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US 6,743,483 B2Granted
Method for manufacturing a foam panel
AssigneeKingspan Research and Developments Limited
InventorsMalcolm Rochefort, Thomas McCabe
Life of this patent
Estimating the term…
Abstract
An insulated foam board is manufactured by leading a first facing from a reel and laying down liquid foam reactants. A second facing from a supply reel is laid over the reactants forming a sandwich. The foam is expanded in an oven and the board is cut to a desired length. One or both facings are removed and re-wound onto a reel for re-use. A coating in the form of a metallized paint is applied in-line to one or both faces of the foam core, after removal of the facings. The painted boards have enhanced heat insulation properties.
Claims18
A method for manufacturing a foam panel comprising the sequential steps of:
- leading a first facing from a first facing supply to a foam lay down area;
- laying liquid foam reactants on the first facing in the foam lay down area;
- leading a second facing from a second facing supply over the liquid foam reactants;
- allowing the foam to expand between the first and the second facings to form a foam panel;
- removing at least one of the first and the second facings from the foam panel to expose at least one face of the foam panel;
- and
- thereafter applying a coating in-line as a paint directly to only the exposed at least one face of the foam panel from which the at least one of the first and the second facings has been removed.
4 more elements
A method for manufacturing a foam panel comprising the sequential steps of:
- leading a first facing from a first facing supply to a foam lay down area;
- laying liquid foam reactants on the first facing in the foam lay down area;
- leading a second facing from a second facing supply over the liquid foam reactants;
- allowing the foam to expand between the first and the second facings to form a foam panel;
- removing at least one of the first and the second facings from the foam panel to expose at least one face of the foam panel;
- and
- thereafter applying a coating directly to only the exposed at least one face of the foam panel from which the at least one of the first and the second facings has been removed;
- wherein the coating limits gas permeability by at least one of CO2, O2, N2 and H2O.
5 more elements
A method for manufacturing a foam panel comprising the sequential steps of:
- leading a first facing from a first facing supply to a foam lay down area;
- laying liquid foam reactants on the first facing in the foam lay down area;
- leading a second facing from a second facing supply over the liquid foam reactants;
- allowing the foam to expand between the first and the second facings to form a foam panel;
- removing at least one of the first and the second facings from the foam panel to expose at least one face of the foam panel;
- and
- thereafter applying a coating directly to only the exposed at least one face of the foam panel from which the at least one of the first and the second facings has been removed,
- after applying the coating, curing the coating on the foam panel, carried out in-line, by at least one of heating and by application of radiation, and curing in an oven.
5 more elements
A method for manufacturing a foam panel comprising the sequential steps of:
- leading a first facing from a first facing supply to a foam lay down area;
- laying liquid foam reactants on the first facing in the foam lay down area;
- leading a second facing from a second facing supply over the liquid foam reactants;
- allowing the foam to expand between the first and the second facings to form a foam panel;
- removing at least one of the first and the second facings from the foam panel to expose at least one face of the foam panel;
- and
- thereafter applying a coating directly to only the exposed at least one face of the foam panel from which the at least one of the first and the second facings has been removed,
- wherein release means being provided between the inner face of at least one of the first and the second facing and the foam panel, the release means being provided on the inner face at least one of the first and the second facing.
5 more elements
A method for manufacturing a foam panel comprising the sequential steps of:
- leading a first facing from a first facing supply to a foam lay down area;
- laying liquid foam reactants on the first facing in the foam lay down area;
- leading a second facing from a second facing supply over the liquid foam reactants;
- allowing the foam to expand between the first and the second facings to form a foam panel;
- removing at least one of the first and the second facings from the foam panel to expose at least one face of the foam panel;
- and
- thereafter applying a coating directly to only the exposed at least one face of the foam panel from which the at least one of the first and the second facings has been removed,
- wherein the first facing being selected from:
- polyolefin films, poly halogenated polyolefins, waxed paper and waxed plastic films, plastic, metal foil and glass films.
6 more elements
A method for manufacturing a foam panel comprising the sequential steps of:
- leading a first facing from a first facing supply to a foam lay down area;
- laying liquid foam reactants on the first facing in the foam lay down area;
- leading a second facing from a second facing supply over the liquid foam reactants;
- allowing the foam to expand between the first and the second facings to form a foam panel;
- removing at least one of the first and the second facings from the foam panel to expose at least one face of the foam panel;
- and
- thereafter applying a coating directly to only the exposed at least one face of the foam panel from which the at least one of the first and the second facings has been removed,
- wherein the second facing being selected from:
- polyolefin films, poly halogenated polyolefins, waxed paper and waxed plastic films, plastic, metal foil and glass films.
6 more elements
Dependencies are inferred from the claim text.