US20130316143A1 - Laminated foam product and methods for making laminated foam products - Google Patents

Laminated foam product and methods for making laminated foam products Download PDF

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Publication number
US20130316143A1
US20130316143A1 US13/899,975 US201313899975A US2013316143A1 US 20130316143 A1 US20130316143 A1 US 20130316143A1 US 201313899975 A US201313899975 A US 201313899975A US 2013316143 A1 US2013316143 A1 US 2013316143A1
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US
United States
Prior art keywords
foam
boards
board
inches
polystyrene
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.)
Abandoned
Application number
US13/899,975
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English (en)
Inventor
John F. Budinscak, JR.
Jeffrey J. Van Sloun
Nikoi Annan
Roland R. Loh
Rodger D. Lightle
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Owens Corning Intellectual Capital LLC
Original Assignee
Owens Corning Intellectual Capital LLC
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Owens Corning Intellectual Capital LLC filed Critical Owens Corning Intellectual Capital LLC
Priority to US13/899,975 priority Critical patent/US20130316143A1/en
Assigned to OWENS CORNING INTELLECTUAL CAPITAL, LLC reassignment OWENS CORNING INTELLECTUAL CAPITAL, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: QI, WEIGANG, ANNAN, NIKOI, LOH, ROLAND R., KUNKLER, William Anthony, LIGHTLE, RODGER D., BUDINSCAK, JOHN F., JR., HETTLER, NEIL ROBERT, VAN SLOUN, JEFFREY J.
Publication of US20130316143A1 publication Critical patent/US20130316143A1/en
Priority to US15/078,510 priority patent/US10500653B2/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1429—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface
    • B29C65/1432—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface direct heating of the surfaces to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C5/00—Milling-cutters
    • B23C5/02—Milling-cutters characterised by the shape of the cutter
    • B23C5/10—Shank-type cutters, i.e. with an integral shaft
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
    • B26D1/01—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work
    • B26D1/12—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a cutting member moving about an axis
    • B26D1/25—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a cutting member moving about an axis with a non-circular cutting member
    • B26D1/26—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a cutting member moving about an axis with a non-circular cutting member moving about an axis substantially perpendicular to the line of cut
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
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    • B21D22/14—Spinning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/28—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools
    • B23P15/34—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools milling cutters
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    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
    • B26D1/01—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work
    • B26D1/12—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a cutting member moving about an axis
    • B26D1/14—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a cutting member moving about an axis with a circular cutting member, e.g. disc cutter
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B26D3/006—Cutting work characterised by the nature of the cut made; Apparatus therefor specially adapted for cutting blocs of plastic material
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1429—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface
    • B29C65/1464—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface making use of several radiators
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/20—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror"
    • B29C65/2007—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror" characterised by the type of welding mirror
    • B29C65/203—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror" characterised by the type of welding mirror being several single mirrors, e.g. not mounted on the same tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B32B37/1054—Regulating the dimensions of the laminate, e.g. by adjusting the nip or platen gap
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/10—Removing layers, or parts of layers, mechanically or chemically
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/18—Handling of layers or the laminate
    • B32B38/1825—Handling of layers or the laminate characterised by the control or constructional features of devices for tensioning, stretching or registration
    • B32B38/1833—Positioning, e.g. registration or centering
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/62—Plastics recycling; Rubber recycling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24496—Foamed or cellular component
    • Y10T428/24504—Component comprises a polymer [e.g., rubber, etc.]

Definitions

  • the present invention relates to polymeric rigid foam boards. It finds particular application in conjunction with polymeric rigid foam boards having a broad thickness range produced using a thermo-laminating process and will be described with particular reference thereto. It will be appreciated, however, that the invention is also amenable to other applications.
  • Engineered extruded polystyrene (XPS) foams have been proven useful in building insulation, and many construction applications.
  • XPS pipe fabrication foam billets are relatively dust free and provide thermal and moisture resistance as well as large format foam to operators for low-temperature cold processes.
  • These engineered XPS applications usually need large format foam to be fabricated, however the extruded foam boards are limited in the thickness in conventional processes, such as less than 300 mm ( ⁇ 12′′), or more likely less than 120 mm ( ⁇ 5′′). It is difficult to extrude thicker products due to many engineering and operational obstacles (e.g., large die lip gaps that are needed in operation, which make it difficult to hold die pressure).
  • the present invention provides a new and improved apparatus and method for making relatively thicker XPS foam boards and foam products made from the thicker XPS foam boards.
  • a foam product is made by thermally bonding at least two extruded polystyrene boards together to make a thick laminated board.
  • the thick laminated board is machined to remove a portion of the extruded polystyrene and thereby form the foam product. The removed polystyrene is recycled.
  • a foam product includes at least two extruded polystyrene boards bonded together two make a thick laminated board. A portion of the extruded polystyrene board is removed to form a shape of the foam product.
  • the formed foam product consists of material of the polystyrene boards.
  • heat and pressure are applied to facing surfaces of a pair of opposed extruded polystyrene boards to flatten the facing surfaces by a factor of at least 2.
  • the pair of extruded polystyrene boards are thermally bonded together to make a thick laminated board.
  • the thick laminated board is machined to remove a portion of the extruded polystyrene and thereby form the foam product.
  • a laminated foam board includes first and second extruded polystyrene boards each having an outer skin that is formed during extrusion of the polystyrene boards.
  • the polystyrene boards are laminated together without removing the outer skin of faces that are bonded together.
  • a bond area between each of the polystyrene boards is substantially planar and has a bond thickness variation of less than 0.020 inches.
  • a foam product comprising at least two extruded polystyrene boards are bonded together to make a thick laminated board.
  • the thick laminated boards are cut into smaller foam pieces.
  • the smaller foam pieces are machined to remove a portion of the extruded polystyrene and thereby form the foam product.
  • a profile tolerance where the smaller foam piece is machined across a thermal bond line between extruded polystyrene boards is less than or equal to 0.015 inches from one side of the bond line to the other.
  • a rotary cutting tool for shaping foam products includes an annular support, cutting elements, and a base.
  • the annular support is formed from sheetmetal.
  • Cutting elements are secured to the sheetmetal annular support.
  • a base is secured to the sheetmetal annular support for rotating the sheetmetal annular support and attached cutting elements.
  • a system for laminating foam boards includes a waiting frame, a foam board laminator, and a receiving frame.
  • the foam board laminator includes a heating frame and an adhering frame.
  • the heating frame includes a heating element for heating a plurality of foam boards.
  • the adhering frame includes a mechanism for applying pressure to the heated foam boards for laminating the foam boards together.
  • the waiting frame positions the boards at an entrance of the heating frame, and the receiving frame receives the boards from an exit of the adhering frame.
  • FIG. 1 is an illustration of an exemplary embodiment of an extruded polystyrene board
  • FIG. 2 is a sectional view of the extruded polystyrene board taken along the plane indicated lines 2 - 2 in FIG. 1 ;
  • FIG. 2A illustrates that the thickness range may be determined by measuring the thickness of the board at various points along the surface of the board
  • FIG. 3 illustrates a first polystyrene board stacked on top of a second polystyrene board
  • FIG. 4 is a Figure taken from U.S. Pat. No. 4,608,103;
  • FIG. 4A is a Figure taken from U.S. Pat. No. 4,608,103;
  • FIG. 4B is a Figure taken from U.S. Pat. No. 4,608,103;
  • FIG. 5 is a schematic illustration of an individual foam board that has been separated from a laminated foam board according to the method illustrated by FIGS. 4 , 4 A, and 4 B;
  • FIG. 6 is a sectional view taken along the plane indicated by lines 6 - 6 in FIG. 5 ;
  • FIG. 7 is a schematic illustration of an exemplary embodiment of an apparatus for flattening a major surface of a foam board
  • FIG. 8 is a schematic illustration of an exemplary embodiment of a foam board having a flattened major surface
  • FIG. 9 illustrates an exemplary embodiment of a first foam board stacked on top of a second foam board with flattened major facing surfaces
  • FIG. 10 is a flowchart that illustrates an exemplary embodiment of a method of making a laminated foam board.
  • FIG. 11 is a schematic illustration of an exemplary embodiment of an apparatus for simultaneously flattening a opposing major surfaces of a pair of foam boards
  • FIG. 12 is a schematic illustration of an exemplary embodiment of an apparatus for pressing the foam boards illustrated by FIG. 11 together to form a laminated foam board;
  • FIG. 13 is a sectional view of an exemplary embodiment of a laminated foam board made by the apparatuses illustrated by FIGS. 11 and 12 ;
  • FIG. 14 is an enlarged portion of an exemplary embodiment of a bond line of the laminated foam board as indicated by reference FIG. 14 in FIG. 13 ;
  • FIG. 14A is a sectional view of an exemplary embodiment of a laminated foam board illustrating a method of measuring variations of a bond area
  • FIG. 15 is a schematic illustration of an exemplary embodiment of an apparatus for simultaneously flattening a opposing major surfaces of a foam board and a laminated foam board;
  • FIG. 16 is a schematic illustration of an exemplary embodiment of an apparatus for pressing the foam board and the laminated foam board illustrated by FIG. 16 together to form a three layer laminated foam board;
  • FIG. 17 is a sectional view of an exemplary embodiment of a laminated foam board made by the apparatuses illustrated by FIGS. 15 and 16 ;
  • FIG. 18 is a schematic illustration of an exemplary embodiment of an apparatus for flattening opposing surfaces of a pair of foam boards and pressing the foam boards together;
  • FIG. 19 is a schematic illustration of an exemplary embodiment of an apparatus for making laminated foam boards
  • FIG. 20 is a schematic illustration of another exemplary embodiment of an apparatus for making laminated foam boards
  • FIG. 21 is an exemplary methodology for laminating foam boards in accordance with one embodiment illustrating principles of the present invention.
  • FIG. 22 illustrates a top view of an exemplary embodiment of an alternate means for passing foam boards through a heating frame in accordance with one embodiment illustrating principles of the present invention
  • FIG. 23 is a schematic illustration of another exemplary embodiment of an apparatus for making laminated foam boards
  • FIG. 23A is a schematic illustration of foam boards passing by heating rods in accordance with one embodiment of an apparatus illustrating principles of the present invention
  • FIG. 23B is a schematic representation of foam boards passing by heating rods in accordance with another embodiment of an apparatus illustrating principles of the present invention.
  • FIG. 24 illustrates an exemplary embodiment of a billet made from a laminated board made in accordance with an exemplary embodiment of the present invention
  • FIG. 25A illustrates an exemplary embodiment of a tool for making foam products out of foam
  • FIG. 25B illustrates an exemplary embodiment of a tool for making foam products out of foam
  • FIG. 26 is a schematic illustration of tools positioned relative to a laminated foam piece
  • FIG. 27 is a schematic illustration of a laminated foam piece after a first cutting operation with a tool
  • FIG. 28 is a schematic illustration of a laminated foam piece after a second cutting operation with a tool
  • FIG. 29 is a schematic illustration of a foam product that is formed after a third cutting operation with a tool
  • FIG. 30 is a perspective view of an exemplary embodiment of a foam product formed from a laminated foam piece
  • FIG. 31 schematically illustrates forming a foam product and recycling foam material that is removed during forming of the foam product to make a new foam board
  • FIG. 32 is a plan view of an exemplary embodiment of a piece of flat sheetmetal
  • FIG. 33 is a side view of the flat piece of sheetmetal illustrated by FIG. 32 ;
  • FIG. 34 is a sectional view of an exemplary embodiment of a sheetmetal annular support of a foam cutting tool
  • FIG. 35 is a sectional view that illustrates the sheetmetal annular support assembled with an exemplary embodiment of a base
  • FIG. 36 is a top view of an exemplary embodiment of a plurality of cutting elements adhered to a bonding material strip
  • FIG. 37 is a side view of the plurality of cutting elements adhered to the bonding material strip illustrated by FIG. 36 ;
  • FIG. 38 is a sectional view of an exemplary embodiment of a rotary cutting tool for shaping foam products.
  • FIG. 1 illustrates an exemplary embodiment of a foam board 110 , such as an extruded polystyrene board.
  • the foam board may be made from a wide variety of different materials.
  • the foam boards 110 can be made from a wide variety of different thermoplastic materials.
  • the foam board 110 is a polystyrene foam board, such as an extruded polystyrene foam board or an expanded polystyrene foam board.
  • the illustrated foam board 110 is rectangular with first and second major face surfaces 112 , 114 , spaced apart by a thickness t.
  • the foam board 110 has side edges 116 , 118 , 120 , 122 that extend between the first and second major surfaces 112 , 114 .
  • Both of the major surfaces 112 , 114 may comprise a skin 124 that is formed during the extrusion process.
  • the extrusion skin 124 is a stratum of polystyrene material that is denser than the interior foamed portion 126 of the board. That is, the thin extrusion skin is substantially solid whereas the foamed portion 126 comprises expanded foam cells.
  • suitable foam boards 110 include the FOAMULAR® Extruded Polystyrene Insulation products that are available from Owens Corning.
  • the foam boards 110 are engineered extruded polystyrene (XPS) foams having a molecular weight of between about 100,000 to about 350,000. In one embodiment, the foam boards 110 have a molecular weight of between about 120,000 and about 150,000 from recycled expanded polystyrene. However, other foams are also contemplated in other embodiments. It is also contemplated that the foam boards 110 are sized to between about 600 mm to about 1524 mm wide x about 1200 mm to about 2769 mm long. The boards are also contemplated to be any sheet stock made of any thermoplastic polymer material.
  • XPS engineered extruded polystyrene
  • FIG. 2 is a sectional view of the foam board 110 .
  • the section lines 2 - 2 in FIG. 1 are normal to the direction in which the board 110 is extruded. That is, in this exemplary embodiment, the section 2 - 2 is across the width of the extruded foam board.
  • FIG. 2 illustrates that there are typically surface variations 200 in the first and second major surfaces 112 , 114 across the width of extruded polystyrene foam boards 110 . The surface variations are exaggerated in FIG. 2 to make it clear that surface variations 200 are present.
  • flatness is the condition of a surface having all elements in one plane.
  • a flatness variation specifies a variation zone defined by two parallel planes within which the surface lies.
  • the flatness variation F 1 is the distance between two parallel planes 202 , 204 that the surface 114 lies between.
  • the flatness variation of the major surface 112 and/or the major surface 114 of a piece of a board 110 that is 2 feet wide by 2 feet long is greater than 0.020 inches, such as greater than 0.050 inches, such as between 0.050 and 0.10 inches, such as between 0.050 inches and 0.08 inches.
  • the original board can be any size.
  • the flatness variation of the major surface 112 and/or the major surface 114 of a piece of a two inch thick board 110 that is 2 feet wide by 2 feet long is greater than 0.020 inches, such as greater than 0.050 inches, such as between 0.050 and 0.10 inches, such as between 0.050 inches and 0.08 inches.
  • the board may have any width, thickness or length.
  • the flatness variation F 1 is estimated by measuring a thickness variation or range.
  • the thickness range may be determined by measuring the thickness of the board 110 at various points along the surface of the board, indicated by arrows 250 in FIG. 2 .
  • the thickness variation is the difference between the maximum and minimum measured thickness.
  • the thickness range of a piece of a board that is 2 feet wide by 2 feet long is greater than 0.078, such as between 0.078 and 0.15 inches, such as about 0.125 inches.
  • the thickness range of a piece of a 2 inch thick board 110 that is 2 feet wide by 2 feet long is greater than 0.078, such as between 0.078 and 0.15 inches, such as about 0.125 inches.
  • the board may have any width, thickness or length.
  • the initial flatness variation F 1 of a board 110 is estimated by dividing the thickness variation by two. This is based on the assumption that the flatnesses of the major surfaces are initially similar.
  • FIG. 3 illustrates a first polystyrene board 110 stacked on top of a second polystyrene board 110 .
  • the abutment between the major surface 114 of the top board with the major surface 112 of the bottom board is not flush due to flatness variations of the major surfaces.
  • voids 302 would be expected to form between the two boards in the bond area 304 .
  • the two boards 110 would not be bonded together in the area of the voids 302 .
  • These voids/unbounded areas 302 would make heat laminated boards made using existing techniques unsuitable for some applications. For example, smaller foam pieces 2400 (See FIG. 24 ) used to make machined foam parts need to be void free, or the machined part will have unacceptable surface imperfections.
  • FIGS. 4 , 4 A, and 4 B are taken from U.S. Pat. No. 4,608,103, which discloses an example of an existing technique for heat laminating two foam boards together.
  • the foam board 110 is fed into the apparatus on a platform defined by a series of rollers 426 which support the board 110 in a horizontal plane.
  • the forward end of the bottom or lower board is positioned under an elongated flat stainless steel heating strip or blade 430 which extends horizontally across the width of the foam board 110 and has opposite end portions attached to a pair of horizontal support plates 432 .
  • the plates 432 also support a spreader member or bar 436 which is spaced with the heating blade 30 above the support rollers 426 by a distance slightly greater than the thickness of the foam board 110 .
  • each of the plates 432 is supported by a pair of machine screws 439 which are threaded into corresponding nuts secured to an angle member 442 .
  • Another pair of nuts are threaded onto the screws 439 for vertical adjustment and support the corresponding plate 432 so that it may move or float vertically by a predetermined distance according to the position of the nuts below the heads of the screws 439 .
  • the vertical spacing of the blade 430 and the bar 436 above the rollers 426 may be adjustably selected according to the thickness of the lower foam board 416 , by means of the machine screws 439 .
  • the spreader bar 436 forms a support for the upper foam board when the board is inserted into the apparatus and positioned directly above the lower foam board in vertical alignment.
  • the spreader bar 436 is positioned slightly above the level of the heating blade 430 so that the forward end of the upper foam board does not contact the heating blade 430 when the foam board is first positioned within the apparatus directly above the lower foam board.
  • a pair of vertically spaced pressure members or rolls 450 are positioned above and below the heating blade 430 , and are driven in opposite directions.
  • the drive system or mechanism for the rolls 450 provides for adjusting the upper rolls 450 in a vertical plane in order to vary the spacing or gap defined between the rolls 450 .
  • the speed of the motor 452 is selected according to the desired processing rate, and a controller 456 is connected by conductors to a temperature sensing element or thermocouple recessed within the leading edge of the heating blade 430 .
  • the rolls 450 are adjusted to define a gap 454 which is slightly less than the combined thicknesses of the foam boards.
  • the heating blade 430 is energized to a predetermined temperature, for example, 500° F.
  • the foam boards are then advanced forwardly until the leading ends of the boards enter the gap 454 which causes the opposing side surfaces of the foam boards to contact the upper and lower sides of the heating blade 430 .
  • the temperature of the blade 430 is selected to soften the skin or surface portions of the foam boards after which the softened surfaces are pressed together by the rolls 450 .
  • the opposing side surfaces of the boards are uniformly heated by the blade 430 along the full length of the boards and are then fused together to form the interface or bond area 304 . Since the thickness of each foam board varies somewhat along its length, for example, by plus or minus 1/16 inch, the heating element or blade 430 is permitted to shift or float vertically as a result of the movement of the support plates 432 on the screws 439 .
  • Prior art U.S. Pat. No. 4,608,103 alleges that a uniform pressure contact is made against the heating blade 430 by each of the foam boards.
  • Prior art U.S. Pat. No. 4,608,103 also alleges that this provides for a uniform and dependable weld at the interface 304 by assuring uniform heating and softening of the opposing side surfaces of the foam boards.
  • Applicant believe that the arrangement disclosed by prior art U.S. Pat. No. 4,608,103 cannot provide a uniform pressure contact along the entire width of two foam boards that each have substantial flatness variations, since the heating blade 430 can only follow the contour of one of the foam boards, not both.
  • the single heating blade 430 arrangement disclosed by Prior art U.S. Pat. No. 4,608,103 cannot provide for a void-free weld between foam boards that have substantial flatness variations, such as the boards illustrated by FIG. 3 and described above.
  • melted foam material 600 (See FIGS. 4 , 4 B and 6 ) has a tendency to accumulate on the heating stationary heating element. Once an excessive amount of material 600 accumulates on the stationary heating element, the material 600 drips off of the heating element and drips onto the lower of the two boards 110 that are being laminated together. This hot material 600 melts trenches 602 that resemble “worm hole” into the foam material of the lower of the two boards 110 . The hot material 600 cools and forms an area 610 of material that is much harder and much denser than the other foam material at the same depth.
  • the trenches 602 and areas 610 of harder and denser material make heat laminated boards made using existing techniques unsuitable for some applications.
  • smaller foam pieces 2400 See FIG. 24
  • the location of higher density material of laminated foam pieces must be known and accounted for, or cutting operations will result in unacceptable surface imperfections.
  • the location and depth of the trenches 602 and areas 610 of harder/denser material is random and therefore unpredictable.
  • the areas 610 of harder/denser material cannot be accounted for in a cutting operation, When a saw blade or other cutting tool unexpectedly hits one of the areas 610 of harder/denser material, a surface imperfection occurs and/or the part is otherwise damaged.
  • FIG. 7 is illustrates an exemplary embodiment of an apparatus 700 for flattening a major surface 112 or 114 of a foam board 110 .
  • the apparatus 700 flattens only one major surface 114 of the foam board 110 .
  • the apparatus 700 flattens both major surfaces 112 , 114 of the foam board 110 .
  • the apparatus 700 applies heat (indicated by arrows 702 ) and pressure (indicated by arrows 704 ) to the foam board 110 to flatten the major surface 114 .
  • the pressure may be applied to the foam board 110 in a wide variety of different ways.
  • the pressure is applied to the foam board 110 by a clamping device 710 .
  • the illustrated clamping device includes an upper clamp member 712 and a lower clamping member 714 .
  • the upper clamp member 712 applies pressure to the major surface 112 and the lower clamp member 714 applies pressure to the major surface 114 .
  • the upper and lower clamp members can take a wide variety of different forms.
  • the upper and lower clamp members 712 , 714 may comprise rollers and/or belts, which may be driven by a motor.
  • the clamp members 712 , 714 may comprise plates that are sized to engage the entirety of the major surfaces 112 , 114 .
  • the heat may be applied to the major surface 114 in a wide variety of different ways.
  • the heat may be applied to the major surface 114 before the application of pressure, during the application of pressure, and/or after the application of pressure.
  • the heat is applied to the major surface 114 by one or more heating elements that are contained in the lower clamp member 714 .
  • the heating elements can take a wide variety of different forms.
  • the heating element can utilize electricity, a heated fluid, such as oil, water, or other liquids that are provided to the heating element and/or a fuel to provide the heat to the major surface 114 . If both sides of the board 110 are to be flattened, the same heating type of heating element can be provided on both sides of the board 110 by the apparatus 700 .
  • FIG. 8 illustrates the foam board 110 shown in FIG. 2 that has been flattened in accordance with the teachings of the present application to provide a flattened major surface 814 .
  • the flattened major surface 814 has a much smaller flatness variation than the unprocessed major surface 114 .
  • the major surface 814 may be flatter that the major surface 114 by a factor of two, a factor of 4, a factor of 10, or even more comparatively flatter than an unprocessed extruded polystyrene board.
  • the flatness variation of the major surface 112 and/or the major surface 114 of a piece of a board 110 that is 2 feet wide by 2 feet long is less than 0.040 inches, such as less than 0.030 inches, such as less than 0.020 inches, such as less than 0.010 inches, such as less than 0.050 inches.
  • the flatness variation of the major surface 112 and/or the major surface 114 of a piece of a board 110 that was originally 2 inches thick, that is 2 feet wide by 2 feet long is less than 0.040 inches, such as less than 0.030 inches, such as less than 0.020 inches, such as less than 0.010 inches, such as less than 0.005 inches.
  • the board may have any width, thickness or length.
  • the flattened board has a much smaller thickness variation than the unprocessed board.
  • the thickness variation in FIG. 8 can be measured in the same manner as in FIG. 2A .
  • the thickness range of a piece of a board (flattened on one side) that is 2 feet wide by 2 feet long is less than 0.078, such as less than 0.062 inches, such as less than 0.031 inches.
  • the thickness range of a piece of a 2 inch thick board that is 2 feet wide by 2 feet long is less than 0.078, such as less than 0.062 inches, such as less than 0.031 inches.
  • the board may have any width, thickness or length.
  • the processed flatness variation F 2 of a flattened major surface of a board that has been flattened on one side is calculated by the following equation:
  • F 2 is the processed flatness variation
  • T 2 is the processed thickness variation
  • T 1 is the original thickness variation.
  • the flatness variation F 2 is 0.004 inches (0.126/2 ⁇ 0.059). This calculation of the flatness variation assumes that the initial surface imperfections are of the same size on the top and bottom major surfaces and therefore contribute equally to the initial thickness variations of the board. That is, the initial flatness variation F 1 is the same on the top major surface as the bottom major surface.
  • FIG. 8 the heating and application of pressure produces a layer 800 of molten material (temporarily, until the material cools and solidifies).
  • This layer 800 of molten material on the flattened major surface 814 allows the boards to be heat laminated together without using an external adhesive and such that the adhesion of the boards is uniform across over the entirety of the facing major surfaces.
  • FIG. 9 illustrates a first polystyrene board 110 having a flattened major surface 814 stacked on top of a second polystyrene board 110 having a flattened major surface 814 . As is illustrated by FIG.
  • the abutment between the flattened major surface 814 of the top board with the flattened major surface 814 of the bottom board is substantially flush due to the abutting major surfaces 814 being substantially flat.
  • the voids 302 See FIG. 3
  • the elimination of the voids/unbounded areas 302 makes heat laminated foam boards suitable for some applications, such as foam pieces 2400 (See FIG. 24 ) used to make machined foam parts.
  • FIG. 10 is a flowchart that illustrates an exemplary embodiment of a method 1000 of making a heat laminated foam board 1300 (See FIG. 13 ).
  • FIGS. 11 , 12 and 18 illustrate examples of apparatus that can be used to perform the method and make a heat laminated foam board 1300 .
  • first and second boards 110 a, 110 b are positioned (steps 1002 , 1004 ) relative to one another such that the major surface surfaces of the boards are substantially aligned.
  • a first foam board 110 a is positioned above a second foam board 110 b.
  • a major surface 112 or 114 of each board is independently flattened 1006 . That is, the flattening of the major surface 114 of the first board 110 a is separate and independent from the flattening of the major surface 112 of the second board 110 b.
  • an independent flattening arrangement 1100 comprises two of the apparatuses 700 illustrated by FIG. 7 .
  • An upper flattening apparatus 700 a flattens the bottom major surface 114 of the first board 110 a.
  • the lower flattening apparatus 700 b is the same as the upper flattening apparatus 700 b, except it is flipped over (i.e. the heated member 714 is on the top and the non-heated member is on the bottom.
  • the lower flattening apparatus 700 b flattens a major surface 112 or 114 of the second board 110 b.
  • each of the upper and lower flattening apparatuses 700 a, 700 b comprise a heated clamping member 714 , in the form of a roller, and a clamping roller 712 that is not heated.
  • the apparatus 1100 includes optional downstream heating elements 770 .
  • the rollers 714 , 712 clamp against the boards 110 a, 110 b to flatten the major surface 114 of the board 110 a and the major surface 114 of the board 110 b.
  • the flattening of each of the two board is achieved using heat and pressure.
  • the optional downstream heating elements 770 are positioned between the flattened surfaces 814 .
  • the heating elements 770 apply heat to control the temperature of the layer 800 of molten material.
  • the heating elements 770 can take a wide variety of different faints.
  • the optional heating elements 770 can take any form that allows the temperature of the layer 800 of molten material to be controlled and kept in a melted state until the boards 110 a, 110 b reach the pressing apparatus 1210 .
  • the heating elements 770 are elongated rods that are spaced apart from the flattened surfaces 814 , downstream from the rollers 714 .
  • the heating elements can have other shapes, such as plates.
  • the heating elements 770 span the width of the boards 110 , 110 b.
  • the heating elements 770 are individually controllable.
  • the flattened surfaces 814 of the boards produced according to the method 1000 are flattened by a factor of two, a factor of four, a factor of 10, or even more comparatively flatter than an unprocessed extruded polystyrene board.
  • the flatness variation of the major surface 814 of a piece of a board 110 that is 2 feet wide by 2 feet long is less than 0.040 inches, such as less than 0.030 inches, such as less than 0.020 inches, such as less than 0.010 inches, such as less than 0.050 inches.
  • the thickness variation range of a piece of a board (flattened on one side) that is 2 feet wide by 2 feet long is less than 0.078, such as less than 0.062 inches, such as less than 0.031 inches.
  • the outer skin 124 is not removed during the independent flattening step 1006 .
  • a layer of molten material 800 is formed on the flattened surfaces 814 .
  • the heated rollers 714 becomes coated with the molten board material 800 .
  • the heated roller 714 attains a steady state. That is, the rate at which molten board material 800 is deposited on the roller 714 equals the amount of molten material that leaves the heated roller 1114 and is deposited on the flattened surface 814 .
  • the trenches 602 and areas 610 shown in FIGS. 5 and 6 do not form.
  • the boards 110 a, 110 b are pressed together 1010 to form the thicker laminated board 1300 .
  • the flattened surfaces 814 are pressed together.
  • the molten material 800 fills any remaining flatness variations in the board surfaces 812 .
  • the material solidifies to uniformly bond the two boards 110 a, 110 b together across the flattened surfaces 814 .
  • FIG. 13 illustrates the formed laminated board 1300 .
  • the boards 110 a, 110 b may be pressed together in a wide variety of different ways.
  • the pressure is applied to the boards 110 a, 110 b by a clamping device 1210 .
  • the illustrated clamping device includes an upper clamp member 1212 and a lower clamping member 1214 .
  • the upper clamp member 1212 applies pressure to the board 110 a and the lower clamp member 1214 applies pressure to the board 110 b.
  • the upper and lower clamp members can take a wide variety of different forms.
  • the upper and lower clamp members 1212 , 1214 may comprise rollers, flat plates, belts or a combination thereof.
  • the clamp members 1212 , 1214 may comprise plates that are sized to press the entirety of the boards 110 a, 110 b together.
  • the clamping device 1210 comprises rollers. The clamp members 1212 , 1214 clamp against the boards 110 a, 110 b together to form the thicker laminated foam board 1300 .
  • FIG. 13 illustrates the formed laminated board 1300 and FIG. 14 illustrates and enlarged portion of FIG. 13 that illustrates a bond area 304 between the polystyrene boards.
  • the variations in thickness of the bond area are highly exaggerated to illustrate the variation.
  • the combination of the independent flattening of the surfaces 814 and the uniform distribution of the molten material 800 by the rollers 714 across the surfaces 814 results in a very small bond thickness variation. That is, the thickness of the denser material 1302 that forms the bond between the two boards varies by only a small amount.
  • the bond thickness variation is shown in FIG. 14 as the difference between the minimum thickness T MIN and the maximum thickness T MAX of the bond material.
  • the bond area between each of the polystyrene boards is substantially planar and the bond thickness variation is less than 0.020 inches, or less than 0.015 inches.
  • the average bond thickness is between 0.015 and 0.045 inches, such as between 0.020 and 0.040 inches, such as between 0.025 and 0.035, such as about 0.030 inches, with a corresponding bond thickness variation of less than 0.020 inches, or less than 0.015 inches.
  • FIG. 14A illustrates another method for measuring variations in the bond area.
  • the laminated board 1300 is cut to expose the plane illustrated by FIG. 14A .
  • Points 1410 and 1412 on the bottom of the bond area 304 at the edges 122 , 120 of the board are identified.
  • Points 1420 and 1422 are marked a fixed distance below the points 1410 and 1412 .
  • a reference line 1424 is drawn between the points 1420 and 1422 .
  • the sample may be cut along the line 1422 .
  • Distances indicated by pairs of arrows 1430 are measured.
  • the variation i.e. the difference between the maximum distance and the minimum distance
  • the distances 1430 is less than 0.100 inches, less than 0.075 inches, less than 0.050 inches, or less than 0.020 inches.
  • FIGS. 15-17 illustrate that a multi-layer the laminated board 1700 (See FIG. 17 ) may be formed from three or more boards 110 .
  • the flattening arrangement 1100 and the clamping device 1210 may be adjustable to accommodate laminating of multiple boards together and to accommodate laminating of boards having different thicknesses.
  • FIGS. 15 and 16 illustrate that use of the flattening arrangement 1100 and the clamping device 1210 to add boards 110 to add layers and form a multiple layer heat laminated foam board 1700 .
  • a single board 110 is added.
  • laminated boards 1300 and/or 1700 can be laminated together to add more than one layer at a time.
  • FIG. 15 illustrates that a foam board 110 is positioned relative to a laminated foam board 1300 such that the major surface surfaces of the boards are substantially aligned.
  • a foam board 110 is positioned below a laminated foam board 1300 .
  • the laminated board 1300 can be positioned on the bottom.
  • the upper flattening apparatus 700 a is adjustable to accept the laminated foam board 1300 .
  • the lower flattening apparatus 700 b is adjustable to accept a laminated foam board or different sized boards.
  • the upper flattening apparatus 700 a is adjusted by vertically adjusting the position of the upper clamp member 712 , while the lower clamp member 714 remains in a fixed position. As such, the vertical position of the surface 1314 being laminated is not changed by the adjustment.
  • the lower flattening apparatus 700 b is adjustable, it is adjusted by vertically adjusting the position of the lower clamp member 714 , while the upper clamp member 714 remains in a fixed position. As such, the vertical position of the surface 1314 being laminated is not changed by the adjustment.
  • a major surface 1314 of the laminated board 1300 and a major surface 112 or 114 of the board 110 is independently flattened. That is, the flattening of the major surface 1314 is separate and independent from the flattening of the major surface 112 of the board 110 being added.
  • the flattening of each of the two board is achieved using heat and pressure.
  • the flattened surfaces 814 , 1314 of the board 110 and the laminated board 1300 are flattened by a factor at least two, a factor of four, a factor of 10, or even more comparatively flatter than an unprocessed extruded polystyrene board or the unprocessed outer surfaces of the laminated board 1300 .
  • the flatness variation of the major surface 814 and the major surface 1314 a piece of a board that is 2 feet wide by 2 feet long is less than 0.040 inches, such as less than 0.030 inches, such as less than 0.020 inches, such as less than 0.010 inches, such as less than 0.050 inches.
  • the thickness variation range of a piece of aboard 110 and 1300 (each flattened on one side) that is 2 feet wide by 2 feet long is less than 0.078, such as less than 0.062 inches, such as less than 0.031 inches.
  • outer skins 124 (See FIGS. 1 and 2 ) of the board 110 and the boards of the laminated board 1300 are not removed during the independent flattening.
  • a layer of molten material 800 is formed on the flattened surfaces 812 , 1314 .
  • the heated rollers 714 becomes coated with the molten board material 800 .
  • the heated roller 714 attains a steady state. That is, the rate at which molten board material 800 is deposited on the roller 714 equals the amount of molten material that leaves the heated roller 714 and is deposited on the flattened surface 814 , 1314 .
  • the trenches 602 and areas 610 shown in FIGS. 5 and 6 do not form between any of the layers of the multiple layer laminated board 1700 .
  • the laminated board 1300 and the board 110 are pressed together 1010 to form the thicker, multi-layer, laminated board.
  • the flattened surfaces 814 , 1314 are pressed together.
  • the molten material 800 fills any remaining flatness variations in the board surfaces 814 , 1314 .
  • the molten material 880 cools, the material solidifies to uniformly bond the laminated board 1300 to the board 110 together across the flattened surfaces 814 , 1314 .
  • FIG. 17 illustrates the formed multi-layer laminated board 1700 .
  • the laminated board 1300 may be pressed together with the board 110 in a wide variety of different ways.
  • the clamping device 1210 illustrated by FIG. 12 may be adjusted to accept the increased thickness of the laminated board.
  • the upper clamping member 1212 is vertically adjusted to accept the laminated board 1300 and the lower clamping member 1214 is not adjusted. This configuration corresponds to the embodiment where the upper flattening apparatus 700 a is adjusted to accommodate the thicker laminated board 1300 and the lower flattening apparatus is not adjusted and flattens single thickness boards.
  • the lower clamping member 1214 is vertically adjusted and the upper clamping member is fixed. This embodiment corresponds to the laminated board being flattened with the lower flattening apparatus.
  • both the upper clamping member 1214 and the lower clamping member 1214 are adjustable.
  • This embodiment corresponds to an embodiment where both the upper and lower flattening apparatuses 700 a, 700 b are vertically adjustable to accommodate different thickness boards and/or laminated boards.
  • pressure is applied to the laminated board 1300 and the board 110 by the clamping device 1210 .
  • the upper clamp member 1212 applies pressure to the laminated board 300 and the lower clamp member 1214 applies pressure to the board 110 .
  • FIG. 17 illustrates the formed multi-layer laminated board 1700 .
  • the combination of the independent flattening of the surfaces 1314 , 814 and the uniform distribution of the molten material 800 by the rollers 714 across the surfaces 1314 , 814 results in a very small bond thickness variation. That is, the thickness of the denser material 1314 that forms the bond between the two boards varies by only a small amount.
  • the bond thickness variation between all of the bonds of a multi-layer laminated board is also very small. That is each of the bonds may be substantially the same thickness and the bond thickness varies only a small amount.
  • the bond areas 304 between each of the polystyrene boards is substantially planar and a bond thickness variation between two bonds that laminate three boards together is less than 0.020 inches, or less than 0.015 inches.
  • the average bond thickness is between 0.015 and 0.045 inches, such as between 0.020 and 0.040 inches, such as between 0.025 and 0.035, such as about 0.030 inches, with a corresponding bond thickness variation of less than 0.020 inches, or less than 0.015 inches.
  • the bond areas 304 between each of the polystyrene boards have variations as measured in the manner described with respect to FIG. 14A are each less than 0.100 inches, less than 0.075 inches, less than 0.050 inches, or less than 0.020 inches.
  • FIGS. 19 , 20 and 23 illustrate simplified component diagrams of exemplary systems 1910 , 2010 , and 23 , respectively, for laminating a plurality of foam boards is illustrated in accordance with the method described above.
  • the system 1910 is described with reference to laminating two (2) boards 110 a, 110 b (e.g., foam boards) together to form a laminated foam board 1300 or 1700 .
  • each of the two foam boards 110 a, 110 b is between about 1 ⁇ 2′′ to about 8′′ thick so that the laminated foam board 1300 is between about 7 ⁇ 8′′ to about 16′′ thick.
  • each of the two (2) foam boards 110 a, 110 b may be comprised of multiple layers of foam that have been thermally laminated together, so that the laminated foam board 1300 is between about 13 ⁇ 4′′ and 32′′ thick.
  • each of the two foam boards 110 a, 110 b is between about 1 15/16′′ and about 1 31/32′′ thick and the resulting laminated foam board is between about 33 ⁇ 4′′ and about 3 15/16′′ thick.
  • the thickness of the laminated board 1300 is less than the total thickness of the original foam boards 110 a, 110 b due to a bond area or thermo weld portion 304 created at the interface between faces of the original foam boards 110 a, 110 b.
  • the bond area or thermal weld portion 304 is relatively denser foam, which is illustrated as a relatively heavier line as opposed to cells in the remainder of the laminated board 1300 or 1700 and the original foam boards 110 a, 110 b.
  • the relatively denser foam results in a reduced thickness of the laminated foam board 1300 or 1700 .
  • the bond area or thermal weld portion 304 is contemplated to be between about 1/64′′ and about 1 ⁇ 8′′ thick.
  • the system 1910 illustrated by FIG. 1910 includes a waiting frame 1924 (e.g., a waiting station), a heating and flattening station 1926 , a pressing station 1930 , and a receiving station 1932 .
  • the heating frame and flattening station 1926 and the pressing station 1930 are referred to as a foam board laminator.
  • Each of the waiting frame 1924 , the heating and flattening station 1926 , the pressing station 1930 , and the receiving frame 1932 includes a respective transport system for moving the foam boards 110 a, 110 b through the frame.
  • the waiting frame 1924 , the heating and flattening station 1926 , the pressing station 1930 , and the receiving frame 1932 are positioned sequentially so that the foam boards 110 a, 110 a are passed from the waiting frame 1924 to the heating and flattening frame 1926 , passed from the heating and flattening frame 1926 to the pressing frame 1930 , and then passed from the pressing frame 1930 to the receiving frame 1932 .
  • the waiting frame 1924 is used for preparing and aligning the foam boards 110 a, 110 b to be laminated together.
  • the first foam board 110 a is positioned on the waiting frame 1924 .
  • the second foam board 110 b is positioned above, and spaced from, the first foam board 110 a so that a face 114 of the first foam board 110 a is adjacent and opposes (e.g., faces) a face 114 of the second foam board 110 b.
  • Respective leading edges 116 of the first and second foam boards 110 a, 110 b are aligned, in a step 2140 , in the waiting frame 1924 . Aligning the leading edges 116 helps ensure an even and smooth leading edge 1950 (See FIG. 18 ) of the laminated foam board 1300 or 1700 .
  • the first foam board 110 a is set on an upper rail 1952 of the waiting frame 1924 .
  • the upper rail 1952 is movable between a closed position and an open position.
  • the upper rail 1952 is in the closed position when the first foam board 110 a is set on the upper rail 1952 .
  • An optional sensor e.g., a photoelectric cell sensor
  • a control circuit not shown
  • the sensor senses the absence of the first foam board 110 a on the upper rail 1952 , and transmits a signal to the control circuit (not shown) to switch the upper rail 1952 back to the closed position.
  • the control circuit not shown
  • the second foam board 110 b is set on the upper rail 1952 .
  • the upper and lower rails 1952 , 1956 act as a spacer to create and maintain an initial space between the faces 114 of the first and second foam boards 110 a, 110 b (See FIG. 23 ).
  • the initial space between the first faces 114 of the first and second foam boards 110 a, 110 is determined by a height setting of the lower rail 1956 , which is adjustable to suit various board thicknesses.
  • the lower rail 1956 may be lowered to accommodate thicker boards and raised to accommodate thinner boards.
  • a pusher plate 1960 (e.g., a pusher) is activated.
  • the pusher plate 1960 aligns the foam boards 110 a, 110 b by pushing trailing edges 118 of the foam boards 110 a, 110 b so that the leading edges 116 of the foam boards 110 a, 110 b contact an optional stop.
  • the pusher plate 1960 pushes the foam boards 110 a, 110 b toward an entrance 1970 of the heating and flattening frame 1926 .
  • an exemplary space of 250 mm is between the waiting frame 1924 and the heating frame 1926 .
  • An exemplary space of 150 mm is between the heating and flattening frame 1926 and the receiving frame 1932 .
  • specific spaces of 250 mm and 150 mm are illustrated between the waiting frame 1924 and the heating frame 1926 and between the heating frame 1926 and the receiving frame 1932 , respectively, it is to be understood that the spaces between the waiting frame 1924 and the heating frame 1926 and between the heating frame 1926 and the receiving frame 1932 are adjustable. For example, the space between the heating frame 1926 and the receiving frame 1932 may be increased for thicker foam boards.
  • the foam boards 110 a, 110 b are received at the entrance 1970 of the heating and flattening frame 1926 .
  • the foam boards 110 a, 110 b engage a means for passing 1972 the foam boards 110 a, 110 b from the entrance 1970 of the heating and flattening frame 1926 to an exit 1974 of the heating and flattening frame 1926 .
  • the means for passing 1972 comprises the rollers of the flattening apparatuses 700 a, 700 b illustrated by FIG. 18 .
  • each of the upper and lower flattening apparatuses 700 a, 700 b comprise a heated roller 714 and a roller 712 that is not heated.
  • the means for passing 1972 may includes additional drive rollers 1992 . All of the rollers 714 , 712 , 1992 may be driven by horizontal shafts. The rollers 714 , 712 clamp against the boards 110 a, 110 b to flatten the bottom major surface 112 or 114 of the board 110 a and the top major surface 112 or 114 of the board 110 b.
  • the flattening of each of the two boards is achieved using heat and pressure applied by the rollers 714 , 712 .
  • the heating and flattening frame 1926 also includes the optional downstream heating elements 770 .
  • a layer of molten material 800 is formed on the flattened surfaces 812 , 814 .
  • the heated roller 814 becomes coated with the molten board material 800 .
  • the heated roller 814 attains a steady state. That is, the rate at which molten board material 800 is deposited on the roller 714 equals the amount of molten material that leaves the heated roller 714 and is deposited on the flattened surface 812 , 814 .
  • the trenches 602 and areas 610 shown in FIGS. 5 and 6 do not form.
  • the optional downstream heating elements 770 keep the layer of molten board material in a melted state as the boards are fed into the pressing frame 1930 .
  • FIG. 20 illustrates another exemplary embodiment of a system 2010 for laminating a plurality of foam boards.
  • the system 2010 illustrated by FIG. 20 is substantially similar to the system 1910 illustrated by FIG. 19 , except the heating and flattening frame 1926 is replaced with another embodiment of a heating frame 2026 .
  • a means for passing 2072 the foam boards 110 a. 110 b through the heating frame 2026 includes at least one pair of chains 2076 , 2080 driven by respective vertical shafts 2082 , which in turn are driven by a motor (not shown) turning respective sprockets on the vertical shafts 2082 .
  • the at least one chain 2076 , 2080 is driven by the sprockets on rollers mounted on the vertical shafts 2082 .
  • other methods for driving the at least one chain 2076 , 2080 are also contemplated.
  • a top view of the pair of the chains 2080 illustrates that the chains 2080 include spikes 2090 that engage (e.g., impale) the foam board 110 b as the foam board 110 b passes through the heating frame 1926 (see FIG. 20 ).
  • the engagement of the spikes 2090 with the foam board 110 b moves the foam board 110 b through the heating frame 2026 (see FIG. 20 ) as the pair of chains 2080 is driven by the vertical shafts 2082 .
  • the engagement of the spikes 2090 with the foam board 110 b also facilitates keeping the foam board 110 b positioned relatively flat, level, and relatively parallel with respect to the other foam board 110 a (see FIG. 20 ).
  • the engagement of the spikes 1990 with the foam board 110 b facilitates keeping the foam board 110 b suspended above the heating element 2106 so the foam board 110 b does not touch the heating element 2106 .
  • Spikes (not shown) on the chains 2076 act to engage (e.g., impale) the foam board 110 a, in a manner similar to the way the spikes 2090 engage the foam board 110 b, to move the foam board 110 a through the heating frame 1926 (see FIG. 20 ) as the pair of chains 2076 is driven by the vertical shafts 2082 .
  • the engagement of the spikes (not shown) with the foam board 110 a also facilitates keeping the foam board 110 a positioned relatively flat, level, and relatively parallel with respect to the other foam board 110 b (see FIG. 20 ) and suspended below the heating element 2106 so the foam board 110 a does not touch the heating element 2106 .
  • FIG. 23 illustrates another exemplary embodiment of a system 2310 for laminating a plurality of foam boards.
  • the system 2310 illustrated by FIG. 23 is substantially similar to the system 2010 illustrated by FIG. 20 , except the heating frame 2026 is replaced with another embodiment of a heating frame 2326 .
  • a means for passing 2372 the foam boards 110 a, 110 b through the heating frame 2326 includes a mechanism having rollers 2392 driven by respective vertical shafts 2394 , which in turn are driven by a motor (not shown) turning respective sprockets on the vertical shafts 2394 .
  • the rollers 2392 frictionally engage the foam boards 110 a, 110 b.
  • First and second roller conveyors 2300 , 2302 facilitate maintaining the first and second foam boards 110 a, 110 b respectively, positioned relatively flat, level, and relatively parallel with respect to each other.
  • Angle gear boxes 2304 permit angular adjustment of the first roller conveyor 2300 to ensure the first roller conveyor 2300 is substantially parallel to the first foam board 110 a.
  • Angle gear boxes, although not illustrated, are also contemplated for similarly permitting angular adjustment of the second roller conveyor 2302 to ensure the second roller conveyor 2302 is substantially parallel to the second foam board 110 b.
  • Other embodiments, in which the mechanism is a tapered plate or a Teflon coated conveyor belt system are also contemplated.
  • the first and second foam boards are heated and flattened as described with respect to FIGS. 7 , 11 , and 18 above.
  • the first and second foam boards 110 a, 110 b are positioned so that the face 114 of the first board 110 a and the face 114 of the second board 110 b pass by a heating element 2106 (e.g., a heating plate) as the first and second foam boards 110 a, 110 b pass through the heating frame 2026 or 2326 . It is contemplated that the heating element 2106 is about the same width as the first and second foam boards 110 a, 110 b.
  • the heating element 2106 is between about 5 mm and about 50 mm thick and, in one embodiment, is between about 20 mm and about 30 mm thick.
  • the initial space between the first faces 114 of the first foam board 110 a (while on the lower rail 1956 ) and second foam board 110 b (while on the upper rail 1952 ) is greater than the thickness of the heating element 2106 (See FIG. 23 ).
  • the heating element 2106 (or the heated rollers 714 in the FIG. 19 embodiment) is heated to a predetermined temperature (e.g., a softening point of the polymer foam).
  • a predetermined temperature e.g., a softening point of the polymer foam.
  • the predetermined temperature is about 240° F., but may be adjusted based on board properties, the distance(s) between the heating element 2106 and the faces 114 of the first and second boards 110 a, 110 b, the speed at which the first and second boards 110 a, 110 b pass by the heating element 2106 , etc.
  • the faces 114 of the first and second boards 110 a, 110 b are heated.
  • the faces 114 of the first and second boards 110 a, 110 b are simultaneously passed by the heating element 2106 (or against the heated rollers 714 in the FIG. 19 embodiment).
  • the face 114 of the first board 110 a passes by a first face 2110 (e.g., bottom face) of the heating element 2106 and the face 114 of the second board 110 b passes by the a second face 2112 of the heating element 2106 .
  • the predetermined temperature of the heating element 2106 , the distances between the heating element 2106 and the faces 114 of the first and second boards 110 a, 110 b and the length of time the faces 114 of the first and second boards 110 a, 110 b are exposed to the heat of the heating element 2106 are set to appropriately heat the first and second boards 110 a, 110 b for lamination to each other. It is understood that the length of time the faces 114 of the first and second boards 110 a, 110 b are exposed to the heat of the heating element 2106 (or the heated rollers 714 in the FIG. 19 embodiment) is determined by the speed at which the means for passing 1972 the foam boards 110 a, 110 b through the heating frame 1926 travels.
  • the initial space between the first and second foam boards 110 a, 110 b is determined by a height setting of the lower rail 1956 , which is adjustable to suit various board thicknesses.
  • the lower rail 1956 may be lowered to accommodate thicker boards and raised to accommodate thinner boards.
  • the heating element 2106 and the upper rail 1952 are also adjustable to different positions (elevations). Therefore, during operation, an operator may adjust the position(s) of the lower rail 2156 and/or the heating element 2106 to accommodate the board thickness while maintaining a gap between the heating element 2106 and the first face 2136 of the first board 110 a.
  • the operator may also adjust the position(s) of the upper rail 1952 and/or the heating element 2106 to accommodate the board thickness while maintaining a gap between the heating element 2106 and the face 114 of the second board 110 b (e.g., an initial gap of between about 1 ⁇ 32′′ and 2′′).
  • a gap between the heating element 2106 and the face 114 of the first board 110 a is adjusted to be about the same size as a gap between the heating element 2106 and the face 114 of the second board 110 b (e.g., an initial gap of between about 1/32′′ and 2′′).
  • the gap between the heating element 2106 and the face 114 of the first board 110 a is adjusted to be a different size gap than between the heating element 2106 and the face 114 of the second board 110 b, are also contemplated. It is also contemplated that not all of the upper rail 1952 , the lower rail 1956 , and the heating element 2106 are adjustable to different positions For example, if only the lower rail 2156 is adjustable, the gap between the heating element 2106 and the face 114 of the second board 110 b is not adjustable by moving the upper rail 1952 and/or the heating element 2106 and, instead, is set by the thickness of the second board 110 b.
  • the foam boards 110 a, 110 b exit the heating frame 1926 , 2026 , or 2326 and are received at an entrance 2114 of the pressing frame 1930 (See step 2220 of the method illustrated by FIG. 21 ).
  • Rollers 1212 , 1214 in the pressing frame 1930 frictionally engage and move the first and second foam boards 110 a, 110 b from the entrance 2114 of the pressing frame 1930 , through the pressing frame 1930 , and to an exit 2121 of the pressing frame 1930 .
  • a height of the pressing frame entrance 2114 is greater than a height of the pressing frame exit 2121 .
  • the opening of the pressing frame 1930 tapers from the pressing frame entrance 2114 to the pressing frame exit 2120 .
  • the height of the pressing frame entrance 2114 is about 6′′
  • the height of the pressing frame exit 2121 is about 4′′.
  • the rollers 1212 , 1214 apply progressively higher pressure to the first and second foam boards 110 a, 110 b as the foam boards 110 a, 110 b move toward the exit 2121 . Therefore, the faces 114 are pushed into contact. Since the faces 114 of the first and second foam boards 110 a, 110 b are still warm and include the melted material 800 , the faces 114 meld together. In other words, the faces 114 form a densified melt and are welded together to form the bond area or thermal weld 304 . Therefore, the first and second foam boards 110 a, 110 b are laminated together to form the laminated board 1300 or 1700 .
  • the heights of the adhering frame entrance 2114 and the adhering frame exit 2120 may be adjustable.
  • FIG. 23A illustrates a variation of the heating frames illustrated by FIGS. 20 and 23 .
  • the face 114 of the first board 110 a and the face 114 of the second board 110 b pass over a first heated rod 2301 which extends the width of the foam boards 110 a, 110 b.
  • the position of the last roll in the second roller conveyor 2302 forces the face 114 of the first board 110 a to come in contact with the first heated rod 2301 .
  • the position of the last roll in the first roller conveyor 2300 forces the face 114 of the second board 110 b to also come in contact with the heated rod 2301 .
  • the temperature of the heated rod 2301 combined with the line speed induce additional molten polystyrene to form on the faces 114 of the foam boards 110 a, 110 b.
  • a second heating rod 2302 which in one embodiment is of a smaller diameter than the first heating rod 2301 .
  • the relatively smaller diameter of the second heating rod 2302 compared with the first heating rod 2301 allows the foam boards 110 a, 110 b to bend adequately to enter the pressing frame 1930 .
  • the temperature of the second heating rod 2302 along with the line speed induces the molten polystyrene on the face 114 of the first board 110 a and the face 114 of the second board 110 b to remain molten in preparation for bonding in the pressing frame 1930 .
  • FIG. 23B illustrates a variation of the heating and flattening frames illustrated by FIGS. 19 , 20 , and 23 .
  • two pairs of heating and compressing rollers 712 , 714 are included.
  • the heating and compressing rollers 712 , 714 may be as described with respect to FIG. 18 .
  • the first and second heated rollers or rods 714 are substantially the same diameter, but are offset in the horizontal and vertical planes. Both of the heating rods 714 are free to rotate or are driven to rotate while melting the foam surface.
  • This provides a mechanism to prevent the build up of too much molten polystyrene on the rods 714 and prevents the molten polystyrene from dripping off the rods and forming the trenches or “worm holes” described above.
  • the rotating heating rods 714 apply a uniform coating of molten polystyrene across the entire foam surface.
  • the height of the adhering frame entrance 2114 is the same as the height of the adhering frame exit 2120 , and the rollers 1212 , 1214 are substantially at the same distance from each other (e.g., parallel).
  • the rollers 1212 , 1214 apply pressure and compress the foam boards 110 a, 110 b together (as discussed above) as the foam boards 110 a, 110 b pass through the pressing frame 1926 .
  • the heights of the adhering frame entrance 2114 and the adhering frame exit 2120 may be adjustable.
  • rollers 1212 , 1214 in the adhering frame 1930 are set up in a tapered or parallel arrangement may be determined as a function of the thickness of the foam boards 110 a, 110 b and a thickness of the heater 2106 .
  • the laminated board 1300 or 1700 is passed from the exit 2120 of the adhering frame 1930 to the receiving frame 1932 . Since being aligned at the waiting frame 1924 , the leading edges 116 of the foam boards 110 a, 110 b remain aligned after the foam boards 110 a, 110 b are laminated into the laminated board 1300 or 1700 .
  • Both polystyrene foam boards to be laminated were in the thickness around 35 MM (1.4′′) each with a density around 27.8 Kg/m 3 (1.73 pcf), and tensile strength around 448 Kpa (65 psi).
  • the laminating bond strength which is evaluated by tensile strength tests demonstrate that the adhesive strength between the laminating layer at least as strong as the original foam strength.
  • the speeds at which the foam boards 110 a, 110 b move through the waiting frame 1924 , the heating and flattening frame 1926 , and the adhering frame 1930 are consistent.
  • the first speed is about the same as (e.g., consistent with) the second speed.
  • each of the foam boards 110 a, 110 b discussed above has been described as respective single boards between about 1 ⁇ 2′′ to about 8′′ thick, it is to be understood that one or both of the foam boards is also contemplated to be previously laminated. If both of the foam boards were previously laminated one time, the thickness of the respective previously laminated foam boards may be between about 7 ⁇ 8′′ to about 16′′ thick. The resulting laminated board will then be between about 15 ⁇ 8′′ to about 32′′ thick. Therefore, it is to be understood that the systems 1910 , 2010 , 2310 and methodology for laminating foam boards described above may be used repeatedly for previously laminated foam boards, with the resulting laminated boards becoming thicker and thicker with each pass through the system 1910 , 2010 , 2310 .
  • systems 1910 , 2010 , 2310 have been described with reference to laminating two (2) foam boards 110 a, 110 b together, it is to be understood that simple modifications to the systems 1910 , 2010 , 2310 , such as the adjustability described with reference to FIGS. 15 , 16 , and 18 , would accommodate laminating any number of foam boards together. For example, additional heating elements would be incorporated into the heating and flattening frame 1926 so additional foam boards may be simultaneously laminated.
  • the systems 1910 , 2010 , 2310 may accommodate different thicknesses for the respective boards and that the systems 1910 , 2010 , 2310 may be designed to accommodate foam boards of various densities and thicknesses.
  • the foam boards may include different surface preparations.
  • at least one of the foam boards includes a relatively smooth surface, which is derived from a process of manufacturing the foam board.
  • at least one of the foam boards includes a planned surface, which is created using an auxiliary cutting process during which the entire surface of the foam board is machined flat.
  • the faces 114 of the first and second foam boards 110 a, 110 b are planed, which exposes cells in the foam board.
  • the planing technique makes a much flatter surface facilitating a more uniform surface adhesion, which is useful in the embodiments disclosed by FIGS. 20 and 23 .
  • both of the faces of the foam boards are planned. Foam boards having both faces planned are contemplated for embodiments including three (3) or more foam boards adhered together to form a relatively thicker final foam board.
  • off-line operation involves an operator manually placing the first and second foam boards 110 a, 110 b on the waiting frame 1924 , as discussed above (from, for example, a transporting facility).
  • On-line operation involves, for example, a machine cutting a continuous strip of foam sheet into the desired lengths to form the foam boards, which are then deposited on the waiting frame 1924 , as discussed above (from, for example, an extruding line).
  • thermo-processes and/or apparatuses described above no additional chemicals (e.g., glue) are required for the lamination. Without any additional chemicals such as glue, the boards thermo-laminated by the process described above may be more easily recycled. More specifically, recycled boards from the process described above would not include any contaminants (e.g., glue) and, therefore, result in a “cleaner” recycled product.
  • additional chemicals e.g., glue
  • boards laminated using additional chemicals are more difficult to cut using a hot wire, since a hot wire does not melt through hardened glue as easily as the foam boards. Consequently, foam boards laminated using chemicals such as glue may need to be cut using a cutter such as a router.
  • FIG. 24 illustrates an exemplary embodiment of a smaller foam piece 2400 .
  • the smaller foam piece 2400 is made by cutting a laminated foam board 1300 or 1700 .
  • the laminated foam board 1300 or 1700 may be cut in a wide variety of different ways to make the smaller foam piece 2400 .
  • a laminated foam board 1300 or 1700 may be cut with a hot wire or a saw blade, such as a band saw blade, a reciprocating saw blade, an abrasive wire or a circular saw blade to foul a plurality of smaller foam pieces.
  • the smaller foam pieces 2400 are made in an appropriate size for making a foam part.
  • a cut surface 2402 of the smaller foam piece 2400 is very smooth across the bond lines 2404 .
  • the thermal bonding processes and apparatus described above make this very smooth cut surface 2402 across the bond lines 2404 possible.
  • the laminated foam boards 1300 , 1700 are free of the cavities or voids 302 (See FIG. 3 ), channels 602 (See FIG. 6 ), and unexpected areas of harder/denser material 600 (See FIG. 6 ).
  • the presence of only a consistently located uniform bond line, without these defects, allows the very smooth cut surface 2402 to be formed.
  • the very smooth cut surface 2402 allows high quality foam parts, without surface imperfections to be made from the billets 2400 .
  • the flatness variation F 3 of the smaller foam piece 2400 across a bond line is less than or equal to 0.005 inches, such as less than 0.004 inches, such as less than 0.003 inches.
  • the laminated foam board 1300 , 1700 or the smaller foam piece 2400 can be cut into foam parts 2900 (See FIG. 29 ) in a wide variety of different ways.
  • the smaller foam piece 2400 is cut into a foam part 2900 with a rotary cutting tool 2500 (See FIGS. 25A and 25B ).
  • the rotary cutting tool 2500 can take a wide variety of different forms.
  • the rotary cutting tool 2500 is a router-type tool with a head 2510 shaped to cut an appropriate shape into the smaller foam piece 2400 and a shaft 2512 for rotating the head.
  • FIGS. 25A and 25B illustrate two examples of rotary cutting tools 2500 for machining the billets 2400 into foam parts 2900 .
  • the cutting head 2510 a illustrated by FIG. 25A cuts an external curved surface 2710 (See FIG. 27 ).
  • the cutting head 2510 b cuts an internal curved surface 2910 (See FIG. 29 ).
  • FIGS. 26-29 illustrate the cutting heads 2510 a, 2510 b machining the billet 2400 to form a part 2900 .
  • the foam part 2900 is one-half of a cylindrical pipe insulation cover (the second half being a copy of the first).
  • the smaller foam piece 2400 and cutting tools 2500 can be configured and used to make a wide variety of different types of foam parts, such as elbows, T-shaped pipe covers, etc. Referring to FIGS.
  • the cutting head 2510 a removes foam material along an edge 2610 to provide the part with a first curved outer surface 2612 , such as a radiused surface. In the example, the cutting head 2510 removes foam material and a portion of the material of the bond line 2404 . Referring to FIGS. 26 and 28 , the cutting head 2510 a removes foam material along an edge 2614 to provide the part with a second curved outer surface 2710 , such as a radiused surface. In the example, the cutting head 2510 removes foam material and a portion of the material of the bond line 2404 . Referring to FIGS.
  • the cutting head 2510 b removes foam material along a bottom surface 2618 to provide the part with a curved inner surface 2622 , such as a cylindrical inner surface.
  • the cutting head 2510 b removes foam material and a portion of the material of the bond lines 2404 .
  • FIG. 30 illustrates the finished foam part 2900 .
  • a machined surface 2710 , 2910 of the foam part 2900 is very smooth and uniform across the bond lines 2404 .
  • the thermal bonding processes and apparatus described above make this very smooth and uniform machined surface 2710 , 2910 across the bond lines 2404 possible.
  • the laminated foam boards 1300 , 1700 are free of the cavities or voids 302 (See FIG. 3 ), channels 602 (See FIG. 6 ), and unexpected areas of harder/denser material 600 (See FIG. 6 ). The presence of only a consistently located uniform bond line, without these defects, allows the very smooth and uniform machined surface 2710 , 2910 to be formed.
  • the profile tolerance PT of the foam part 2700 across a bond line 2404 is less than or equal to 0.015 inches, such as less than 0.010 inches, such as less than 0.005 inches.
  • the profile tolerance PT is the difference between the intended or designed shape and the actual shape of the part in the area of the bond line, such as the bond line and 1 ⁇ 4 inch on each side of the bond line.
  • the intended shape of the outer surface of the part 2900 illustrated by FIG. 30 may be a four inch diameter cylinder.
  • the profile tolerance PT in the area of the bond line may be 0.010 inches.
  • the part 2900 would be outside of the profile tolerance.
  • FIG. 31 illustrates an exemplary embodiment of a method of making a foam product 2900 and recycling the polystyrene foam to make new polystyrene boards 3100 .
  • a smaller foam piece 2400 is provided that is machined from one of the laminated polystyrene boards 1300 , 1700 described herein. Since the laminated polystyrene boards 1300 , 1700 are made only from the polystyrene material of the boards, the smaller foam pieces also only include polystyrene.
  • the billet 2400 is machined to remove a portion 3102 of the extruded polystyrene to form the foam product 2900 . For example, the billet 2400 may be machined as illustrated by the embodiment of FIGS.
  • the removed polystyrene material 3102 is recycled to make another polystyrene product.
  • the polystyrene material 3102 may be recycled to make a new polystyrene board or be mixed with virgin polystyrene material that is used to make a new polystyrene board 3100 .
  • FIG. 38 illustrates an exemplary embodiment of a rotary cutting tool 2500 for shaping foam products, such as the foam product 2900 illustrated by FIG. 30 .
  • the rotary foam cutting tool 2500 can be used to cut a wide variety of different foams including, but not limited to, single layer foam boards or pieces and multilayer foam boards and pieces.
  • the rotary cutting tool can cut multilayer foam boards or pieces that are thermally laminated together and/or that are bonded together with an adhesive.
  • the illustrated rotary cutting tool 2500 includes an annular support 3802 made from sheetmetal, such as aluminum or steel, and cutting elements 3804 secured to the annular sheetmetal support 3802 .
  • a base 3820 is secured to the sheetmetal annular support 3802 for rotating the sheetmetal annular support 3802 and attached cutting elements 3804 .
  • the annular sheetmetal support 3802 can be made in a wide variety of different ways.
  • the sheetmetal support can be made by spin-forming, stamping, drawing, deep drawing, or any other conventional sheetmetal forming technique.
  • FIGS. 32 and 33 illustrate that the annular support 3802 can be formed from a flat, circular sheetmetal disk 3200 .
  • the sheetmetal disk 3200 can be formed into the annular support 3802 shape illustrated by FIG. 34 by spin-forming, stamping, drawing, deep drawing, or any other conventional sheetmetal forming technique.
  • the cutting elements 3804 can be secured to the annular sheetmetal support 3802 in a wide variety of different ways.
  • the cutting elements 3804 can be secured to the annular sheetmetal support 3802 by brazing, welding, with an adhesive or any other conventional adhesion technique.
  • the cutting elements can take a wide variety of different forms.
  • the cutting elements 3804 are made from a material that wears very slowly when cutting polystyrene foam, such as carbide, hardened steel, ceramics and other hard materials.
  • the cutting elements 3804 are spaced apart a sufficient distance that prevents the build up and retention of the polystyrene foam.
  • the cutting elements 3804 are initially provided on a tape 3600 , such as a brazing tape or an adhesive tape.
  • the tape 3600 is provided over the cutting surface 3602 of the sheetmetal support 3802 and then processed to permanently secure the cutting elements 3804 to the sheetmetal support 3802 .
  • the tape 3600 may be heated to braze the cutting elements 3804 to the sheetmetal support 3802 or cure an adhesive of the tape to secure the cutting elements to the sheetmetal support.
  • the base 3820 can take a wide variety of different forms.
  • the base 3820 includes a circular plate 3830 .
  • the base can comprise any structure for supporting and rotating the sheetmetal support 3802 .
  • the resulting cutting tool 2500 is hollow and lightweight. This hollow and lightweight configuration allows foam machining tools to be made in sizes that were not previously possible.
  • the following table, with columns corresponding to the dimensions on FIG. 38 provides examples of cutting tools 3800 with the hollow and light weight configuration. Each row provides a different example. All dimensions in the following table are in inches. As can be seen from the chart and FIG. 34 , tools 3800 having diameters A over 5 inches, over 10 inches, over 15 inches and over 20 inches can be made with the hollow sheetmetal design.
  • the present application discloses several different embodiments of thermally laminated foam boards, methods for making thermally laminated foam boards, apparatus for making thermally laminated foam boards, smaller foam pieces made from thermally laminated foam boards, methods for making smaller foam pieces from thermally laminated foam boards, parts made from thermally laminated foam boards, methods for making parts from thermally laminated foam boards, and tools for making parts from thermally laminated foam boards.
  • Any of the features of any of the embodiments disclosed in this application can be combined with any of the features of any of the other embodiments disclosed by this application. Additional exemplary embodiments of the present application comprise combinations and subcombinations of the features of the exemplary embodiments described above.

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  • Thermal Sciences (AREA)
  • Electromagnetism (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Forests & Forestry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • High Energy & Nuclear Physics (AREA)
  • Plasma & Fusion (AREA)
  • Laminated Bodies (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
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  • Extrusion Moulding Of Plastics Or The Like (AREA)
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WO2013177271A2 (en) 2013-11-28
MX2014014206A (es) 2015-06-04
CN104487239A (zh) 2015-04-01
CN105643698A (zh) 2016-06-08
US10500653B2 (en) 2019-12-10
CA2874498A1 (en) 2013-11-28
US20160303663A1 (en) 2016-10-20
WO2013177271A3 (en) 2014-01-30

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