Laminated panels are made in a process whereby a starting foam formulation is processed through a mixhead, passed through a branched distribution system and dispensed through multiple outlets of the distribution system to produce a foam layer on a bottom facing layer. The foam layer is monitored for the presence of surface bubbles. When surface bubbles are observed, the backpressure in the mixhead is increased to reduce or eliminate the surface bubbles. An apparatus for performing the process includes an adjustment means at or upstream of a first branch point in the distribution system to increase or decrease the backpressure in the mixhead.

An adjustable distributor apparatus (10) for dispensing a foam forming mixture comprising a main body (20) and adjustment plate, the main body featuring at least one inlet, one channel, and one outlet, the inlet, channel and outlet in fluid connection such that a fluid may pass through the inlet into the channel and exit from the channel through the outlet, and the outlet being coupled with at least one adjustment plate (40), the adjustment plate featuring at least a first face, a second face opposing the first face, and an outlet hole, enabling a seal between either the outlet of the main body or the second face of a second adjustment plate, and the outlet hole extending from the first face to the second face by way of a fluid connection through the adjustment plate.

Described is a system for controlling the sizing of a rising foam emulsion web travelling on a conveyor. The system includes a plate arrangement and an actuating arrangement. The plate arrangement includes at least a first and a second plate, each having a web-facing lower side and an opposite upper side. The second plate is configured to be located downstream of the first plate with respect to the direction of travel of the foam emulsion web. The actuating arrangement includes a base portion and a top portion. The top portion is movable relative to the base portion and operatively connected to the plate arrangement. The actuating arrangement is configured to individually adjust for each plate a separating distance relative to the base portion, for controlling the rising of the foam emulsion web along at least a part of its travel.

Method of designing and manufacturing a distributor bar for use in a production line comprising a mixing head for providing a viscous foamable liquid mixture, a laminator with a predefined speed of at least 20 m/min, the distributor bar having a central inlet fluidly connected to a number of outlets via a main channel. The method comprises: choosing (3001) a geometry for the distributor bar and defining a set of geometrical parameters; assigning (3002) values to said parameters; creating (3003) a virtual model; simulating (3005) flow in said model by performing a Computational Fluid Dynamics simulation (CFD), taking into account (3004) a non-Newtonian shear thinning model; e) evaluating the simulated flow; building (2007) a physical distributor bar. A distributor bar, a production line, and a computer program product.

Laterally-coalesced foam slabs and methods and apparatus, including foaming dies, for making and using such foam slabs.

Foam slabs and methods and apparatus, including foaming dies, for making and using foam slabs.

Apparatus for supplying multiple foam machines with foam precursor chemicals. The apparatus comprises first and second totes having a top opening and a bottom drain and containing first and second foam precursor chemicals, first and second supply lines connected to the bottom drains of the first and second totes and in fluid communication with first and second sets of batcher stands, and first and second sets of batcher pumps each of which is positioned in a respective one of the first and second sets of batcher stands. Each batcher pump is adapted to be in fluid communication with a respective one of the foam machines.

The invention relates to a device (100) for applying a foaming reaction mixture (600) onto a top layer (500), in particular for producing a composite element, comprising at least one casting rake (200, 260) with a tubular hollow body (210), said hollow body (210) extending along a central axis (250) and having at least two outlet openings (220) for discharging the foaming reaction mixture (600). The casting rake (200, 260) and the top layer (500) can be moved relative to each other along a longitudinal axis (510). According to the invention, the central axis (250) of the at least one casting rake (200, 260) and the longitudinal axis (510) of the movement form an angle (400, 410) of <=80 DEG relative to each other.

The invention relates to a device (100) for applying a foaming reaction mixture (600) onto a top layer (500), in particular for producing a composite element, comprising at least two casting rakes (200, 260), each of which comprises a tubular hollow body (210), said hollow body (210) extending along a central axis (250) and having at least two outlet openings (220) for discharging the foaming reaction mixture (600). The casting rakes (200, 260) and the top layer (500) can be moved relative to one another in a longitudinal axis (510), and the casting rakes (200, 260) are arranged on a receiving element (700). According to the invention, each arrangement of the casting rakes (200, 260) on the receiving element (700) has a joint (805), by means of which the casting rakes (200, 260) are movably arranged on the receiving element (700) and can be oriented at an angle (400, 410) of <=80 DEG relative to the longitudinal axis (510) of the movement.

A high-density foam cover board, including a high-density foam layer, wherein the high-density foam layer comprise polyurethane, polyisocyanurate, a filler, and a viscosity additive.