DE102005023065A1 - Lightweight construction board has at least one latch plate between two finishing layers essentially formed by fibrous material containing sealing compound - Google Patents

Abstract

The board (1) has a first finishing layer (3), to which a core layer (2) with a number of. cavities is attached, a second finishing layer (4) attached to the core board on the side facing away from the first finishing layer and at least one latch plate (7) between the two finishing layers essentially formed by a fibrous material containing a sealing compound. At least some cavities of the core layer and/or the outside edge of the core layer are held by the sealing compound. Independent claims are also included for the following: (A) a method of manufacturing at least one latch plate for an inventive device (B) a method of manufacturing an inventive board (C) and a core layer for an inventive board.

Description

The The present invention relates to methods for producing bars, Process for the production of lightweight panels and core layers and lightweight panels and their use.

lightweight panels are used for example for the production of room doors, furniture elements, Panel elements or the like used. Such lightweight panels usually consist of two cover layers, between which a core situation is brought, which is a variety of cavities has to reduce the weight and yet provide adequate To ensure rigidity of the plate. The edge of such a lightweight board is usually by longitudinal and Crossbar, which usually form a frame generated. Exist here the bars typically made of chipboard material, plywood or Solid wood.

The Production of a known in the art lightweight panel is described for example in DE-A 103 13 055. This is in the edge region on a first cover layer and / or one of the first Cover layer facing first side of the frame latch an adhesive layer applied and the frame bolt merged with the first cover layer. Farther becomes a core layer with its first cover layer facing and provided with an adhesive layer first side between the frame latch introduced and on the second page of the core layer as well as the second page of the Frame latch is in turn applied to a second overlay adhesive to stick together. Finally the cover layers are pressed with the core layer and the frame bolts.

To The attached on the edge bars can also within the lightweight panel Bolt be provided.

The Bar construction met this several tasks. On the one hand there is a stabilization of Lightweight panel through the full-surface Bonding. Continue to take over the calibration bars attached to the edge of the lightweight board of the component by defined strength and sufficient compressive strength, which is the final pressing process of the method described above is of importance. Furthermore, the Latch for receiving, for example, hardware or connection technology be used. Likewise ensure the measures provided for at the edge of the lightweight board latch a defined Completion of the lightweight panel edge.

The Disadvantages of using bars known in the art lie in particular in the fact that these are formatted in advance and need to be provided what a cut of the bar length and strength required before making the lightweight board. The required for this Machine technology is extremely complex and costly.

Especially in the manufacture of lightweight panels in continuous operation at higher feeds the preparation, magazining and feeding the latch very complex and often needs up to three additional ones Employee.

by virtue of the fact that chipboard and thus also for the production of bars made of chipboard (residues), MDF, HDF or solid wood in general only certain standard dimensions be available, is no continuous variation in the thickness of lightweight panels feasible. For stronger ones Plates need the bars are, for example, doubled.

It Therefore, there is a need in the art for flexible production of bars, wherein their production as easily as possible in a continuous process should be integrated.

A The object of the present invention is thus the generation of a Tie for Lightweight panels, in which the above-described disadvantages of the prior The technique be at least partially avoided.

• a) Bereitstellen einer Kernlage mit einer Vielzahl von Hohlräumen;
• b) Einbringen einer Faserstoffe enthaltenden flüssigen Vergussmasse in einen für die Erzeugung des Riegels vorgesehenen Bereich, wobei der Bereich zumindest teilweise einen Teil der Hohlräume der Kernlage und/oder des äußeren Randes der Kernlage enthält;
• c) vollständige Aushärtung der Vergussmasse.

The object is achieved by a method for producing at least one bolt for a lightweight board, comprising the steps

• a) providing a core layer having a plurality of cavities;
• b) introducing a liquid potting compound containing fibers into a region provided for the production of the bolt, the region at least partially containing a portion of the cavities of the core ply and / or the outer edge of the core ply;
• c) complete curing of the potting compound.

It has now been found that the production of such a bolt by means of a potting compound as indicated above a flexible way to flexibly produce bars of any thickness, width, height and geometry. Furthermore, results from the use of fiber-containing potting compounds improved properties, in particular better pull-out values for fitting technology, the to be introduced in the area of the bolt.

• (a) Aufbringen einer Kernlage mit einer Vielzahl von Hohlräumen auf einer ersten Decklage;
• (b) Aufbringen einer zweiten Decklage auf die der ersten Decklage abgewandten Seite der Kernlage;
• (c) Einbringen einer Faserstoffe enthaltenden flüssigen Vergussmasse in einen für die Erzeugung des Riegels vorgesehenen Bereich, wobei der Bereich zumindest teilweise einen Teil des äußeren Randes der Kernlage enthält;
• (d) vollständige Aushärtung der Vergussmasse.

Another object of the present invention is a method for producing a lightweight board, comprising the steps

• (A) applying a core layer having a plurality of cavities on a first cover layer;
• (b) applying a second cover layer to the side of the core layer facing away from the first cover layer;
• (c) introducing a fibrous grout containing grout into a region intended to create the tie, the region at least partially containing a portion of the outer edge of the core sheet;
• (d) complete cure of the potting compound.

in this connection can for the case that the supernatant the first and / or second cover layer is insufficient to a bolt desired Width to produce in the edge region, the core position for example after Apply the second cover layer to the edge to be removed accordingly. This can be done for example by milling.

• a) Aufbringen einer Kernlage mit einer Vielzahl von Hohlräumen auf eine erste Decklage;
• b) Einbringen einer Faserstoffe enthaltenden flüssigen Vergussmasse in einem für die Erzeugung mindestens eines Riegels vorgesehenen Bereich auf der die Kernlage aufweisende Seite der ersten Lage, wobei der Bereich zumindest teilweise einen Teil der Hohlräume der Kernlage und/oder des äußeren Randes der Kernlage enthält;
• c) Aufbringen einer zweiten Decklage auf die der ersten Decklage abgewandten Seite der Kernlage;
• d) vollständige Aushärtung der Vergussmasse.

Another object of the present invention is a method for producing a lightweight board, comprising the steps

• a) applying a core layer having a plurality of cavities on a first cover layer;
• b) introducing a fiber-containing liquid potting compound in an area provided for the production of at least one bar on the side of the first layer having the core layer, wherein the region at least partially contains a portion of the cavities of the core layer and / or the outer edge of the core layer;
• c) applying a second cover layer on the side of the core layer facing away from the first cover layer;
• d) complete curing of the potting compound.

It is also possible that first the core layer is applied to a first cover layer, inside and optionally in the edge region bars are generated and then after Applying the second cover layer continues in the edge region latch be formed.

at the first topsheet may be a topsheet already for example, part of a lightweight panel. In this case finds one so-called doubling place. Likewise, the second cover layer as "first Cover layer "one another lightweight board or the like serve.

Under in the inventive method core layer used is preferably a Füllmateriallage to understand which largely consists of bars, which are interconnected and cavities Include a variety of forms. in this connection are honeycomb or tubular structures preferred, on the one hand in conjunction with give the top layers a very high strength and on the other hand have an extremely low weight based on the volume. Especially preferred are Honicel or swap honeycombs. The core situation typically exists made of cardboard, paper, MDF or HDF. However, there may be other materials to be used, taking into account is that one possible low weight of the core layer should be achieved.

in the Within the scope of the present invention, a "core layer" also includes a multiplicity of core layers to understand that together like a single core layer in a lightweight board Act.

The Length, Width and thickness of the core layer can be the intended use be adjusted. Usually is the thickness of the core layer 5 mm to 100 mm.

The Cover layers used to make the lightweight board are in usually thin and consist of chipboard, MDF, HDF, plywood, veneer, plastic or metallic material.

ever for strength the cover layers can this plate-shaped be introduced for the production of lightweight panels. It is but equally possible, at sufficiently low strength, that these are stored in rolls and accordingly in the production of Lightweight panel can be used directly from the roll. The first and second top layer can be the same or be different.

typically, is the thickness of the layers 1 mm to 15 mm. Preferred are 3 mm to 4 mm.

Around a permanent connection between first cover layer, core layer and make second cover layer, it is advantageous to bond provided. A typical means of bonding is glue.

The Bonding can be carried out in such a way that initially a Cover layer is provided with adhesive and the core layer applied becomes. Alternatively, however, the adhesive may also be on the core layer or on the respectively facing surfaces of core layer and first Cover layer are applied. The same applies to the bonding the second cover layer with the core layer. An advantage of the present Invention is that when using a potting compound, the adhesiveness is, at least in the areas of the formed bars or of the formed Riegel no additional Applying adhesive is necessary because the bonding of the formed bolt with the cover layers by the potting compound itself can be done.

Especially with small workpieces alone, the adhesive effect of the potting compound can be sufficient to effect the entire bond, so that no further adhesive, such as Glue is required.

The Potting compound is in liquid Condition introduced for example by means of a nozzle.

The contains used potting compound Fibers. These are preferably during or immediately before Introducing the potting compound mixed into the intended area.

The Fibers can be introduced as cut fibers in the potting compound. Usually can therefor Glass, carbon or aramid fibers in each case individually or in combination be used. However, they are in principle any inorganic ones and organic fibers used. Preferably, wood fibers, used in particular in the form of sawdust. It can but also other natural fibers or other fibers such as plastic fibers be used.

The Potting compound is preferably made of a two-component potting compound based on polyurethane. Here, usual 2K PU systems be used.

These 2K PU casting compounds can as foams be designed. An advantage of using foams on Polyurethane base is that these by their extent and during curing can completely fill the cavities provided for generating the bolt. It is, however, on it to pay attention to it during the the foam expansion did not create pressure or detachment damage the outer layers comes.

As a general rule can used as potting compounds based on polyurethane and one-component potting compounds become. About that In addition, the use of epoxy potting compounds or the use of thermoplastic enamels as potting possible.

by virtue of the use of fibers in the potting compound is this after fully cured fiber reinforced.

This has other advantages. The bars produced in this way have a comparable with chipboard compressive strength, which in use a non-fiber reinforced Potting compound usually not the case. It can furthermore high screw extraction values due to the connection of the fibers be generated with the potting compound. Furthermore, during further processing Standard woodworking devices, for example, for edge processing or the fitting assembly are used. As the fibers are also called fillers act, the consumption of potting compound can be kept as low and therefore cost become.

Of the Area in which the potting compound extends and the or Latch for a lightweight board forms or form, can be indoors or in the Edge region of the core layer lie.

Provided the interior of the core layer is affected, the potting compound into the corresponding cavities the core situation introduced. In this way, an inner bar is produced, which as longitudinal or crossbar may be formed. However, it is not a restriction in the Given the geometry of the bolt. Likewise, a Latch be arranged diagonally to the cover plate geometry. To a bolt can form on the edge also cavities be filled in the edge region of the core layer with the potting compound. Subsequently can by cutting in the region of the bar thus formed an edge be generated, said bar then as edge bars in Appearance occurs. Likewise, only the outer edge of the core layer can Make contact with the potting compound. Furthermore, both areas of the cavities as also the edge of the core situation for the formation of a bolt may be provided.

Consequently An edge latch can also be generated by the fact that over the Side edge of the core layer beyond an introduction of the potting compound takes place. However, it is advantageous that at least the side edge of the Core layer with its cavities through the potting compound is recorded. When introducing the potting compound after Applying the second cover layer, however, only the outer edge the core situation.

As well it is expedient to avoid that the potting compound over extends the side edge of the first and / or second cover layer. This can For example, be avoided by providing stop means avoid this and to a flush completion of the potting compound with the margins causes the first and second cover plate.

are in the lightweight panel only outside provided lying bolt is advantageously also a subsequent Introducing the potting compound in the open edges of the otherwise Already glued lightweight board possible. To a deeper penetration of the Potting compound in the lightweight board and thus wider bars too enable can be done as above for this purpose, prior to introduction of the potting compound, the outer edge of the core ply, e.g. by milling be removed.

In the event that potting compound nevertheless extends beyond the side edges, can also a blank to make a flush completion of the edge latch with the side edges of the first and second cover plate.

The Edging bar can both as edge length as well as Kantenquerriegel be generated. Again, though also conceivable that the lines of the cover plate or cover plates not exactly, but more or less by any Geometry is given. This can be, for example, in use a lightweight board for furniture production to be required.

advantageously, the complete curing of the Potting compound by the ambient humidity, in particular by Humidity. In a multi-component potting compound (such a 2-K system) can be fully cured by the reaction of the optionally added components with the involvement of the ambient humidity respectively.

Also Advantageously, the process steps find at least partially in continuous operation.

One Another object of the present invention is a core layer for use in the manufacture of lightweight panels with a Variety of cavities with at least one bar which is substantially formed by a fiber-containing potting compound, wherein at least one Part of the cavities the core layer and / or the outer edge the core layer is covered by the potting compound.

One Another object of the invention is a lightweight board containing a first cover layer on which a core layer with a plurality of cavities is applied and a second layer on top of the first cover layer opposite side of the core plate is applied, and at least a latch between the two cover layers, wherein the latch substantially is formed by a fiber-containing potting compound and wherein at least a part of the cavities of the core layer and / or the outer edge the core layer is covered by the potting compound.

By the introduction of the potting compound in the cavities of the core layer is the bar formed, this in addition to the potting compound itself in addition to the Webs (inner or peripheral webs) of the core layer containing the cavities, in which the potting compound is introduced form. However, since the webs one represent a negligible proportion of the produced bar, the bolt can be formed as essentially by the potting compound to be viewed as.

in the The scope of the present invention thus means that "the bar essentially formed by a fibrous material Casting compound "that this at least by the potting compound and in contact with this standing webs of the core layer is formed.

One Another object of the present invention is the use a fiber-containing potting compound for generating at least a latch for a lightweight board.

As well An object of the present invention is the use of a Core plate, as described above, for the production of a lightweight board. moreover An object of the present invention is the use of a Lightweight panel, as described above, for the production of room doors, furniture elements or panel elements.

following the invention will be explained in more detail with reference to FIGS.

It demonstrate

1 a schematic, partially sectioned perspective view of a lightweight panel according to an embodiment of the present invention;

2A to 2F various embodiments of a core layer with multiple bars.

In 1 is a lightweight board 1 represented, which is a core location 2 as well as a first cover layer 3 and a second (not shown in the figure) cover layer 4 having. The edge of the lightweight board 1 is formed by edge rails 5 . 5 ' and edge cross bar 6 . 6 ' , Also in the 1 recognizable is a reinforcement 7 which can serve to provide recesses in the region of the reinforcement, for example to receive door handles or fittings or the like. The reinforcement can also be generated by the potting compound. It is also possible to dimension the bar or bars in such a way that a corresponding recess is provided in the bar.

2 shows different geometries of bars that are in a core location 2 are located. If internal bars are present, the core layer can be divided into several segments. In the context of the present invention, however, these segments are considered as a core layer.

In 2A are edge length latches 5 . 5 ' intended.

In 2E is still an inner longitudinal bar 8th shown.

2C has two opposite edge rails 5 . 5 ' and two opposite edge crossbars 6 . 6 ' on that a frame like in 1 shown form. Here were the first bars 5 . 5 ' and then the crossbars 6 . 6 ' , However, it is obvious to the person skilled in the art that first of all the transverse and then the longitudinal bars or alternately longitudinal and transverse or transverse and longitudinal bars can be introduced, for example, in a clockwise or counterclockwise direction.

2D points opposite 2C two further bars in the form of the inner crossbar 9 . 9 ' on. With respect to the order of introduction of the bolt applies to 2C listed analog. In 2D a variant is reproduced, wherein initially the longitudinal and then the crossbars were introduced.

In 2E is additionally compared to 2C an inner longitudinal bar 8th educated. Here as well as for 2F the order of generation of the bars is arbitrary. at 2E were initially the edge longitudinal bars 5 . 5 ' , then the edge crossbars 6 . 6 ' and finally the inner longitudinal bar 8th brought in.

2F shows in comparison to 2D another bolt in the form of an inner longitudinal bar 8th on. The order of introduction of the bar starts here with the Kantenlängsriegeln 5 . 5 ' , then the cross bars and finally the inner longitudinal bar 8th ,

It is clear to the person skilled in the art that a multiplicity of bar geometries can be produced. In particular, a flexible design is possible by the inventive method for producing bars. Thus, for example, transversely to the geometry of the core layer 2 or further, for example, circular geometries are generated.

Advantageous However, is a parallel and / or rectangular arrangement of the bolt. Here, longitudinal and Crossbar preferably generated at a distance of about 400 mm to a preferred plate dimension of 2100 mm × 6000 mm to realize.

at the simultaneous introduction of longitudinal and cross bars in the the same lightweight board is preferably at the crossover each one the later introduced latch interrupted running, to avoid that Form area where multiple potting compound is introduced.

1

lightweight panel

2

core layer

3

first topsheet

4

second topsheet

5.5 '

Edge longitudinal bars

6.6 '

Edge cross bar

7

reinforcement

8th

Internal longitudinal bars

9.9 '

Interior crossbars

Claims (21)

Method for producing at least one bar for one Lightweight panel containing the steps (a) Provide a core layer having a plurality of cavities; (b) bringing in a Fiber-containing liquid Potting compound in a for the generation of the bolt provided area, the area at least partly a part of the cavities the core layer and / or the outer edge the core situation; (C) full curing the potting compound. Method for producing a lightweight board, containing the steps (a) Applying a core situation with a Variety of cavities on a first cover layer; (b) applying a second cover layer on the side facing away from the first cover layer of the core layer; (C) Introducing a fiber containing liquid potting compound in a for the Generating a bolt provided area, the area at least partly a part of the outer edge of the Core situation contains; (D) full curing the potting compound. Method for producing a lightweight board, containing the steps (a) Applying a core situation with a Variety of cavities on a first cover layer; (b) introducing a fibrous material containing liquid Potting compound in a for the generation of at least one bar provided area the for the core layer having side of the first cover layer, the area at least partly a part of the cavities the core layer and / or the outer edge the core situation; (C) Applying a second cover layer facing away from the first cover layer Side of the core situation; (d) complete cure of the potting compound. Method according to Claims 1 to 3, characterized that the core layer is a honeycomb insert. Method according to one of claims 2 to 4, characterized in that with application of the core layer on the first cover layer and / or with application of the second cover layer on the side facing away from the first cover layer side of the core layer, an adhesion of the corresponding layers takes place together. Method according to one of claims 1 to 5, characterized that the introduction of the liquid Potting compound with the help of a nozzle he follows. Method according to one of claims 1 to 6, characterized that the potting compound the fibers during or immediately before Introducing the potting compound mixed into the intended area become. Method according to one of claims 1 to 7, characterized that the fibers are sawdust. Method according to one of claims 1 to 8, characterized that the potting compound on a one or two-component potting compound Polyurethane base, an epoxy potting compound or a thermoplastic Is melt. Method according to claim 9, characterized in that that the potting compound is a polyurethane-based foam. Method according to one of claims 1 to 10, characterized that the intended area is an interior area or edge area of the core location is, with the edge area over can extend the side edge of the core layer. Method according to one of claims 2 to 11, characterized that the edge area is over the side edge of the core layer but not over the side edge of the first and / or second cover layer extends. Method according to claim 12, characterized in that that at least when introducing the potting sling provided that is, extending the potting compound over the side edge of the first and / or second topsheet. Method according to one of claims 1 to 13, characterized that the at least one bar is selected from the group consisting from inner longitudinal bars, Internal crossbar, edge latches and edge cross bar. Method according to one of claims 1 to 14, characterized that the complete curing of the Potting compound is effected by the ambient humidity. Method according to one of claims 1 to 15, characterized that the method steps are carried out at least partially in continuous operation. Core situation for use in the production of Lightweight panels having a plurality of cavities with at least one bar, which is essentially formed by a fiber-containing Potting compound, wherein at least a portion of the cavities of the core layer and / or the outer edge the core layer is covered by the potting compound. Lightweight panel containing a first cover layer, applied to the one core layer with a plurality of cavities is and a second top layer, on the first top layer opposite side of the core plate is applied, and at least a latch between the two cover layers, wherein the latch substantially is formed by a fiber-containing potting compound and wherein at least a part of the cavities of the core layer and / or the outer edge the core layer is covered by the potting compound. Use of a fiber-containing potting compound for producing at least one bolt for a lightweight board. Use of a core layer according to claim 17 for the production a lightweight board. Use of a lightweight board according to claim 18 for the production of room doors, furniture components or panel elements.