation panel according to the invention comprises 80% to 85% by volume of recycled material obtained from synthetic hybrid fabrics and composite fabrics in the form of tufted material and 15% to 20% by volume of hardened polyurethane, and wherein the volume weight of the panel is 150 kg / m3 to 250 kg / m3. The invention also relates to a method for manufacturing such a sheet and to a kit for carrying out the method.

Description

Technical Field

[0001] The present invention relates to a retaining, drainage and cultivation board suitable as a construction element for forming retaining areas, such as large green roofs or facades, sidewalks and parking lots. The invention also relates to a method for producing the board and a production device thereof. Background Art

[0002] There is a growing demand for buildings with green roofs or green facades. A key component of such roofs or facades is the substrate, which typically consists of a layer of soil and a specialized substrate rich in water-retaining minerals. The recommended substrate thickness for growing vegetation is at least 50 to 100 mm. However, at these thicknesses, the overall surface density of the saturated substrate composition limits the size of the roof surface and increases the load-bearing requirements of the facade structure. Consequently, there is a need to reduce the load on the roof covering.

[0003] The solution is to replace part of the substrate with another, lighter component that is supposed to maintain the holding and drainage functions of the original substrate and allow the vegetation to take root, meaning that even if the board is completely soaked with water, it will still have enough internal space for the roots and free air.

[0004] Currently, such components are made from regularly deposited minerals or synthetic textile fibers. Their disadvantage is that they have a stronger holding capacity than the original substrate. This means that while they allow plants to take root, there is a risk of waterlogging and root death due to the high water-holding capacity of these components.

[0005] Furthermore, mineral and textile, regularly deposited fiber components lose their inherent retaining function and dimensional stability under pressure. Therefore, they are not suitable for permanent load-bearing areas. In a water-saturated state, at maximum retaining capacity, these components also have limited maneuverability and can cause damage. This limits their use in rainy conditions.

[0006] Another disadvantage of mineral and textile fiber components is that they cannot be separated from the soil matrix and vegetation at the end of their useful life, resulting in hazardous mixed waste. Furthermore, their attachment is limited on higher roof slopes, requiring additional auxiliary materials. In vertical structures, they are virtually unusable due to structural instability. Consequently, they are rarely used for green facades.

[0007] The requirement to reduce the load on the roof covering can also be met by reducing the thickness of the roof substrate (soil). The retention function of this substrate is reduced by using a separate water-retaining lining, which is usually made of plastic. This water-retaining lining mainly takes the form of cups with varying volumes. The disadvantages of this type of retaining lining are the inability to perform cultivation and limited drainage. Summary of the Invention

[0008] The above-mentioned drawbacks are overcome by the holding, drainage and cultivation board of the present invention, which comprises 80% to 85% by volume of recycled material obtained from synthetic mixed and composite fabrics in the form of tufted materials and 15% to 20% by volume of hardened polyurethane, and wherein the bulk weight of the board is 150 kg / m 3 Up to 250kg / m 3 .

[0009] The tufted material consists of cuttings and / or strips and / or fragments of a hardened fabric and non-woven particles containing dispersed, randomly arranged, interwoven and entangled fibers carrying particles, wherein these elements are almost uniformly distributed and together form a cohesive assembly with a spatial tufted structure, and wherein at least one component of the assembly is preferably obtained by recycling worn parts and / or residual parts of products used in transport devices.

[0010] Such tufted materials can be produced, for example, as follows: An input material comprising a stiffened fabric and mixed textile-nonwoven components is first chopped to a defined maximum chop size on a chopper. A tufting machine is then used to split, crush, segment, and shred the chopped pieces into tufts. These tufts contain particles of the input material surrounded by agglomerated, shredded fibers. The tufts are then mechanically modified into a uniform assembly of elements whose spatial structure features an approximately uniform distribution of elements.

[0011] Preferably, the tufts can also be made in the manner described in Patent No. SK288377B6, page 2, lines 38 to 48, Example 1 and claims 2 to 4.

[0012] Patent No. SK288377B6, page 2, line 49 to page 3, line 14, Examples 2 and 3, and Claims 5 to 10 describe a suitable tufting machine.

[0013] The tufts are preferably made of several types of technical textiles. Technical textiles contain at least 80% synthetic fibers. Technical textiles can be made of pure fiber components (wovens, nonwovens) and can also be composed of several types of textile components and composite materials, wherein the textile components are supplemented by nonwoven components.

[0014] The retention, drainage, and cultivation board according to the invention can partially or completely replace the soil matrix used in retention areas such as large green roofs, with its surface density being 4 to 7 times lower than that of the soil matrix itself. The composition of the tufted board, the original textile mass, and the non-textile part closely resembles that of soil, a specialized matrix with a high mineral content that retains water. The tufts provide the water-binding function, while the interconnected, protruding fibers of the tufts create air spaces for plant roots.

[0015] The tufted panels also provide excellent drainage capabilities, allowing excess water to escape that exceeds the holding capacity of the tufts. Therefore, the soil substrate layer can preferably be reduced to 0 mm to 25 mm.

[0016] The plate according to the invention as a substitute for a matrix has the following advantages: - Allows vegetation to take root, greatly reducing or eliminating the need for soil and specialized substrates. - Holding Capacity - The board holds water up to 50% of its volume, thus completely replacing the water-holding function of the replaced substrate. - The water absorption of the board is at least 30% higher than that of the original substrate. -It also has a drainage function, ensuring that excess water can be drained away smoothly when the maximum holding capacity is reached. - At maximum holding capacity - sufficient air space is maintained for the plant roots, meaning there is virtually no risk of waterlogging - roots becoming soaked by water. - The board is characterized by high mechanical resistance, both in dry and saturated state, without damaging the board and its retaining function. - Even if the panel is placed in an inclined and / or vertical position, at least 10% of its volume Keep enough solid water in the mixture.

[0017] Compared to previous solutions that replaced the original matrix with various components, the new benefits of this board are: - It allows for the molding of grooves to accommodate hose lines for additional water distribution. - Auxiliary anchoring elements, such as metal sheets, can be pressed into the plate. - Ability to spread drip irrigation water over the entire surface of the board. The low diffusion resistance of the plate structure allows the capillary action of water to occur, causing it to evaporate gradually from the surface. - The board allows mechanical and chemical anchoring to the substrate - wind resistant, suitable for sloping roofs and vertical walls. - 80% to 85% of the board composition consists of materials recycled from waste. - At the end of the life cycle of the board, the board can be separated from the substrate and the vegetation part and put back into the waste recycling process.

[0018] Another aspect of the present invention is a method for manufacturing a retaining, drainage and cultivation board, the method comprising the steps of: a. The bulk density of the tufted material will be 50kg / m 3 Up to 70kg / m 3 Tufting materials within the range Recycled material in the form of synthetic hybrid and composite fabrics (preferably tufted material protected by patent No. SK288377B6) is mixed with water having a maximum temperature of 15°C and an amount of 15 kg to 25 kg of water per cubic meter of bulk tufted material. b. Compact the wet tufting material mixture to 100kg / m 3 Up to 120kg / m 3 density, which is achieved by downward pressure from rollers placed transversely on the conveyor belt on which the wet tufted material moves. c. mixing the mixture with a one-component polyurethane-based adhesive until a substantially homogeneous mixture of tufting material and adhesive is formed, wherein the amount of adhesive is 10 kg to 20 kg per cubic meter of bulk tufting material. d. Compact the wet tufting material and adhesive mixture to 100kg / m 3 120 kg / m 3 The density is achieved by downward pressure of rollers placed transversely on a conveyor belt on which the wet tufting material and adhesive move. e. The mixture is evenly distributed in the mold and compressed with a pressure that ensures that the mixture is compressed to 2.5 to 3.5 times, that is, a pressure of 6 to 10 atm on the piston of the upper part of the mold with dimensions of 1,200 mm x 600 mm. This compression will give a final density of the mixture of 200 kg / m 3 Up to 250kg / m 3 . f. Remove the mixture from the mold only after the adhesive has completely solidified. At a minimum, observe the adhesive's reaction time. After removing the pressurized mixture from the mold, the adhesive's solidification status can be confirmed by ensuring that the plate maintains the same dimensions as the mold.

[0019] According to a preferred embodiment, before step a), the tufted material is mixed so that the final tufted material bulk density reaches 50 kg / m 3 Up to 70kg / m 3 within the range.

[0020] According to a preferred embodiment, a stock of mixed tufted material is preformed and stored in a storage chamber before steps (a) to (f) are performed.

[0021] According to a preferred embodiment, step a) is performed by regularly distributing the tufted material on a conveyor belt and spraying water from above onto the already spread, moving tufted material.

[0022] According to a preferred embodiment, in step c), the mixture is mixed using a planetary mixer. In addition, between step d) and step e), the mixture can preferably be mixed using a planetary mixer.

[0023] Production is preferably carried out on a conveyor belt.

[0024] Different types of textile tufts are mixed to produce a mixture containing individual tufts of varying distribution and intertwining, wherein the resulting tufted material has a bulk density of 50 kg / m 3 Up to 70kg / m 3 within the range of . The mixing can be carried out in an apparatus for mixing textile mixtures, in which a plurality of sets of smaller diameter cylinders rotate in opposite directions around a main rotating cylinder. The stirred tufted mixture can be deposited in a storage chamber before the mixture is dispersed on a conveyor belt. Cold water (up to 15°C) is sprayed into the tufted mixture, wherein approximately 15kg to 25kg of water are sprayed per cubic meter of tufts. The tufted mixture advances together with the water on a conveyor belt under a drum which compresses it. The downward pressure of the drum must ensure that the tufted mixture is compacted to 100kg / m 3 Up to 125kg / m 3 In the next step of the mixture, a one-component polyurethane-based adhesive is added, with 10 to 20 kg of adhesive added per cubic meter of tufting mixture. The mixture is then mixed using a planetary mixer. The stirred tufting mixture and the adhesive travel on a conveyor under rollers that compress it. The downward pressure of the rollers must ensure that the tufting mixture is compacted to 100 kg / m 3 Up to 120kg / m 3 The tufting mixture is stirred using a planetary mixer. The mixture is removed and weighed to the size of the product mold. The mixture is preferably dispensed directly from the conveyor belt into the mold placed on a scale. The weighed mixture is evenly distributed over the entire surface of the mold with a high degree of consistency. The decomposed mixture is encapsulated in the mold according to the shape of the product (usually a plate) and compressed with a pressure that ensures that the decomposed mixture is compressed 2.5 to 3.5 times. The mold is opened only after the adhesive has completely solidified.

[0025] According to a preferred embodiment, before closing the mold and applying pressure, spraying water at a temperature of 65 to 85° C. into the dispersed mixture can accelerate the setting time of the adhesive, wherein 15 to 25 kg of water is sprayed per cubic meter of mixture.

[0026] According to a preferred embodiment, before placing the mixture in the mold and / or after dispersing it in the mold, shoes are also inserted into the mold to form molded shapes in the plate, such as grooves for guiding water distribution hoses, metal anchoring sheets, etc.

[0027] Another aspect of the present invention is a kit for carrying out the method according to the present invention. The kit comprises: - a storage chamber, which is preferably used to store the stirred tufting mixture -Continuous conveyor belt with conveying speed control - Cold water dosing equipment; preferably consisting of a set of nozzles for spraying water along the width of the conveyor belt - First pressure roller; the diameter of the pressure roller is usually 1 / 3 of the width of the conveyor belt. The cylinder pressure is generated by its weight and / or other pressure regulators - Polyurethane-based adhesive dosing equipment; preferably consisting of a set of outlet pipes across the width of the conveyor belt. The adhesive is squeezed out of the reservoir by a dosing pump. The outlet part of the dosing equipment is made of replaceable and sealable components. - a first planetary mixer; the planetary mixer preferably comprises two rotating plates located on a horizontal plane above the conveyor belt, wherein each rotating plate preferably stirs the mixture by two to four rod stirrers mounted perpendicular to the plane of the rotating plate - A second pressure roller; preferably of the same design as the first pressure roller - A second planetary mixer; preferably of the same design as the first planetary mixer - pressurized moulds and dosing equipment, preferably in the form of a scale The pressurizing device is preferably a piston pressurizing device with a thruster. DETAILED DESCRIPTION

[0028] Example 1

[0029] The utility model relates to a green roof with a water distribution function, and a board for a green exterior wall.

[0030] The input raw material consists of tufted materials of various surplus technical fabrics in approximately the same proportions as they are used in the construction of new vehicles (interior and exterior, mixed and composite fabrics). Tufts of this mixture of fabrics are mixed together. Their bulk weight is 60 kg / m 3. The board is formed by moistening the mixture with water, wherein 20 liters of water are added per cubic meter of mixture. A polyurethane-based adhesive is added to the wet tufting mixture in a ratio of 20% by weight of adhesive to 80% by weight of dry tufting mixture. After mixing this wet tufting mixture with the added adhesive, an appropriate amount is weighed and layered in a mold. Before closing the mold and pressurizing it, a liner is inserted on the surface of the dispersed mixture to form an impression of a distribution channel for accommodating a drip hose. At a temperature of 65°C, the surface of the dispersed mixture is sprayed with water, wherein 20 liters of water are sprayed per cubic meter of mixture. The mold is closed and pressurized with a pressure of 6atm to 8atm, which increases the density of the dispersed mixture by 2.6 times to 200kg / m 3 The final bulk density of the board was determined to be 50 mm. After the adhesive had completely reacted, the board was removed from the mold.

[0031] These panels meet all the parameters of the technical regulations and are suitable for large green roofs with water distribution or active green walls with water runoff from the top edge of the wall. The free pores in the structure of the pressurized tufted panels allow for a water retention capacity of up to 50% of the total panel volume. Even if the panel is completely hydrated, there is still enough free space for air (almost 30% of the panel volume). This allows vegetation to uproot and prevents the root system from becoming saturated with water.

[0032] To plant the vegetation, the board is saturated with water. When it no longer absorbs water, sedum cuttings are spread out and the board can be covered with a soil substrate designed for green roofs and / or crushed gravel. The vegetation will take root in the board within 2 to 4 months.

[0033] Example 2

[0034] Plates designed for holding, loading and other areas.

[0035] The input raw material consists of tufted materials of various surplus technical fabrics in approximately the same proportions as they are used in the construction of new vehicles (interior and exterior, mixed and composite fabrics). The tufts of this mixture of fabrics are mixed together. The bulk weight is determined to be 60 kg / m 3. The board is formed by moistening the mixture with water, wherein 20 liters of water are added per cubic meter of mixture. A polyurethane-based adhesive is added to the wet tufted mixture in a ratio of 15% by weight of adhesive to 85% by weight of the dry tufted mixture. After mixing this wet tufted mixture with the added adhesive, an appropriate amount is weighed and layered in a mold. Before the mixture is placed in the mold and pressurized, a metal sheet is inserted into the bottom of the mold. At a temperature of 65°C, the surface of the dispersed mixture is sprayed with water, wherein 20 liters of water are sprayed per cubic meter of mixture. The mold is closed and pressurized with a pressure of 8atm to 10atm, which increases the density of the dispersed mixture by 3.3 times to 250kg / m 3 The final bulk density of the board was determined to be 50 mm. After the adhesive had completely reacted, the board was removed from the mold.

[0036] These panels meet all the parameters of the technical regulations and are suitable for areas with water retention and water evaporation from the surface. The free pores in the structure of the pressurized tufted panels allow for water retention of up to 50% of the total panel volume. Even if the panel is completely hydrated, there is still enough free space for air (almost 30% of the panel volume). This allows vegetation to uproot and prevent the roots from becoming saturated with water.

[0037] To plant the vegetation, the board is saturated with water. When it no longer absorbs water, sedum cuttings are spread out and the board can be covered with a soil substrate designed for green roofs and / or crushed gravel. The vegetation will take root in the board within 2 to 4 months.

Claims

1. A retaining, drainage and cultivation board, characterized in that, 80% to 85% of its volume consists of synthetic mixed textile recycled material and composite textile recycled material in tufted form and 20% to 15% of its volume consists of hardened polyurethane, and wherein the bulk density of the board is 150 kg / m 3 Up to 250kg / m 3 .

2. The plate according to claim 1, characterized in that The tufted material comprises shavings and / or strips and / or fragments of hardened textiles and a tufted material of non-woven particles, the non-woven particles comprising dispersed, randomly arranged, interwoven and entangled fibers with particles, which are almost evenly distributed and together form a bonded assembly with a spatial tufted structure.

3. The plate according to claim 2, characterized in that At least one component of the tufts is obtained by recycling worn parts and / or residual parts of products used in transport devices.

4. A method for manufacturing a retaining, drainage and cultivation board according to any one of claims 1 to 3, characterized in that The manufacturing method comprises the following steps: a) The bulk density of the tufted material should be 50kg / m 3 Up to 70kg / m 3 Recycled materials obtained from synthetic mixed textiles and composite textiles in the form of tufted materials within the scope of the present invention are mixed with water having a maximum temperature of 15°C, wherein the amount of water is 15 kg to 25 kg per cubic meter of tufted material. b) compacting said mixture of wet tufted material to a density of 100 to 120 kg / m, preferably by rolling, c) mixing the mixture with a one-component polyurethane-based adhesive until a substantially homogeneous mixture of the tufting material and the adhesive is formed, wherein the amount of adhesive is 10 kg to 20 kg per cubic meter of bulk tufting material, d) compacting said mixture of wet tufting material and adhesive to a density of 100 to 120 kg / m, preferably by rolling, e) distributing the mixture evenly in a mold and compressing it, applying a pressure that ensures the mixture is compressed 2.5 to 3.5 times, until the density is 200 kg / m 3 Up to 250kg / m 3 , f) The mixture is removed from the mould only after the binder has completely set.

5. The method according to claim 4, characterized in that Before step a), the tufted materials are mixed so that the final tufted material bulk density reaches 50 kg / m 3 Up to 70kg / m 3 within the range.

6. The method according to claim 5, characterized in that A mixed tufting material stock is formed, wherein the stock is stored in a storage chamber and steps (a) to (f) are subsequently performed.

7. The method according to claim 5 or 6, characterized in that Step a) is performed by regularly distributing the tufted material on a conveyor belt and spraying water from above onto the already spread, moving tufted material.

8. The method according to any one of claims 4 to 7, characterized in that In step c), the mixture is stirred using a planetary stirrer.

9. The method according to claim 5 or 6, characterized in that Between step d) and step e), the mixture is stirred, preferably using a planetary stirrer.

10. The method according to any one of claims 4 to 9, characterized in that In step e), before closing the mold, water at a temperature of 65 to 85° C. is sprayed into the dispersed mixture, wherein an amount of 15 to 25 kg of water is sprayed per cubic meter of the mixture.

11. The method according to any one of claims 4 to 10, characterized in that In step e), a liner is placed in the mold before and / or after placing the mixture in the mold to form a molded shape or anchoring structure.

12. A system for carrying out an apparatus according to any one of claims 4 to 11, characterized in that The system includes a continuous conveyor belt capable of controlling a conveying rate, and the following devices are arranged above the continuous conveyor belt in the order mentioned: a cold water dispensing device; a first pressure roller; a polyurethane-based adhesive dispensing device; a first planetary mixer; a second pressing roller; and a second planetary mixer, wherein a compound dispensing device, a compression mold, and a pressing device are provided behind the continuous conveyor belt.

13. The system according to claim 12, wherein: The dispensing device for the mixture is a scale.

14. The system according to claim 12 or 13, characterized in that The pressurizing device is a piston pressurizing device.

15. The system according to any one of claims 12 to 14, characterized in that A hot water distribution device is placed between the distribution device and the pressurizing device.