Apparatus and method for forming panels from moldable material

An apparatus to form liners for aircraft engines from moldable material comprising:

• a) a material storage and feeding container comprising an adjustable grid for placing and sizing moldable material on a first sheet of peel ply material atop a conveyor;
• b) said grid being adjustable to regulate the thickness of the dispensed moldable material;
• c) said conveyor having a roughened surface for gripping the first sheet of peel ply material thereon, said conveyor passing over a base plate having one distal end placed so that said material storage and feeding container can dispense moldable material on said conveyor and a second distal end adjacent where said conveyor departs the first sheet of peel ply material;
• d) a sizing plate under which the second sheet of peel ply material passes, said sizing plate configured to regulate the thickness of the moldable material as it exits said material storage and feeding container, said sizing plate being positioned to place the second sheet of peel ply material over the moldable material to form a web having a bottom side and a top side, the bottom side of the web formed by the first sheet of peel ply material covered by the dispensed moldable material and the top side formed by the second sheet of peel ply material covering the moldable material, said sizing plate configured to prevent breaks and voids in the moldable material, said sizing plate being positioned to prevent excess moldable material leaving said material holding and feeding container;
• e) a compression zone having a plurality of sides and at least one compression plate positioned to further compress the moldable material;
• f) a friction reducing material lining said compression plate and a plurality of sides of said compression zone to reduce friction forces between the top side of the web, the sides of the web and the corresponding inner surfaces of said compression zone;
• and
• g) a receiving device for receiving the web from said conveyor.

A method for making panels from moldable material comprising:

• a) dispensing and leveling a moldable material on a first sheet of peel ply material placed on a conveyor;
• b) providing a roughened surface on the conveyor to create gripping action between the conveyor and the first sheet of peel ply material;
• c) providing a sizing plate and configuring the sizing plate to further level the moldable material and place a second sheet of peel ply material on top of the moldable material to form a web;
• d) moving the web with the conveyor;
• e) providing a compression zone to compress the moldable material of the web into a given shape and size;
• and
• f) removing the web from the conveyor.

A method for making sound insulating and protective liners for aircraft engines comprising:

• a) feeding a first sheet of peel ply material onto a conveyor and dispensing and leveling a moldable material on top of the peel ply material;
• b) providing a roughened surface on the conveyor to create a gripping action between the conveyor and the first sheet of peel ply material;
• c) providing a sizing plate and configuring the sizing plate to further level the web and prevent voids and cracks in the moldable material, configuring the sizing plate and second sheet of peel ply material to place the second sheet of peel ply material on top of the moldable material to form a web having a bottom side and a top side, the bottom side of the web formed by the first sheet of peel ply material covered by the dispensed moldable material and the top side formed by the second sheet of peel ply material covering the moldable material, and configuring the sizing plate to prevent excess moldable material leaving the material storage and feeding container;
• d) moving the web with the conveyor;
• e) providing a compression zone to compress the moldable material of the web into a given shape and size, and lining the compression zone with friction reducing material;
• and
• f) removing the web from said conveyor.