WO2005011950A2 - Insulating panel, process and apparatus for manufacturing thereof, with expansible resin spraying - Google Patents
Insulating panel, process and apparatus for manufacturing thereof, with expansible resin spraying Download PDFInfo
- Publication number
- WO2005011950A2 WO2005011950A2 PCT/IT2003/000577 IT0300577W WO2005011950A2 WO 2005011950 A2 WO2005011950 A2 WO 2005011950A2 IT 0300577 W IT0300577 W IT 0300577W WO 2005011950 A2 WO2005011950 A2 WO 2005011950A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- resin
- sprayed
- spraying
- panels
- expansible
- Prior art date
Links
Classifications
-
- 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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
- B29C44/32—Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements
- B29C44/326—Joining the preformed parts, e.g. to make flat or profiled sandwich laminates
-
- 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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
- B29C44/22—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length consisting of at least two parts of chemically or physically different materials, e.g. having different densities
-
- 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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/36—Feeding the material to be shaped
- B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
- B29C44/388—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length into moving moulds
-
- 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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/36—Feeding the material to be shaped
- B29C44/46—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length
- B29C44/461—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length dispensing apparatus, e.g. dispensing foaming resin over the whole width of the moving surface
Definitions
- Insulating panel process and apparatus for manufacturing thereof, with expansible resin spraying
- the invention relates in general to the production of composite insulating panels.
- these panels which are also commonly known as “sandwich” panels, are widely used in the civil and industrial construction field to form walls, roofs, coverings, slabs, sectional doors, etc.; they are also used to construct cold-storage rooms, or containers intended for low temperatures.
- the panels considered herein comprise basically two opposed faces between which there is an insulating core made of expanded resin, also commonly known as foam; the latter is generally a polyurethane foam but may also be phenolic foam or foam of another type.
- foam also commonly known as foam; the latter is generally a polyurethane foam but may also be phenolic foam or foam of another type.
- the resin is applied on the lower strip and then expands whilst the strips pass through a continuos press which keeps them apart by a distance equal to the thickness of the finished panel.
- the discontinuous production of the panels is more suitable for small series or for special panels; the latter may have outer faces made of metal or another material, such as for example plastic materials (polycarbonate or the like) or others (i.e. wood etc.).
- the faces of the panels are prepared separately and then arranged in a mould where the polymer resin application and expansion take place, thereby forming the insulating foam. It can be appreciated that this production process requires a longer time with respect to the continuous one, since there are unavoidably idle times when the faces must be accommodated in the mould and the finished panel removed therefrom.
- this known application method appears to depend significantly on the viscosity of the resin since the effect of the air thereon will clearly be different according to how liquid the resin is.
- the known method may be difficult to implement according to the type of panels to be produced; thus, for example, it is not stated that it is effective in the same manner both for the production of panels with polyurethane resins and for the production of panels with phenolic resins.
- the problem underlying the present invention is therefore that of providing a method for the continuous production of insulating panels in which the polymer resin is applied uniformly to at least one of the strips in a manner such as to prevent the formation of bubbles in the vicinity of the strips, also achieving improved adhesion between the foam and the surface of the strip.
- the concept for the solution of this problem consists in the spray application of a first layer of resin onto the surface of the strip; the surface is in fact thus covered uniformly without lack of homogeneity which might give rise to bubbles.
- a second layer of liquid resin can be poured thereon, thus producing an insulating core of the desired thickness and density.
- FIG. 1 shows schematically apparatus for the continuous production of panels according to the invention
- FIG. 2 shows a detail of the apparatus of Figure 1
- Figure 3 is a section taken on the line m-IH of Figure 1,
- Figure 4 is a perspective view of a panel formed in accordance with the invention.
- Figures 5 and 6 show a variant of the above-mentioned apparatus in views similar to those of Figures 2 and 3, respectively;
- Figures 7 and 8 show a perspective view and a sectional view of a variant of the panel of the invention
- Figures 9 and 10 are a section and a perspective view of a manufacturing phase of the panel in fig. 7, 8;
- Figure 11 is a variant of the manufacturing phase in fig. 9.
- the first of these drawings shows an apparatus, generally indicated 1, for the continuous manufacturing of panels according to the invention, starting from two coils 2, 3 of metal strips 4 and 5.
- the strips are processed by respective forming machines 6 and 7 to form therein the usual edges, ribs, profiling, etc., in known manner.
- the strips 4 and 5 advance close together up to the zone for the application of expansible resin; this operation is performed in two steps.
- the first step is constituted by the spraying application of a quick- reaction resin by a head 9; for this purpose, the head 9 moves to and fro (as indicated by the arrows in Figure 3) along a cross-member 10 arranged above the strip 4 and is provided with a spray nozzle of a type known er se and not shown in the drawings.
- the speed of advance of the lower strip 4 is set in a manner such that the resin sprayed thereon expands (at least partially), forming a layer 13 which covers the strip 4 uniformly, before reaching a position below a second cross-member 11.
- a pouring nozzle 12 of known type (which may be a single nozzle or a comb nozzle such as that of German published application No. 197 41 523) is movable to and fro along the second cross-member 11 and performs the second resin- application step, by pouring onto the expanded layer 13 a resin of the same type as that sprayed previously but in the liquid condition (the vertical broken line in Figure 3 indicates the pouring line).
- the liquid resin then expands, filling the space between the strips 4 and 5 whilst they pass through a continuous press 14, also known er se. Downstream of the continuous press, a semi-finished product 16 formed by the two strips 4 and 5 with the expanded sprayed layer 13 and an insulating core 17 of foam of the second resin is thus obtained; the semi-finished product is then cut by a cutter 18, thereby obtaining finished panels 20 like that of Figure 4.
- the production process described above solves the problem underlying the invention.
- the spray application distributes the resin uniformly over the entire surface of the strip 4, so that the resulting layer 13 is free of internal voids or bubbles. This is due to the atomization of the resin supplied by the spray system, which enables the surface of the strip 4 to be covered with a thin film of small droplets similar to that of paints applied by the same method, wherein gas bubbles cannot build up.
- the speed of movement of the head 9 along the cross-member 10 it will suffice to select the speed of movement of the head 9 along the cross-member 10 appropriately in dependence on various parameters such as, for example, the width of the strip, its speed of advance, the type of spray nozzle mounted on the head 9, the supply pressure of the nozzle, its distance from the strip, the type of resin applied, etc.
- the resin since the resin is of the quick-reaction type, it produces a film 13 of foam on which the liquid resin can subsequently be applied in known manner; the interface between the two resins advantageously reduces the presence and/or the size of any voids in the mass of the second resin when it expands.
- this production method is reliable, easy to implement and does not require complex adaptive modifications when the resin, the speed of the strip 4, or other production parameters are changed.
- polymer resins polyurethane resins or the like
- this technique is well known and has been used since a long time, so that changes in the type of resin do not alter the efficacy of the production process of the invention.
- the production process may include also heating steps carried out with ovens or lamps disposed along the path of the strips 4 and 5, as is already known in the panel manufacturing; for example, an oven or lamps may be arranged upstream of the resin-application zone, that is before the spray head 9 and the cross-member 10, in order to accelerate the expansion of the resin sprayed onto the lower strip 4.
- the nozzles will be selected among the most suitable for the operative conditions existing, such as the size and shape of the panel (profiled, corrugated, flat, curved, etc.), the type of apparatus
- the spraying of the resin may also be performed on the upper strip, as an alternative to or in combination with the spraying on the lower strip; there may consequently be methods and apparatus for the production of panels in accordance with the invention, wherein the spraying is carried out on only one of the strips (that is, only the upper strip or the lower strip) or on both strips.
- a spraying head like that of fig. 3 or a nozzle bar as in fig. 6; in both cases after the sprayed layer has expanded, liquid resin will be poured and the mould closed so as to let it expand thereby obtaining the desired thickness of the panel.
- the peculiar feature of the architectural panels referred to as 40 is that they have outer faces 41 and 42 without fretting, ribbing or the like; they are therefore smooth and this renders critical the manufacturing process, because the presence of air bubbles between the outer faces and the foam of the insulating core 43, gives rise to surface defects which can disfigure the facade of the building where the panels are applied.
- the lack of ribbings renders the outer faces of the panels less stiff and more deformable, so that actually they do not remain plane when there are defects in the core of insulating foam.
- Another particular feature of the aforesaid panels is that they are generally mounted upon structures formed by pillars and beams 45, 46 by means of bolts 47, brackets 48 and similar; as a consequence their peripheral edges are shaped with long and thin appendices 49, to allow the coupling of the panels with the mounting elements.
- the sprayed resin is preferably of the rapid reaction type, because it has resulted that this allows to obtain better results.
- the resin can be sprayed also on the other face
- the discontinuous manufacturing process of the panels is carried out using a vacuum support plane or base 52 where it is laid the sheet metal of the face 41 of the panel 40.
- This plane is provided inside with channels 54 through which air is sucked in a manner known per se, thereby obtaining a depression under the face 41 which keeps it adhering to the plane 52 and eliminates the aforesaid undulations.
- the plane 52 is also horizontally movable (as indicated by the arrow in fig. 8 and
- porous support planes could be used, which do not require channels formed therein because the air can be sucked through them: to this purpose reference can be made to planes made of chipboards, plastic material with open cells or spongy material.
- Pneumatic vacuum systems like that considered before can operate on all types of surfaces, either metallic, plastic or other, for keeping the planarity of the faces where the resin is sprayed.
- the first of these alternatives is shown in fig. 11 where the support plane 52 is provided with magnets incorporated therein, which apply an attractive force on the face 41 made of sheet metal; the magnets can be either of natural type or electromagnets and, as mentioned above, they might be replaced with suction caps or other equivalent holding means.
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2003274717A AU2003274717A1 (en) | 2003-08-01 | 2003-09-29 | Insulating panel, process and apparatus for manufacturing thereof, with expansible resin spraying |
EP03758680A EP1651416A2 (en) | 2003-08-01 | 2003-09-29 | Insulating panel, process and apparatus for manufacturing thereof, with expansible resin spraying |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/IT2003/000491 WO2005011951A1 (en) | 2003-08-01 | 2003-08-01 | Process and apparatus for manufacturing insulating panels, with sprayed expansible resins |
ITPCT/IT03/00491 | 2003-08-01 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2005011950A2 true WO2005011950A2 (en) | 2005-02-10 |
WO2005011950A3 WO2005011950A3 (en) | 2005-03-10 |
Family
ID=34113401
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/IT2003/000491 WO2005011951A1 (en) | 2003-08-01 | 2003-08-01 | Process and apparatus for manufacturing insulating panels, with sprayed expansible resins |
PCT/IT2003/000577 WO2005011950A2 (en) | 2003-08-01 | 2003-09-29 | Insulating panel, process and apparatus for manufacturing thereof, with expansible resin spraying |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/IT2003/000491 WO2005011951A1 (en) | 2003-08-01 | 2003-08-01 | Process and apparatus for manufacturing insulating panels, with sprayed expansible resins |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP1651416A2 (en) |
CN (1) | CN1839025A (en) |
AU (2) | AU2003253303A1 (en) |
WO (2) | WO2005011951A1 (en) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2008060346A1 (en) * | 2006-11-16 | 2008-05-22 | Wayne-Dalton Corp. | Continuous lamination of door panels |
WO2008104492A3 (en) * | 2007-02-28 | 2009-01-22 | Basf Se | Method for producing composite elements on the basis of foamed material based on isocyanate |
EP2289684A1 (en) * | 2009-08-27 | 2011-03-02 | Siempelkamp Handling Systeme GmbH | Coating construction element layers, in particular for producing sandwich elements |
US7955460B2 (en) | 2008-05-02 | 2011-06-07 | Overhead Door Corporation | Movable barriers having transverse stiffeners and methods of making the same |
RU2493004C2 (en) * | 2007-12-17 | 2013-09-20 | Басф Се | Method of producing composite articles from isocyanate-based foam plastics |
RU2524395C2 (en) * | 2009-03-25 | 2014-07-27 | Байер Матириальсайенс Аг | Composite sandwich elements |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3541639A (en) * | 1967-01-23 | 1970-11-24 | Enroc Lab Dev Co | Apparatus for making an athletic mat member |
US3834967A (en) * | 1971-04-30 | 1974-09-10 | Control Building Syst Inc | Apparatus for forming foamed panels |
US3872199A (en) * | 1971-06-16 | 1975-03-18 | Champion Int Corp | Method of manufacturing a foamed urethane structural product having high and low density portions |
EP0767037A2 (en) * | 1995-10-05 | 1997-04-09 | Atoma International Inc. | Headliner assembly and method of manufacture |
JP2000052466A (en) * | 1998-08-11 | 2000-02-22 | Moriya Field:Kk | Manufacture of heat insulation panel |
Family Cites Families (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH0651304B2 (en) * | 1990-12-28 | 1994-07-06 | 大同鋼板株式会社 | Heat insulation panel manufacturing method and manufacturing apparatus |
-
2003
- 2003-08-01 WO PCT/IT2003/000491 patent/WO2005011951A1/en active Application Filing
- 2003-08-01 AU AU2003253303A patent/AU2003253303A1/en not_active Abandoned
- 2003-09-29 AU AU2003274717A patent/AU2003274717A1/en not_active Abandoned
- 2003-09-29 WO PCT/IT2003/000577 patent/WO2005011950A2/en active Application Filing
- 2003-09-29 CN CNA038271540A patent/CN1839025A/en active Pending
- 2003-09-29 EP EP03758680A patent/EP1651416A2/en not_active Withdrawn
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3541639A (en) * | 1967-01-23 | 1970-11-24 | Enroc Lab Dev Co | Apparatus for making an athletic mat member |
US3834967A (en) * | 1971-04-30 | 1974-09-10 | Control Building Syst Inc | Apparatus for forming foamed panels |
US3872199A (en) * | 1971-06-16 | 1975-03-18 | Champion Int Corp | Method of manufacturing a foamed urethane structural product having high and low density portions |
EP0767037A2 (en) * | 1995-10-05 | 1997-04-09 | Atoma International Inc. | Headliner assembly and method of manufacture |
JP2000052466A (en) * | 1998-08-11 | 2000-02-22 | Moriya Field:Kk | Manufacture of heat insulation panel |
Non-Patent Citations (2)
Title |
---|
PATENT ABSTRACTS OF JAPAN vol. 0170, no. 26 (M-1354), 19 January 1993 (1993-01-19) -& JP 04 250009 A (DAIDO STEEL SHEET CORP), 4 September 1992 (1992-09-04) * |
PATENT ABSTRACTS OF JAPAN vol. 2000, no. 05, 14 September 2000 (2000-09-14) & JP 2000 052466 A (MORIYA FIELD:KK), 22 February 2000 (2000-02-22) * |
Cited By (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2008060346A1 (en) * | 2006-11-16 | 2008-05-22 | Wayne-Dalton Corp. | Continuous lamination of door panels |
WO2008104492A3 (en) * | 2007-02-28 | 2009-01-22 | Basf Se | Method for producing composite elements on the basis of foamed material based on isocyanate |
AU2008220882B2 (en) * | 2007-02-28 | 2012-03-29 | Basf Se | Method for producing composite elements on the basis of foamed material based on isocyanate |
RU2466019C2 (en) * | 2007-02-28 | 2012-11-10 | Басф Се | Method of making composite elements using isocyanate-based foam plastics |
KR101458238B1 (en) | 2007-02-28 | 2014-11-04 | 바스프 에스이 | Method for producing composite elements on the basis of foamed material based on isocyanate |
EP2125323B1 (en) | 2007-02-28 | 2015-08-19 | Basf Se | Method for producing composite elements on the basis of foamed material based on isocyanate |
RU2493004C2 (en) * | 2007-12-17 | 2013-09-20 | Басф Се | Method of producing composite articles from isocyanate-based foam plastics |
US7955460B2 (en) | 2008-05-02 | 2011-06-07 | Overhead Door Corporation | Movable barriers having transverse stiffeners and methods of making the same |
US8220519B2 (en) | 2008-05-02 | 2012-07-17 | Overhead Door Corporation | Movable barriers having transverse stiffeners and methods of making the same |
RU2524395C2 (en) * | 2009-03-25 | 2014-07-27 | Байер Матириальсайенс Аг | Composite sandwich elements |
EP2289684A1 (en) * | 2009-08-27 | 2011-03-02 | Siempelkamp Handling Systeme GmbH | Coating construction element layers, in particular for producing sandwich elements |
Also Published As
Publication number | Publication date |
---|---|
AU2003274717A1 (en) | 2005-02-15 |
WO2005011950A3 (en) | 2005-03-10 |
CN1839025A (en) | 2006-09-27 |
WO2005011951A1 (en) | 2005-02-10 |
AU2003274717A8 (en) | 2005-02-15 |
AU2003253303A1 (en) | 2005-02-15 |
EP1651416A2 (en) | 2006-05-03 |
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