A manufacturing line for manufacturing a multilayer foam panel member including: (a) a storage of the components for 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 foam-forming fluid reactive mixture; (c) a flexible fluid dispensing device for receiving the foam-forming fluid reactive mixture; (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 dispensed from the flexible dispensing device; (f) a means for allowing the foam-forming fluid to react, as the fluid travels on the moving bottom sheet substrate, wherein a foam material forms inbetween the moving first bottom sheet substrate and a second top sheet substrate to form a panel structure; (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 to form an integral part of the top and bottom sheet substrates and to form a cured panel structure; and (i) a cutting means for cutting the panel structure into predetermined discrete panel member sections; and a process for manufacturing a multilayer foam panel member using the above manufacturing process.

A thermal insulation injection gun includes a pointed nozzle that prevents blocking of the nozzle by a distal panel of a building cavity and/or by pre-existing insulation within the cavity. In embodiments, the pointed nozzle can be pressed through a panel, thereby forming the injection hole. An enhancement port can be provided through which an enhancing material such as a carrier fluid, particulate or fibrous insulating material, a binder, or a fire retardant can be added and mixed with the insulating material. Embodiments include expanding nozzle wings that can compress pre-existing insulation to create a space on a proximal or distal side thereof for injecting the insulation. A compressible sheath installed over the nozzle can prevent dripping of excess insulation from the panel hole. Exchangeable collars can be used to fix an insertion depth of the nozzle and/or to block selected lateral dispensing ports of the nozzle.

The present disclosure relates generally to methods, devices and systems for insulation, e.g., of cavities associated with walls, ceilings, floors and other building structures, with foam insulation. In one aspect, the disclosure provides a method for providing a cavity of a building with a predetermined amount of foam insulation. The method includes actuating a valve to begin dispensing foam insulation into the cavity, the actuation being performed by a user, the actuation by the user fixing a start time and/or a zero volume of a time and/or volume meter; then, dispensing the foam insulation from the insulation dispenser into the cavity as the time and/or volume meter counts time and/or volume dispensed; then when a predetermined time after the start time elapses or a predetermined volume of the foam insulation beyond the zero volume is dispensed as measured by the time and/or volume meter, actuating the valve to stop dispensing the foam insulation into the cavity.

A device adapted to deliver an insulation enhancing polyurethane foam within profiles used in doors, windows and related applications comprising an insulating material supply member (1) extending into a polyurethane forming and discharge member (2) adapted to enter and move linearly along a chamber (25, 35) of a thermally insulated sash or frame profile assembly and deliver therein a polyurethane foam that absolutely abuts onto the walls of the chamber without exerting undesirable stresses thereupon. The insulating material supply member (1) comprises independent pipes (8, 9) delivering a polyol constituent (A) and an isocyanate constituent (B) that are mixed together with a supply of air within a mixing compartment (4) of the polyurethane forming and discharge member (2) to produce the desired insulating material. The polyurethane supplying assembly starts injection at one end of the profile bar having an industrial standard length and moves rearwards to fill the chamber with the polyurethane insulating material.

Cellular solids combine the properties of the solid material that forms the cell walls and edges with the properties of the matter that fills the cells. This results in unique properties that for many applications are superior to the properties of the single-phase, solid materials. Presented herein, accordingly, are an apparatus and a method for the manufacture of cellular solids with predictable microstructure. The apparatus includes an internally hollow housing defining an extrusion channel, a cell-fluid feeding unit for injecting cell-fluid into the extrusion channel, a conveying element, and a mold or a surface. The method includes injecting cell-fluid into a plasticized matrix in the extrusion channel to form a plasticized foam and dispensing the plasticized foam through an exit port of the extrusion channel into a mold or on a surface.

A thermal insulation injection gun includes a pointed nozzle that prevents blocking of the nozzle by a distal panel of a building cavity and/or by pre-existing insulation within the cavity. In embodiments, the pointed nozzle can be pressed through a panel, thereby forming the injection hole. An enhancement port can be provided through which an enhancing material such as a carrier fluid, particulate or fibrous insulating material, a binder, or a fire retardant can be added and mixed with the insulating material. Embodiments include expanding nozzle wings that can compress pre-existing insulation to create a space on a proximal or distal side thereof for injecting the insulation. A compressible sheath installed over the nozzle can prevent dripping of excess insulation from the panel hole. Exchangeable collars can be used to fix an insertion depth of the nozzle and/or to block selected lateral dispensing ports of the nozzle.

A method for filling a cavity with an expanding insulating foam component includes the following. First, providing a closed cavity comprising at least one elongated wall surface that extends along a first direction and includes first and second opposite sides, a top side and a bottom side. Next, forming a plurality of openings in the elongated wall surface arranged along the first direction and being alternating close to the first or the second opposite sides. Next, inserting a dispense tube through a first opening of the plurality of openings, and injecting a first portion of the expanding insulating foam into the closed cavity. The first opening is located close to the bottom side and close to the first side of the elongated wall surface. The injected foam expands along the bottom side and the first side and forms a first sloped top surface that has a positive slope angle. Next, inserting the dispense tube through a second opening of the plurality of openings located close and above the first opening and close to the opposite second side, and injecting a second portion of the expanding insulating foam into the closed cavity. The injected foam expands along the first sloped top surface and the second side and forms a second sloped top surface that has a negative slope angle.

The present disclosure relates generally to methods, devices and systems for insulation, e.g., of cavities associated with walls, ceilings, floors and other building structures, with foam insulation. In one aspect, the disclosure provides a method for providing a cavity of a building with a predetermined amount of foam insulation. The method includes actuating a valve to begin dispensing foam insulation into the cavity, the actuation being performed by a user, the actuation by the user fixing a start time and/or a zero volume of a time and/or volume meter; then, dispensing the foam insulation from the insulation dispenser into the cavity as the time and/or volume meter counts time and/or volume dispensed; then when a predetermined time after the start time elapses or a predetermined volume of the foam insulation beyond the zero volume is dispensed as measured by the time and/or volume meter, actuating the valve to stop dispensing the foam insulation into the cavity.

Mold for producing a panel assembly comprising a panel and a gasket, which gasket is adhered to the panel, and extends along at least a portion of the periphery thereof, the mold comprising a first mold part and a second mold part that are formed such that the panel can been closed thereby forming a closed cavity the inner boundaries of which are formed by a first mold surface, a second mold surface and the periphery of the panel, and wherein the second mold part comprises a resilient lip extending along the periphery, the resilient lip being provided for being displaced by an applicator device to provide access to the closed cavity.

A device adapted to deliver an insulation enhancing polyurethane foam within profiles used in doors, windows and related applications comprising an insulating material supply member (1) extending into a polyurethane forming and discharge member (2) adapted to enter and move linearly along a chamber (25, 35) of a thermally insulated sash or frame profile assembly and deliver therein a polyurethane foam that absolutely abuts onto the walls of the chamber without exerting undesirable stresses thereupon. The insulating material supply member (1) comprises independent pipes (8, 9) delivering a polyol constituent (A) and an isocyanate constituent (B) that are mixed together with a supply of air within a mixing compartment (4) of the polyurethane forming and discharge member (2) to produce the desired insulating material. The polyurethane supplying assembly starts injection at one end of the profile bar having an industrial standard length and moves reawards to fill the chamber with the polyurethane insulating material.