CH720100A2 - Plant and process for the production of insulating panels for vehicles suitable for food transport, panels made with said method and vehicle suitable for food transport. - Google Patents

Abstract

The invention concerns a plant for the production of insulating panels for vehicles suitable for food transport, said plant (1) comprising: a thermoforming station (100), comprising: an automated loading member (110), configured to take a material in sheet (2) from a loading position (P1) and place said material (2) in an operational position (P2), wherein said material (2) is a plastic material comprising one or more of: Polystyrene, High impact, Acrylonitrile-Butadiene-Styrene, Polymethylmethacrylate, Polypropylene, Polyvinylchloride and similar; a pair of heating walls (120), each controllable between a distal position (PD) and a proximal position (PP) with respect to said operating position (P2); a motorized mold (130), configured to be brought to said operating position (P2) in order to thermoform said material (2) into a sheet; a pressure system (140), configured to operate on said operating position (P2) so that said thermoforming takes place under controlled pressure conditions. The thermoforming station (100) is configured to output thermoformed sheets (3), to obtain an assembly of thermoformed panels (4), comprising one or more thermoformed panels. The system (1) further comprises a foaming station (500), comprising 3 presses, each of which comprises: a lower plate, an intermediate plate and an upper plate, each extending substantially along a horizontal plane, in which the intermediate plate is configured to house thermoformed panels derived from a first plate (41, 42, 43), and the lower plate is configured to house thermoformed panels derived from a second plate, a foaming member, configured to perform foaming on the thermoformed panels derived from a first plate (41, 42, 43) housed in the intermediate plate and on the thermoformed panels derived from a second plate housed in the lower plate (540), respectively obtaining the foamed thermoformed panels; and thermoformed foam panels; movement members, active on the lower plate and on the intermediate plate; a control unit configured to control said movement members so that: the intermediate plate is brought into contact with the upper plate, forming a mold on the foamed thermoformed panels; the lower plate is brought into contact with the intermediate plate, forming a mold on the foamed thermoformed panels. The invention also concerns a process for the production of insulating panels for vehicles suitable for transporting food, a panel made according to this process and a vehicle suitable for transporting food.

Description

[0001] The present invention refers to a plant for the production of insulating panels for vehicles suitable for food transport.

[0002] The present invention also refers to a process for the production of insulating panels for vehicles suitable for food transport.

[0003] The present invention also refers to insulating panels for vehicles suitable for food transport made with the aforementioned method.

[0004] The production of insulating panels suitable for covering vans or other vehicles suitable for food transport is currently carried out by initially spreading a film of wax on a negative mold - this film of wax is then useful at the end of the process, to facilitate the detachment of the panel from the mold.

[0005] A layer of spray gelcoat is then deposited on the mould, so as to create a smooth and compact surface layer, protecting the panel and at the same time giving it a shiny characteristic. This layer also has the purpose of making the panel suitable for food transport.

[0006] A further layer is then deposited, composed of glass fiber and polymer resin, for example via the Spray Lay Up process. In practice, finely cut glass fiber is sprayed inside the mold together with a resin, until the desired thickness is obtained.

[0007] Once the deposition of the resin is completed, rollers are used to manually uniform the thickness in all areas of the panel.

[0008] Once the polymer curing time has elapsed, the mold is closed with a counter-mould, to give the desired shape to the rear part of the panel made of polyurethane. For this purpose, polyurethane in liquid form is injected from a single point and allowed to polymerize for a preset time.

[0009] The last phase consists in opening the mold and extracting the piece.

[0010] The Applicant first of all observes that this type of process includes a considerable number of steps carried out manually. This inevitably involves the possibility of inaccuracies and errors, as well as the intrinsic non-repeatability of the process itself. From a practical point of view, one of the consequences is the creation of products of inconsistent quality and shape. Furthermore, by injecting the polyurethane in a single point, it is not possible to precisely control the distribution of the polyurethane itself, thus obtaining a non-homogeneous product. To this must be added the fact that the polymerization temperature is not controlled, in fact the molds are not thermoregulated.

[0011] The Applicant also observes that the materials used cannot be recycled, with obvious economic and environmental consequences; the materials used can also usually cause health problems for the operators involved, if the latter do not adopt adequate safety/protection measures.

[0012] Finally, returning to the topic of the preponderance of manual operations, it is evident that by using known methods, a single operator can work on only one panel at a time.

[0013] The aim of the present invention is to provide a system and a method, as well as an insulating panel, which can solve the drawbacks listed above.

[0014] In particular, in accordance with a first aspect, the object of the present invention is a plant for the production of insulating panels for vehicles suitable for food transport. Preferably, said plant comprises a thermoforming station.

[0015] Preferably, the thermoforming station comprises an automated loading member.

[0016] Preferably, the automated loading member is configured to pick up a sheet material from a loading position and place said material in an operational position.

[0017] Preferably, said material is a plastic material comprising one or more of: Polystyrene (PS), High Impact Polystyrene (HIPS), Acrylonitrile-Butadiene-Styrene (ABS), Polymethylmethacrylate (PMMA), Polypropylene (PP), Polyvinylchloride (PVC) and similar.

[0018] Preferably, the thermoforming station comprises a pair of heating walls.

[0019] Preferably, each heating wall can be controlled between a distal position and a proximal position with respect to said operating position.

[0020] Preferably, the thermoforming station comprises a motorized mould.

[0021] Preferably, the motorized mold is configured to be brought to said operating position in order to thermoform said sheet material.

[0022] Preferably, the thermoforming station comprises a pressure system.

[0023] Preferably, the pressure system is configured to operate on said operating position so that said thermoforming takes place in a vacuum condition. As the heated sheet softens, it could sink in the center due to the weight, for this reason the pressure in the lower part of the sheet is increased. To do this, the thermoforming machine body must be watertight. Preferably there is a system that controls the pressure difference between the bottom and the top of the plate. Preferably, the vacuum (or rather the air suction phase) occurs when the mold is approached, to make the sheet adhere to the mold itself.

[0024] Preferably, said thermoforming station is configured to provide thermoformed sheets at the output, to obtain thermoformed panels.

[0025] Preferably, said thermoformed panels comprise at least a first thermoformed panel and a second thermoformed panel. From a single sheet it is possible to obtain from 1 to N thermoformed panels depending on the size of the panels. Preferably, the thermoforming mold has maximum dimensions of 5100 x 2300 mm (same as the raw material sheets).

[0026] Preferably, the plant includes a trimming station.

[0027] Preferably, the trimming station comprises an automated cutting device for separating said thermoformed panels from each other and/or trimming edges of said thermoformed panels.

[0028] Preferably, said trimming station includes a chip suction apparatus.

[0029] Preferably, the system includes a tipping and cleaning station.

[0030] Preferably, the overturning and cleaning station includes a robotic member to perform an overturning of said thermoformed panels.

[0031] Preferably, the tipping and cleaning station includes a cleaning member, for sucking waste material.

[0032] Preferably, said tipping and cleaning station is placed between the trimming station and the storage bays.

[0033] Preferably, the system comprises one or more storage bays.

[0034] Preferably the storage bays are placed between the tipping station and the foaming station.

[0035] Preferably, a handling member is provided which takes the panels from the tipping station and places them in the storage bay, the storage bays can move horizontally and vertically to approach the arm of the handling member.

[0036] Preferably, said system includes a foaming station.

[0037] The foaming station includes an area used for loading and unloading the moving floors and a press area.

[0038] There can be, for example, 3 presses and the foaming process can be carried out on all 3 presses independently.

[0039] Preferably the foaming station comprises a lower plate for each press.

[0040] Preferably the foaming station comprises an intermediate plate for each press.

[0041] Preferably the foaming station comprises an upper plate for each press.

[0042] Preferably, for each press the configuration is as follows: Preferably, the lower plate extends substantially along a horizontal plane. Preferably, the intermediate plate extends substantially along a horizontal plane. Preferably, the upper plate extends substantially along a horizontal plane.

[0043] The molds for foaming are mounted on these plates.

[0044] Preferably, the intermediate plate is configured to house the thermoformed panels deriving from a first sheet.

[0045] Preferably, the lower plate is configured to house the thermoformed panels deriving from a second plate, thermoformed subsequently to the first.

[0046] Preferably, the foaming station comprises a foaming member.

[0047] Preferably, the foaming member is configured to perform foaming on the thermoformed panels deriving from a first sheet housed in the intermediate plate, obtaining foamed thermoformed panels deriving from a first sheet.

[0048] Preferably, the foaming member is configured to perform foaming on the thermoformed panels deriving from a second sheet housed in the lower plate, obtaining foamed thermoformed panels deriving from a second sheet.

[0049] Preferably, the foaming station includes movement members.

[0050] Preferably, the movement members are active on the lower plate.

[0051] Preferably, the movement members are active on the intermediate plate.

[0052] Preferably, the foaming station comprises a control unit.

[0053] Preferably, said control unit is configured to control said movement members so that the intermediate plate is moved towards a loading area, in which it receives the thermoformed panels deriving from the first plate.

[0054] Preferably, said control unit is configured to control said movement members so that, after the thermoformed panels deriving from the first plate have been subjected to foaming, the intermediate plate is returned to the operating area.

[0055] Preferably, said control unit is configured to control said movement members so that, after the thermoformed panels deriving from the first plate have been subjected to foaming and brought back to the operating area, the intermediate plate is moved against the upper plate , forming the mold for the thermoformed panels deriving from the first foamed sheet.

[0056] Preferably, said control unit is configured to control said movement members so that the lower plate is moved towards a loading area, in which it receives the thermoformed panels deriving from the second plate.

[0057] Preferably, said control unit is configured to control said movement members so that, after the thermoformed panels deriving from the second plate have been subjected to foaming, the lower plate is returned to the operating area.

[0058] Preferably, said control unit is configured to control said movement members so that, after the thermoformed panels deriving from the second plate have been subjected to foaming and brought back to the operating area, the lower plate is moved against the intermediate plate , forming the mold for the thermoformed panels deriving from the second foamed sheet.

[0059] In accordance with a second aspect, the invention has as its object a process for the production of insulating panels for vehicles suitable for transporting food.

[0060] Preferably, the method comprises picking up, via an automated loading member, a sheet material from a loading position and positioning said material in an operational position.

[0061] Preferably, said material is a plastic material comprising one or more of: Polystyrene (PS), High Impact Polystyrene (HIPS), Acrylonitrile-Butadiene-Styrene (ABS), Polymethylmethacrylate (PMMA), Polypropylene (PP), Polyvinylchloride (PVC) and similar.

[0062] Preferably, the method comprises heating said sheet material.

[0063] Preferably, the method comprises bringing a motorized mold to said operating position.

[0064] Preferably, the process comprises carrying out a thermoforming of said sheet material.

[0065] Preferably, said thermoforming is carried out under controlled pressure conditions. As the heated sheet softens, it could sink in the central area due to the weight, for this reason the pressure in the lower part of the sheet is increased. To do this, the thermoforming machine body must be watertight. Preferably there is a system that controls the pressure difference between the bottom and the top of the plate. Preferably, the vacuum (or rather the air suction phase) occurs when the mold is approached, to make the sheet adhere to the mold itself.

[0066] Preferably, one or more thermoformed panels are obtained from a single sheet since the molds of the thermoforming machine and the presses contain the "imprints" of one or more panels for each mold. From a single sheet it is possible to obtain N thermoformed panels (depending on the size of the panels), the thermoforming mold has maximum dimensions of, for example, 5100 x 2300 mm, like the raw material sheets.

[0067] Preferably, the process comprises a cutting and/or trimming operation to cut and/or trim said thermoformed panels.

[0068] Preferably, the process includes a chip suction operation at least partially during said cutting and/or trimming operation.

[0069] Preferably, the process includes an operation for overturning the thermoformed panels.

[0070] Preferably, the process includes a cleaning operation carried out on said thermoformed panels to suck up waste material.

[0071] Preferably, the overturning operation is temporally interposed between the cutting and/or trimming operation and the storage operation in the bays.

[0072] Preferably, the process includes storing the thermoformed panels in storage bays before carrying out the foaming operation.

[0073] Preferably, the process comprises activating automated handling members to collect the thermoformed panels from the storage bays and supply them at the entrance to a foaming station for carrying out the foaming operation.

[0074] Preferably, the method includes providing a lower plate for each of the 3 presses.

[0075] Preferably, the method includes preparing an intermediate plate for each of the 3 presses.

[0076] Preferably, the method includes providing an upper plate for each of the 3 presses.

[0077] Preferably, the lower plate of each press extends substantially along a horizontal plane.

[0078] Preferably, the intermediate plate of each press extends substantially along a horizontal plane.

[0079] Preferably, the upper plate of each press extends substantially along a horizontal plane.

[0080] Preferably the process for each press is the same.

[0081] Preferably, the method comprises housing the thermoformed panels deriving from the first sheet in the intermediate plate.

[0082] Preferably, the loading of the thermoformed panels deriving from the first sheet into the intermediate plate takes place in a loading area.

[0083] Preferably, the process comprises foaming the thermoformed panels deriving from the first sheet, obtaining foamed thermoformed panels deriving from the first sheet.

[0084] Preferably, the process comprises bringing the intermediate plate into contact with the upper plate, forming a mold for the thermoformed panels deriving from the first foamed plate.

[0085] Preferably, the intermediate plate comes into contact with the upper plate in an operating area (press area).

[0086] Preferably, the method comprises housing the thermoformed panels deriving from the second sheet in the lower plate.

[0087] Preferably, the loading of the thermoformed panels deriving from the second sheet into the lower plate takes place in a loading area.

[0088] Preferably, the process comprises foaming the thermoformed panels deriving from the second sheet, obtaining foamed thermoformed panels deriving from the second sheet.

[0089] Preferably, the process comprises bringing the lower plate into contact with the intermediate plate, forming a mold for the thermoformed panels deriving from the second foamed plate.

[0090] Preferably, the lower plate comes into contact with the intermediate plate in the operating area (press area).

[0091] In accordance with a third aspect, the invention has as its object an insulating panel for vehicles suitable for food transport, made with the aforementioned process.

[0092] In accordance with a fourth aspect, the invention has as its object a vehicle suitable for transporting food.

[0093] Preferably, the vehicle comprises a chassis.

[0094] Preferably, the vehicle comprises movement means associated with said chassis.

[0095] Preferably, the vehicle includes a compartment for housing food items, mounted on said chassis.

[0096] Preferably, said space is delimited by one or more walls.

[0097] Preferably, said one or more walls comprises one or more of the aforementioned panels.

[0098] Preferably, said vehicle comprises a refrigeration system.

[0099] Preferably, said refrigeration system is associated with said compartment to maintain it at a controlled temperature.

[0100] Further characteristics and advantages will become clearer from the detailed description of examples of embodiment of the invention, provided below. The description will refer to the attached figures, which also have purely illustrative and therefore non-limiting purposes, in which: – Figure 1 shows a block diagram of a system in accordance with the present invention; – Figure 2 shows a block diagram of a station of the system in figure 1; – Figures 3a-3d show different operating configurations of the station in figure 2; – Figures 4a-4b show different configurations of another station of the system in figure 1; – Figure 5 schematically shows a vehicle on which panels made using the system in figure 1 are used.

[0101] With reference to the attached figures, 1 generally indicates a plant for the production of insulating panels for vehicles suitable for food transport, in accordance with the present invention.

[0102] The plant 1 (figure 1) includes a thermoforming station 100.

[0103] The thermoforming station 100, as will become clearer later, has the task of giving the panels the desired shape.

[0104] The thermoforming station 100 includes an automated loading member 110, configured to pick up a sheet material 2 from a loading position P1 and position this material 2 in an operating position P2.

[0105] In more detail, a plurality of stacked plates are initially positioned in the loading position P1. This operation can be carried out either manually or automatically. The automated loading member 110, created for example as a set of automated motorized suction cups, picks up and positions, one at a time, the slabs on a horizontally moving trolley. The latter transfers each sheet to the P2 operating position, so that it can be subjected to the thermoforming operation. The same mobile carriage, once it arrives in the operational position, will then be loaded by the thermoformed sheet in the previous cycle. The latter, in particular, will be positioned in the upper part of the trolley and then extracted and transferred to an unloading area.

[0106] The material of the plate 2 is a plastic material comprising one or more of: Polystyrene (PS), High Impact Polystyrene (HIPS), Acrylonitrile Butadiene Styrene (ABS), Polymethyl methacrylate (PMMA), Polypropylene (PP), Polyvinyl chloride (PVC) and similar.

[0107] The thermoforming station 100 also includes a pair of heating walls 120, each controllable between a distal position PD and a proximal position PP with respect to the operating position P2. In practice, each heating wall 120, through respective movement members, is brought to the operating position P2 when a sheet must be heated, up to its softening temperature, for thermoforming. For example, the heating walls 120 are arranged horizontally, substantially parallel to the ground, and are moved horizontally, to be moved between the distal position PD and the proximal position PP.

[0108] Figure 4a shows schematically, according to a simplified side view, the heating walls 120 in the proximal position PP, when the sheet material 2 is in the operating position P2; figure 4b shows schematically, according to a simplified side view, the heating walls 120 in the distal position PD, when there is no sheet material in the operating position P2.

[0109] In one embodiment, the heating walls 120 are composed of quartz resistors, mounted inside reflective parabolas to increase the degree of radiation and to limit heat dispersion.

[0110] Preferably, the heating walls 120 are equipped with an infrared pyrometer, capable of reading the temperature of the sheet in such a way as to allow the processing cycle to proceed once the set temperature has been reached.

[0111] The Applicant observes that the pyrometer allows you to save time during machine startup and to always have the sheets formed at the same temperature.

[0112] In one embodiment, it is possible to adjust the power of each individual resistor or individual groups of resistors forming part of the heating walls 120. For example, the power of each individual resistor of the upper heating wall can be adjusted, while the adjustment of the resistances of the lower heating wall can be carried out in pairs.

[0113] Advantageously, the use of an energy monitoring technique is envisaged, which allows reducing electricity consumption when the heating walls are in the distal PD position.

[0114] Once the thermoforming temperature has been reached (for example between 120°C and 230°C), the heating walls 120 are returned to the distal position PD a, a sealed environment is created around the material 2 being processed.

[0115] The thermoforming station 100 includes a motorized mold 130 which, at this point of the process, is brought to the operating position P2 so as to thermoform the material 2 into a sheet.

[0116] Preferably, to prevent the softened sheet material 2 from giving way under its own weight before the mold 130 arrives, the area beneath the material 2 itself is put under pressure.

[0117] Thanks to a pressure system 140, a vacuum condition is created around the operating position P2 (which, as mentioned, is at this point in a sealed environment), so that the sheet material 2 (previously softened from the heating walls 120) adheres to the motorized mold 130.

[0118] Once the material 2 has been thermoformed, it is extracted from the mold 130 and taken by the trolley to an unloading area.

[0119] In light of the above, it can be noted that the thermoforming station 100 is configured to provide thermoformed sheets 3 as output, from which a set of thermoformed panels 4 are then obtained.

[0120] With reference to figure 1, a first non-thermoformed sheet 2 is inserted into the thermoforming station 100 which thermoforms the sheet 2 to give a thermoformed sheet 3. The thermoformed sheet 3 is trimmed in the trimming station 200 and overturned and cleaned in the tipping and cleaning station 300.

[0121] We specify that the thermoformed sheet 3 is a single sheet with two or more pre-formed panels. The thermoformed sheet 3 having, for example, three panel shapes is directed into the trimming station 200 and is transformed into three panels 41, 42 and 43.

[0122] The set of the three panels 41, 42 and 43 form a package or assembly of panels (called 4) which is directed towards the overturning and cleaning station 300 where the three panels are in fact overturned and cleaned.

[0123] Subsequently, the package for example of the three panels 41, 42 and 43 is directed to the storage bays 400 in stock.

[0124] At this point a new non-thermoformed sheet 8 (not indicated in figure 1), having the same characteristics as sheet 2, is inserted into the thermoforming station 100 and, following all the operations described above, gives a second package or assembly of panels (called 7), composed for example of panels 71, 72 and 73 which is directed to the stock storage bay.

[0125] In figure 1 the assembly of thermoformed panels 4 includes at least a first thermoformed panel 41, a second thermoformed panel 42, and also a third thermoformed panel 43. It is reiterated that the number of panels of which the assembly is made up is established according to the dimensions of the panels themselves, but for convenience we will refer to assemblies composed, for example, of 3 panels.

[0126] Preferably, downstream of the thermoforming station 100, a trimming station 200 is provided.

[0127] The trimming station 200 includes an automated cutting device 210, to separate the thermoformed panels 41,42 and 43 from each other and/or trim the edges of said thermoformed panels 41,42 and 43.

[0128] Note that each thermoformed sheet can coincide with a thermoformed panel, or comprise a multiplicity of thermoformed panels. In the first case, the trimming station 200 will have the task of trimming the edges; in the second case, the trimming station 200 will also separate the various panels forming part of each thermoformed sheet.

[0129] In one embodiment, the trimming station 200 may include a chip extraction apparatus 220.

[0130] For example, a 5-axis CNC milling machine can be used for trimming.

[0131] The movement from the unloading area of the thermoforming station 100 to the trimming station 200 can be performed by a robotic arm.

[0132] The waste material is automatically collected and recycled.

[0133] In one embodiment, downstream of the trimming station 200, and more generally downstream of the thermoforming station 100, a tipping and cleaning station 300 is provided.

[0134] From a practical point of view, at the end of the trimming carried out in the trimming station 200, the thermoformed panels 41,42 and 43 are facing with the concave surface downwards (in the case of a positive mold in the thermoforming machine) and can processing chips are still present. It is therefore advisable to carry out a cleaning and tipping operation, to facilitate subsequent storage and foaming operations. A pick-up system takes the thermoformed panels 41,42 and 43 from the trimming station 200 and deposits it in a hermetically closed box. The thermoformed panels 41,42 and 43 are overturned with the help of a robotic arm equipped with grippers. During movement, the cleaning member 320 (made for example as a suction system) removes residual chips from processing and excess material.

[0135] The tipping and cleaning station 300 includes a robotic member 310 to perform a tipping of the thermoformed panels 41,42 and 43; in practice, the thermoformed panels 41,42 and 43 are rotated 180° around a horizontal axis.

[0136] The tipping and cleaning station 300 is advantageously also equipped with a cleaning member 320, to suck waste material from the assembly of thermoformed panels 4, and prevent this waste material (deriving from previous processes) from interfering with the subsequent foaming operation.

[0137] Preferably, the tipping and cleaning station 300 is interposed between the trimming station 200 and the foaming station 500 which will be described later. Immediately after the tipping station 300 there are the loading bays 400, after these there is the skimming bay 500.

[0138] In one embodiment, the system 1 includes one or more storage bays 400, interposed between the thermoforming station 100 and the foaming station 500. More specifically, the storage bays 400 are interposed between the station of tipping and cleaning 300 and the foaming station 500.

[0139] The storage bays 400 are equipped with automated movement members 410 which allow each bay to move into position to accommodate the set of thermoformed panels 4 which a robotic arm picks up from the tipping station 300.

[0140] The storage operation is useful since foaming (which will be described later) requires longer times than thermoforming/trimming/tipping operations.

[0141] For this purpose, at the exit of the tipping and cleaning station 300 the set of thermoformed panels 4 is picked up by a pick-up system which places it in the assigned storage bay 400; the bay is automatically brought into position by a rail translation system. This system also allows the bay to also translate along the vertical axis.

[0142] As mentioned above, the system 1 includes a foaming station 500.

[0143] The foaming station 500 is located downstream of the thermoforming station 100 and, more particularly, downstream of the storage bays 400.

[0144] The foaming station 500 is made up of 3 presses, each of the 3 presses includes a lower plate 510, an intermediate plate 520 and an upper plate 530. In Figures 2, 3a, 3b, 3c and 3d the operation of a single press. Each of the plates 510, 520, 530 extends substantially along a horizontal plane.

[0145] The intermediate plate 520 is shaped at the top so as to house the thermoformed panels derived from a first plate 41-42-43.

[0146] The upper plate 530 is shaped at the bottom so as to form, in cooperation with the intermediate plate 520, a mold for thermoformed panels derived from a first plate 41-42-43 after the latter have been subjected to the foaming operation .

[0147] The lower plate 510 is shaped at the top so as to house thermoformed panels derived from a second plate 71-72-73.

[0148] The intermediate plate 520 is shaped at the bottom so as to form, in cooperation with the lower plate 510, a mold for thermoformed panels derived from a second plate 71-72-73 etc. after the latter have been subjected to the foaming operation.

[0149] The foaming station 500 includes a foaming member 540, configured to perform foaming on the thermoformed panels derived from a first plate 41-42-43 housed in the intermediate plate 520 and on the thermoformed panels derived from a second plate 71-72 -73 housed in the lower plate 510. In this way, thermoformed panels derived from a first foamed sheet 41'-42'-43' and thermoformed panels derived from a second foamed sheet 71'-72'-73' are respectively obtained.

[0150] In one embodiment, the foaming member 540 is composed of a double-head foamer. One of the foaming heads is moved automatically on a Cartesian manipulator, while the other has the possibility of being moved by an operator using a motorized trolley. The head moved by the Cartesian manipulator is used for open mold foaming (better described below), while the second is used for closed molding (should it be necessary, for example in the case of so-called "sandwich panels").

[0151] Preferably, the foaming member 540 further comprises two or more tanks to contain the substances necessary for the formation of the foam. For example, polyol and isocyanate are stored in special steel tanks. These tanks are thermoregulated; in fact, in the tank jacket there is a resistance that allows a specific fluid to be heated in order to keep the reagents at a controlled temperature. From the tanks, the reagents are injected into a high pressure dosing group, using special recipes designed and recalled when necessary. The reagents then pass into the high pressure mixing heads where they are mixed so that the foam (e.g. polyurethane) can be dispensed onto the set of thermoformed panels 4 and onto the set of thermoformed panels 7.

[0152] The foaming station 500 includes, for each press, movement members 550, active on the lower plate 510 and on the intermediate plate 520.

[0153] The lower plate 510 is movable horizontally and vertically.

[0154] The intermediate plate 520 is movable horizontally and vertically.

[0155] The upper plate 530 is instead preferably fixed (for example mounted on a frame integral with the ground).

[0156] In one embodiment, each plate 510, 520, 530 is made of perforated solid steel.

[0157] Preferably, each plate 510, 520, 530 is heated with water, to a maximum temperature of about 70-80° C and a maximum pressure of about 10 bar. The heating water flows inside the plates through special channels created during the production of the plates themselves.

[0158] For horizontal movements, for example, trolleys are provided; a piston system is provided for the vertical movement of the intermediate plate 520 and the lower plate 510.

[0159] The foaming station 500 includes a control unit 560, configured to control the movement members 550 to carry out different phases within the foaming operation.

[0160] In greater detail, for each of the 3 presses, the plates 510, 520, 530 are initially aligned vertically, as schematically shown in figure 2. The area in which the plates are located in this configuration is identified as the operating zone Z0 .

[0161] The intermediate plate 520 is moved from the operating zone Z0 to a loading zone Z1, in which it receives thermoformed panels derived from a first plate 41-42-43 (figure 3a). This movement is preferably rectilinear and horizontal.

[0162] The intermediate plate 520, which at this point houses the thermoformed panels derived from a first plate 41-42-43, is brought back to the operating zone Z0. During this movement, the foaming member 540 delivers foam onto the thermoformed panels derived from a first plate 41-42-43.

[0163] When the intermediate plate 520 reaches the operating zone Z0, the foaming operation of the thermoformed panels derived from a first plate 41-42-43 is finished, and the foamed thermoformed panels 41'-42'- have thus been obtained 43'.

[0164] The intermediate plate 520 is then moved vertically, so as to close on the upper plate 530 (figure 3b). As mentioned, the cooperation between the intermediate plate 520 and the upper plate 530 forms a mold for the foamed thermoformed panels 41'-42'-43'. Once a predetermined time has elapsed, the intermediate plate 520 is moved away from the upper plate 530 and the finished product can be removed.

[0165] The lower plate 510 is moved from the operating zone Z0 to the loading zone Z1 (figure 3b). This movement is preferably rectilinear and horizontal. Preferably, this movement occurs while the intermediate plate 520 is returning from the loading zone Z1 to the operating zone Z0 and/or while the intermediate plate 520 is in contact with the upper plate 530.

[0166] In the loading zone Z1, the thermoformed panels derived from a second plate 71-72-73 are loaded onto the lower plate 510.

[0167] The lower plate 510 is then returned to the operating zone Z0 (figure 3c). During this movement, the foaming member 540 carries out the foaming operation on the thermoformed panels derived from a second plate 71-72-73. As mentioned, in this way the thermoformed foamed panels 71'-72'-73' were obtained.

[0168] Once the lower plate 510 has returned to the operating zone Z0, the foaming of the thermoformed panels 71-72-73 is finished.

[0169] The lower plate 510 can then be moved vertically upwards, until it closes on the intermediate plate 520 and forms, as mentioned, a mold for the foamed thermoformed panels 71'-72'-73' (figure 3d).

[0170] After a predetermined time has elapsed, the lower plate 510 is lowered and brought to the zone Z1 and the finished product can be unloaded.

[0171] Note that the foaming operation takes place in an open mold; in other words, the foam is deposited on the entire surface of the thermoformed panels assembly 4 and of the thermoformed panels assembly 7 via a mobile head fixed on a Cartesian manipulator.

[0172] The Applicant observes that this solution allows obtaining important advantages compared to state-of-the-art processes; the latter, in fact, typically involve an injection of the foam from a single point in a closed mould, a technique with which, however, the foam is unable to reach all areas of the product homogeneously, both due to geometries which may present irregularities, and because as the polyurethane leaves the injector head it begins to polymerise, increasing its viscosity and making its path towards the more distant areas more difficult. Otherwise, by injecting in an open mold, the foam is deposited homogeneously over the entire affected area and during polymerization the expansion direction is mainly in height.

[0173] Advantageously, the foaming operation can be entirely automated; the path, the quantity of foam to be deposited and the working parameters are pre-stored and recalled according to the specific operation to be performed.

[0174] Through the system 1 and the process carried out by it it is possible to obtain insulating panels.

[0175] Such panels can be conveniently used for vehicles suitable for food transport.

[0176] For example, a vehicle 600 suitable for transporting food is schematized in figure 5.

[0177] In a per se known manner, the vehicle 600 includes a frame 610, movement means 620 (engine, transmission, wheels, etc.) associated with the frame 610 and a compartment 630 mounted on the frame 610 itself.

[0178] The compartment 630 is configured to contain temperature-controlled foodstuffs. For this purpose, the vehicle 600 further includes a refrigeration system 640, associated with the compartment 630, to maintain the same at a controlled temperature.

[0179] The compartment 630 is delimited by one or more walls 631; such one or more walls can comprise or be formed by insulating panels made using the system 1 and the process carried out by the same.

[0180] The invention achieves important advantages.

[0181] First of all, the panels are made in a precise, accurate and repeatable way, thanks to the automation of most of the operations carried out.

[0182] Another advantage consists in the fact that, by virtue of the technical solutions object of the invention, it is possible to process multiple plates/panels substantially simultaneously, significantly increasing production efficiency.

[0183] Furthermore, open mold foaming allows a controlled and homogeneous distribution of the foam, thus obtaining panels with homogeneous properties along their entire extension.

[0184] A further advantage lies in the fact that the materials used are entirely recyclable, with evident positive effects from the point of view of production costs and environmental impact.

Claims (17)

1. Plant for the production of insulating panels for vehicles suitable for food transport, said plant (1) including: a thermoforming station (100), comprising: – an automated loading member (110), configured to take a sheet material (2) from a loading position (P1) and position said material (2) in an operating position (P2), in which said material (2) it is a plastic material comprising one or more of: Polystyrene (PS), High Impact Polystyrene (HIPS), Acrylonitrile-Butadiene-Styrene (ABS), Polymethylmethacrylate (PMMA), Polypropylene (PP), Polyvinylchloride (PVC) and similar; – a pair of heating walls (120), each controllable between a distal position (PD) and a proximal position (PP) with respect to said operating position (P2); – a motorized mold (130), configured to be brought to said operating position (P2) in order to thermoform said material (2) into a sheet; – a pressure system (140), configured to operate on said operating position (P2) so that said thermoforming takes place under controlled pressure conditions; wherein said thermoforming station (100) is configured to provide thermoformed sheets (3) as output, to obtain an assembly of thermoformed panels (4). a foaming station (500), comprising: – 3 double-compartment presses, each including: a lower plate (510), an intermediate plate (520) and an upper plate (530), each extending substantially along a horizontal plane, wherein the intermediate plate (520) is configured to house the thermoformed panels derived from a first plate 41 -42-43, and the lower plate (510) is configured to house thermoformed panels derived from a second plate 71-72-73; – a foaming member (540), configured to perform foaming on the thermoformed panels derived from a first sheet 41-42-43 housed in the intermediate plate (520) and on the thermoformed panels derived from a second plate 71-72-73 housed in the lower plate (510), obtaining respectively the foamed thermoformed panels 41'-42'-43' and the foamed thermoformed panels 71'-72'-73'; – movement members (550), active on the lower plate (510) and on the intermediate plate (520); – a control unit (560) configured to control said movement members (550) so that for each press: the intermediate plate (520) is brought into contact with the upper plate (530), forming a mold for the foamed thermoformed panels 41'-42'-43'; the lower plate (510) is brought into contact with the intermediate plate (520), forming a mold for the foamed thermoformed panels 71'-72'-73'. 2. System according to claim 1 in which said control unit (560) is configured to control said movement members (550) so that: the intermediate plate (520) is moved from an operating area (Z0) towards a loading area (Z1), in which it receives thermoformed panels derived from a first plate 41-42-43 and, after the thermoformed panels derived from a first plate 41-42-43 have been subjected to foaming, the intermediate plate (520) is moved against the upper plate (530), forming the mold for the foamed thermoformed panels 41'-42'-43' the lower plate (510) is moved, from an operating area (Z0), towards the loading area (Z1) to receive the thermoformed panels derived from a second plate 71-72-73 and, after the thermoformed panels derived from a second plate 71-72-73 have been subjected to foaming, the lower plate (510) is brought back to the operational area (Z0); After the lower plate (510) has been returned to the operating zone (Z0), it is moved against the intermediate plate (520) to form the mold for the foamed thermoformed panels 71'-72'-73'. 3. System according to claim 1 or 2 comprising a trimming station (200), comprising an automated cutting member (210) for separating the set of thermoformed panels (4) from each other and/or trimming edges of said set of panels thermoformed (4). 4. System according to claim 3 in which said trimming station (200) includes a chip suction apparatus (220). 5. System according to any one of the preceding claims comprising a tipping and cleaning station (300), which includes: a robotic member (310) to overturn said assembly of thermoformed panels (4); a cleaning member (320), to suck up waste material. 6. System according to claims 3 and 5 in which said tipping and cleaning station (300) is interposed between the trimming station (200) and the foaming station (500). 7. System according to any of the previous claims, further comprising one or more storage bays (400), interposed between the thermoforming station (100) and the foaming station (500), each storage bay (400) being equipped with automated handling members (410) to pick up said set of thermoformed panels (4) and supply them to the foaming station (500). 8. Process for the production of insulating panels for vehicles suitable for food transport, comprising: take, via an automated loading device (110), a sheet material (2) from a loading position (P1) and position said material (2) in an operating position (P2), in which said material (2) is a plastic material comprising one or more of: Polystyrene (PS), High Impact Polystyrene (HIPS), Acrylonitrile Butadiene Styrene (ABS), Polymethyl methacrylate (PMMA), Polypropylene (PP), Polyvinyl chloride (PVC) and similar; heating said sheet material (2); bring, to said operating position (P2), a motorized mold (130) and carry out thermoforming of said sheet material (2), said thermoforming being carried out under controlled pressure conditions, so as to obtain thermoformed sheets (3) for the production of assemblies of thermoformed panels (4), comprising at least one or more thermoformed panels, for example a first thermoformed panel (41) and a second thermoformed panel (42); for each of the 3 presses prepare a lower plate (510), an intermediate plate (520) and an upper plate (530), each extending substantially along a horizontal plane for each press; house the thermoformed panels derived from a first sheet 41-42-43 in the intermediate plate (520); perform a foaming of the thermoformed panels derived from a first sheet 41-42-43, obtaining 41'-42'-43' for the foamed thermoformed panels; bring the intermediate plate (520) into contact with the upper plate (530), forming a mold for the foamed thermoformed panels 41'-42'-43'; house the thermoformed panels derived from a second sheet 71-72-73 in the lower plate (510); perform a foaming of the thermoformed panels derived from a second sheet 71-72-73, obtaining the foamed thermoformed panels 71'-72'-73'; bring the lower plate (510) into contact with the intermediate plate (520), forming a mold for the foamed thermoformed panels 71'-72'-73'. 9. Process according to claim 8 in which for each press the loading of the thermoformed panels derived from a first plate 41-42-43 into the intermediate plate (520) and the loading of thermoformed panels derived from a second plate 71-72-73 into the plate lower (510) occur in a load zone (Z1); wherein the intermediate plate (520) contacts the upper plate (530) in an operational zone (Z0), and the lower plate (510) contacts the intermediate plate (520) in an operational zone (Z0), in which the foaming of the thermoformed panels derived from a first sheet 41-42-43 occurs during the movement of the intermediate plate (520) from the loading area (Z1) to the operating area (Z0), in which the foaming of the thermoformed panels derived from a second plate 71-72-73 occurs during the movement of the lower plate (510) from the loading area (Z1) to the operational area (Z0). 10. A method according to claim 8 or 9 comprising a cutting and/or trimming operation for cutting and/or trimming said assembly of thermoformed panels (4). 11. Process according to claim 10 comprising a chip suction operation at least partially during said cutting and/or trimming operation. 12. Method according to any of claims 8-11, further comprising: an overturning operation of the assembly of thermoformed panels (4); a cleaning operation carried out on said assembly of thermoformed panels (4) to suck up waste material. 13. Process according to claims 10 and 12 in which the overturning operation is temporally interposed between the cutting and/or trimming operation and the foaming operation. 14. Process according to any of claims 8-13, comprising: store, in storage bays (400), the set of thermoformed panels (4) before carrying out the foaming operation; activate automated handling devices (410) to pick up the set of thermoformed panels (4) and supply the same as input to a foaming station (500) to carry out the foaming operation. 15. Insulating panel for vehicles suitable for food transport, made with the process in accordance with any of claims 8-14. 16. Vehicle suitable for food transport, including: a frame (610); handling means (620) associated with said frame (620); a compartment (630), mounted on said frame, for housing food items, said compartment (630) being delimited by one or more walls (631); wherein said one or more walls (631) comprise one or more panels according to claim 15. 17. Vehicle according to claim 16 further comprising a refrigeration system (640), associated with said compartment (630) to maintain the same at a controlled temperature.