Panel member production line
A manufacturing line for manufacturing a multilayer foam panel member including: (a) a storage; (b) a dosing system for flowing the components of the foam-forming fluid reactive mixture to a chamber for mixing the components; (c) a flexible fluid dispensing device; (d) a means for flowing the foam-forming fluid through the flexible fluid dispensing device to dispense the foam-forming fluid; (e) a moving first bottom sheet substrate for receiving the foam-forming fluid; (f) a means for allowing the foam-forming fluid to react; (g) a panel structure comprising the foam material disposed inbetween the top metal sheet and the bottom metal sheet; (h) a means for curing the foam material; and (i) a cutting means; and a process for manufacturing a multilayer foam panel member using the above manufacturing process.
1 . A production line for manufacturing a multilayer foam panel member comprising:
(a) a storage system for components of a foam-forming fluid reactive mixture;
(b) a dosing system for flowing the components of the foam-forming fluid reactive mixture to a chamber for mixing the components of the foam-forming fluid reactive mixture to form the foam-forming fluid reactive mixture;
(c) a flexible fluid dispensing device for receiving the foam-forming fluid reactive mixture;
the flexible fluid dispensing device including:
i) a flexible multilayer film having:
at least one fluid inlet aperture;
a plurality of fluid outlet apertures; and
a series or pattern of flexible fluid flow path ducts defined within the flexible multilayer film that connect the least one fluid inlet aperture with the plurality of fluid outlet apertures;
ii) a rigid frame disposed at least partially about a perimeter of the flexible multilayer film and in contact with side edges of the flexible multilayer film; and
iii) a hermetic connector positioned on the rigid frame for connecting the at least one fluid inlet aperture to an outlet of the chamber;
wherein:
the foam-forming fluid reactive mixture enters the at least one fluid inlet aperture, flows through the flexible fluid dispensing device, and exits the plurality of fluid outlet apertures to dispense the foam-forming fluid reactive mixture onto a surface of a first bottom sheet substrate;
the first bottom sheet substrate moves and receives the foam-forming fluid reactive mixture dispensed from the flexible fluid dispensing device;
the foam-forming fluid reactive mixture to reacts and travels on the first bottom sheet substrate and a foam material forms between the first bottom sheet substrate and a second top sheet substrate to form a panel structure; and
the foam material cures to form the multilayer foam panel member comprising the second top sheet substrate, the first bottom sheet substrate, and the foam material cured integrally therebetween.
2 . The production line of claim 1 , wherein each of the first bottom sheet substrate and the second top sheet substrate is a metal substrate.
3 . The production line of claim 1 , wherein the foam material is a polyurethane foam.
4 . The production line of claim 1 , wherein the foam material is a polyisocyanurate foam.
5 . The production line of claim 1 , wherein the production line is a double band lamination production line.
6 . The production line of claim 1 , wherein the components of the foam-forming fluid reactive mixture include an isocyanate component and an isocyanate-reactive component.
7 . A process for manufacturing the multilayer foam panel member using the production line claimed in claim 1 .
8 . The process of claim 7 wherein the foam-forming fluid reactive mixture is dispensed during a double band lamination production process to provide an even distribution of the foam-forming fluid reactive mixture from the flexible fluid dispensing device onto the surface of the first bottom sheet substrate.
9 . The production line of claim 1 , wherein the flexible multilayer film includes at least one layer made of a heat-sealing material that is heat sealed such that the at least one layer defines the series or pattern of flexible fluid flow path ducts within the flexible multilayer film.
10 . The production line of claim 1 , wherein the rigid frame is coupled to the side edges of the flexible multilayer film.
11 . The production line of claim 1 , wherein the side edges of the flexible multilayer film are distinct from portions of the flexible multilayer film that define the series or pattern of flexible fluid flow path ducts defined within the flexible multilayer film, the at least one fluid inlet aperture, and the plurality of fluid outlet apertures.
12 . The production line of claim 1 , wherein the series or pattern of flexible fluid flow path ducts defined within the flexible multilayer film are branched.
13 . The production line of claim 1 , wherein the at least one fluid inlet aperture is positioned on a front end of the flexible multilayer film.
14 . The production line of claim 1 , wherein the plurality of fluid outlet apertures are positioned on a back end of the flexible multilayer film.
15 . The production line of claim 1 further comprising a cutting tool for cutting the multilayer foam panel member into predetermined discrete panel sections.