Method and apparatus for the continuous production of PIR/PUIR/PUR foam cored sandwich panels

Abstract

The present invention provides a method for the continuous production of a PIR/PUIR/PUR foam cored sandwich panel (12) with metal sheets (16, 18) as facings at top and bottom, wherein the upper metal sheet (16) and the lower metal sheet (18) are continuously fed into a double belt (28), wherein a PIR/PUIR/PUR core material is applied between the upper metal sheet (16) and the lower metal sheet (18), wherein an adhesive is applied to the lower metal sheet (18), wherein a portion of the adhesive applied to the lower metal sheet (18) is applied to the upper metal sheet (16) by means of a rotating brush. The present invention further provides an apparatus for the continuous production of a PIR/PUIR/PUR foam cored sandwich panel (12) with metal sheets (16, 18) as facings at top and bottom.

Claims

1. A method for the continuous production of a PIR/PUIR/PUR foam cored sandwich panel with an upper metal sheet and a lower metal sheet, the method comprising: continuously feeding the upper metal sheet and the lower metal sheet (18) into a double belt, inserting a PIR/PUIR/PUR core material between the upper metal sheet and the lower metal sheet, and applying an adhesive to the lower metal sheet, wherein a portion of the adhesive applied to the lower metal sheet is applied to the upper metal sheet via a rotating brush.

2. The method according to claim 1, wherein the rotating brush extends in a direction parallel to a width of the upper metal sheet and the lower metal sheet.

3. The method according to claim 1, wherein the adhesive is applied to an inner surface of the lower metal sheet and a portion of the adhesive applied to the lower metal sheet is applied to an inner surface of the upper metal sheet via the rotating brush.

4. The method according to claim 3, wherein an amount of the adhesive applied to the inner surface of lower metal sheet is 200 g/m.sup.2 to 300 g/m.sup.2.

5. The method according to claim 1, wherein the adhesive is applied over a complete width of the lower metal sheet.

6. The method according to claim 1, wherein 40% to 60% of the adhesive applied to the lower metal sheet is applied to the upper metal sheet via the rotating brush.

7. The method according to claim 1, wherein a rotation speed of the rotating brush is 60 rpm to 90 rpm.

8. The method according to claim 1, wherein the rotating brush comprises a plurality of blades, wherein each of the plurality of blades comprises a plurality of bristles.

9. The method according to claim 8, wherein the plurality of blades are arranged in rows spaced apart in a circumferential direction around the rotating brush, wherein the rows extend parallel to a rotational axis of the rotating brush.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) By way of example, a method and an apparatus for the continuous production of a PIR/PUIR/PUR foam cored sandwich panel in accordance with the present invention will now be described with reference to the accompanying drawings in which:

(2) FIG. 1 shows a side view of an apparatus for producing PIR/PUIR/PUR foam cored sandwich panels;

(3) FIG. 2 shows a side view of a rotating brush;

(4) FIG. 3 shows a first cross-sectional view of the rotating brush;

(5) FIG. 4 shows a second cross-sectional view of the rotating brush;

(6) FIG. 5 shows a perspective view of a first row of blades; and

(7) FIG. 6 shows a perspective view of a second row of blades.

DETAILED DESCRIPTION

(8) FIG. 1 shows a side view of an apparatus 10 for the continuous production of a PIR/PUIR/PUR foam cored sandwich panel 12. Such a sandwich panel 12 comprises a foam core 14, which is made of polyisocyanurate (PIR), polyurethane-modified-polyisocyanurate (PUIR) or polyurethane (PUR), an upper metal sheet 16 and a lower metal sheet 18 as facings which sandwich the foam core 14.

(9) The apparatus 10 comprises an upper roller 20 on which the upper metal sheet 16 is provided or rolled up and a lower roller 22 on which the lower metal sheet 18 is provided or rolled up. The apparatus 10 further comprises an adhesive dispenser 24 for applying an adhesive, a core material dispenser 26 for applying a PIR/PUIR/PUR core material as foam core material and a double belt 28 for conveying the upper metal sheet 16 and the lower metal sheet 18. Between the adhesive dispenser 24 and the core material dispenser 26, a rotating brush 30 is arranged. With respect to a conveying direction of the upper metal sheet 16 and the lower metal sheet 18, the rotating brush 30 is arranged downstream from the adhesive dispenser 24. Particularly, the rotating brush 30 is arranged at a distance of 300 cm to 500 cm, preferably 350 cm to 450 cm and most preferably 370 cm to 430 cm from the adhesive dispenser 24, for example 400 cm. Further, with respect to a conveying direction of the upper metal sheet 16 and the lower metal sheet 18, the rotating brush 30 is arranged upstream from the core material dispenser 26. Particularly, the rotating brush 30 is arranged at a distance of 40 cm to 80 cm, preferably 45 cm to 75 cm and most preferably 50 cm to 70 cm from the core material dispenser 26, for example 60 cm.

(10) The rotating brush 30 extends in a direction parallel to a width of the upper metal sheet 16 and the lower metal sheet 18. Thus, a rotational axis 32 of the rotating brush 30 extends substantially parallel to the upper metal sheet 16 and the lower metal sheet 18. More particularly, the rotational axis 32 extends in a direction parallel to the width of the upper metal sheet 16 and the lower metal sheet 18. Preferably, the rotational axis 32 extends in a horizontal direction, i.e. a direction perpendicular with respect to the direction of gravity.

(11) FIG. 2 shows a side view of the rotating brush 30. The rotating brush 30 comprises a plurality of blades 34. The blades 34 are arranged on a cylindrical body 36 of the rotating brush 30. The body 36 comprises a diameter of 110 mm. Further, a drive shaft 38, which defines the rotational axis 32, extends through the body 36. The drive shaft 38 comprises a diameter of 28 mm. The drive shaft 38 is connected to a pneumatic motor 40 for rotating the rotating brush 30 (FIG. 1). The pneumatic motor 40 may be an air driven motor. The blades 34 are at least partially made of polytetrafluoroethylene. The blades 34 are arranged in rows 42 evenly spaced apart in a circumferential direction around the rotating brush 30. In the embodiment shown, four rows 42 are present. The rows 42 extend parallel to the rotational axis 32 of the rotating brush 30.

(12) FIG. 3 shows a first cross-sectional view of the rotating brush 30 taken along line A-A in FIG. 2 and running through first and third ones of the rows 42. The first and third ones of the rows 42 are split by a gap 44 into two symmetrically arranged groups 46 of blades 34, each having a width 48 of 540 mm. The gap 44 has a width 50 of 35 mm. The overall construction of the rotating brush 30 including the drive shaft 38 has a width 52 of 1710 mm. Thus, the drive shaft 38 protrudes from the body 36 on either side of the body 36 with lengths 54, 56 of 300 mm and 295 mm, respectively.

(13) FIG. 4 shows a second cross-sectional view of the rotating brush 30 taken along line B-B in FIG. 2 and running through second and fourth ones of the rows 42. The construction of the blades 34 of the second and fourth ones of the rows 42 is almost identical to the first and third ones of the rows 42. However, it is to be noted that the blades 34 of two adjacent rows 42 are arranged relative to one another in a direction parallel to the rotational axis 32 of the rotating brush 30 as will be explained in more detail below.

(14) FIG. 5 shows a perspective view of a first row 42 of the blades 34. More particularly, FIG. 5 shows a perspective view of a first group 46 of a first row 42 of the blades 34. The blade 34 comprises a plurality of extension portions 58 and a foot portion 60. The foot portion 60 is adapted to be fixed to the body 36 of the rotating brush 30. The extension portions 58 protrude from the foot portion 60 in a radial direction with respect to the rotational axis 32 of the rotating brush 30. The extension portions 58 are spaced from one another in a direction of the rotational axis 32 with a distance 62 of 30 mm. Each of the extension portions 58 comprises a width 64 of 30 mm except for the extension portions 58 adjacent the gap 44 which comprise a width 66 of 60 mm. Each of the plurality of blades 34 comprises a length 68 of 30 mm to 150 mm. The length 68 is defined by a length 70 of the extension portions 58 and a length 72 of the foot portion 60. The length 68 depends on the thickness of the metal sheets 16, 18. For example, the plurality of blades 34 may comprise a length 68 of 105 mm for metal sheets 16, 18 having a thickness of 4-8 inches and may comprise a length 68 of 70 mm for metal sheets 16, 18 having a thickness of 2-4 inches. Further, each of the blades 34 comprises a plurality of bristles 74. The bristles 74 are arranged at a leading end 76 of the extension portions 58 (FIGS. 3 and 4). Even though not shown in detail, at least in use the bristles 74 protrude from the extension portions 58 in a radial direction with respect to the rotational axis 32 of the rotating brush 30.

(15) FIG. 6 shows a perspective view of a second row 42 of the blades 34 adjacent to the first row 42. More particularly, FIG. 6 shows a perspective view of a second group 46 of a first row 42 of the blades 34. The construction of the blades 34 of the second row 42 is almost identical to the first row 42. However, as mentioned above, it is to be noted that the blades 34 of two adjacent rows 42 are arranged relative to one another in a direction parallel to the rotational axis 32 of the rotating brush 30. With other words and with reference to FIGS. 5 and 6, the extension portions 58 of the first row 42 are shifted relative to the extension portions 58 of the second row 42 in a direction parallel to the rotational axis 32 of the rotating brush 30. More particularly, with reference to FIGS. 5 and 6, the extension portions 58 of the row 42 shown in FIG. 5 are shifted to the right relative to the extension portions 58 of the row 42 shown in FIG. 6.

(16) Now, a method for the continuous production of a PIR/PUIR/PUR foam cored sandwich panel 12 will be explained. The method may be carried out by use of the apparatus 10.

(17) Generally, the upper metal sheet 16 is unrolled from the upper roller 20 and the lower metal sheet 18 is unrolled from the lower roller 22. The upper metal sheet 16 and the lower metal sheet 18 are conveyed towards the double belt 28. It is to be noted that the upper metal sheet 16 and the lower metal sheet 18 are fed through the double belt 28 with the same speed. The speed may be of 3.0 meter per min to 6.0 meter per min. With respect to the illustration of FIG. 1, the conveying direction of the upper metal sheet 16 and the lower metal sheet 18 are fed through the double belt 28 is from the right to the left.

(18) By means of the adhesive dispenser 24, an adhesive is applied to the lower metal sheet 18. More particularly, the adhesive is applied to an inner surface 78 of the lower metal sheet 18. The adhesive may be a one- or two-component adhesive. The adhesive may be an isocyanate-based or isocyanate-polyol reaction adhesive. Preferably, the adhesive may comprise at least a polyol component and an isocyanate component.

(19) For example, the adhesive may be composed as follows:

(20) TABLE-US-00001 32 parts polyetherol, containing sucrose, glycerine and propylene oxide, functionality 5, hydroxyl number 450 mg KOH/g 29.8 parts polyetherol, containing glycerine and propylene oxide, functionality 3, hydroxyl number 400 mg KOH/g 15.0 parts flame retardant Tris(1-chloro-2-propyl) phosphate (TCPP) 10.0 parts di-propylene-glycol, functionality 2, hydroxyl number 837 mg KOH/g 11.3 parts polyetherol, containing glycerine and propylene oxide, functionality 3, hydroxyl number 230 mg KOH/g 0.9 parts silicone surfactant 0.7 parts amine catalyst 0.3 parts green pigment.

(21) An amount of the adhesive applied to the inner surface 78 of the lower metal sheet 18 may be 200 g/m.sup.2 to 300 g/m.sup.2, preferably 220 g/m.sup.2 to 280 g/m.sup.2 and most preferably 230 g/m.sup.2 to 270 g/m.sup.2, for example 250 g/m.sup.2. The adhesive is applied over a complete width of the lower metal sheet 18. The upper metal sheet 16 and the lower metal sheet 18, which has the adhesive applied thereon, are further conveyed towards the rotating brush 30. The rotating brush 30 is driven by means of the pneumatic motor 40. A rotation speed of the rotating brush 30 is 60 rpm to 90 rpm, preferably 65 rpm to 85 rpm and most preferably 70 rpm to 80 rpm, for example 75 rpm. A portion of the adhesive applied to the lower metal sheet 18 is applied to the upper metal sheet 16 by means of the rotating brush 30 which takes up a portion of the adhesive applied to the lower metal sheet 18 and strips it off onto the upper metal sheet 16. More particularly, the portion of the adhesive applied to the lower metal sheet 18 is applied to an inner surface 80 of the upper metal sheet 16 by means of the rotating brush 30. Preferably, 40% to 60% of the adhesive applied to the lower metal sheet 18 is applied to the upper metal 16 sheet by means of the rotating brush 30, for example 50%.

(22) In this respect, it is to be noted that the reactivity of the adhesive is crucial for the function of the rotating brush 30 as it needs to have slow reactivity and may not cure until the upper metal sheet 16 and the lower metal sheet 18 are inside the double-belt 28. The term slow here refers to a gelling time of the adhesive which may be any gelling time longer than 120 seconds at 20 C. Preferably, the gelling time of the adhesive is 164 seconds at 20 C. The adhesive mixture has to remain liquid and comprise a low viscosity for a longer time than usual to allow for the rotating brush 30 to take up the adhesive mixture from the lower metal sheet 18 and to apply it to the upper metal sheet 16, which can only be done effectively and adhesive distributed to the upper metal sheet 16 if the adhesive remains in a liquid state. In the present embodiment, the adhesive is applied to the lower metal sheet 18 at a temperature of 30 C. to 40 C., preferably 32 C. to 38 C. and most preferably 33 C. to 37 C., for example 35 C. The viscosity is low enough due to the polyol component and the isocyanate component of the adhesive. For example, the adhesive comprises a viscosity of 0.5 Pa*s at a temperature of 35 C.

(23) The upper metal sheet 16 and the lower metal sheet 18 having the adhesive applied thereon are then fed into the double belt 28, wherein a PIR/PUIR/PUR core material is applied between the upper metal sheet 16 and the lower metal sheet 18 by means of the core material dispenser 26. The PIR/PUIR/PUR core material reacts so as to form the foam core 14 and comes into contact with the adhesive applied to the upper metal sheet 16 and the lower metal sheet 18. Further, the adhesive cures and the foam core 14 is adhered to the upper metal sheet 16 and the lower metal sheet 18. The upper metal sheet 16 and the lower metal sheet 18 having the foam core 14 sandwiched therebetween is cut such that a foam cored sandwich panel 12 is formed with metal sheets 16, 18 as facings at top and bottom.