FR2499460A1 - Chassis based moulds for casting insulation panels of phenolic foam - for simplicity of casting on site in various sizes - Google Patents

Abstract

Modular panels of insulating matl. are pref. cast on site using moulds formed from rigid panels mounted on a suitable rigid chassis and pivotted to release the mouldings. Esp. claimed, but not exclusively, for making panels from phenolic foam cast into vertical mould cavities. The foam is contained within a rigid frame made from wood or metal. The position of the mould panel hinge supports and mechanical clamps are pref. adjustable to suit different product thicknesses. Typically the core foam is extended to 20-40 kg/m3, to provide a coefficient of thermal conductivity of 0.029-0.033 W/m.deg,C and a class M1 fire rating. The main chassis may be long enough to mould several panels simultaneously. Simpler than use of conventional hydraulic platen compression press moulding techniques.

Description

 The subject of the invention is a process for manufacturing thermal and / or phonic insulating panels intended for the building industry, and more precisely a principle of composition of a self-supporting or self-supporting modular panel with filling in situ with a cellular insulating material which is preferably a foam of the formo-phenolic type # L wnvention also includes the implementation process.

 There are very many types of panels using cellular components made from expanded resins in situ, or sheets of cellular plastics glued between facings, as insulation material. The bonding technique has the disadvantage of requiring both an installation for pre-cutting the plates to the required dimensions, with loss of raw material, and a bonding installation most generally comprising significant press equipment and / or an installation hardening glues of an expensive investment.

 The in-situ expansion technique using casting or injection between facing of reactive mixtures, such as for example polyurethane foams or formo-phenolic foams uses formulations such that the foam obtained directly contributes to the mechanical strength Signs.

Such formulations develop upon expansion a thrust of several hundred grams / cm, which requires extremely resistant molds and / or powerful presses.

 The two aforementioned techniques entail high production and raw material costs which are often incompatible with the economic requirements of the building industry.

 A third technique is also sometimes used, which consists simply of inserting the insulation, whether cellular or fibrous, between the facings of the panel. This technique has a serious drawback: the insulator does not form one body with the structure of the panel, which results in very unpleasant resonance effects for the user of buildings constructed with this type of panel. In addition, if it is a fibrous type of insulation, the packing thereof over time is facilitated, leading to a reduction in the insulation characteristics.

 The invention eliminates the drawbacks inherent in the above techniques.

 According to the invention, the process for manufacturing "water panels" with in-situ injection of a foaming mixture is characterized by the fact that the function of the insulator is dissociated from the mechanical characteristics of the panel, while retaining perfect cohesion between insulation and the structure of the panel.

The method is characterized in that the composition of the foaming formula is such that it allows perfect filling of one or more cavities of the panel in order to generate expansion thrust, the density of the foam being between 20 and 40 Kg / m3. Consequently, a foam of the for-io-phenolic type of known formulation is preferably used, and tested inter alia by the applicant since 1972. Such a formulation meets all the criteria for implementing the process described in the present invention. also meets the best standards of insulation and security, with a & of 0.02 to 0.033 (coefficient of thermal conductivity expressed in Watt per meter and a C) and a classification M 1 (according to prescription ministerial decree da 4-6- 1973) with no emission of toxic gases or opacifying fumes e
According to the process, the composition of the panel essentially comprises a frame, preferably made of wood, on which are fixed, by nailing, stapling, gluing, or any other existing process, parents which, apart from being extremely varied according to the envisaged uses. formed on one of the sides of the frame allows the introduction of the foam injection cannula. The injection of the foam is carried out using machines with two or three components which ensure the dosing and mixing of components and the use of which is well known.

 Prior to injection, it is possible to install inserts in the panel such as tubes for wiring passage, aerators, ducts, and in general any parts that may be necessary for the construction system. These inserts are then perfectly coated with the insulator during its expansion and the risks of thermal bridge thus eliminated.

 According to a variant of the principle, the composition of the panel is produced in such a way that the memebrures forming the frame are arranged to allow the panels to fit together and / or the structure of the construction.

 An example is given in the appendix by FIG. 1. The frames forming the frame (1) are fixed on the facings (2) with an offset in the vertical and horizontal direction allowing the interlocking on the four edges of the panel. The moldings can be simple or include different forms of complementary embedding such as for example shown in (3). The foaming mixture is injected at (4) and expands at (5) by coating an optional insert (6), for example an electric tube.

 According to the process, an extremely simple modular conforming system is used for manufacturing, the schematic diagram of which is given in the appendix. The conformator is designed to keep the panel in a vertical position during injection. These walls also make it possible to ensure the parallelism of the facings when they are thin and / or deformable by their nature. This can be the case for example in the production of panels comprising a flexible or semi-rigid facing such as plastic film, celloderm, bituminized and / or aluminized kraft and in general all the coatings which can be used to ensure sealing and / or additional insulation.

 According to the invention, the length of the shaper has no limit. We simply split the moving parts for convenience during maneuvers. The implementation process makes it possible, according to the principle previously described, box panels of very long lengths or alternatively elements of smaller size.

Figure 2 in annex is a sectional view of the modular double shaper, the left part being shown closed shaper, with a panel in place, and the right open part ready to receive a panel to be injected. As it is shown, the shaper comprises crosspieces (7) fixed at regular intervals on three beams forming the chassis (8) for fixing to the ground. In the middle of the horizontal crosspieces are fixed vertical uprights (9). At the two ends of each crosspiece a series of holes (10) is provided for the passage of the axis of rotation of the movable ribs (11)
The movable ribs are connected to each other by an axis (12) serving as a bar: maneuver for opening and closing.

The top of the vertical uprights (9) is connected by an axis (43) on which pivot locking bars (14) connected together by an axis (15) which wine hook in (16) on the upper part provided for this effect on vertical members. The position of the axis (15) can be moved in the holes (17) depending on the position of the axis of rotation (18) of the movable ribs. The walls of the shaper (19) (20) and (21) are preferably made of light material and generally with any material in the form of rigid plates which can be screwed onto the structure of the shaper.

 As shown in FIG. 2, a double adjustment is possible for the production of panels of ten thick annuities: either by displacement of the axes of rotation of the ribs therefore of the movable wall, or by displacement by wedging of the fixed wall.

 In a first variant of the method, the thickness is adjusted by an electro-mechanical, pneumatic or hydraulic process of any kind ensuring progressive translation of the movable wall.

 In the process, the introduction and evacuation of the panel is done either by the ends of the shaper or by the sides thereof, completely tilting the movable walls.

 According to a second variant of the method, the opening and closing of the shaper are controlled by jacks or any other automated system or not.

 According to a third variant, the lower wall (21) of the shaper is constituted by a raceway extending beyond the ends of the device in order to facilitate handling operations.

 According to a fourth variant of the method, the former is transformed into a mold for the manufacture of foam blocks, by adding joints ensuring the tightness of the walls.

 As can be seen, the process applies to the semi-continuous industrial manufacture of insulation panels of the "panel-box" type defined in the principle of the invention and also to all types of manufacture of cellular insulation panels very long or modular.

Claims (8)

 REVpNDICATICNS  1- Thermal and / or sound insulation panel forming a box in which the insulator, preferably of formo-phenolic origin, is injected and expanded with a low pressure on the walls allowing the use of a simple modular conformator of large dimensions.  2- box-panel according to claim 1 characterized in that the members (1) are assembled with the facings (2) so as to allow the panels to be pushed together.  3 ~ Conformer according to claim 1 characterized by a composition of elements assembling.int continuously on a single frame (8)  4- Shaper according to claim 2 characterized in that the opening and closing are done manually by tilting the movable walls (11-20) on a variable position axis (18), the locking being effected by bars # hooking (14-15).  5- Conformator according to claim 4 characterized in that the adjustment and the opening-fitting are controlled by an electro-mechanical or actuator system, automated or not.  6- Conformer according to claim 3 characterized in that the lower wall (21) is a raceway.  7- Conformer according to claims 3,4,5 and 6 characterized in that it can be transformed into a waterproof mold for the production of block foam.  8- Insulation panel according to claim 1 characterized in that the injected insulation can Qtre of all kinds other than formo-phenolic.