DEVICE AND METHOD FOR PRODUCEING FOIL TUBE FROM A FOIL STRIP USING THE SHEAR FORM WELDING METHOD

Description

[0001] The invention relates to a device for producing a foil tube in widths of 100 mm to 285 mm and lengths over 250 m from a foil strip using a forming shoulder welding process for further processing into cable penetration and expansion and movement joint seals that can be filled with air or liquid media according to the preamble of claim 1, and a method according to the preamble of claim 5.

[0002] From WO2012 / 106783 A1, a method and a device are known that are applicable in the manufacture of cans, bottles, and more. The laminated film 2 moves at a relatively constant speed and is formed around the mandrel 1. A compression / cooling bar 10 with a cooling channel 11 is arranged above the film edge 7, and a compression / cooling bar 12 with a cooling channel 13 is arranged above the second edge 8. The profile of the mandrel 1 in the heating area of ​​the overlapping edges 7 and 8 of the film 2 has a step 5 between edges 7 and 8 leading to the Bonner cavity 6.

[0003] Heating unit 3 is a nozzle that supplies hot air into cavity 6. The melting of the foil 1 is limited to the area not in contact with compression / cooling rods 10 and 12 and mandrel 1. During the Luther movement of the foil 2 due to the change in the profile of mandrel 1, which transitions into plane 9, end s is raised, while end 7 and the two are compressed together in the compression / cooling rod 10. After the welding area, the cutting edge 4 must cut the tube into tubular bodies.

[0004] European patents EP 1867 904.B1, DE 10 2006 027888, EP No. 17166 769.4, PCT-EP 2017 / 065542, PCT-EP 16712 216.7 (2017) describe the application possibilities and EP 3056621 (2015) the production of the film tube equivalent to patent no. EP 1797764 B1 (2005).

[0005] Between 2003 and 2005, Fibre Optics CT GmbH and its partner Getex Lenz GmbH developed an alternative to patent WO 9314335 for welding 0.6 m lengths of foil tubing with section-by-section folding and welding using a manual sealing welding process, up to a length of 23 m. This production process has been used since 2013 for manufacturing expansion and movement joint seals and was approved by T-COM on August 11, 2005, with a qualification audit ("Development Sample Examination").

[0006] The invention relates to a device that is particularly suitable for producing a foil tube up to 500 m long from a 5-layer aluminum composite foil strip up to 500 µm thick, consisting of a forming shoulder welding device, wherein the overlapping foil strip is pressed centrally by means of a forming shoulder in combination with a heat exchanger and welded in the direction of tension with a hot gas welding device and the folds of the longitudinal edges of the foil tube are flattened by the heated forming shoulder.

[0007] The transport of the film tape and the film tube to be transported to the winding spool is carried out via driven rollers for pressing the center weld seam and driven transport rollers to the goods storage area.

[0008] To control the material speed of the film belt and film tube up to the product storage and material speed up to the winding spool, dancers (pendulums) with on / off switches are located between two longitudinal drives to adjust speed and transport force.

[0009] For the most well-known devices for manufacturing an aluminum composite foil tube up to 500 µm thick from a foil strip for equivalent applications and their requirements, the test principles PG-DMPK-1 and 2 for cable protection pipe and building penetration seals and PG-FMPB-1 and 2 for expansion and movement joint seals apply, namely Variant 1: Film tube made from a 180° folded film strip whose overlapping longitudinal edges are welded using a mirror welding process. Variant 2: Film tube made from a 180° folded film strip whose overlapping longitudinal edges are welded using a mirror welding process, and subsequently the welded film tube is pressed together longitudinally by 180° and the overlapped welded longitudinal edges are bent over by 180°. Variant 3: Film tube made from a film strip with an internal separating layer of siliconized paper or a trailing tongue, whose film strip is welded in the folded area using a hot gas nozzle (heated air). Utility model DE 20 2019 002 027 A1. Variant 4: Film tube made from a film strip whose overlapping longitudinal and transverse edges are welded manually using a mirror welding process has the known disadvantages. Variant 1: Folded by 180° and longitudinally overlapped mirror-welded foil tubesThe requirements according to test principles PG-DMPK 2 regarding the required burst pressure resistance of the weld (approx. 4 bar) are not met. Variant 2: Folded by 180° and overlapped longitudinally. mirror-welded foil tubes These are pressed and folded again after welding so that the overlapped weld is located in the center of the flat hose. While these may not meet the requirements according to the test principles, they may exhibit a higher leakage rate with regard to flexural strength when used as cable penetration seals, particularly according to PG-DMPK-2, due to the 4-layer longitudinally overlapping foil tape transverse welding. Variant 3: Longitudinally folded, rail gas welded foil hoses The requirements according to the test principles for cable penetration and expansion and movement joint seals consist only of a foil tape with an internal separating layer or drag tongue in the hot gas welding area (heated air). with very high testing effort and high failure rates.Problems exist: uncontrolled overlapping of the foil tape without forced fixation can lead to asymmetrical overlapping and uncontrollable, alternating longitudinal edge welding, which, in the case of transverse welding, results in leaks. Non-stick separating inserts with siliconized paper, when heated with air up to 100 l / min, cause the separating insert to fuse with the foil's top and bottom surfaces due to displacement within the foil tube. Missing foil tube edges or hot-folded edges lead to cold cracking of the aluminum foil and a loss in leakage rate. Variant 4: Foil tubes with overlapped longitudinal and transverse foil edges, welded using a manual mirror welding process, generally meet the requirements of test principles PG-DMPK-1 and 2 for cable protection pipe and building penetration seals and PG-FMPB-1 and 2 for expansion and movement joint seals, but have the disadvantage of being uneconomical to manufacture.

[0010] The known methods variant no. 1 to variant no. 3 also have the decisive disadvantage that, without regulating the transport speed via heat storage, dancers, on / off switches, etc., it is not possible to produce longer lengths with consistent quality.

[0011] Devices and properties for the film tube and film tape are publicly known and published under EP No. 3256656, DE 102015 101 963.9. The claims are presented here in part: "13. Device according to one of claims 1, 2, 3, 7, 8, 9, 10 and 11, characterized in that the flat tube cushion (1, 1', 1", 6', 6", 16, 20, 21‴) is made of a folded tape (1‴) or tube, which, depending on the application, consists of thermoplastics, elastomers and / or flame-retardant thermoplastic-elastomer mixtures, wherein these materials have metallic and / or metal-free inserts. 14. Device according to one of claims 1, 2, 3, 7 to 11 and 13, characterized in that the tape (1‴) of the flat tube cushion (1, 1', 1", 6', 6", 16, 20, 21‴) preferably made of at least a five-layer thermoplastic composite film (1‴) with the structure - 150-250 µm PE - 150-250 µm PE - 15-30 µm PET - 15-30 µm PET - 9-23 µm ALU - 9-23 µm LEAD - 15-30 µm PET - 15-30 µm PET - 150-250 µm PE - 150-250 µm PE is manufactured. 15. Device according to one of claims 1, 2, 3, 7, 8, 9, 13, and 14, characterized in that, that the flat hose cushion has a total leakage rate of L = ..... 5.5 ≤ 6.2 x 10-8 mbarl / s, corresponding to 2.7 mbarl / year, with the supplied valve end cap. 16. Device according to claims 1, 4 and 15, characterized by that the flat tube cushion with Burst pressure resistance up to 9 bar, notch toughness up to 40 N / cm², chemical resistance to pH2, pH12, gasoline, diesel, kerosene, paraffin oil and temperature resistance from -60°C to +70°C.

[0012] The invention is defined in a first aspect by a device according to claim 1.

[0013] The weld can be formed by means of compression rollers and / or transported by conveyor belt rollers (11) to the product storage (12) via movable rollers (13) and dancer rollers (14) with a designed automatic on / off switch (15) to the winding spool.

[0014] Preferably, the end product made from the foil tube is designed to meet the requirements in application areas of cable penetration sealing according to test principles PG-DMPK 1 and 2 and expansion and movement joint sealing according to test principles PG-FMPB-1 and 2.

[0015] Particularly preferred is the provision of the device for the continuous production of film tape to film tube and their end products, as described, for example, in EP 1867 904.B1, DE 10 2006 027888, EP No. 17166 769.4, PCT-EP 2017 / 065542, PCT-EP 16712 216.7.

[0016] It is expediently provided that the film strip (2) is universally folded and guided to the forming shoulder (4) and that the forming shoulder (4) is only designed for replacement in the case of different film tube widths.

[0017] Preferably, a heat exchanger (6) is provided on the underside of the film strip (1) for cooling during the welding (5) of the film strip (2), which is centrally overlapped at the forming shoulder (4) with a fixed Teflon plate, and / or a hot gas welding device (7) is provided at the forming shoulders (4), preferably with a fixed Teflon plate, between the overlapping film strip for welding (5) to form the film tube (8). Particularly preferred are two driven welding press rollers (9) and / or heated forming shoulders (10) and / or two driven transport rollers (11) provided for forming the film tube along its longitudinal edge.

[0018] Preferably, the deviations of the circumferential speeds of the rollers (1, 9, 11) and the winding spool (16) via movable rollers (13), dancer rollers (14), winding spool on / off switch (15) and film hose winding spool (16), are distributed / compensated for controlling material speed and force from the film tape unwind roller (1) to the driven film tube welding points (8) (8a) of the folded film tape, compression rollers (9) and driven film tube transport rollers (11) to the winding spool (15), namely the deviations of the circumferential speeds of the rollers (1, 9, 11) and the winding spool (16) via movable rollers (13), dancer rollers (14), winding spool on / off switch (15) and film tube winding spool (16), preferably in the material storage (12).

[0019] The invention is defined in a second aspect by a method according to claim 5. The invention will now be explained in more detail with reference to exemplary embodiments. The following are shown: Fig. 1 Invention: Forming shoulder hot gas welding process for producing a film tube from a film strip. View of the system consisting of film strip unwinding roller (1), film strip (2), film strip folding device (3), heat exchanger (6), forming shoulder (4), hot gas welding device (7), welding (5a) to form the film tube (8a), heated forming shoulder (10), transport rollers (11) to the product storage (12). Fig. 2 Fig. 2 Invention: Control of the material speed of film tape and film tube up to the winding spool. Side view and a perspective view extending from the Fig. 1consisting of the film tube (8a) to be transported up to the product storage (12), movable rollers (13), dancer rollers (14), take-up spool with automatic on / off switch (15a), dancer rollers (14), off / off switch (15b), dancer rollers (13), film tube take-up spool (16). Fig. 3 Invention: Forming shoulder assembly A cross-sectional view of the device according to the invention and features for welding the film strip (2a, b, c) to the film tube (8a) by means of forming shoulder (4), heat exchanger (6), hot gas welding device (7), welding (5a), stationary plate (5a), forming shoulder (4) (5c). Fig. 4 Separating inserts for web gas welding process Shows a cross-sectional view of a film tube welding device with separating insert (17) and features for welding the equivalent film strip (2a, b, c) to the film tube in an uncontrolled manner using the web gas welding process.Fig. 5a Mirror welding process of variant 1 and 2 Shows a cross-sectional view of a foil tube mirror welding device and its properties for welding the equivalent foil strip (2a, b, c) folded by 180° to form a foil tube (8a) in a controlled manner. Fig. 5b Foil tube 180° folding process of variant 2 Shows a 180° folded longitudinal edge overlap (5a) of the transverse weld of the foil tube (8a) welded using the mirror welding process. Fig. 5c Fig. 5c Pressure-resistant foil tube cross closures of the Fig. 5bFig. 5d Shows a cross-sectional view of the film tube with longitudinal edges folded by 180° (8d) for pressure-resistant film tube transverse closures (24) in the sealing welding process (22b). Fig. 5d Pressure-resistant film tube transverse closures in the sealing welding process. Shows a cross-sectional view of the sealing welding device (22) for producing pressure-resistant transverse closures of a film tube (8a). Fig. 6a Shows a cross-sectional view of the film tape folding device (23b). Fig. 6b Shows a cross-sectional view of the longitudinal edge overlap produced in the sealing welding process (22). Fig. 6c Shows a perspective view of pressure-resistant transverse closures (24) of the film tube (8a).

[0020] In Fig. 1 A device for folding a film tape unwind roll (1) into a film tube (8a) is shown.

[0021] The film strip (2), preferably in widths from 200 mm to > 600 mm, consisting of materials PE preferably 150–250 µm (2a), PET preferably 15–30 µm (2b), 9-aluminum strip preferably 23 µm (2c), PET preferably 15–30 µm (2b), PE (2a) preferably 150–250 µm, and preferably hot melt adhesive layers, is preferably folded into the forming shoulders 1 to 3 (4) to form a film tube (8a) via a heat exchanger (6) using a universally adjustable film strip folding device (3). The overlapping longitudinal edges (5a) between the forming shoulders (4), with a width of 28 to 30 mm, are welded using a hot gas welding device (7). The film tube (8 a) is drawn by compression rollers (9) over the heated forming shoulder (10) with a recess of the longitudinal edge overlap (5 a) to a fold of the film tube (8c) by transport rollers (11) and transported to the product storage (12).

[0022] In Fig. 2A device for controlling the material speed of the film tube (8 a) in lengths up to about 500 m is shown, which is transported from the film tape unwinding roller (1) via the film tape folding device (3), the hot gas welding device (7), compression rollers (9), transport rollers (11), movable transport rollers (13), dancer rollers (14) to the film tube winding spool (16).

[0023] Since it is virtually impossible to transport the stretched film strip (2) and film tube (8a) to the take-up reel (16) with controlled web and static friction, and to synchronize the tensile force and winding speed of the film tube (8a) on the take-up reel (16), even with just two longitudinally driven compression rollers (9) and transport rollers (11), at least two dancer rollers (14) and at least six movable rollers (13) are required. The stroke of the dancer rollers (14) is measured directly and converted into an electrical signal. When the dancer (15b) reaches its upper zero position, the transport through the take-up reel (16) is switched off. When the weight and tensile force of the dancer rollers (15a and 15b) cause the dancer (15a) to reach its lower zero position, the take-up reel (16) is switched on again.

[0024] The material lengths from the storage area (12) are taken at high speed from the dancer rollers (14) with the film tube winding spool.

[0025] In Fig. 3 is a cross-sectional view of the forming shoulder (4) according to the invention, device and features for the production of film tube (8 a) and in particular the welding of the longitudinal edge overlap (5 a) of the film strip (2 a, b, c) folded in this way.

[0026] The forming shoulder (4) with fixed plate stabilizes (5 c) the longitudinally folded film tube (8 a) and prevents or reduces penetration of the hot air (18) of the hot gas welding device (7) to the heat exchanger (6) of the cooled film tube underside (8 b), so that in the future fusion to longitudinal edge overlap (5 a) with the film tube underside (8 b) and thus film tube scrap as when using the Fig. 4 be avoided.

[0027] In Fig. 4is a device and features for the production of film tubing (8 a) and in particular the welding of the longitudinal edge overlap (5 a) of the folded film strip (2a, b, c) in direct comparison.

[0028] Between the longitudinal edge overlap of the film strip (5a), heated air (18) and / or a non-stick separating layer (siliconized paper) (17) is preferably applied to the underside (8b) of the film tube via a hot gas nozzle (19) using a web gas welding process (7), and folded and / or welded (8a) to form a film tube. Due to the lack of forced fixation of the longitudinal edge overlap of the film strip (5a) and the absence of a barrier layer (18) and film tube transport, asymmetrical overlaps of the film longitudinal edges (8a) and fusion of the top (8a) and bottom (8b) surfaces of the film tube occur.

[0029] In Fig. 5ais shown a device and properties for the production of foil tubing (8 a), in particular in the mirror welding process (20) in direct comparison to Fig. 3 and Fig. 4 .

[0030] Between the 180° folded film strip (2) and the film tube (8a), a mirror welding device (20) is located between the films of the longitudinal edge overlap. This device consists of a weight of the compression device (21a) and fixed plates (21b). The folded and welded film tube (8a) can be transported during the mirror welding process (20). However, it is not suitable for pressure-filled sealing systems and their requirements according to test principles PG-DMPK-1 and 2.

[0031] In Fig. 5b is a longitudinal edge overlap of the foil tape of the Fig. 5a a foil tube (8 a) produced by mirror welding, with a longitudinal edge overlap of 180° for further processing Fig. 5 c.

[0032] In Fig. 5c Figure 8d shows a cross-sectional view of the film tube with longitudinal edges folded by 180°, for pressure-resistant film tube cross-closures (24) using the sealing welding process (22b).

[0033] After the longitudinal edge overlap and welding (5 a), the film tube (8 a) is folded so that the laterally overlapping weld (5 a) is located in the center of the film tube (8 d). The sealing welding device (22 b) for pressure-resistant transverse welding (24) of the film tube consists of heating cartridges (21 c), a heated weight (21 a), and a heated, stationary plate (21 b).

[0034] In Fig. 5d A cross-sectional view of the foil tube (8 a) is shown, variant 1 Fig. 5a for pressure-resistant foil tube cross closures (24) using the sealing welding process (22 b).

[0035] The sealing welding device (22 b) for pressure-resistant transverse welding (24) of the foil tube consists of a weight (21 a) equipped with heating cartridges (21 c) and a stationary plate (21 b) equipped with heating cartridges.

[0036] In Fig. 6a A foil tape folding device of a foil tape (2a, b, c) is shown, in a pneumatic foil tape folding device (23b) and heated forming blade (23a).

[0037] In Fig. 6b is a cross-sectional view of the longitudinal edge overlap of a foil strip (2, b, c) shown in a sealing welding device (22) with < 1 m length, a weight-heated plate (21), heating cartridge (21c) and stationary, teflon-coated insulating plate (21d) for welding the longitudinal edge overlap (22a) to form the foil tube (5a).

[0038] In Fig. 6cA perspective view of the pressure-resistant transverse welding (24) of the foil tube (8a) is shown, variant 4 and end product Fig. 3 and invention for the production of patented end products of cable, expansion and movement joint seals, foil tape (2a, b, c) in 3 layers after welding the longitudinal edge overlap (22a, 5 a) with the underside (8 b), pressure-resistant transverse welding of the foil tube (22) in the sealing welding process (22 b) consisting of a Teflon-coated weight plate (22 c), heated weights (21 a) of the pressing device, fixed plate (21 b) and heating cartridge (22 c). Reference symbol list Glossary / Abbreviations used

[0039] 1 Foil tape unwind roll 2 Foil tape 2 a 150 - 250 µm PE Crystallite melting point 105 - 155°C 2 b 15 - 30 µm PET Crystallite melting point 255 - 260°C 2 c 15 - 30 µm Aluminum Crystallite melting point Hot melt adhesive between each layer 3 Foil tape folding device 4 Form shoulder 5 Welding 5 a the longitudinal edge overlap 5 b The longitudinal edge overlap is bent over 180° 5 c fixed plate 6 Heat exchanger 7 hot gas welding machine 8 Foil tube 8 a folded / welded 8 b bottom 8 c Edge fold 8 d folded, welded with 180° longitudinal fold 9 Pressing rollers 10 Heated shaping shoulder 11 Transport rollers 12 Warehouse 13 Movable rollers 14 Dancers Roll Reference symbol list Glossary / Abbreviations used

[0040] 15 winding spool 15 a (14) automatic switch 15 b (13) automatic off switch 16 Foil tube, winding spool 17 Non-stick separating sheet, silicone-coated paper, sliding tongue 18 Heated air 80-100 l / min 19 Hot gas jet 20 Mirror welding process 21 Pressing weld seam 21 a Weight 21 b Fixed plate 21 c Heating element 21 d fixed Teflon-coated insulating panel 22 Seal welding process 22 a Longitudinal welding, length < 1 m 22 b Cross-welding 22 c heated Teflon-coated weight plate 22 d stationary, heated Teflon-coated weight plate 22 e Heating cartridges 23 a heated dividing blade 23 b pneumatic foil tape folding device 24 Pressure-resistant foil tube cross closures

Claims

1. Device for a forming shoulder welding process, for producing a tubular film for further processing into cable penetrations and expansion and movement joint seals that can be filled with air or liquid media for special operating conditions such as preferably leak rate 2.7 mbar l / year, 10 N tension and 9 bar pressure from a five-layer film strip up to 500 µm thick in widths from 100 mm to 285 mm and lengths over 250 m, wherein a film strip unwinding roll (1) is provided, from which film strip (2) can be fed to a film strip folding device (3), which has a heat exchanger (6) for the film strip and a forming shoulder (4), which are provided to arrange the film strip longitudinal edges overlapping in the center of the film strip (2) formed into the tubular film (8) and a hot gas welding device (7) is provided, which is aligned between or on the overlapping longitudinal edges of the film strip and is designed to weld this into a tubular film (8) characterized in that heated forming shoulders (10) are provided and aligned to flatten tubular film longitudinal edges (8).

2. Device according to claim 1 characterized in that compression rollers (9) are provided for fusing the film longitudinal edge overlap, in particular for forming a weld seam of the tubular film.

3. Device according to claim 1 characterized in that transport belt rollers (11) are provided to feed the tubular film to a material storage (12) via movable rollers (13) and dancer rollers (14) to a winding spool (16), wherein the movable rollers and dancer rollers compensate for deviations in the circumferential speeds of the transport belt rollers, compression rollers and / or the film strip unwinding roll (1, 9, 11).

4. Device according to any of the preceding claims characterized in that the forming shoulder (4) is designed to be exchangeable for different tubular film widths.

5. Method for producing a tubular film for further processing into cable penetrations and expansion and movement joint seals that can be filled with air or liquid media, preferably for special operating conditions such as for example leak rate 2.7 mbar l / year, 10 N tension and 9 bar pressure from a five-layer film strip up to 500 µm thick in widths from 100 mm to 285 mm and lengths over 250 m, wherein the film strip (2) is fed from a film strip unwinding roll (1) via a film strip folding device (3), a heat exchanger (6) and a forming shoulder (4) and is formed into the tubular film (8) with overlap of the film strip longitudinal edges in the center of the film strip (2), wherein the film strip is welded into the tubular film (8) by means of a hot gas welding device (7), and characterized in that the welding is formed by compression rollers (9) and the tubular film longitudinal edges (8) are flattened by heated forming shoulders (10).

6. Method according to claim 5 characterized in that the tubular film is transported by means of transport belt rollers (11) up to the material storage (12) via movable rollers (13) and dancer rollers (14) with integrated automatic on and off switches (15) up to the winding spool.

7. Method according to claim 5 or 6, characterized in that the film strip (2) is universally folded up to the forming shoulder (4).