US3650871A - Method of producing insulating panels - Google Patents

Method of producing insulating panels Download PDF

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US3650871A
US3650871A US831508A US3650871DA US3650871A US 3650871 A US3650871 A US 3650871A US 831508 A US831508 A US 831508A US 3650871D A US3650871D A US 3650871DA US 3650871 A US3650871 A US 3650871A
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panels
honeycomb structure
boards
honeycomb
insulating
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US831508A
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Karl Waldemar Bentfors
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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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • 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
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/18—Filling preformed cavities
    • B29C44/186—Filling multiple cavities
    • 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
    • B29C44/206—Using expandable particles or beads as starting material
    • 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
    • B29C44/34—Auxiliary operations
    • B29C44/3415—Heating or cooling
    • B29C44/3426—Heating by introducing steam in the mould
    • 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
    • B29C44/44—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length in solid form
    • B29C44/445—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length in solid form in the form of expandable granules, particles or beads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D24/00—Producing articles with hollow walls
    • B29D24/002—Producing articles with hollow walls formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled
    • B29D24/005—Producing articles with hollow walls formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled the structure having joined ribs, e.g. honeycomb
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B29D99/0021—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/046—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • 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
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • 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
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/146—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers whereby one or more of the layers is a honeycomb structure
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
    • E04C2/365—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels by honeycomb structures
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00—Thermal insulation in general
    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/34—Moulds or cores; Details thereof or accessories therefor movable, e.g. to or from the moulding station
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/022—Foam
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/024—Honeycomb
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • 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
    • B32B2317/00—Animal or vegetable based
    • B32B2317/12—Paper, e.g. cardboard
    • 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
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1003—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina by separating laminae between spaced secured areas [e.g., honeycomb expanding]
    • 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
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1084—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing of continuous or running length bonded web
    • 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.]
    • Y10T428/24149—Honeycomb-like
    • Y10T428/24157—Filled honeycomb cells [e.g., solid substance in cavities, etc.]

Definitions

  • ABSTRACT A method for producing insulated panels of a honeycomb structure surrounded by a frame, in which the panels are continuously fed below a discharging device which fills the honeycomb with polystyrene, granular or ground waste material having insulating properties. Before or after filling, the honeycomb structure may be closed by a subjacent cover board or sheet, and'an upper cover board or sheet is applied after filling, the upper and lower cover boards or sheets being adhesively bonded to the honeycomb.
  • Insulating boards made of polystyrene cellular plastic are very brittle and easy to break. It is therefore necessary to reinforce them by using relatively thick cover boards on each side of the insulating boards, so that they can be used for instance as wall panels.
  • the principal object of the invention is to improve the strength of such insulating boards, so that thinner materials can be used as skin, for instance thin metal plates, paper, plastic-coated fabrics, glass fiber materials etc.
  • Still another object of the invention is to use as filler in the cells ground waste material having insulating properties, e.g., wood, bark, paper and cardboard.
  • FIG. 1 is a cell structure built up of edgewise disposed strips connected to each other at points along their length and comprising a number of cell openings.
  • This structure a so called honeycomb structure, is placed within a surrounding frame 2, the cell openings of the structure according to the invention being filled up with an insulating material.
  • the filling takes place during the continuous feed of the board 1,2.
  • a first conveyor 3 and a second conveyor 4 are used, these conveyors for instance being of the perforated steel band type.
  • the boards are fed one after the other from the left to the right in the drawing, in which three such boards and part of the fourth are shown.
  • Above the conveyor 3 there is a hopper 5 for preexpanded polystyrene granulate which flows like a falling curtain by gravity into the cell openings of the honeycomb structure 1, when this is continuously fed by the conveyor 3.
  • the filled board is further fed between two steam supplying means, a lower one 6 and an upper one 7, in order to heat the granulate. From the conveyor 3 the board 1,2 is transferred to the conveyor 4. Above this is a further conveyor 8.
  • a sheet 10 of paper, plasticcoated fabric, glass fiber material, thin metal plate or material like that is withdrawn and passes over the upper side of the conveyor 4.
  • a sheet 12 of the same or other kind of material than the sheet 10 is withdrawn and passes beneath the underside of the conveyor 8.
  • adhesive applying means 13 and 14 The adhesive is applied to the sides of the sheets 10 and 12 which face the boards 1,2. This means that the boards during their continuous feed will be provided with a skin on each side and this skin is thereafter by means of a cutting device cut ofi between each board.
  • the sheets 10 and 12 may have such properties in practical and decorative respect that the board will be directly usable as a wall panel without any following treatment, such as web coating, wall-papering or something similar.
  • the boards can also be used as facing panels, in such cases preferably being metal or plastic coated on the intended outside, the coating being carried out in the way described above.
  • Two further steam supplying means a lower one 15 and an upper one 16 are placed in the vicinity of the conveyors 4 and 8 respectively in order to bring about the final blowing and expanding of the polystyrene granulate.
  • the boards are thereafter transported past a cooling device, not shown.
  • the upper conveyor 8 and the steam supplying means 7 and 16 can be adjusted to the proper level with respect to the thickness of the board.
  • plastic foam is used in the cells of the honeycomb structure the injection can be done by means of a nozzle 19.
  • This nozzle eliminates the hopper 5 and also the steam supplying means 6,7,15 and 16 are replaced by coolers.
  • the honeycomb structure If it is desired to have on both sides of the honeycomb structure a thicker, non-rollable board, such as a plaster wall board, a fiber board or the like the sheets 10 and 11 are not used, if another finishing is intended.
  • the structure 1 and the frame 2 from the beginning is provided with a lower such cover board. After the structure has been filled with the insulating material the upper cover board is applied.
  • cellular plastic can as filler in the honeycomb structure also other insulating materials can also be used as fillers in the honeycomb structure.
  • waste material having insulating properties such as wood, bark, paper and cardboard, the paper and cardboard waste material otherwise often being transported to a garbage disposal plant to be incinerated. This waste material is ground to a proper particle size and is filled into the cell openings of the structure. In order to have this material resist the ravages of time it may be preferred to mix into the material some sort of a preservative, for instance resin.
  • a pressing procedure may be used to have the insulated material better packed in the cell openings.
  • a method for producing insulating panels comprising a honeycomb structure surrounded by a frame, comprising feeding a plurality of said panels one behind the other with their frames in abutting relationship thereby to provide a continuous panel expanse in the feed direction of the panels, continuously discharging insulating material into said continuous panel expanse in the form of a continuously falling curtain of insulating material of a width equal to the width of the honeycomb structure thereby continuously filling said material into the cell openings of said honeycomb structure, applying to said plurality of panels with their frames in abutting relationship subjacent and superposed covers of continuous flexible material that bridge over the joints between the abutting frames, and severing said flexible material between said frames.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Laminated Bodies (AREA)
  • Panels For Use In Building Construction (AREA)

Abstract

A method for producing insulated panels of a honeycomb structure surrounded by a frame, in which the panels are continuously fed below a discharging device which fills the honeycomb with polystyrene, granular or ground waste material having insulating properties. Before or after filling, the honeycomb structure may be closed by a subjacent cover board or sheet, and an upper cover board or sheet is applied after filling, the upper and lower cover boards or sheets being adhesively bonded to the honeycomb.

Description

United States Patent Bentfors 51 Mar. 21, 1972 [54] METHOD OF PRODUCING INSULATING PANELS [72] Inventor: Karl Waldemar Bentfors, Utsiktsvagen 14,
Motala, Sweden [22] Filed: June 9,1969
[21] Appl.No.: 831,508
3,170,827 2/1965 Voelker ..l6l/l68 X 3,099,518 7/1963 Wetzler ..l56/79 X 3,249,659 5/1966 Voelker..... ..l56/79 X Primary Examiner-Benjamin A. Borchelt Assistant ExaminerG. E. Montone Attorney-Young & Thompson 5 7] ABSTRACT A method for producing insulated panels of a honeycomb structure surrounded by a frame, in which the panels are continuously fed below a discharging device which fills the honeycomb with polystyrene, granular or ground waste material having insulating properties. Before or after filling, the honeycomb structure may be closed by a subjacent cover board or sheet, and'an upper cover board or sheet is applied after filling, the upper and lower cover boards or sheets being adhesively bonded to the honeycomb.
1 Claims, 1 Drawing Figure O/O(//OOOOOQOOOO O O 0 o O O O O O 0 O O O O O METHOD OF PRODUCING INSULATING PANELS This invention relates to methods of producing insulating panels, especially suitable for building purposes.
Insulating boards made of polystyrene cellular plastic are very brittle and easy to break. It is therefore necessary to reinforce them by using relatively thick cover boards on each side of the insulating boards, so that they can be used for instance as wall panels.
The principal object of the invention is to improve the strength of such insulating boards, so that thinner materials can be used as skin, for instance thin metal plates, paper, plastic-coated fabrics, glass fiber materials etc.
It is another object of the invention to use a honeycomb structure as reinforcement for the insulating board and to have the cells of the honeycomb filled up with cellular plastic.
Still another object of the invention is to use as filler in the cells ground waste material having insulating properties, e.g., wood, bark, paper and cardboard.
Other objects and advantages of the present invention will become apparent upon reading the following specification and referring to the accompanying drawing in which apparatus for practicing the invention is diagrammatically shown in elevatron.
In the drawing 1 is a cell structure built up of edgewise disposed strips connected to each other at points along their length and comprising a number of cell openings. This structure, a so called honeycomb structure, is placed within a surrounding frame 2, the cell openings of the structure according to the invention being filled up with an insulating material.
According to the method shown in the drawing the filling takes place during the continuous feed of the board 1,2. For this purpose a first conveyor 3 and a second conveyor 4 are used, these conveyors for instance being of the perforated steel band type. The boards are fed one after the other from the left to the right in the drawing, in which three such boards and part of the fourth are shown. Above the conveyor 3 there is a hopper 5 for preexpanded polystyrene granulate which flows like a falling curtain by gravity into the cell openings of the honeycomb structure 1, when this is continuously fed by the conveyor 3.
The filled board is further fed between two steam supplying means, a lower one 6 and an upper one 7, in order to heat the granulate. From the conveyor 3 the board 1,2 is transferred to the conveyor 4. Above this is a further conveyor 8.
From a lower supply roll 9 a sheet 10 of paper, plasticcoated fabric, glass fiber material, thin metal plate or material like that is withdrawn and passes over the upper side of the conveyor 4. From an upper supply roll 11 a sheet 12 of the same or other kind of material than the sheet 10 is withdrawn and passes beneath the underside of the conveyor 8. Immediately after the supply rolls 9 and 11 the sheets 10 and 12 pass adhesive applying means 13 and 14. The adhesive is applied to the sides of the sheets 10 and 12 which face the boards 1,2. This means that the boards during their continuous feed will be provided with a skin on each side and this skin is thereafter by means of a cutting device cut ofi between each board.
The sheets 10 and 12 may have such properties in practical and decorative respect that the board will be directly usable as a wall panel without any following treatment, such as web coating, wall-papering or something similar. The boards can also be used as facing panels, in such cases preferably being metal or plastic coated on the intended outside, the coating being carried out in the way described above.
Two further steam supplying means, a lower one 15 and an upper one 16 are placed in the vicinity of the conveyors 4 and 8 respectively in order to bring about the final blowing and expanding of the polystyrene granulate. Preferably the boards are thereafter transported past a cooling device, not shown.
In order to have the sheets supplied evenly to the boards and keep the boards flat there is arranged below the conveyor 4 and above the conveyor 8 adjacent the feed path of the boards two series of su port rollers l 7.
By means of hydrau ic lift devices 18 the upper conveyor 8 and the steam supplying means 7 and 16 can be adjusted to the proper level with respect to the thickness of the board.
If plastic foam is used in the cells of the honeycomb structure the injection can be done by means of a nozzle 19. This nozzle eliminates the hopper 5 and also the steam supplying means 6,7,15 and 16 are replaced by coolers.
If it is desired to have on both sides of the honeycomb structure a thicker, non-rollable board, such as a plaster wall board, a fiber board or the like the sheets 10 and 11 are not used, if another finishing is intended. In this case the structure 1 and the frame 2 from the beginning is provided with a lower such cover board. After the structure has been filled with the insulating material the upper cover board is applied.
Except cellular plastic can as filler in the honeycomb structure also other insulating materials can also be used as fillers in the honeycomb structure. It is also possible to use waste material having insulating properties, such as wood, bark, paper and cardboard, the paper and cardboard waste material otherwise often being transported to a garbage disposal plant to be incinerated. This waste material is ground to a proper particle size and is filled into the cell openings of the structure. In order to have this material resist the ravages of time it may be preferred to mix into the material some sort of a preservative, for instance resin. A pressing procedure may be used to have the insulated material better packed in the cell openings.
1 claim:
1. A method for producing insulating panels comprising a honeycomb structure surrounded by a frame, comprising feeding a plurality of said panels one behind the other with their frames in abutting relationship thereby to provide a continuous panel expanse in the feed direction of the panels, continuously discharging insulating material into said continuous panel expanse in the form of a continuously falling curtain of insulating material of a width equal to the width of the honeycomb structure thereby continuously filling said material into the cell openings of said honeycomb structure, applying to said plurality of panels with their frames in abutting relationship subjacent and superposed covers of continuous flexible material that bridge over the joints between the abutting frames, and severing said flexible material between said frames.
US831508A 1969-06-09 1969-06-09 Method of producing insulating panels Expired - Lifetime US3650871A (en)

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US83150869A 1969-06-09 1969-06-09
GB3007169 1969-06-13
DE1932761A DE1932761C3 (en) 1969-06-09 1969-06-27 Isolation plate in sandwich construction
FR6923132A FR2054469A1 (en) 1969-06-09 1969-07-08

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DE (1) DE1932761C3 (en)
FR (1) FR2054469A1 (en)
GB (1) GB1234373A (en)

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US3962016A (en) * 1973-09-14 1976-06-08 Dynamit Nobel Aktiengesellschaft Process for joining abutting thermoplastic synthetic-resin foam sheets
US3986918A (en) * 1972-08-28 1976-10-19 Erling Berner Apparatus for forming laminated molded bodies
US3990936A (en) * 1973-07-20 1976-11-09 Lancaster Research And Development Corporation Mastic composition and composite structural panels formed therefrom
US3994769A (en) * 1972-04-14 1976-11-30 Hermann Berstorff Maschinenbau Gmbh Apparatus for continuously laminating a continuous strip of chipboard with decorative film
US4282049A (en) * 1974-05-30 1981-08-04 Kemlite Corporation Method for making resin panels
US4294875A (en) * 1978-08-31 1981-10-13 Schramm Arthur G Insulation panel
US4301198A (en) * 1977-08-22 1981-11-17 Prior John C Building component and method of making the same
US4303707A (en) * 1977-08-22 1981-12-01 John Prior Building component and method of making the same
US4343669A (en) * 1977-08-22 1982-08-10 Prior John C Building component and method of making the same
US4416715A (en) * 1978-08-31 1983-11-22 Doralyn Ann Hardy Method and apparatus for fabricating insulative panel
US4510010A (en) * 1980-05-27 1985-04-09 Schramm Arthur G Method and apparatus for fabricating insulative panel
US4964936A (en) * 1988-10-11 1990-10-23 Imi-Tech Corporation Method of making foam-filled cellular structures
EP0410432A3 (en) * 1989-07-26 1991-07-24 Centro Sviluppo Settori Impiego S.R.L. Process for preparing heat-insulating structural elements and products obtained thereby
US5043034A (en) * 1987-02-26 1991-08-27 Bayer Aktiengesellschaft Post forming semi-finished product for the manufacture of moulded parts resistant to bending
US5215248A (en) * 1988-12-29 1993-06-01 Hexacomb Corporation Collapsible shipping carton
US5827385A (en) * 1994-07-15 1998-10-27 Vacupanel, Inc. Method of producing an evacuated insulated container
US6412243B1 (en) 1997-04-30 2002-07-02 Franklin S. Sutelan Ultra-lite modular composite building system
FR2854419A1 (en) * 2003-04-29 2004-11-05 Jean Philippe Pisano Insulating panel with sandwich structure has metal skins and cardboard honeycomb core having cells filled with insulating material
WO2004096542A1 (en) * 2003-04-28 2004-11-11 Polyvision, Naamloze Vennootschap Method for manufacturing visual communication panels and device used thereby
US6852386B2 (en) 2001-03-08 2005-02-08 Norbord Inc. Composite board with OSB faces
US20060154551A1 (en) * 2004-12-27 2006-07-13 Matsushita Electric Industrial Co., Ltd. Panel feeding device, panel feeding method, and panel assembling device
US20090056867A1 (en) * 2003-07-31 2009-03-05 Livedo Corporation Method and device for manufacturing sheet-shaped body and method for manufacturing disposable absorbent article using the sheet-shaped body
WO2009013124A3 (en) * 2007-07-20 2009-06-18 Fritz Egger Gmbh & Co Lightweight building panel
FR2928861A1 (en) * 2008-03-20 2009-09-25 Sainte Marie Const Isothermes Thermal insulation and non-combustible sandwich panel i.e. self-supporting M0-type sandwich panel, manufacturing method for forming wall of e.g. building, involves placing coverings on sides of insulation material to form assembly
US20100263315A1 (en) * 2009-04-17 2010-10-21 Tapco International Corporation Molded siding having integrally-formed i-beam construction
US20120193032A1 (en) * 2009-06-29 2012-08-02 Angelo Candiracci Installation and process for making panels
US20210238855A1 (en) * 2019-12-20 2021-08-05 Continuus Materials Intellectual Property, Llc Roof Cover Board Derived From Engineered Recycled Content
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US4572865A (en) * 1983-12-05 1986-02-25 The Celotex Corporation Faced foam insulation board and froth-foaming method for making same
FR2559523B1 (en) * 1984-02-10 1987-03-06 Boulay Freres PROCESS FOR THE MANUFACTURE OF A CONSTRUCTION ELEMENT, PARTICULARLY FOR THE CONSTRUCTION OF A WALL, AND CONSTRUCTION ELEMENT OBTAINED BY THE IMPLEMENTATION OF THIS PROCESS
US4900616A (en) * 1989-05-31 1990-02-13 Fiberglas Canada, Inc. Phenolic foam roof insulation of improved dimensional stability
DE19932366B4 (en) 1999-07-13 2005-06-16 Porextherm-Dämmstoffe Gmbh Insulator with cellular framework and method of manufacture
GB2427384B (en) * 2005-06-21 2011-01-19 Patrick Beirne A method and apparatus for forming a laminated heat insulating panel
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Cited By (33)

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Publication number Priority date Publication date Assignee Title
US3994769A (en) * 1972-04-14 1976-11-30 Hermann Berstorff Maschinenbau Gmbh Apparatus for continuously laminating a continuous strip of chipboard with decorative film
US3986918A (en) * 1972-08-28 1976-10-19 Erling Berner Apparatus for forming laminated molded bodies
US3990936A (en) * 1973-07-20 1976-11-09 Lancaster Research And Development Corporation Mastic composition and composite structural panels formed therefrom
US3962016A (en) * 1973-09-14 1976-06-08 Dynamit Nobel Aktiengesellschaft Process for joining abutting thermoplastic synthetic-resin foam sheets
US4282049A (en) * 1974-05-30 1981-08-04 Kemlite Corporation Method for making resin panels
US4343669A (en) * 1977-08-22 1982-08-10 Prior John C Building component and method of making the same
US4301198A (en) * 1977-08-22 1981-11-17 Prior John C Building component and method of making the same
US4303707A (en) * 1977-08-22 1981-12-01 John Prior Building component and method of making the same
US4294875A (en) * 1978-08-31 1981-10-13 Schramm Arthur G Insulation panel
US4416715A (en) * 1978-08-31 1983-11-22 Doralyn Ann Hardy Method and apparatus for fabricating insulative panel
US4510010A (en) * 1980-05-27 1985-04-09 Schramm Arthur G Method and apparatus for fabricating insulative panel
US5043034A (en) * 1987-02-26 1991-08-27 Bayer Aktiengesellschaft Post forming semi-finished product for the manufacture of moulded parts resistant to bending
US4964936A (en) * 1988-10-11 1990-10-23 Imi-Tech Corporation Method of making foam-filled cellular structures
US5215248A (en) * 1988-12-29 1993-06-01 Hexacomb Corporation Collapsible shipping carton
EP0410432A3 (en) * 1989-07-26 1991-07-24 Centro Sviluppo Settori Impiego S.R.L. Process for preparing heat-insulating structural elements and products obtained thereby
AU629374B2 (en) * 1989-07-26 1992-10-01 Centro Sviluppo Settori Impiego S.R.L. Process for preparing heat-insulating structural elements, and products obtained thereby
US5827385A (en) * 1994-07-15 1998-10-27 Vacupanel, Inc. Method of producing an evacuated insulated container
US6412243B1 (en) 1997-04-30 2002-07-02 Franklin S. Sutelan Ultra-lite modular composite building system
US6852386B2 (en) 2001-03-08 2005-02-08 Norbord Inc. Composite board with OSB faces
WO2004096542A1 (en) * 2003-04-28 2004-11-11 Polyvision, Naamloze Vennootschap Method for manufacturing visual communication panels and device used thereby
BE1015482A3 (en) * 2003-04-28 2005-04-05 Polyvision Nv Method for manufacturing of visual communication panels and device used thereby.
US20060249879A1 (en) * 2003-04-28 2006-11-09 Leo Gypen Method for manufacturing visual communication panels and device used thereby
FR2854419A1 (en) * 2003-04-29 2004-11-05 Jean Philippe Pisano Insulating panel with sandwich structure has metal skins and cardboard honeycomb core having cells filled with insulating material
US20090056867A1 (en) * 2003-07-31 2009-03-05 Livedo Corporation Method and device for manufacturing sheet-shaped body and method for manufacturing disposable absorbent article using the sheet-shaped body
US7743903B2 (en) * 2004-12-27 2010-06-29 Panasonic Corporation Panel feeding device, panel feeding method, and panel assembling device
US20060154551A1 (en) * 2004-12-27 2006-07-13 Matsushita Electric Industrial Co., Ltd. Panel feeding device, panel feeding method, and panel assembling device
WO2009013124A3 (en) * 2007-07-20 2009-06-18 Fritz Egger Gmbh & Co Lightweight building panel
FR2928861A1 (en) * 2008-03-20 2009-09-25 Sainte Marie Const Isothermes Thermal insulation and non-combustible sandwich panel i.e. self-supporting M0-type sandwich panel, manufacturing method for forming wall of e.g. building, involves placing coverings on sides of insulation material to form assembly
US20100263315A1 (en) * 2009-04-17 2010-10-21 Tapco International Corporation Molded siding having integrally-formed i-beam construction
US20120193032A1 (en) * 2009-06-29 2012-08-02 Angelo Candiracci Installation and process for making panels
US20210238855A1 (en) * 2019-12-20 2021-08-05 Continuus Materials Intellectual Property, Llc Roof Cover Board Derived From Engineered Recycled Content
US11718995B2 (en) * 2019-12-20 2023-08-08 Continuus Materials Intellectual Property, Llc Roof cover board derived from engineered recycled content
US12221788B2 (en) 2019-12-20 2025-02-11 Continuus Materials Intellectual Property, Llc Roof cover board derived from engineered recycled content

Also Published As

Publication number Publication date
DE1932761C3 (en) 1980-02-28
DE1932761A1 (en) 1971-03-11
FR2054469A1 (en) 1971-04-23
DE1932761B2 (en) 1979-06-21
GB1234373A (en) 1971-06-03

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