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.

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.

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 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 multilayer foam panel member including: (a) at least one top sheet substrate; (b) at least one bottom sheet substrate; and (c) a middle substrate of foam material disposed inbetween, and integral with, the top and bottom sheet substrates; wherein the foam material is produced by dispensing a reactive foam-forming fluid mixture onto a moving or stationary bottom sheet substrate of a foam manufacturing line; and wherein the foam manufacturing line includes a flexible film fluid dispensing device for dispensing the reactive foam-forming fluid mixture onto the moving or stationary bottom sheet substrate to form a multilayer foam panel member; wherein the middle substrate of foam material of the panel member has improved thermal and mechanical properties; and a process for manufacturing the above multilayer foam panel member.

A multilayer foam panel member including: (a) at least one top sheet substrate; (b) at least one bottom sheet substrate; and (c) a middle substrate of foam material disposed inbetween, and integral with, the top and bottom sheet substrates; wherein the foam material is produced by dispensing a reactive foam-forming fluid mixture onto a moving or stationary bottom sheet substrate of a foam manufacturing line; and wherein the foam manufacturing line includes a flexible film fluid dispensing device for dispensing the reactive foam-forming fluid mixture onto the moving or stationary bottom sheet substrate to form a multilayer foam panel member; wherein the middle substrate of foam material of the panel member has improved thermal and mechanical properties; and a process for manufacturing the above multilayer foam panel member.

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.

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.