CA1104050A - Method and apparatus for laminating cellular material - Google Patents
Method and apparatus for laminating cellular materialInfo
- Publication number
- CA1104050A CA1104050A CA281,029A CA281029A CA1104050A CA 1104050 A CA1104050 A CA 1104050A CA 281029 A CA281029 A CA 281029A CA 1104050 A CA1104050 A CA 1104050A
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- Canada
- Prior art keywords
- powdery
- laminating material
- laminating
- plies
- liquid reactant
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Abstract
ABSTRACT OF THE DISCLOSURE
A method and apparatus for laminating plies of cellular material together wherein a liquid reactant is applied to the surfaces to be laminated, a reactive, powdery laminating material is applied over the liquid reactant and the liquid reactant is again applied over the powdery laminating material and, thereafter, the so treated surfaces are sandwiched together and the laminating material is permitted to set. The powder applicator used is vertically adjustable and is also provided with tem-plates so that various powder applicating patterns can be produced.
A method and apparatus for laminating plies of cellular material together wherein a liquid reactant is applied to the surfaces to be laminated, a reactive, powdery laminating material is applied over the liquid reactant and the liquid reactant is again applied over the powdery laminating material and, thereafter, the so treated surfaces are sandwiched together and the laminating material is permitted to set. The powder applicator used is vertically adjustable and is also provided with tem-plates so that various powder applicating patterns can be produced.
Description
This inventi.on xelates to means and methods for laminating cellular sheets~ ~lies, slabs, blocks and/or shaped members or the like together. In parti-cular, the invention pertains to laminating cel1ular gla3s or glassy cellular members together for use as thermal insulation, as building material or in other useful appli~ations.
In the manufacture of cellular glass or .~ike rigid cellular materials it is frequently desirable to laminate a pluxality of pl~es of the material together to provide articles o~ increased thickness~ In the past, this has been accomplished by pxemixing a batch of pasty laminating material, generally a fask setting plaster~
in a suitahle pot or other container, applying the pas~y laminating materia~. to the companion surfaces o~ the ob-jects to be laminated, sandwichin~ the objects together and permitting the laminatin~ material to cure or set~
Howev~x,~ it was found that: tl) the time spen~ on mixing small batches and cleaning up afterwards was excessiver ~2) mixing p~ior to application to the cellular material, e.g~, cellular ~lass, limited ~he time of application to w.ithin ahout a 20 minute period of "pot life" available before the plaster ma~erial would set up; and (3) cleaning the small containers ~or the ,, . , . , ,; .
plaster material after use often caused plugging of effluient drains. Accordirlgly, a need was present for the development of a suitable method and apparatus for lami-nating cellular materials that obviated the deficiencies of the prior art techin~ue of laminating.
In accordance with the present invention,there is provided a method for laminating plies of cellular ma-terial that comprises applying a liquid reactant to the surface to be laminated. Applying a reactive, powdery laminating material over the liquid reactant. Applying additional liquid reactant over the powdery laminating material. Sandwiching the so treated surfaces together.
Interposing a sheet o scrim abric between the treated surfaces before they are sandwiched together. And there-after, permitting the laminating material to set.
There is also provided apparatus for laminating plies of cellular material comprising a conveyor system for transporting a plurality of pairs of said plies in series from a loading end to an assembly end. The con-veyor system comprises three sections, a first section along the path of the conveyor system having a spray means for applying a liquid to the upper surEace of the plies~
~J _ 3 -;, "
`
`~ A second, intermediate station along the path having a vertically adjustable powder applicating means for apply-ing a powder to the upper surface and a third station along the path having spray means for applying additional liquid to the upper surface. Each of the conveyor sec-tions encompassing one of the stations and extending for a distance beyondO
In accordance with the present invention, each of the above-mentioned l'pot laminating" and "pot life"
constraints has been overcome. The lamination of cellular glass artilcles is accomplished by (1) applying a liquid reactant, e.g., water, to the surfaces to be laminated;
~2) applying a reactive, powdery lami~atiny material, `~ e.g~, hydrous calcium sulfate, over the liquid reactant;
t3) applying additional liquid reactant, e.g., water, over the powdery laminating material; (4) sandwiching the so treated surfaces together; and (S) permitting the lami-nating material to set. In the furtherance oE this invention, there is porvided, inter alia, a novel powder applicator device that is constructed and arranged to be vertically adjustable and is also provided with foraminous templates so that various powder applicating patterns can be produced.
? - 4 In the drawings, wherein like numerals are used to indicate like parts throughout the same:
Figure 1 is a schematic perspective of a typical laminated article produced in accordance with this inven-tion:
Figure 2 is a schematic side elevation of a portion o a laminating assembly line employing the princip1es of this invention;
Figure 3 is a schematic plan of a pair of parallel, laminating assembly lines designed to incor-porate the features o this invention;
Figure 4 is a front elevation partly borken away, of a preferred powder applicator assembly of this invention; and Figure 5 i5 a right elevation of the assembly o Pigure 4.
Reerring to Figure 1, there is shown a typical cellular glass laminate comprised of a pair of rectangu-lar, cellular glass sheets 12 bonded together by a lami-nating layer of interlayer 14. Interlayer 14 is prefer ably comprised of substantially continuous layer or matrix of fast setting plaster 16 containing in the body thereof a reinforcement 4a material r ~uah a~ a c:ontinuou~ sheet of ~crim cloth 18 .
5crim cls:~th 18 may be o~ ~la~ ~ibrou~ m~t~rial or oth~r matarial Q~ ~ynthetic ~i~rous ma~erial, as de~ired, and may be either a woveT~,knîtt~d o~ nonwoYen fabric. Pla~ter 16 i~ preferably comprised of hydrou~ calcium sulfa~e, scld und~r th~ ~a~nark 1I H~DROCAI." b~r U ., S ., GSrp~um Company .
~he cellular gla38 ~heets lZ may be manu~aatured by any lcnown proct3s~, ~uch a~ that de~cribed ~n United States ~?atent 3,532,430 and may be of ~ny composition c:ommonly identi~ied a~ "cellular gla~t' or "multicallular gla~
a~ s~t Xorth in said patent.
~a~erring now t~o Figure~ 2 ~nd 3, ~h~re i~ ~hown ~ -re~p~ctiY~ly, a ~ahematic ~ide elevatiola o~ tha prin~ipal portion of a laminat~ng as~ ly line 20 of this in~ention and a ~ahematic plan o~ ~ pa~ o~ parallel, lamina~lng a~sem-bl~ ne~ 20 ~mploying the princip~es herein disclosed. In aocQrdanae with the prackîae o~ this invention, cellular gla~ Ln the ~orm o~ rectallgular ~he~t~ 1~ or any other suit-al~le shape or ~orm are prov~ded ~rom a ~ource 2~, such a3- one ~0 or mc~e pall~t~. A loader po~itioned at a ~takion 24 r ad~a-aent tha beginning or up~tream end of ass2mbly llne or line~
20 " tran~fe~ ~h~ets 12 or o~her cellular ~las~ shapes from source 22 ~o the upstream end of an a~embly line 20. Con-venientl~, where two dif ~ren~1y shaped articla~ are ~eing `:~
~ `
laminated concurrently, the arrangement of Figure 3 permits the use of separate laminating assembly lines ~or each shape Howe~er, since each laminating assembly line 20 i3 substantially identical ln cvnstruction and mode of operation, ;
further discussîon will be conined to a single line pro-cassing cellular glass ~heets 12 As best shown in Figure 2, the transport mechan ism of assembly line 20 is preferably comprised of three aligned conveyor belt seations 26, 28 and 30, that are suit-ably power driven by conventional means (not shown) and which are followed or terminated by a downwardly inclined roller surge conveyor sectlon 31 that i~ not powered Power driven belt conveyor sectlons are preferred over a power driven rolLer conveyor system, although the latter could be employed, .. : :
~` if desired Also; the surge aonveyor section could be power driven, if desired, and may either comprise a roller conveyor .
section or a belt conveyor section For reasons that will shor~ly be apparent, conveyor sections 26 and 30 are called -~ "wet`'~ conveyor~, whereas intermediate conveyor section 28 is called a "dry'i conveyor Also, where desirable for spacing purposes, one or more idler rolls, such as idler roll 32, may b- di~posed between conveyor sections .. . : , .- . ~
Disposed above each "wet" conveyor ~ection 26 and 30, at a location intermediate their respective lengths, is a watermist spray bar manifold 34. Manifolds 34 are each suitably connected to a source of water ~not shown) and a source of air tnot~shown) and are provided with appropriate ..
apertures or noæ71a~ so as to deliver a fine, low velocity, mist or spray of water 36 downwardl~ toward its ~ub~acent conveyor section, ~6 or 30, in a divergent spray pattern.
Disposed above l'dry" conveyor ~ection 28, at a location intermediate its length, is a powder applicator 38.
As best shown in Figures 4 and 5, powder applicator 38 is com-prised of a hopper 40, a hopper-access door 42, a rotary feed device 44, a rotary drive means 46, a template ~ection 48, a :::
scr en bin~S0, a vibratory screen section 52 and a vibrator 54, all ~uitably mounted on a framework 56 spanning the dry con-veyor section 28. Referring now in greater detail, hopper ~0 ~:
i~ desirably of ~he funnel-like configuration, as shown, to promote a continuous, free flow of powder material therethrough and is construoted to extend laterall~ or transversely across the conveyor or substantially the full width of the conveyor belt 58. As shown, hingedly attached-~at the top of hopper 40 is hopper-access door 42. Hopper 40 is securely affixed, both ~:~
front and rear, to adjustable tie bars 69 (one o which is shown~ which, in turn, axe securely affixed at each end to an adjustable channel member 62 fitted abouk each of our stanch-ions 64 comprising an integral part o framework 56.
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4~
Adjustable channel member~ 62 are each provided at ~:
their lower exkremity with a laterally extenaing bearing plate :~ ~
66 and reinforcing gu~sets 68. ~i~posed ~herebelow and secure- :
ly affixed to stanchion~ 64 are similar plates 70 and reln~orc-ing gus~ets 72, with each plate 70: having an aperture (not shown) therein. An elongated threaded, adjusting bolt 74 :~
;
passes through the aperture in each plate 70 and is threadably secured to a nut 76 that res~s on the upper surface of plates 70 and also extends into contact with the lower surface of ~: 10 bearing plates 66. Additionally, adjustable channel members : 62 are each provided with a pair o~ vertiaal slots 78 laterally ~.
aligned with apextures (not shown) in ~tanchions 64 so that, in a well known manner, l~k scre~s 80 extending through slots 78 and the apertures~in~stanchions 64 can ~e threadably received :
: :~ by nuts (not shown) and:j upon tightening screw~ 80 to said nuts, :
channel member~ 62 are fi~mly secured to stanchions 64. As will be clearer shortly, when heigh~ adjustment o~ the hopper 40 and related components of powder ap~licator 38 i8 desired, lock screw~ 80 are loo~ened, adjusting bolts 74 are rotated :with respec~ to nuts 76 and, when the desired raised or lowered ; position is reached, lock screws 80 are retightened to secure applicator 38 in its new elevation above conve~or 28, :: ., 4L~
Rotary feed device 44 may be of any desirecl con~
struction suitable for maintaining a continuous, free flow of powder material from hopper 40. Generally, rotary feed device 44 will comprise an elongated rotary paddle and a paddle wiper assemb}y to assist in maintaining said frae flow. In the em-bodiment shown, rotary feed device 44 is driven by a rotary dxive means 46 comprised of an electric motor suitably clutched to a variable speed transmission having a maximum output speed :
of 126 R.P.M. and a minimum output speed of 12.~ R.P.M. The output of rotary drive means 46 is transmitted to rotary feed : :~
device 44 by means o~ a chain drive 82 and gears 84 and 86. As wiIl be noted~ rotary drive means 46 is mounted on a support :
-i~ plate 88 that is s~cured by the rods 90 to channel members 92 which, in turn~ are se~urely fixed to the ad~ustable channel mambers 62 on the left side of the powder applicator 38, as viewed in Figure 4. ~ccordingly, i.t will be understood that operation of the height adjustment means of applicator 38, as hereinabove described, permits maintaining the same relation or fixed position of rotary drive means 46 with respect to rotary feed device 44.
: Suitahly fixed to powder applicator 38, below xotary feed device 44, and in communication with feed device 44 via an elongated opening is template section 48~ Template section 48 preferably comprises slide tracks ~not shown~ and a suitable template plate or slide plate received thereby and attached to a handle 94 for convenie~ce of in~ertion and removal. As will be appreciatedl because of the various sized, shapes and configuration~ of lamînate~ desired, it is appropriate and clesirable to confine the laminating powder distribution to a pattern particularly suitable to the laminate being prepared.
Accordingly, foraminous templates are made available having : an aperture array of suitable si~e or si2es to provide various powder applicating patterns~
Disposed below template sections 48 and secured thereto is an elongated creen bin 50 that provides a tempor-ary or transition holding zone for laminating powder dispensed : from template section 58. Attached at the lower extremity of screen bin 5~0 is a reciprocable screen housing 96 containing a screen for ine distribution of the laminating powder 98.
Screen housing 96 may be mounted in an~ desired manner, such as on slides provided on screen bin 5~0 to permit transverse ; reciprocation thereof with respeat to conve~or section 28.
Attached to screen housing 96~is a vibrator 54, preferably an air actuated vibrator provided with a source of compressed air (not shown) through flexible conduit 100.
Returning to Figure 2, there is additionally shown, below wet conveyor section 26, a liquid or water recepticle 102 containing a drain 104 to receive and drain exce~s water : that may be xeceived therein, by gravity fl~w, from the con-~ veyor belt of wet aonveyor ~ection 26. A similar water re-: :.
cepticle 106 ~ontaining a drain 108 is ~hown disposed below wet conveyor 30 for the same intended purpose. Desirable, as shown, both r~cepti~le 102 and recepticle 106 extend~omewhat beyond the end of their re pe¢tive wet conveyor sections 26 and 30. Also shown disposed beIow the tarminal portion of dry conveyor 28 and extending slightly therebeyond is a powder xecepticle:}lO fi~ted with a suitable elongated brush 112 or ;~
the like to remove excess powdery laminating material from belt 58 by contact with the return section thereof.
Reverting:to an earlier portion of this disclosure, in accordance with the practice of this invention a loader positioned at a station 24 ~ransfer~ cellular glass ~heets 12 or the like in a closely spaaed series from a source 22 onto the initlal con~e~ance portion of wet conveyor 26. As sheets 12 traverse wet conveyor 26 they are successivel~
sprayed with a mist of water. Excess water i9 collected in recPpticle 102 and disposed of via drain 104, After travers-ing wet conveyor sectLon 26~ sheets 12 ara successively con-veyed below laminating powder applicator 38 wherein h~drous calcium silicate or a like reactive/ powdery laminating material 98 i5 dispensed in a desired applicating pattern to the wet cellular glass substrate. As the process proceeds, excess powdery laminating material is brushed or removed from the return section of wet conveyor belt 58 by brush or other suitable scraper 112 and xeceived in recepticle 110 and sheets 12 are, thereafter, sequen~ially conveyed onto a second wet belt conveyor 30. An additional spray or mist of water is applied over or to the powder~, water-r~active laminating material 98 and excess water or a water-laminating powder mix-ture is collected in recepticle 106 and disposed o via drain 108. Thereafter, sheets 12 are fed hy gravity across surge conveyor section 31 to a ~uitable stop 114. A first sheet 12 is removed to an as~embly table 118 by an operator poqitioned at assembly station 116. A sheet o~ scrim cloth is applied to the laminating material of said first ~heet, ancl a subse ~uent sheet 12 with its laminating material facing said scrim cloth is andwiched over said first ~heet, and thereafter, re-moved to a drying ~tation 120~ such as a pallet, to permit the laminating material to set or cure.
Some of the obvious alternatives to the method and apparatus of this invention have already been disclosed.
Others will occur to those skilled in the art. According~y, within the scope of the appended claims, this invention is not intended to be limited, except as ~pecifically set forth.
In the manufacture of cellular glass or .~ike rigid cellular materials it is frequently desirable to laminate a pluxality of pl~es of the material together to provide articles o~ increased thickness~ In the past, this has been accomplished by pxemixing a batch of pasty laminating material, generally a fask setting plaster~
in a suitahle pot or other container, applying the pas~y laminating materia~. to the companion surfaces o~ the ob-jects to be laminated, sandwichin~ the objects together and permitting the laminatin~ material to cure or set~
Howev~x,~ it was found that: tl) the time spen~ on mixing small batches and cleaning up afterwards was excessiver ~2) mixing p~ior to application to the cellular material, e.g~, cellular ~lass, limited ~he time of application to w.ithin ahout a 20 minute period of "pot life" available before the plaster ma~erial would set up; and (3) cleaning the small containers ~or the ,, . , . , ,; .
plaster material after use often caused plugging of effluient drains. Accordirlgly, a need was present for the development of a suitable method and apparatus for lami-nating cellular materials that obviated the deficiencies of the prior art techin~ue of laminating.
In accordance with the present invention,there is provided a method for laminating plies of cellular ma-terial that comprises applying a liquid reactant to the surface to be laminated. Applying a reactive, powdery laminating material over the liquid reactant. Applying additional liquid reactant over the powdery laminating material. Sandwiching the so treated surfaces together.
Interposing a sheet o scrim abric between the treated surfaces before they are sandwiched together. And there-after, permitting the laminating material to set.
There is also provided apparatus for laminating plies of cellular material comprising a conveyor system for transporting a plurality of pairs of said plies in series from a loading end to an assembly end. The con-veyor system comprises three sections, a first section along the path of the conveyor system having a spray means for applying a liquid to the upper surEace of the plies~
~J _ 3 -;, "
`
`~ A second, intermediate station along the path having a vertically adjustable powder applicating means for apply-ing a powder to the upper surface and a third station along the path having spray means for applying additional liquid to the upper surface. Each of the conveyor sec-tions encompassing one of the stations and extending for a distance beyondO
In accordance with the present invention, each of the above-mentioned l'pot laminating" and "pot life"
constraints has been overcome. The lamination of cellular glass artilcles is accomplished by (1) applying a liquid reactant, e.g., water, to the surfaces to be laminated;
~2) applying a reactive, powdery lami~atiny material, `~ e.g~, hydrous calcium sulfate, over the liquid reactant;
t3) applying additional liquid reactant, e.g., water, over the powdery laminating material; (4) sandwiching the so treated surfaces together; and (S) permitting the lami-nating material to set. In the furtherance oE this invention, there is porvided, inter alia, a novel powder applicator device that is constructed and arranged to be vertically adjustable and is also provided with foraminous templates so that various powder applicating patterns can be produced.
? - 4 In the drawings, wherein like numerals are used to indicate like parts throughout the same:
Figure 1 is a schematic perspective of a typical laminated article produced in accordance with this inven-tion:
Figure 2 is a schematic side elevation of a portion o a laminating assembly line employing the princip1es of this invention;
Figure 3 is a schematic plan of a pair of parallel, laminating assembly lines designed to incor-porate the features o this invention;
Figure 4 is a front elevation partly borken away, of a preferred powder applicator assembly of this invention; and Figure 5 i5 a right elevation of the assembly o Pigure 4.
Reerring to Figure 1, there is shown a typical cellular glass laminate comprised of a pair of rectangu-lar, cellular glass sheets 12 bonded together by a lami-nating layer of interlayer 14. Interlayer 14 is prefer ably comprised of substantially continuous layer or matrix of fast setting plaster 16 containing in the body thereof a reinforcement 4a material r ~uah a~ a c:ontinuou~ sheet of ~crim cloth 18 .
5crim cls:~th 18 may be o~ ~la~ ~ibrou~ m~t~rial or oth~r matarial Q~ ~ynthetic ~i~rous ma~erial, as de~ired, and may be either a woveT~,knîtt~d o~ nonwoYen fabric. Pla~ter 16 i~ preferably comprised of hydrou~ calcium sulfa~e, scld und~r th~ ~a~nark 1I H~DROCAI." b~r U ., S ., GSrp~um Company .
~he cellular gla38 ~heets lZ may be manu~aatured by any lcnown proct3s~, ~uch a~ that de~cribed ~n United States ~?atent 3,532,430 and may be of ~ny composition c:ommonly identi~ied a~ "cellular gla~t' or "multicallular gla~
a~ s~t Xorth in said patent.
~a~erring now t~o Figure~ 2 ~nd 3, ~h~re i~ ~hown ~ -re~p~ctiY~ly, a ~ahematic ~ide elevatiola o~ tha prin~ipal portion of a laminat~ng as~ ly line 20 of this in~ention and a ~ahematic plan o~ ~ pa~ o~ parallel, lamina~lng a~sem-bl~ ne~ 20 ~mploying the princip~es herein disclosed. In aocQrdanae with the prackîae o~ this invention, cellular gla~ Ln the ~orm o~ rectallgular ~he~t~ 1~ or any other suit-al~le shape or ~orm are prov~ded ~rom a ~ource 2~, such a3- one ~0 or mc~e pall~t~. A loader po~itioned at a ~takion 24 r ad~a-aent tha beginning or up~tream end of ass2mbly llne or line~
20 " tran~fe~ ~h~ets 12 or o~her cellular ~las~ shapes from source 22 ~o the upstream end of an a~embly line 20. Con-venientl~, where two dif ~ren~1y shaped articla~ are ~eing `:~
~ `
laminated concurrently, the arrangement of Figure 3 permits the use of separate laminating assembly lines ~or each shape Howe~er, since each laminating assembly line 20 i3 substantially identical ln cvnstruction and mode of operation, ;
further discussîon will be conined to a single line pro-cassing cellular glass ~heets 12 As best shown in Figure 2, the transport mechan ism of assembly line 20 is preferably comprised of three aligned conveyor belt seations 26, 28 and 30, that are suit-ably power driven by conventional means (not shown) and which are followed or terminated by a downwardly inclined roller surge conveyor sectlon 31 that i~ not powered Power driven belt conveyor sectlons are preferred over a power driven rolLer conveyor system, although the latter could be employed, .. : :
~` if desired Also; the surge aonveyor section could be power driven, if desired, and may either comprise a roller conveyor .
section or a belt conveyor section For reasons that will shor~ly be apparent, conveyor sections 26 and 30 are called -~ "wet`'~ conveyor~, whereas intermediate conveyor section 28 is called a "dry'i conveyor Also, where desirable for spacing purposes, one or more idler rolls, such as idler roll 32, may b- di~posed between conveyor sections .. . : , .- . ~
Disposed above each "wet" conveyor ~ection 26 and 30, at a location intermediate their respective lengths, is a watermist spray bar manifold 34. Manifolds 34 are each suitably connected to a source of water ~not shown) and a source of air tnot~shown) and are provided with appropriate ..
apertures or noæ71a~ so as to deliver a fine, low velocity, mist or spray of water 36 downwardl~ toward its ~ub~acent conveyor section, ~6 or 30, in a divergent spray pattern.
Disposed above l'dry" conveyor ~ection 28, at a location intermediate its length, is a powder applicator 38.
As best shown in Figures 4 and 5, powder applicator 38 is com-prised of a hopper 40, a hopper-access door 42, a rotary feed device 44, a rotary drive means 46, a template ~ection 48, a :::
scr en bin~S0, a vibratory screen section 52 and a vibrator 54, all ~uitably mounted on a framework 56 spanning the dry con-veyor section 28. Referring now in greater detail, hopper ~0 ~:
i~ desirably of ~he funnel-like configuration, as shown, to promote a continuous, free flow of powder material therethrough and is construoted to extend laterall~ or transversely across the conveyor or substantially the full width of the conveyor belt 58. As shown, hingedly attached-~at the top of hopper 40 is hopper-access door 42. Hopper 40 is securely affixed, both ~:~
front and rear, to adjustable tie bars 69 (one o which is shown~ which, in turn, axe securely affixed at each end to an adjustable channel member 62 fitted abouk each of our stanch-ions 64 comprising an integral part o framework 56.
.
4~
Adjustable channel member~ 62 are each provided at ~:
their lower exkremity with a laterally extenaing bearing plate :~ ~
66 and reinforcing gu~sets 68. ~i~posed ~herebelow and secure- :
ly affixed to stanchion~ 64 are similar plates 70 and reln~orc-ing gus~ets 72, with each plate 70: having an aperture (not shown) therein. An elongated threaded, adjusting bolt 74 :~
;
passes through the aperture in each plate 70 and is threadably secured to a nut 76 that res~s on the upper surface of plates 70 and also extends into contact with the lower surface of ~: 10 bearing plates 66. Additionally, adjustable channel members : 62 are each provided with a pair o~ vertiaal slots 78 laterally ~.
aligned with apextures (not shown) in ~tanchions 64 so that, in a well known manner, l~k scre~s 80 extending through slots 78 and the apertures~in~stanchions 64 can ~e threadably received :
: :~ by nuts (not shown) and:j upon tightening screw~ 80 to said nuts, :
channel member~ 62 are fi~mly secured to stanchions 64. As will be clearer shortly, when heigh~ adjustment o~ the hopper 40 and related components of powder ap~licator 38 i8 desired, lock screw~ 80 are loo~ened, adjusting bolts 74 are rotated :with respec~ to nuts 76 and, when the desired raised or lowered ; position is reached, lock screws 80 are retightened to secure applicator 38 in its new elevation above conve~or 28, :: ., 4L~
Rotary feed device 44 may be of any desirecl con~
struction suitable for maintaining a continuous, free flow of powder material from hopper 40. Generally, rotary feed device 44 will comprise an elongated rotary paddle and a paddle wiper assemb}y to assist in maintaining said frae flow. In the em-bodiment shown, rotary feed device 44 is driven by a rotary dxive means 46 comprised of an electric motor suitably clutched to a variable speed transmission having a maximum output speed :
of 126 R.P.M. and a minimum output speed of 12.~ R.P.M. The output of rotary drive means 46 is transmitted to rotary feed : :~
device 44 by means o~ a chain drive 82 and gears 84 and 86. As wiIl be noted~ rotary drive means 46 is mounted on a support :
-i~ plate 88 that is s~cured by the rods 90 to channel members 92 which, in turn~ are se~urely fixed to the ad~ustable channel mambers 62 on the left side of the powder applicator 38, as viewed in Figure 4. ~ccordingly, i.t will be understood that operation of the height adjustment means of applicator 38, as hereinabove described, permits maintaining the same relation or fixed position of rotary drive means 46 with respect to rotary feed device 44.
: Suitahly fixed to powder applicator 38, below xotary feed device 44, and in communication with feed device 44 via an elongated opening is template section 48~ Template section 48 preferably comprises slide tracks ~not shown~ and a suitable template plate or slide plate received thereby and attached to a handle 94 for convenie~ce of in~ertion and removal. As will be appreciatedl because of the various sized, shapes and configuration~ of lamînate~ desired, it is appropriate and clesirable to confine the laminating powder distribution to a pattern particularly suitable to the laminate being prepared.
Accordingly, foraminous templates are made available having : an aperture array of suitable si~e or si2es to provide various powder applicating patterns~
Disposed below template sections 48 and secured thereto is an elongated creen bin 50 that provides a tempor-ary or transition holding zone for laminating powder dispensed : from template section 58. Attached at the lower extremity of screen bin 5~0 is a reciprocable screen housing 96 containing a screen for ine distribution of the laminating powder 98.
Screen housing 96 may be mounted in an~ desired manner, such as on slides provided on screen bin 5~0 to permit transverse ; reciprocation thereof with respeat to conve~or section 28.
Attached to screen housing 96~is a vibrator 54, preferably an air actuated vibrator provided with a source of compressed air (not shown) through flexible conduit 100.
Returning to Figure 2, there is additionally shown, below wet conveyor section 26, a liquid or water recepticle 102 containing a drain 104 to receive and drain exce~s water : that may be xeceived therein, by gravity fl~w, from the con-~ veyor belt of wet aonveyor ~ection 26. A similar water re-: :.
cepticle 106 ~ontaining a drain 108 is ~hown disposed below wet conveyor 30 for the same intended purpose. Desirable, as shown, both r~cepti~le 102 and recepticle 106 extend~omewhat beyond the end of their re pe¢tive wet conveyor sections 26 and 30. Also shown disposed beIow the tarminal portion of dry conveyor 28 and extending slightly therebeyond is a powder xecepticle:}lO fi~ted with a suitable elongated brush 112 or ;~
the like to remove excess powdery laminating material from belt 58 by contact with the return section thereof.
Reverting:to an earlier portion of this disclosure, in accordance with the practice of this invention a loader positioned at a station 24 ~ransfer~ cellular glass ~heets 12 or the like in a closely spaaed series from a source 22 onto the initlal con~e~ance portion of wet conveyor 26. As sheets 12 traverse wet conveyor 26 they are successivel~
sprayed with a mist of water. Excess water i9 collected in recPpticle 102 and disposed of via drain 104, After travers-ing wet conveyor sectLon 26~ sheets 12 ara successively con-veyed below laminating powder applicator 38 wherein h~drous calcium silicate or a like reactive/ powdery laminating material 98 i5 dispensed in a desired applicating pattern to the wet cellular glass substrate. As the process proceeds, excess powdery laminating material is brushed or removed from the return section of wet conveyor belt 58 by brush or other suitable scraper 112 and xeceived in recepticle 110 and sheets 12 are, thereafter, sequen~ially conveyed onto a second wet belt conveyor 30. An additional spray or mist of water is applied over or to the powder~, water-r~active laminating material 98 and excess water or a water-laminating powder mix-ture is collected in recepticle 106 and disposed o via drain 108. Thereafter, sheets 12 are fed hy gravity across surge conveyor section 31 to a ~uitable stop 114. A first sheet 12 is removed to an as~embly table 118 by an operator poqitioned at assembly station 116. A sheet o~ scrim cloth is applied to the laminating material of said first ~heet, ancl a subse ~uent sheet 12 with its laminating material facing said scrim cloth is andwiched over said first ~heet, and thereafter, re-moved to a drying ~tation 120~ such as a pallet, to permit the laminating material to set or cure.
Some of the obvious alternatives to the method and apparatus of this invention have already been disclosed.
Others will occur to those skilled in the art. According~y, within the scope of the appended claims, this invention is not intended to be limited, except as ~pecifically set forth.
Claims (10)
1. A method for laminating plies of cellular material comprising, applying a liquid reactant to the surface to be laminated, applying a reactive, powdery laminating material over the liquid reactant, applying additional liquid reactant over the powdery laminating material, sandwiching the so treated surfaces together, and permitting the laminating material to set, interposing a sheet of scrim fabric between said treated surfaces before they are sandwiched together.
2. A method according to claim 1 where in the powdery laminating material comprises hydrous calcium sulfate.
3. A method according to claim 2 wherein the liquid reactant comprises water.
4. A method according to claim 3 wherein said water is applied by spraying.
5. A method according to claim 1 wherein said powdery laminating material is applied by vibratory dusting.
6. A method according to claim 1 which includes placing a plurality of plies of cellular glass in series on a conveyor system, sequentially applying said liquid reactant, said reactive, powdery laminating material and said additional liquid reactant to said plies as they traverse said conveyor system, interposing scrim fabric between successive said plies prior to sandwiching the so treated surfaces together, and transferring said sand-wiched plies to a drying station.
7. A method according to claim 6 which further includes collecting excess liquid reactant below said conveyor system and disposing of said collected liquid.
8. A method according to claim 7 which further includes collecting excess reactive, powdery laminating material below said conveyor system.
9. A method according to claim 6 wherein said powdery laminating material is dusted onto said plies from a powder applicator and the powder applicating pattern is in part controlled by adjusting the height of said powder applicator above said conveyor system.
10. A method according to claim 6 wherein said powdery laminating material is dusted onto said plies from a powder applicator and the powder applicating pattern is in part controlled by inserting a foraminous template into said powder applicator.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US70551676A | 1976-07-15 | 1976-07-15 | |
| US705,516 | 1991-05-24 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1104050A true CA1104050A (en) | 1981-06-30 |
Family
ID=24833827
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA281,029A Expired CA1104050A (en) | 1976-07-15 | 1977-06-21 | Method and apparatus for laminating cellular material |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1104050A (en) |
-
1977
- 1977-06-21 CA CA281,029A patent/CA1104050A/en not_active Expired
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