Method and device for processing rigid foam boards and board stacks made therefrom

Abstract

Arrangement of rigid foam panels (42-46) which are laminated on at least one flat-sided surface with a film (8), and the web (53) formed from the connected rigid foam panels (42-46) is designed as a transportable roll, wherein the arrangement is designed as a panel stack (40) with a rectangular or square cross-section, in which the rigid foam panels (42-46) are connected at their respective end faces (52) by folding edges (54) formed from cut joints (41) and are folded there.

Description

[0001] The subject matter of the invention is a method and a processing line for processing rigid foam boards and board stacks produced therefrom according to the preamble of patent claim 1.

[0002] A processing line for processing rigid foam boards consisting of several processing stations is known, for example, from DE 2 452 754 A1. However, in this document, the rigid foam boards are embossed, which is not the subject of the present invention.

[0003] EP 1 162 003 B2, which goes back to the same applicant, discloses a processing machine with a film lamination, in which there is an application roller extending across the width of the web-like material and in doing so applies an adhesive layer to one side of a rigid foam web in order to stick thereon a film extending across the entire width.

[0004] A similar subject matter also arises from DE 20 2005 015 824 U. The production of such rigid foam boards, which are obtained from a web-like material, is also described, for example, in DE 20 2020 101 007 U.

[0005] The laminating line described in EP 1 162 003 B2 is used for laminating rigid foam boards for use in underfloor heating or cooling systems. These generally involve EPS board products in various thicknesses, preferably in the range of 20 to 50 mm. It has been found that, in addition to the production process, the size and shape of the sheet-like boards produced by the processing line are also of great importance. Likewise, the transport of the rigid foam boards wound into rolls to the construction sites is a significant cost factor, considering the space utilization in the transport vehicle and in the warehouse.

[0006] The invention is therefore based on the object of EP 1 162 003 B2 to further develop a method and a device for processing rigid foam boards in such a way that a high production output is achieved with smaller machine dimensions and that the rigid foam boards produced with the processing line can be packaged and transported in a space-saving manner.

[0007] To achieve the stated object, the invention is characterized by the technical teaching of independent claim 1, which proposes a special space-saving design of a stack of panels made of rigid foam panels.

[0008] A method for producing such a space-saving plate stack is the subject of independent claim 6 and a processing line suitable for producing such space-saving plate stacks is the subject of independent claim 9.

[0009] All features of the subject matter presented in independent claims 1, 6 and 9 can be combined in any desired combination with the remaining features according to the subject matter of the present subclaims and are essential to the invention in any combination.

[0010] A laminating system according to the invention describes a new system for underfloor heating using EPS rigid foam boards, whereby the processing line is suitable for the production of single and folded boards as well as for roll production in a single system.

[0011] With an hourly output of 800 m 2 or a capacity per shift of about 6,000 m 2 There's nothing comparable on the market. This laminating machine can also be equipped with a packaging station with film sealing. It can operate automatically without user intervention.

[0012] A benefit is that each panel format can be manufactured with an adjustable film overlap, eliminating cold bridges at the panel joints. Furthermore, the application of a double-sided adhesive strip creates a sealed connection to previous EPS insulation sheets, thus preventing cold bridges.

[0013] In a preferred embodiment, for rigid foam board thicknesses in the range of 20 to 50 mm and in the format 1000 × 1000 mm, a hotmelt coating with an adjustable adhesive application quantity of approximately 30 to 50 g / m 2 used at temperatures up to 180°C, whereby a P-foil with fabric reinforcement is applied to the stove foam panels.

[0014] This ensures an optimal bond between the laminated film and the adhesive after it has cooled. The rigid foam boards according to the invention are particularly designed for floor-side support on subfloors in buildings, and heating hoses with a diameter of 6 to 20 mm are laid on top of the film-coated rigid foam boards. The heating hoses are attached using clamp-shaped hose fastening elements that grip the respective heating hose with a round profile and, with barb-shaped tips, penetrate the film and are anchored in the material of the rigid foam board. These hose connecting elements are designed in such a way that the hose is lifted off the film when screed is laid, so that the hoses are then fully encased in the screed and only remain in the screed. This results in better heat transfer in the screed area.

[0015] With regard to optimal packaging, it has been found that the current loading area of ​​light goods vans has a width of 80 to 2,500 mm. If one wants to maximize this loading area, two Euro pallets could be transported side by side. However, the current standard size for conventional rigid foam boards of 1,000 x 1,000 mm is not ideal for this. It has also been proven disadvantageous to wrap the rigid foam boards in a circular roll, wrap them in a suitable packaging film, and then load them into the cargo area of ​​a van.

[0016] Such stacks of panels are known as roll goods, and in order to enable the winding up of a round roll of such a rigid foam panel web, it has been customary to arrange a so-called slitting station at the entrance to the processing line, with which slits are made at a distance of, for example, 10 cm, perpendicular to the transport direction and across the width and extending into the material of the rigid foam panel, in order to subsequently enable the film-laminated web to be rolled up into a round roll.

[0017] As explained, such plate stacks, which are designed as circular coils, have the disadvantage that they waste unnecessary space on the loading area of ​​a transporter because they cannot be stacked conveniently.

[0018] The invention is therefore based on the further object of developing a method and a processing line as well as a plate stack produced therefrom in such a way that it can be packaged and transported in a particularly simple and space-saving manner.

[0019] A more advantageous solution has emerged: instead of a circular coil of rigid foam boards, a board stack with a rectangular or square cross-section is now proposed. This means that a circular coil is no longer created from the foil-laminated board web, but rather a rectangular or square board stack, which consequently has peripheral edges or lines that adjoin one another at an angle of 90°. This allows a board stack produced in this way to be transported in a particularly space-saving manner, as there are no longer any air gaps above, below, or to the sides of such stacked board stacks, which was a disadvantage with the circular coils mentioned above.

[0020] Such a rectangular stack of plates can also be called a flat stack because the individual plates stacked on top of each other are connected at the edges, forming a folded flat stack in a winding direction either clockwise or counterclockwise. The flat stack then has a rectangular or square shape, with a roughly box-shaped outline.

[0021] In addition to the winding of the plates stacked on top of one another in a specific winding direction, it can be provided in another embodiment of the invention that the plates connected at the edge on the front side are laid together in a zigzag shape, so that a first plate comes into contact with its upper side on the back of a second plate folded onto it and thus a flat stack is also formed.

[0022] According to the invention, it is therefore preferred if the rectangular or square stacks of panels are formatted in such a way that they can be stacked in a space-saving manner on a Euro pallet with dimensions of 1000 x 1000 or 1200 mm and thus make space-saving use of the rectangular or square air space of the Euro pallet.

[0023] A further advantage is that the slitting stations arranged on the inlet side of a processing line are no longer required. A slitting station of this type was necessary with the known rigid foam round reels in order to be able to wind them into a round reel without the rigid foam material breaking during the winding process. This made it necessary to arrange the slitting station laterally and at right angles to the processing and transport direction of the rigid foam sheets in order to be able to create a slit groove extending across the width. The mutual spacing of the slits extending across the width had to be short, e.g. 10 centimeters, in order to enable the rigid foam sheet to be wound into a round reel. However, the closely spaced slits impaired the insulating properties of the rigid foam sheet.

[0024] The lateral attachment of the slitting station to the processing line had the further disadvantage that the processing line, which consists of several stations connected in series, was very wide and thus an unnecessary waste of space in the production plant had to be accepted.

[0025] By eliminating the slitting station according to the invention, valuable production space can now be saved, as the lateral attachment of such a slitting station to a processing line can now be eliminated, and the processing line is now only equipped with processing stations arranged one after the other in the transport direction, without the need for a lateral attachment of a slitting station on the input side. By eliminating the parallel slits, the insulating properties of the rigid foam sheet could also be improved.

[0026] This meant that on the previous production machines, the 1,000 × 1,000 mm panels had to be fed around the corner at a 90° angle on the inlet side so that they could then be slit lengthwise every 10 cm and rolled. A total of nine slitting knives – one every 10 cm – were used for this 1,000 mm panel format.

[0027] According to the invention, this disadvantageous slitting is eliminated and it is provided according to the subject matter of independent claim 6 that only one cutting joint is provided for forming folding edges at defined distances from one another, preferably 100 cm, in order to enable the webs interrupted by the folding edges to be folded over by 180° in order to form rectangular or square flat stacks of rigid foam boards lying one above the other and running parallel to one another.

[0028] A further advantage of the invention is that slitting only takes place after the adhesive has been applied and the film has been laminated to the web. This has the advantage that the resulting cuts can be made very deeply into the material of the rigid foam board. Preferably, only a short residual web of 1 or 2 mm is left in the board material in the direction of the underlying film in order to achieve particularly favorable folding of the board material in the area of ​​the cuts and to largely avoid breakage damage in the area of ​​the residual web in the board material. The slitting station in landscape format described later works with all board thicknesses from 20 to 50 mm and can now be slit to the same depth for all thicknesses. The deep slits make it particularly easy to wind or lay the boards into a flat stack.

[0029] The advantage here is that the slotted panels remain connected by the underlying film and are only connected to each other by the small remaining web. This means they cannot fall apart, shift, or otherwise disrupt the production process.

[0030] According to the invention, rectangular or square stacks of 1000 mm or even 1200 mm in length are produced from the rigid foam boards stacked on top of each other in this way, which, due to their angular shape, are easy to stack for loading utilization in the transport space.

[0031] The subject matter of the invention arises not only from the subject matter of the individual patent claims, but also from the combination of the individual patent claims with each other.

[0032] All information and features disclosed in the documents, including the abstract, in particular the spatial configuration depicted in the drawings, could be claimed as essential to the invention, insofar as they are novel, individually or in combination, compared to the prior art. The use of the terms "essential" or "according to the invention" or "essential to the invention" is subjective and does not imply that the features so named must necessarily be part of one or more patent claims.

[0033] The invention is explained in more detail below with reference to drawings illustrating only one embodiment. Further essential features and advantages of the invention will become apparent from the drawings and their description.

[0034] They show: Fig. 1: Perspective side view of a processing line according to the invention. Fig. 2: The top view of the machining line after Fig. 1. Fig. 3: Another side view of the machining line after Fig. 1 and Fig. 2. Fig. 4: A perspective view of the cutting station. Fig. 5: The top view of the cutting station after Fig. 4. Fig. 6: A perspective view of the rectangular or square plate stack produced by the method and device in partially developed form. Fig. 7: A cross-section through a section of a rigid foam board.

[0035] In the Fig. 1 to 3 show a processing line 1 for the production and processing of rigid foam boards. The line consists of an inlet-side feed station 2 into which the rigid foam boards, preferably with a format of 1000 mm x 1000 mm, are fed in the direction of arrow 5 and stored there in a stacking space 4 to which a lifting frame 3 is assigned. With the lifting frame 3, one board at a time is fed in the direction of arrow 5 into an infeed gap 12 of a downstream processing machine 10, in which lamination with a film 8 takes place. At the output of the processing machine 10, a cutting station 15 is arranged, with which the rigid foam sheet is provided with a cutting joint 41 running continuously across the width at a specific grid spacing 58, 59.

[0036] The advantage here is that the panels fed from the feed station 2 into the feed gap 12 of the processing machine 10 are gripped by a transport roller 11 and lie against one another end to end, without any gap, and are laminated on the underside with a film 8 using an adhesive layer 47. Such a laminating process is described, for example, in EP 1 162 003 B2. The seamless juxtaposition of the rigid foam panels 9 fed from the feed station 2 takes place with the aid of a push drive 6 with a push carriage 7, so that they lie against one another end to end, thus forming a continuous rigid foam sheet.

[0037] The Fig. 1 and Fig. 2 also shows that the processing machine 10 is assigned a storage container 11 for holding a hot-melt adhesive. In the gluing station 14, the film 8 is laminated onto the underside of the rigid foam sheets 9, which preferably lie against one another without abutting edge.

[0038] At the output of the processing machine 10 there is a cutting station 15, which is Fig. 4 and Fig. 5. The cutting station 15 essentially consists of a longitudinal profile 36 aligned in the transport direction 5, on which a sliding carriage 35 is arranged in a displaceable manner, which allows the entire cutting station 15 to be moved in the direction of the arrows 37 (parallel to the transport direction). A rotating cutting disk is preferably used as the cutting blade 33, which is driven in rotation by a drive 34. With the aid of the toothed chain 38 and an associated toothed chain drive, the cutting blade 33 can thus be moved in the direction of the arrows 39 transversely to the transport direction and moved in the transport direction and brings the Fig. 7. By synchronizing the displacement movement transverse to the transport direction in the arrow directions 39 in conjunction with the displacement movement in the arrow direction 37, it is possible to synchronize the two displacement directions 37, 39 in such a way that, as the panel web is advanced beneath the cutting station 15, the cutting blade creates a cutting gap 41 extending perpendicular to the longitudinal direction across the entire width of the panel web.

[0039] At the output of the processing machine 10, a folding station 20 is arranged, which, with a turning bracket 21, is able to fold the panels fed to it, which are connected to one another by cutting joints while maintaining a residual web 49, by 180° in order to form panels 42-46 that lie on top of one another but are connected at the end, which are collectively referred to as a panel stack 40. For this purpose, clamping jaws 24 are used in the folding station 20, which, with a feed cylinder 32, clamp and hold down the individual panels 42-46 laterally in order to achieve a folding of the individual panels with the turning bracket 21. Folding can take place clockwise or counterclockwise; likewise, the panels 42-46 that are connected at the end can be placed on top of one another in a zigzag pattern in order to form a flat stack (panel stack 40). For this purpose, a feed 22 is used in the transfer station 23.

[0040] With regard to the previously described processing machine 10, it is further stated that a coating roller 17 is provided for the application of the hot-melt adhesive and the film 8 is unwound from a supply roll 18 and is fed to the underside of the material web via a dancer shaft 19, as shown in Fig. 7 is shown.

[0041] At the exit of the folding station 20, the stack 40 of panels, which are stacked parallel to one another and have an approximately rectangular or square cross-section, is pushed into a packaging station 25, where it can be wrapped with film in a packaging space 26. For this purpose, a film station 27 is provided, which is suitable for completely wrapping the stack 40 of panels, in order to place it, after complete wrapping, onto a stacking conveyor 28 and to feed it to a collection station in the direction of arrow 29.

[0042] As from Fig. 3, the material web of the rigid foam boards 9 is transported on an upper transport level 30 in the direction of arrow 5 through the processing line 1 and formed in the folding station 20 into a stack of boards 40 which is then folded in the folding space 31 and introduced into the packaging station 25 in the transport direction.

[0043] The Fig. 6 shows the advantageous dimensions of such a plate stack 40, which in the illustrated embodiment has a rectangular cross-section and consists of a plurality of parallel, stacked individual plates, wherein, starting from a central plate 42, a first plate 43 is connected to each end face, which in turn is connected to a second plate 44 and a third plate 45, as well as a fourth plate 46. The plates 42-46 are separated from one another by cutting joints 41, 41', 41'', 41''' and are essentially held together only by the film 8, without them being able to shift or tilt during processing.

[0044] The cutting joints 41 thus result in folded edges 44 which divide the respective end face 52 over the entire length in the width of the panel, resulting in panels extending over the long side 51 in the preferred format of 1,000 x 1,000 mm or 1,000 x 1,250 mm.

[0045] In Fig. 6, the not yet cut web 53 is also shown for better clarity, and it can be seen that the cutting lines 55, 56, 57 have an uneven mutual distance 58, 59, because in order to create the plate stack 40 it is necessary to space the cutting joints 41 from each other in such a way that the Fig. 6. Such a rectangular or square stack of panels 40, which is rectangular or square in cross-section, allows for optimal utilization of the transport space of a freight transporter and the Euro pallets accommodated in the freight transporter. Approximately 30% more stacks of panels 40 can be accommodated in the same space than with the previous, state-of-the-art circular coils.

[0046] The Fig.Figure 7 shows the advantageous arrangement of the cut joint 41, which shows that it can reach almost to the adhesive layer 47 in order to achieve a residual web 49 made of rigid foam with a very small height of preferably 1 to 2 mm. If the rigid foam panel 9 is then bent by 180° in the direction of arrow 50, cracks occur in the rigid foam material in the area of ​​the residual web 49, and these cracks are so slight that a slight folding by 180° in the direction of arrow 50 is possible, so that the adjacent rigid foam panels 9 are essentially connected via the film 8. The resulting cut joint 41 is narrow and only needs to be provided at a distance of, for example, 100 cm, so that the insulating properties of the panels 42-46 unwound from the panel stack and laid out on a bare floor are only slightly affected.This is in contrast to the prior art, in which the plates had to be slit at intervals of 10 cm in order to form a circular coil, which is avoided with the technical teaching of the invention by forming a flat stack. Drawing legend 1 processing line 2 feed stations 3 lifting frame 4 stacking space 5 Arrow direction 6 Thrust drive 7 push carriages 8 Slide 9 rigid foam board 10 processing machines 11 Transport roller 12 Insertion gap 13 storage containers 14 Gluing station 15 cutting stations 16 hold-down clamps 17 Coating roller 18 supply rolls 19 Dancer Wave 20 folding stations 21 reversible brackets 22 feed 23 transfer station 24 clamping jaws 25 packaging stations 26 Packaging room 27 Foil station 28 stacking track 29 Arrow direction 30 transport level 31 folding room 32 feed cylinders 33 cutting blades 34 Drive 35 sliding carriages 36 Longitudinal profile 37 arrow directions (of 35) 38 Tooth chain 39 arrow directions (of 33) 40 plate stacks 41 kerf 41', 41'', 41''' 42 rigid foam board (inner panel) 43 rigid foam board 44 rigid foam board 45 rigid foam board 46 rigid foam board 47 adhesive layer 48 ---- 49 Remaining bridge 50 Arrow direction 51 Long side 52 front side 53 track 54 fold edge 55 Cutting line 56 Cutting line 57 Cutting line 58 distance 59 distance QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 2 452 754 A1

[0002] EP 1 162 003 B2 [0003, 0005, 0006, 0036] DE 20 2005 015 824

[0004] DE 20 2020 101 007 U

[0004]

Claims

[1] Arrangement of rigid foam panels (42-46) which are laminated on at least one flat surface with a film (8) and the web (53) formed from the connected rigid foam panels (42-46) is designed as a transportable roll, characterized by that the arrangement is designed as a stack of plates (40) with a rectangular or square cross-section, in which the rigid foam plates (42-46) are connected at their respective end faces (52) by folding edges (54) formed from cutting joints (41) and are folded there. [2] Arrangement of rigid foam boards according to claim 1, characterized by that the rigid foam panels (42-46) form a continuous web (53) and on the adjoining end faces (52) a cut joint (41) passes through the material of the rigid foam panels (42-46) except for a residual web (49), so that they are essentially only connected by the film (8) and are therefore foldable. [3] Arrangement according to claim 1 or 2, characterized by that it consists of stacks of rigid foam panels (42-46) arranged vertically one above the other and lying flat against each other, which are folded by 180 degrees in the area of ​​their broad-side cutting joints (41). [4] Arrangement according to one of claims 1 to 3, characterized by that the web (53) formed from the unfolded rigid foam panels (42-46) is laminated on its upper side with a film (8) spanning the entire web. [5] Arrangement according to one of claims 1 to 4, characterized bythat the cutting joint (48) separating the respective rigid foam panel (42-46) from the adjacent rigid foam panel on the broad side is aligned in a perpendicular direction to the surface of the rigid foam panel (42-46) and extends into the depth of the material of the rigid foam panel (42-46) while leaving a residual web (49) so that the residual web (49) breaks at least partially when the rigid foam panels are folded and the folding edge (54) is predominantly formed by the foldable film (8). [6] Method for producing an arrangement of rigid foam panels (42-46) which are laminated on at least one flat surface with a film (8) and the web (53) formed from the connected rigid foam panels (42-46) is designed as a transportable roll, characterized by that in a first process step, cutting joints (41) are introduced into the web (53) formed from the uncut rigid foam boards (42-46) at different distances (58, 59), that in a second process step the folding edges (54) formed by the cutting joints (41) are folded by 180 degrees, and that in a third method step the folding of the adjacent rigid foam panels (42-46) takes place in such a way that a panel stack (40) with a rectangular or square cross-section is formed. [7] Method according to claim 6, characterized by that the mutual distance (58, 59) between the cutting joints (41) of interconnected rigid foam panels (42-46) increases linearly according to the thickness of the rigid foam panels wound up to form the panel stack (40). [8] Method according to claim 6 or 7, characterized by that the cutting joint (41) extending over the front side of the rigid foam board (42-46) is applied during the advance of the rigid foam board (42-46) through the cutting station (15). [9] Processing line (1) for producing an arrangement of rigid foam boards (42-46) which are laminated on at least one flat surface with a film (8) and the web (53) formed from the connected rigid foam boards (42-46) is designed as a transportable roll, characterized by that it consists of a feed station (2) with a plate storage in a stacking space (4), to which a processing machine (10) is connected in the transport direction (5), in which the lamination of a web (53) consisting of rigid foam plates with the film (8) takes place and that a cutting station (15) is arranged at the output of the processing machine (10). [10] Processing line according to claim 9, characterized by that a folding station (20) is arranged at the exit of the cutting station (15), in which the hard foam panels (42-46) cut on the broad side can be folded by 180 degrees at the folding edges (54) formed by cutting joints (48). [11] Processing line according to claim 9 or 10, characterized by that the folding station (20) is followed by a packaging station (25), in which the plate stack (40) formed in the folding station is wrapped with a packaging film. [12] Processing line according to claim 11, characterized by that a stacking conveyor (28) for removing the foil-wrapped plate stacks is arranged at the exit of the packaging station (25). [13] Processing line according to one of claims 9 to 12, characterized by that the feed station (2) is connected to the processing machine (10) at the front and in the transport direction (5). [14] Processing line according to one of claims 9 to 13, characterized bythat in the processing station (10) the arrangement of rigid foam panels is designed as a panel stack (40) with a rectangular or square cross-section, in which the rigid foam panels (42-46) are connected at their respective end faces (52) by folding edges (54) formed from cutting joints (41) and are folded there. [15] Processing line according to one of claims 9 to 14, characterized by that in the cutting station (15) the feed of the slide (35) in the transport direction (5) of the rigid foam board (42-46) is synchronized with the cutting movement of the cutting knife (33) in the transverse direction (39)

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