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    • 专利摘要:
    The present invention relates to a production unit for continuously producing a layered styrene-polymerized expanded sheet comprising a main layer and at least one top layer for introducing expanded or expandable styrene-polymerized granules into the top layer.
    公开号:BE1020212A5
    申请号:E201100523
    申请日:2011-09-02
    公开日:2013-06-04
    发明作者:Thierry Vereecke
    申请人:Tech Bureel Panigo Nv；
    IPC主号:
    专利说明:

    Production of layered styrene polymerized sheets
    Technical field
    This invention describes a new production unit and a new production process for foamed plate-shaped elements of styrene-polymerized expanded granules, whereby styrene-polymerized plates with a layered structure can be produced in a continuous and simple manner in a continuous manner.
    BACKGROUND OF THE INVENTION
    Foamed elements from styrene-polymerized expanded beads are produced from pre-expanded beads that are brought into a closed form. By adding steam, the grains tend to expand further and merge slightly and merge into one another. In this way a foamed element is obtained afterwards with a shape that is similar to the closed shape where the granules were introduced. This form can then be edited later.
    It is also possible to form foamed sheets from styrene-polymerized expanded beads by a continuous process. The expandable styrene-polymerized granules are pre-expanded and are then placed between 2 moving belts. There they are exposed to steam so that the plate grows continuously because more and more styrene-polymerized expanded beads adhere to the end of the plate. Thus plates are obtained with a random length. This latter process also makes it easy to produce foamed expanded sheets that are formed from several layers of different material. An example of such a method can be found in the following patent applications: US3885009, US 3037897, US 3616162 and FR 1373519. In these methods, layers are produced that consist of styrene-polymerized expanded beads of different density or with the addition of other types of beads such as grains from polysulfides to reduce flammability.
    However, these methods as described in the above patent applications all fall short to ensure a good mechanical quality and / or a good control of the thickness of these layers, especially when a thin top layer has to be applied. In order to obtain a good mechanical quality, it is important that the pre-expanded granules are pressed with great pressure between the two moving belts. This will allow these grains to fuse together better when exposed to steam. This has the consequence that the resulting foamed plate can have much better mechanical properties.
    In US 3037897, the majority of the layers are exposed to steam twice or more. This is detrimental to the mechanical quality of the foamed sheets.
    In US 3885009, US 3037897, US 3616162 and FR 1373519, the pellets are fed by a conveyor belt without a system capable of feeding the pellets with a constant, sufficiently large force between the moving belts. As a result, the foamed sheet will not meet the mechanical requirements that are imposed today.
    It is difficult to apply a very thin top layer with such systems; after all, a breakthrough to the surface of the main layer will occur regularly. Most top layers, however, have a protective function, whereby the layer must be at least one centimeter thick to be effective or because further post-processing is done. For example, it is possible that half a centimeter to one centimeter is sanded / cut to improve surface roughness.
    The object of the present invention is to describe a new production unit and process through which foamed elements consisting of styrene-polymerized expanded granules can be made consisting of a main layer and a, preferably thin, top layer. The thickness of the top layer can preferably be determined fairly accurately. The layered foamed plate will have good mechanical and / or uniform properties in the feed direction. By using a production unit described by the present invention, a foamed layered plate with one or more top layers on one or both surfaces can be obtained, whereby the thickness of that top layer / top layers is easy to control. The foamed plate itself can exhibit uniform properties in the feed direction and the plate can exhibit good mechanical properties.
    Summary
    The present invention describes a new production unit for the production of foamed plate-shaped elements of styrene-polymerized expanded granules, with which styrene-polymerized plates with a, preferably thin, top layer can be produced continuously on one or two sides in a simple and smooth manner. and wherein the thickness of that top layer can be determined fairly accurately.
    The present invention also relates to a new method which comprises the use of a specific production unit that can be integrated into a larger machine that allows continuous production of a layered plate, preferably a plate with a top layer on one or two sides .
    In a first aspect, the invention relates to a production unit for continuously producing a layered styrene polymerized expanded sheet comprising a main layer and at least one top layer, the production unit comprising: (a) two straps positioned vertically one above the other (1) and (2) made of perforated metal or perforated flexible material, and rotating drums (3) and (4), the belts (1) and (2) being continuously under the influence of the drums (3) and (4) having the same moving speed, (b) a space (5) between belts (1) and (2), (c) a steam chamber (8), suitable for blowing steam through the belts via the perforations, (d) optionally, a vacuum chamber (9), (e) optional, a cooling section (10), in which preferentially air is used as the cooling gas, (f) optionally, a stabilizing section (11), (g) optional, a cutting unit, and (h) one or a plurality of systems (20) comprising one or more closure pieces (12) coupled to the drums ( 3) and / or (4), wherein the one or more systems (20) comprise a casing with an opening coupled to a screw or venturi system (13) or silo (50), optionally comprising a feed device (51) suitable for introducing pre-expanded or expandable styrene-polymerized beads into the top layer.
    The invention also relates to a production unit for the continuous production of a layered styrene polymerized expanded plate consisting at least of: two belts (1) and (2) positioned vertically one above the other made of perforated metal or perforated flexible material mounted on rotating drums ( 3) and (4), wherein both belts move continuously under the influence of the drums at the same rotational speed; a space (5) between belts (1) and (2); a steam chamber (8) through which steam is blown through the belts via the perforations; optionally, a vacuum chamber (9); optionally, a cooling section (10) in which preferably air is used as the cooling gas; optionally, a stabilization section (11); optionally, a cutting unit, and, one or more systems (20) incorporated in one or more closing pieces (12) present on the drums (3) and (4), or, as a separate part coupled to the production unit; consisting of a metal casing in which a slot (22) is made, through which a metal plate (23) can be slid, and wherein the plate can be fixed to the casing. In a preferred form of the invention, the screw or venturi system (13) forms an angle of 90 ° with the belts (1) and (2).
    In a preferred form of the invention, the screw or venturi system (13) or the feed device (51) can be adjusted to exert a controllable continuous force or a controllable periodic force.
    In a preferred form of the invention, the feed device (51) comprises a wheel (52) with a set of rotating fingers (53) and the feed device (51) comprises a set of fixed fingers (54). In a preferred form of the invention, the angle between the screw or venturi system (13) with the belts (1) and (2) can be adjusted.
    In a preferred form of the invention, the production unit comprises an additional screw or venturi system (6), suitable for introducing pre-expanded or expandable styrene-polymerized beads into the main layer between the belts (1) and (2), wherein preferably the additional screw or venturi system (6) forms an angle of 0 ° with the belts (1) and (2).
    In a preferred form of the invention, the one or more systems (20) comprise a slot (22) through which a metal plate (23) is slid, wherein the distance to which the plate protrudes from the casing of the system (20) is adjustable and / or wherein the inclination of the plate with respect to the casing is adjustable.
    In a preferred form of the invention, the production unit comprises two hinges (30) comprising a threaded rod (31) at the height of the slot (22) on the outside of the casing, and the metal plate comprises profiles (32), in which the plate can be fixed to the casing by means of nuts (33), one of the ends of the threaded bars (31) resting against the plate.
    In a preferred form of the invention, the production unit comprises threaded bars (34) on the inside of the casing, wherein the threaded bars (34) are fixed against the casing by means of nuts.
    In a preferred form of the invention, the production unit comprises straps on the sides of the space (5) that move under the influence of additional drums, or the production unit comprises support straps that are vertically above each other and between which there are several profile straps.
    In a preferred form of the invention, the interfaces between the belts and the rest of the production unit with the material comprise a layer with a low coefficient of friction, preferably Teflon, and / or small drums (7) are present on these interfaces. by the movement of the belts, wherein these drums are preferably made from or coated with material with a low coefficient of friction, preferably Teflon.
    In a preferred form of the invention, the sides of the steam and / or vacuum chamber are shielded with metal plates, preferably coated with a material with a low coefficient of friction, preferably Teflon, and / or the drums comprise closing pieces (12), and / or the space between the two drums is closed with plates.
    In a preferred form of the invention, the distance between the two moving belts is adjustable and / or the belts are laterally movable.
    In a preferred form of the invention, the production unit comprises partitions, whereby different compartments are created in the system (20).
    In a second aspect, the invention relates to a machine for continuously producing a layered styrene polymerized expanded sheet comprising at least one or more production unit (s) according to the first aspect of the invention.
    The present invention also relates to a new method which comprises the use of a specific production unit which can be integrated into a larger machine that allows the continuous production of a top layered plate on one or two sides.
    In a third aspect, the invention relates to a method for continuously producing a layered styrene polymerized expanded sheet, using a production unit according to the first aspect of the invention or using a machine according to the second aspect of the invention, the method comprising the steps of: (a) introducing, preferably pre-expanded, styrene-polymerized granules into the space (5), thereby forming a main stream of granules, preferably by means of a screw or venturi system (6), (b ) introducing another type of styrene-polymerized granules by means of a force perpendicular to the main stream, so that a part of the granules of the main stream is pressed away in a controlled manner and the granules of the other type take their place, and (c) optionally, providing a plate (23) which, just before inserting the other type of styrene-polymerized granules, the main cream locally.
    In a preferred form of the method according to the invention, the grains of the different type of grains comprise with a different density with respect to the grains of the main stream.
    In a preferred form of the method according to the invention, the grains of the other type of grains whose concentration of athermanic substances, preferably the concentration of graphite, carbon black, metal or metal oxide particles, which are homogeneously distributed in the styrene-polymerized grains, comprise different from that of the grains of the main stream.
    In a preferred form of the method according to the invention, the cooling gas is applied in the cooling section with a high pressure.
    With the insight to better show the characteristics of the invention, a few preferred embodiments are described below with reference to the accompanying drawings as an example without any limiting character.
    Detailed description of the figures
    Figure 1: production unit according to a preferred form of the invention, mounted on a continuous production process for plates of expanded styrene-polymerized granules with one main layer and one top layer, the screw system (6) being placed vertically.
    Figure 2: production unit according to a preferred form of the invention, mounted on a continuous production process for plates of expanded styrene-polymerized granules with one main layer and one top layer, whereby an expansion plate with a slot is used.
    Figure 3: machine represented in Figure 2 in operational mode.
    Figure 4: detail drawing of the inside of the casing according to a preferred form of the invention.
    Figure 5: Detailed drawing of the outside of the casing according to a preferred form of the invention.
    Figure 6: production unit according to a preferred form of the invention, mounted on a continuous production process for plates of expanded styrene-polymerized granules with one main layer and one top layer, the screw system (6) being placed horizontally.
    Figure 7: detail drawing of the outside of the casing according to a preferred form of the invention.
    Figure 8: detail drawing of a production unit according to a preferred form of the invention, mounted on a continuous production process for plates of expanded styrene-polymerized granules with one main layer and one top layer, comprising a silo (50) and a feed device (51) that allows to styrene-polymerized granules of the top layer with a constant continuous force.
    Figure 9: detail drawing of a feeder (51) of a production unit according to a preferred form of the invention, comprising a wheel (52) with rotating fingers (53) and fixed fingers (54).
    Detailed description of the invention
    As further used in this text, the singular forms "a", "the", "the" include both the singular and the plural form unless the context is clearly different.
    The terms "include", "includes" as used further are synonymous with "inclusive", "include" or "contain," contain "and are inclusive or open and do not exclude additional, unnamed members, elements or method steps. The terms "include", "includes" include the term "contain".
    The enumeration of numerical values based on numerical ranges includes all values and fractions in these ranges, as well as the cited endpoints.
    The term "about", as used when referring to a measurable value such as a parameter, a quantity, a duration, and so on, is intended to encompass variations of +/- 10% or less, preferably +/- 5% or less, more preferably +/- 1% or less, and even more preferably +/- 0.1% or less, from and from the specified value, insofar as the variations apply to function in the disclosed invention . It is to be understood that the value to which the term "approximately" refers per se has also been disclosed.
    All documents quoted in the current specification are fully incorporated herein by reference.
    Unless defined otherwise, all terms disclosed in the invention, including technical and scientific terms, have the meaning that those skilled in the art usually understand. As a further guide, definitions are included for further explanation of terms used in the description of the invention.
    A foamed element with a layered structure composed of a main layer and a top layer on one or two sides, each layer being composed of styrene-polymerized expanded granules or from a mix of various styrene-polymerized expanded granules, offers many advantages since the properties of each layer can be tailored to a specific application. This can result in major cost reductions.
    For example, it is possible for the top layer to function as a mechanical protective layer. An example of this is a foamed element that is made up of a thick layer of styrene-polymerized expanded grain that offers sufficient thermal or acoustic insulation, and a thin top layer made of styrene-polymerized expanded grain with a higher density and therefore also a higher compressive strength. Due to its stiffer nature, this top layer prevents the installation of the fingerprints of the installer after the installation of this plate in a roof construction. This would be the case with such an installation with plates that would be entirely composed of the styrene-polymerized expanded granules of the thickest layer. A plate consisting entirely of the higher density granules used in the top layer would be too expensive. This example only serves as an illustration, there are more areas of application for sheets with a layered structure whose density can be adjusted for each layer.
    Another example of a layered structure can be given by a top layer with expanded polysulfide polymerized beads in combination with a main layer of styrene polymerized beads. The polysulfide polymerized pellet will then protect the main layer against fire, while the main layer provides the insulation value. It is of course important that the top layer is not too thin (too little protection) or too thick (poorer insulation value due to thinner main layer).
    It is also possible, for example, to produce a layered foamed element, the main layer of which consists of styrene-polymerized expanded granules with the addition of athermanic substances (metal powder, oxides, graphite, carbon black). These grains are known for their good insulation value (see patent applications EP0981574B1 and EP0902804 A1) but due to the addition of athermanic substances they are less resistant to sunlight. The top layer in this case can then consist of styrene-polymerized expanded beads without the addition of athermanic substances. These do show a good resistance to sunlight. However, if the top layer is too thick, the insulation value of the board as a whole will deteriorate, which is economically disadvantageous. If the thickness of the top layer is too small, the styrene-polymerized granules with the addition of athermanic substances may appear in concentrated groups on the surface of the plate, as a result of which it is no longer resistant to sunlight. Good control of the thickness of the layers is therefore of great importance. If the athermanic substances are present in concentrations of 3 to 25 w% in the styrene-polymerized expanded grain, these substances will minimize the heat of loss due to heat radiation and thus increase the thermal insulation value of the foamed element. On the other hand, these grains distort a lot of sunlight, which is detrimental to certain applications. The term "w%" herein refers to the weight percentage of a substance in the grain, whereby the weight percentage is calculated on the total weight of the grain.
    With the production process of the present invention, it is possible to produce a layered foamed element in which one layer consists of styrene-polymerized expanded granules containing 3 to 25 w% athermic substances in a homogeneous distribution and where this layer is responsible for the thermal insulation value of the whole. The other layer may then consist of styrene-polymerized expanded granules containing 0.05% to 2.5 w% of athermanic substances homogeneously distributed throughout the granule. These styrene-polymerized expanded grains have a poorer insulation value but deform less on sunlight. The layered foamed element is thus better protected against deformation in relation to the sunlight.
    In a first aspect, the invention relates to a production unit for continuously producing a layered styrene polymerized expanded sheet comprising a main layer and at least one top layer, the production unit comprising: (a) two straps positioned vertically one above the other (1) and (2) made of perforated metal or perforated flexible material, and rotating drums (3) and (4), the belts (1) and (2) being continuously under the influence of the drums (3) and (4) having the same moving speed, (b) a space (5) between belts (1) and (2), (c) a steam chamber (8), suitable for blowing steam through the belts via the perforations, (d) optionally, a vacuum chamber (9), (e) optional, a cooling section (10), in which preferentially air is used as the cooling gas, (f) optionally, a stabilizing section (11), (g) optional, a cutting unit, and (h) one or a plurality of systems (20) comprising one or more closure pieces (12) coupled to the drums (3) and / or (4), wherein the one or more systems (20) comprise a casing with an opening coupled to a screw or venturi system (13) or silo (50), optionally comprising a feed device (51), suitable for introducing pre-expanded or expandable styrene-polymerized beads into the top layer.
    The thickness of the top layer is preferably between 0.1 and 2 cm, more preferably between 0.2 and 1 cm, most preferably between 0.3 and 0.5 cm. In a preferred form of the invention, the opening is coupled to a screw or venturi system. In a preferred form of the invention, the opening is coupled to a screw system. In a preferred form of the invention, the opening is coupled to a silo. Preferably, the silo comprises a feed device for feeding the pre-expanded or expandable styrene-polymerized beads. The feed device preferably comprises a wheel.
    In this production unit, the cooling, vacuum, stabilization and / or cutting sections are optional. However, if it is absent, it is recommended that the plate be held between the two belts for a while behind the steam chamber as the plate exerts great pressure on the belts and only gradually decreases them. The function of the stabilization section can also, for example, if they are long enough, be taken over by the cooling and / or vacuum section. After this production unit, it is also possible to carry out an elastification process, for example. The latter process serves to better insulate the board acoustically. Furthermore, it is also cheaper to have this process carried out right after the production process.
    In the production unit of the present invention, for example, a plate can be produced consisting of a layer, preferably the main layer, containing (black) grains with the addition of graphite, carbon black, metal or metal oxide grains, and, a layer, preferably the top layer, comprising, for example, ordinary white or light gray grains.
    The invention also includes the possibility of producing foamed elements of polypropylene, polyethylene or polysulfides in addition to foamed elements of polystyrene. Expandable granules made from a copolymer of styrene and olefins can also be used in the process of this invention. In a preferred form of the invention, these granules can have a styrene content of 100, 95, 90, 85, 80, 75, 70, 65, 60, 55 or 50%, the percentage being a weight percentage based on the total weight of the granules .
    The present invention also relates to a production unit as described above, in which the grains of the main layer are introduced by a screw or venturi (6) between the 2 belts (1 and 2). This stream will be referred to herein as the "main stream". In a preferred form of the invention, the production unit comprises an additional screw or venturi system (6), suitable for introducing pre-expanded or expandable styrene-polymerized beads into the main layer between the belts (1) and (2), wherein preferably the additional screw or venturi system (6) forms an angle of 0 ° with the belts (1) and (2).
    In a preferred form of the invention, the granules of the top layer / top layers are inserted by a system (20) where they are pushed into the main stream at the bottom and / or at the top by a force as constant as possible. As a result, the original styrene-polymerized grains of the main stream are compressed a little more and the place created by this is taken up by the grains of the top layers. Thus, the flow going between the two belts does not become thicker by the addition of the styrene-polymerized granules of the main layer and the pressure in this flow is maintained so that the mechanical quality of the resulting foamed sheet remains good.
    This system (20) can be positioned to add the grains of the top layer / top layers to the main flow after the main flow has passed through the screw / venturi (6) but before the flow of grains reaches the belts (1 and 2). In a preferred form of the invention, the system (20) is kept as short as possible to avoid excessive energy dissipation since the coefficient of friction between the styrene-polymerized beads is high. Therefore, a closing piece of one of the drums (3) and (4) is used preferentially for the system (20).
    In a preferred form of the invention, the force with which this screw (13) propels the styrene-polymerized granules is controllable. M.a.w. the force with which the granules, which are in the system (20), push on the main stream, can therefore be adjusted. This makes it possible to precisely control the thickness of the top layer within narrow limits. In a preferred form of the invention, the screw or venturi system (13) or the feed device (51) can be adjusted to exert a controllable continuous force or a controllable periodic force.
    It is also possible that the screw or venturi systems (13) and (6) at an angle between 0 ° and 90 ° with the belts (1) and (2), provide the system (20) with styrene-polymerized granules. The slope can also be adjusted between 0 and 90 °, in particular the slope can also be 5 °, 10 °, 15 °, 20 °, 25 °, 30 °, 35 °, 40 °, 45 °, 50 °, 55 ° , 60 °, 65 °, 70 °, 75 °, 80 ° or 85 °. In a preferred form of the invention, the angle between the screw or venturi system (13) with the belts (1) and (2) can be adjusted. In a preferred form of the invention, the additional screw or venturi system (6) forms an angle of 0 ° with the belts (1) and (2).
    The supply of the styrene-polymerized expanded beads to the system (20) is most easily achieved by placing a screw (13) or venturi on it vertically. This allows it to directly exert a continuous force on the styrene-polymerized granules of the main layer. In a preferred form of the invention, the screw or venturi system (13) forms an angle of 90 ° with the belts (1) and (2).
    If the screw (13) were to be horizontal, the force of this screw is not optimally transferred to the main layer due to the large friction between the styrene-polymerized granules.
    In a preferred form, the system (20) is coupled to a silo (50) filled with styrene-polymerized granules, the granules being introduced through a feeder (51). This feeding device (51) is capable of pushing these granules into the main layer with controllable constant force or periodic force with high frequency. In a preferred form of the invention, the feed device (51) comprises a wheel (52) with a set of rotating fingers (53) and / or the feed device (51) comprises a set of fixed fingers (54). In a preferred form, the system (20) is coupled to a screw system (13), wherein the pellets are introduced through a feed device (51).
    In an alternative embodiment of the invention, the screw (13), which grains the system (20), is placed horizontally and the system (20) comprises a printing device capable of providing the styrene-polymerized grains of the top layer with an adjustable force force vertically or obliquely on the main layer. It is not a requirement that the magnitude of the force is constant, a periodic force with a sufficiently large frequency can also suffice.
    In a preferred form of the invention, the formed top layer has a variable thickness that lies between two limit values. The frequency of the periodic force can be chosen lower if the thickness of the top layer must lie between these two boundary layers.
    In an embodiment of the invention, a metal plate (23) can be mounted on the system (20) that will locally disrupt the main layer by a metal protrusion and create some space. The expanded styrene-polymerized granules can then be pressed into this. The grains are preferably pressed with a sufficient force, otherwise the grains of the main layer can push the introduced grains of the top layer back upwards due to elasticity and disturb a constant thickness of the top layer. In a preferred form of the invention, the one or more systems (20) comprise a slot (22) through which a metal plate (23) is slid, wherein the distance to which the plate protrudes from the casing of the system (20) is adjustable and / or wherein the inclination of the plate with respect to the casing is adjustable.
    It is possible to construct the system (20) so that the size of the metal protrusion and the angle it makes with the system (20) can be adjusted. In a preferred form of the invention, the metal plate (23) can then move freely so that it can be determined to what extent the plate may protrude from the casing of the system (20), and / or as a result of which the slope of the plate relative to the cover can be arranged. The slope can be adjusted between 5 and 85 °, in particular the slope can also be 10 °, 15 °, 20 °, 25 °, 30 °, 35 °, 40 °, 45 °, 50 °, 55 °, 60 °, 65 °, 70 °, 75 °, 80 °.
    The present invention also relates to a production unit as described above, in which an opening is provided in the casing of the system (20) through which pre-expanded or expandable styrene-polymerized granules can be introduced. The present invention also relates to a production unit as described above, with two such systems (20) mounted on it: one at the top and one at the bottom. The resulting foamed plate will then have a top layer along either side, the thickness of which can be controlled separately.
    The present invention also relates to a production unit as described above wherein the system (20) is mounted at the bottom so that the top layer will be positioned on the bottom of the resulting foamed plate.
    The present invention also relates to a production unit as described above, in which at the level of the slot (22) on the outside of the casing there are two hinges (30) comprising a threaded rod (31), on which the metal plate (23) profiles (32) are mounted, and in which the plate can be fixed to the cover by means of nuts (33). In this production unit, threaded rods (34) on the other side of the metal plate can be fixed against the envelope by means of nuts, one of the ends of the rods resting against the plate. In a preferred form of the invention, the production unit comprises two hinges (30) comprising a threaded rod (31) at the height of the slot (22) on the outside of the casing, and the metal plate comprises profiles (32), in which the plate can be fixed to the casing by means of nuts (33), one of the ends of the threaded bars (31) resting against the plate. In a preferred form of the invention, the production unit comprises threaded bars (34) on the inside of the casing, wherein the threaded bars (34) are fixed against the casing by means of nuts.
    The present invention also relates to a production unit as described above, in which on the sides of the space (5) there are also belts that move under the influence of additional drums, or in which support belts are present which are vertically above each other and between which multiple profile belts. In a preferred form of the invention, the production unit comprises straps on the sides of the space (5) that move under the influence of additional drums, or the production unit comprises support straps that are vertically above each other and between which there are several profile straps.
    The present invention also relates to a production unit as described above, in which the interfaces between the belts and the rest of the production unit with the material contain a layer with a low coefficient of friction (e.g. teflon), and / or on which interfaces small drums (7) are present driven by the movement of the belts (preferably made from or coated with material with a low coefficient of friction (eg Teflon)). In a preferred form of the invention, the interfaces between the belts and the rest of the production unit with the material comprise a layer with a low coefficient of friction, preferably Teflon, and / or small drums (7) are present on these interfaces. by the movement of the belts, wherein these drums are preferably made from or coated with material with a low coefficient of friction, preferably Teflon.
    The term friction coefficient herein refers to the static friction coefficient of the material with steel. Preferably the low coefficient of friction is lower than 0.10, more preferably lower than 0.09, more preferably lower than 0.08, more preferably lower than 0.07, more preferably lower than 0.06, more preferably lower than 0.05, most preferably lower than 0.04.
    The present invention also relates to a production unit as described above, in which the sides of the steam and / or vacuum chamber are shielded with metal plates, preferably coated with material with a low coefficient of friction (eg Teflon), and / or closing pieces (12) are present on the drums, and / or plates are present which close off the space between the two drums. In a preferred form of the invention, the sides of the steam and / or vacuum chamber are shielded with metal plates, preferably coated with a material with a low coefficient of friction, preferably Teflon, and / or the drums comprise closing pieces (12), and / or the space between the two drums is sealed with plates.
    The present invention also relates to a production unit as described above, in which the distance between the two moving belts is adjustable and / or the belts can be moved laterally. In a preferred form of the invention, the distance between the two moving belts is adjustable and / or the belts are laterally movable. The present invention also relates to a production unit as described above, in which different compartments were created in the system (20) with the aid of partitions. A different type of granules can be added to each compartment. In a preferred form of the invention, the production unit comprises partitions, whereby different compartments are created in the system (20).
    In a second aspect, the invention relates to a machine for continuously producing a layered styrene polymerized expanded sheet comprising at least one or more production unit (s) according to the first aspect of the invention.
    The invention also relates to the use of a production unit described above or a machine described above, for the production of a layered styrene-polymerized expanded sheet, which preferably consists of a main layer and one or more top layers.
    In a third aspect, the invention relates to a method for continuously producing a layered styrene polymerized expanded sheet, preferably with a main layer and one or more top layers, using a production unit according to the first aspect of the invention or using of a machine according to the second aspect of the invention, the method comprising the steps of: (a) introducing, preferably pre-expanded, styrene-polymerized beads into the space (5), thereby forming a main stream of beads, preferably by means of a screw or venturi system (6), (b) introducing a different type of styrene-polymerized granules by a force perpendicular to the main flow, so that a part of the main flow granules is pushed away in a controlled manner and the granules of the main flow other types take their place, and (c) optionally, providing a plate (23) which, just before insertion v of the other type of styrene-polymerized granules, locally disrupts the main stream.
    The invention also relates to a method for continuously producing a layered styrene-polymerized expanded sheet using a production unit described above or using a machine described above, comprising the steps of: (a) introducing pre-expanded styrene-polymerized granules into space ( 5) forming a main stream of grains, (b) locally blocking the free passage of the grains of the main stream (41) through one end (24) of one or more metal plates, and (c) introducing pre-expanded grains of another type (42) along said one or more metal plates.
    The present invention also relates to a method as described above, wherein the grains are of a different type of grains with a different density from the grains introduced via the main stream, or wherein the grains of a different kind are grains whose concentration of athermanic substances (graphite, carbon black, metal or metal oxide particles) that are homogeneously distributed in the styrene-polymerized grain is different from that of the main stream. In a preferred form of the method according to the invention, the grains of the different type of grains comprise with a different density with respect to the grains of the main stream.
    In a preferred form of the method according to the invention, the grains of the other type of grains whose concentration of athermanic substances, preferably the concentration of graphite, carbon black, metal or metal oxide particles, which are homogeneously distributed in the styrene-polymerized grains, comprise different from that of the grains of the main stream.
    The present invention also relates to a method as described above, wherein the styrene polymerized granules of the main layer are not introduced directly between the 2 belts (1) and (2) but are introduced into a horizontal screw (6) or venturi system in the upper and / or lower end piece of the drums. One can then, among other things, use the other closing piece to mount the system (20).
    The present invention also relates to a method as described above, wherein the beads are inserted directly between the two belts by means of a screw (6) or a pneumatic pusher, or indirectly introduced by means of a screw (6) or a allow the pneumatic pusher to open into one of the end pieces of the drums.
    The present invention also relates to a method as described above, wherein the cooling gas is applied in the cooling section at a high pressure.
    Preferably the high pressure corresponds to an overpressure of more than 1000 Pa, preferably more than 2500 Pa, more preferably more than 5000 Pa, more preferably more than 10000 Pa, more preferably more than 25000 Pa, more preferably more than 50,000 Pa, most preferably more than 100,000 Pa.
    A styrene-polymerized expanded plate is also disclosed herein, with a top layer on one or both sides of the foamed plate obtained from one of the methods described above.
    In the following, specific embodiments of the invention will be described in more detail with reference to the figures. Figure 1 shows a production unit according to a preferred form of the invention, mounted on a continuous production process for plates of expanded styrene-polymerized granules with one main layer and one top layer. Figure 2 shows a production unit according to a preferred form of the invention, mounted on a continuous production process for plates of expanded styrene-polymerized granules with one main layer and one top layer, whereby an expansion plate is used. Figure 3 shows a machine according to a preferred form of the invention in operational mode. Figure 4 shows a detail drawing of the inside of the casing according to a preferred form of the invention. Figure 5 shows a detail drawing of the outside of the casing according to a preferred form of the invention. Figure 6 shows a production unit according to a preferred form of the invention, mounted on a continuous production process for plates of expanded styrene-polymerized granules with one main layer and one top layer, the screw system (6) being placed horizontally. Figure 7 shows a detail drawing of the outside of the casing according to a preferred form of the invention. Figure 8 shows a detail drawing of a production unit according to a preferred form of the invention, comprising a silo (50) and a feed device (51) that allows to introduce the styrene-polymerized granules of the top layer with a constant continuous force. Figure 9 shows a detail drawing of a feed device (51) of a production unit according to a preferred form of the invention, comprising a wheel (52) with rotating fingers (53) and fixed fingers (54).
    The production unit of the present invention can either be incorporated into the machine for the continuous production process of styrene-polymerized expanded sheets or can be incorporated into this machine with some modifications. This process is usually composed of two vertically positioned horizontal belts, (1) and (2), which lie on rotating drums, (3) and (4). Both belts move continuously with respect to the drums with the same rotational speed. Between these two belts a space (5) is created in which the pre-expanded styrene-polymerized granules can be introduced by means of a screw (6) or a venturi system or a pneumatic pusher (not shown). It is preferred to work with a screw for this invention.
    The two straps consist of perforated metal or a perforated flexible material (the perforations are not drawn). It is optionally possible to also place two belts on the sides of the formed space which also move with respect to drums. Another possibility is to work with two support straps that are vertically above each other but between which are three to four profile straps.
    The pre-expanded styrene-polymerized beads are placed between these profile belts to obtain geometric shapes other than a simple plate shape.
    Various techniques can be used to reduce the friction between the metal belt and the machine parts. For example, the interfaces between the belts and the rest of the machine can be covered with a material with a low coefficient of friction. In this invention, the use of teflon is preferred.
    Another possibility is to install groups of small drums (7) on these interfaces. These drums are not driven by a machine but only by the movement of the belts themselves. The material from which these drums are made preferably also has a low coefficient of friction. Teflon is also preferred for this invention.
    The last way is to apply a high pressure to the air used as cooling gas in the cooling section so that a kind of air cushion forms between the rest of the machine and the metal belts. Nevertheless, it is also wise here to coat the interfaces between the machine and the belts with a material with a low coefficient of friction. Teflon is also chosen here.
    When a mass of expandable or pre-expanded styrene-polymerized beads is introduced between these two belts, the continuous movement of these belts will ensure that the mass of beads also moves continuously. This mass is thus introduced into the steam chamber (8) through which steam is blown through the belts via the perforations. There the grains will overflow into each other so that a plate is formed.
    Subsequently, this newly formed plate of expanded styrene-polymerized granules will travel to the vacuum chamber (9), after which the plate will be cooled, for example, by a cooling gas in the cooling section (10). Air is used as cooling gas in most setups. Eventually the plate comes into the stabilization section (11), so that the plate can first stabilize a little and cool down further in order to make any further operations run more smoothly and accurately. The vacuum chamber and the cooling section can optionally be omitted.
    The sides of the steam and vacuum chamber can be shielded with metal plates so that less steam will escape to the environment (not shown on the drawing). Here too material with a small resistance coefficient such as teflon will be used to reduce the friction between the metal plate and the plate made of styrene-polymerized expanded grains. To limit the loss of steam to a minimum, it is also possible to mount end pieces (12) on the large drums and the space between the two drums can also be closed by means of a plate (not drawn).
    Behind this continuous production process there may be a cutting unit that cuts off a plate with the desired length from the whole. It is also possible that there are more assessment processes here.
    A disadvantage of this process is that plates are always produced with the same cross-section. However, the distance between the two moving belts can be adjustable. This makes the height of the plate obtained adjustable. It is also possible to move the belts laterally so that the width of the plate can also be chosen.
    In a preferred embodiment of this continuous production process, the expandable styrene-polymerized beads are introduced either directly between the two belts by a screw (6) or a venturi system or by having the screw (6) or a venturi system open into one of the end pieces of the drums.
    The system (20) is preferably mounted in the cap of one of the drums (3) and (4) and is provided with expanded styrene-polymerized beads either by a screw (13) or venturi system that is positioned vertically or obliquely or by a silo (50) which will feed the granules by means of a feed device (51) present in the system (20).
    The force with which the screw (13) or the venturi system propels the expanded granules is adjustable. The granules that are added in the system (20) will push against the styrene-polymerized expanded granules of the main layer and displace them locally so that some space is created. As a result, the grains contained in system (20) will nestle in this space. The size of this space, which is related to the thickness of the top layer, will be determined by the force with which the screw (13) or venturi system propels its grains. In this way a foamed sheet of high mechanical quality with a top layer on one or two sides, the thickness of which can be accurately determined, is produced.
    The feeder (51) present in the system (20) when a silo (50) is responsible for the introduction of styrene-polymerized granules from the top layer, should preferably be capable of supplying these granules with a controllable continuous force or a controllable periodic force with a push high frequency against the styrene-polymerized expanded granules of the main layer and displace them locally so that some space is created. As a result, the grains that are in system (20) can nestle in this space. The size of this space, which is related to the thickness of the top layer, will be determined by the force with which the feed device propels the grains. In this way a foamed sheet of high mechanical quality is produced with a top layer along one or two sides, the thickness of which can be accurately determined.
    A non-limiting example of a feeding device (51) suitable for the present invention is a rotating wheel (52) that consists of a set of fingers (53) that rotate and whose distance between the fingers is preferably between 0.5 mm and 20 mm . The thickness of the fingers themselves is preferably between 0.5 mm and 20 mm. A preferred form of the invention also includes a set of fixed fingers (54). These are positioned so that the rotating set of fingers (53) and the fixed set of fingers (54) can rotate into each other without difficulty. The thickness of the fingers of the fixed set is preferably between 0.5 and 20 mm, more preferably between 1 and 15 mm, most preferably between 5 and 10 mm, and the distance between these fingers is preferably between 0.5 and 20 mm , more preferably between 1 and 15 mm, most preferably between 5 and 10 mm.
    When the wheel is rotating, the space between the fingers is first filled with styrene-polymerized granules of the silo (50), then this space between the fingers is protected by an accessory (56) so that the granules can no longer leave. Ultimately, these grains are driven out of this space by another set of fingers (54) fixedly mounted in the feeder (51) and pushed into a channel (55). This channel (55) flows above or below the grains of the main layer so that they are locally displaced by the styrene polymerized grains of the top layer.
    Due to the small space between the fingers, the styrene-polymerized grains of the top layer will not fall smoothly between the fingers. This means that with a low rotational speed, a jam can occur between two fingers, causing local stress between the grains. This means that the grains will hold each other and are not inclined to enter the narrow space between the fingers. The distance between the fingers will therefore preferably also not be smaller than the average diameter of the expanded styrene-polymerized granules of the top layer.
    In a preferred form of the invention, an attachment (57) is placed between the end of the channel (55) and the metal band (2) which holds the resulting layered structure in place.
    In a preferred form of the invention, the direction of the channel (55) is best chosen according to the tangent to the circular motion of the rotating fingers. The angle between the channel and the horizontal can be selected between 0 ° and 90 °. More specifically, the angle can also be 5 °, 10 °, 15 °, 20 °, 25 °, 30 °, 35 °, 40 °, 45 °, 50 °, 55 °, 60 °, 65 °, 70 °, 75 ° , 80 ° or 85 °.
    In a preferred form of the invention, at a small angle between the channel and the horizontal, the mass of styrene-polymerized granules in the channel can be pushed against an oblique part (58) so that this mass can with a greater force into the styrene-polymerized granules of the top layer to push.
    Because the speed of the rotating wheel can be determined, the pressure at which the granules are pushed into the channel, and therefore also into the main layer, can be selected. The thickness of the top layer can also be regulated in this way. As an extension, it is possible to have the screw (13) or venturi system reach the system (20) horizontally, but then an additional device will preferably be present in the system that presses the styrene-polymerized granules against the main layer with an upward or downward force. The magnitude of this force can be a constant or periodic. In addition, a metal plate (23) can be mounted in the system (20), the protrusion (24) locally blocking the main current. As a result, the styrene-polymerized granules that are visible in the system (22) can be incorporated more easily into the main stream. An additional upward / downward force that pushes these grains into the main stream is also preferred here.
    The metal plate (23) can be mounted in the system (20) such that the projection (24) is of length and that the angle between the system (20) and the projection (24) can be selected. For this a slot (22) is made through which a metal plate (23) can be pushed inwards. The slot is preferably sufficiently high so that the metal plate can still move freely: the plate can therefore be slid deeper and the inclination of the plate with respect to the envelope can be adjusted between 5 and 85 °. The casing is designed in such a way that the metal plate (23) is sufficiently long that the plate leaves the casing again when it is pushed far enough into the slot. Thus, a piece (24) of the metal plate locally blocks the free passage of the grains of the main stream (41). This is utilized by introducing granules of another type (42) pre-expanded along the metal plate into the process by an upward / downward force. Once the plate (23) has been brought into the correct position, it can be fixed to the system (20). In what follows, only one example is given of one particular way of achieving this.
    At the level of the slot (22), hinges (30) can be welded to the outside of the casing 2. A threaded rod (31) (not shown) is also provided on each hinge. Profiles (32) are mounted on the metal plate so that the plate can also be slid onto the bars while the plate is pushed through the slot. With the help of nuts (33) this can then be fixed.
    An analogous mechanism can be used at the other end. Here, for example, rods with screw thread (34) can be fixed against the metal casing by means of nuts. All bars are positioned so that their one end rests against the metal plate. This plate (23) is then completely fixed.
    The invention is illustrated with this extension in FIG. On this figure a foamed plate is produced with a main layer and top layer. The two layers have each been given a different color. This is only for clarification of the drawing. In reality, these two layers consist of, for example, a white grain with a different density.
    It is also possible to mount a system (20) in both closing pieces of the drums (3) and (4). This will produce a foamed sheet with a main layer and a top layer on both sides.
    Another option is to add more than one composition of pre-expanded styrene-polymerized beads through the system (20). In that case it is necessary to divide this system into different compartments by using partitions. A different composition can then be added to each compartment with a separate screw or venturi system. The top layer thus obtained consists of several strips, each strip containing its specific composition.
    When the production process is started, it is clear from Fig. 3 that one end of the metal plate is pushing down the (main) stream of expandable or pre-expanded styrene-polymerized granules, such that a space is created in which another stream of expandable or pre-expanded styrene-polymerized granules can be pushed through a screw or venturi system (13). A plate with a top layer is thus obtained.
    Due to the structure of this invention, it is clear that the height of the layer can be selected by changing the force with which the screw or venturi system (13) adds the grains in the system (20). The process can optionally be made more smoothly by placing a metal protrusion (24) just before the introduction of the styrene-polymerized expanded granules of the top layer. The length and the slope of this plate can be freely selected. All this means that the height of each layer is easy to manipulate.
    In addition to the production process, this invention also relates to the products formed therewith. This relates in particular to a plate of expanded styrene-polymerized granules having a top layer on one or both sides, each layer having its specific composition of pre-expanded granules with a specific density and / or its own specific concentration of athermal substances homogeneously distributed over the expanded styrene polymerized bead. The thickness of the top layer can be determined fairly accurately while the mechanical quality of the foamed sheet is high.
    A top layer plate can only be talked about if the main layer and the top layer differ in properties. Since the density has a large influence on the properties of the later product and it is possible to freely choose the density for each layer, the properties of each layer can be optimally selected in function of the later application.
    The specific properties of the main and top layers are largely determined by the density and / or the concentration of athermanic substances that are homogeneously distributed in the styrene-polymerized grain. The density will largely determine the mechanical properties and the insulation value of the layer. The concentration of athermanic substances can still significantly improve this insulation value. In this way the properties of each layer can be chosen optimally.
    Preferably, each layer will consist of an expandable styrene-polymerized bead that expands under the same process conditions so that the adhesion between the various foamed layers and the cohesion in each foamed layer is good. A styrene-polymerized granule is also understood to mean granules which are only partly composed of styrene-containing polymers. An example of this is given in European patent application no. 2144959 where an example is given of expandable granules consisting of polystyrene and polyolefins.
    The present invention also describes an analog product produced in the manner described above of which at least one top layer is split into two or more rectangular zones. These zones can each contain a composition of expanded styrene-polymerized granules with a specific density and / or expanded granules with a specific concentration of athermal substances homogeneously distributed in the granule.
    The present invention shows that this new process is easy to apply and provides good control over the thickness of the layers.
    It is self-evident that the description of the present invention may within its scope relate to alternative embodiments of the invention
    权利要求:
    Claims (22)
    [1]
    A production unit for continuously producing a layered styrene polymerized expanded sheet comprising a main layer and at least one top layer, the production unit comprising: (a) two straps (1) and (2) positioned vertically one above the other perforated metal or perforated flexible material, and rotating drums (3) and (4), the belts (1) and (2) moving continuously under the influence of the drums (3) and (4) at the same speed, (b) a space (5) between belts (1) and (2), (c) a steam chamber (8), suitable for blowing steam through the belts via the perforations, (d) optionally, a vacuum chamber (9), (e) optionally, a cooling section (10), in which preferentially air is used as the cooling gas, (f) optionally, a stabilizing section (11), (g) optionally, a cutting unit, and (h) one or more systems (20), which comprise one or more end pieces (12) coupled to the drums (3) and / or (4), wherein the one or more sys elements (20) comprise a casing with an opening coupled to a screw or venturi system (13) or silo (50), optionally comprising a feed device (51) suitable for introducing pre-expanded or expandable styrene-polymerized granules into the top layer.
    [2]
    The production unit according to claim 1, wherein the one or more systems (20) comprise a casing with an opening coupled to a screw or venturi system (13), preferably a screw (13).
    [3]
    The production unit according to claim 2, wherein the screw or venturi system (13) forms an angle of 90 ° with the belts (1) and (2).
    [4]
    The production unit according to claim 2, wherein the screw (13) forms an angle of 0 ° with the belts (1) and (2) and wherein the system (20) comprises a printer capable of forming the styrene-polymerized granules of the top layer with an adjustable force vertically or obliquely on the main layer.
    [5]
    The production unit according to any of the preceding claims 1-4, wherein the screw or venturi system (13) or the feed device (51) can be adjusted to exert a controllable continuous force or a controllable periodic force.
    [6]
    The production unit according to any of claims 1-5, wherein the feeding device (51) comprises a wheel (52) with a set of rotating fingers (53) and wherein the feeding device (51) comprises a set of fixed fingers (54) includes.
    [7]
    The production unit according to any of claims 1-6, wherein the angle between the screw or venturi system (13) with the belts (1) and (2) can be adjusted.
    [8]
    The production unit according to any of claims 1-7, further comprising an additional screw or venturi system (6) suitable for introducing pre-expanded or expandable styrene-polymerized beads into the main layer between the belts (1) and (2), wherein preferably the additional screw or venturi system (6) forms an angle of 0 ° with the belts (1) and (2).
    [9]
    The production unit according to any one of the preceding claims 1-8, wherein the one or more systems (20) comprise a slot (22) through which a metal plate (23) is slid, in which the distance to which the plate leaves the casing of the system (20) is adjustable, and / or wherein the inclination of the plate relative to the envelope is adjustable.
    [10]
    The production unit according to claim 9, comprising two hinges (30) comprising a threaded rod (31) at the level of the slot (22) on the outside of the casing, wherein the metal plate comprises profiles (32), and in which the plate can be fixed to the casing by means of nuts (33), one of the ends of the threaded bars (31) resting against the plate.
    [11]
    The production unit according to claim 10, comprising threaded bars (34) on the inside of the casing, wherein the threaded bars (34) are fixed against the casing by means of nuts.
    [12]
    The production unit according to any one of the preceding claims 1-11, which comprises belts on the sides of the space (5), which move under the influence of additional drums, or which comprises support belts that are vertically above each other and between which several profile belts are situated are located.
    [13]
    The production unit according to any of the preceding claims 1-12, wherein the interfaces between the belts and the rest of the production unit with the material comprises a layer with a coefficient of friction lower than 0.10, preferably teflon.
    [14]
    The production unit according to any of the preceding claims 1-13, wherein the sides of the steam and / or vacuum chamber are shielded with metal plates, preferably coated with material with a coefficient of friction lower than 0.10, preferably Teflon, and / or, wherein the drums comprise closing pieces (12), and / or wherein the space between the two drums is sealed with plates.
    [15]
    The production unit according to any of the preceding claims 1-14, wherein the distance between the two moving belts is adjustable and / or wherein the belts are movable laterally.
    [16]
    The production unit according to any of the preceding claims 1-15, which comprises partitions, whereby different compartments are created in the system (20).
    [17]
    A machine for continuously producing a layered styrene polymerized expanded sheet comprising at least one or more production unit (s) according to any one of the preceding claims 1-16.
    [18]
    A method for continuously producing a layered styrene polymerized expanded plate, using a production unit according to any of the preceding claims 1-16 or using a machine according to claim 17, comprising the steps of: (a) introducing , preferably pre-expanded, styrene-polymerized granules into the space (5), thereby forming a main stream of granules, preferably by means of a screw or venturi system (6), (b) introducing another type of styrene-polymerized granules by means of a force perpendicular to the main stream, so that some of the grains of the main stream are pushed away in a controlled manner and the grains of the other type take their place, and (c) optionally, providing a plate (23) which, just for insertion of the other type of styrene-polymerized granules, the main stream disrupts locally.
    [19]
    A method according to claim 18, wherein step b) is replaced by step b '): b') introducing another type of styrene-polymerized granules by means of a system (20) comprising an envelope with an opening coupled to a screw or venturi system (13) or silo (50).
    [20]
    A method according to claim 18 or 19, wherein the grains of the different type of grains comprise with a different density with respect to the grains of the main stream.
    [21]
    A method according to any one of the preceding claims 18-20, wherein the grains comprise the other type of grains whose concentration of athermanic substances, preferably the concentration of graphite, carbon black, metal or metal oxide particles, which are homogeneously distributed in the styrene-polymerized grains , is different from that of the grains of the main stream.
    [22]
    A method according to any one of the preceding claims 18-21, wherein the cooling gas is applied in the cooling section with a high pressure.
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    同族专利:
    公开号 | 公开日
    BE1019507A5|2012-08-07|
    引用文献:
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    法律状态:
    2020-08-03| HC| Change of name of the owners|Owner name: GAMORINE NV; BE Free format text: DETAILS ASSIGNMENT: CHANGE OF OWNER(S), CHANGEMENT DE NOM DU PROPRIETAIRE; FORMER OWNER NAME: TECHNISCH BUREEL PANIGO NV Effective date: 20200508 |
    优先权:
    申请号 | 申请日 | 专利标题
    BE201000556A|BE1019507A5|2010-09-17|2010-09-17|PRODUCTION OF LAYERED STYRENE POLYMERIZED PLATES.|
    BE201000556|2010-09-17|EP11181592A| EP2431148A1|2010-09-17|2011-09-16|Production of laminated styrene-polymerised sheets|
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