Abstract An improved building panel is disclosed comprising a foam core having bonded to opposite sides thereof an outer skin or cover plate. The outer skins are bent along the two longwise edges thereof and receive a wooden edging member therebetween, the edging member being bonded to both the outer skins and the foam core. The edging members are preferably tongue and groove, i.e., having a tongue construction along one longitudinal edge of the panel and a groove construction along the opposite longitudinal edge of the panel. The tongued edging has a plurality of latch means disposed therealong while the grooved edge has a plurality of matching latch pins disposed therealong, said tongue and groove construction and latches and latch pins enabling a rigid connection between adjacent panels. A superior panel is produced that avoids delamination under extreme conditions. The bond is produced by a two adhesive system. A first adhesive is applied to the foam core and a second adhesive is applied to the outer skins and edging members. The foam core adhesive must be compatible with the foam and the second adhesive and preferably is a water base polychloroprene adhesive. The second adhesive, applied to the outer skin and edging is a solvent based adhesive which is normally incompatible with the foam. When the two adhesives are brought together in a virtually non tacky state, however, the foam core adhesive prevents destruction of the foam by the solvent based adhesive and, upon curing, the two adhesives provide a superior laminate bond. A process for manufacturing the panel is also disclosed and claimed.
A process for producing a building panel comprising the steps of: a. preparing outer skins and edge members and applying a solvent based adhesive to selected portions thereof; b. preparing a foam core and applying a water dispersed adhesive thereto; c. drying said adhesives to a substantially non tacky state; d. assembling the outer skins, edge members and foam core to provide a panel; e. applying pressure to said assembled panel, said pressure being sufficient to expel air therefrom; f. heating said panel to occure the adhesive compositions; and g. applying further pressure said panel while said panel is hot to insure complete bonding and expel further air therefrom.
Claim 2
Dependent Claim
109 words
A process for producing a building panel comprising the steps of: a. preparing outer skins and edge members and applying a solvent based adhesive to selected portions thereof; b. preparing a foam core and applying a water dispersed adhesive thereto; c. drying said adhesives to a substantially non tacky state; d. assembling the outer skins, edge members and foam core to provide a panel; e. applying pressure to said assembled panel, said pressure being sufficient to expel air therefrom; f. heating said panel to occure the adhesive compositions; and g. applying further pressure said panel while said panel is hot to insure complete bonding and expel further air therefrom.
Claim 3
Dependent Claim
32 words
The process as defined in claim 1 wherein the panel is heated by passing same through a tunnel oven at a temperature in the range of from about 140°F to about 150°F.
Claim 4
Dependent Claim
24 words
The process as defined in claim 2 wherein said panel is conveyed through said oven at a rate of about 2 feet per minute.
Claim 5
Dependent Claim
22 words
The process as defined in claim 1 wherein said first pressure application is made by passing said panel between opposing steel rollers.
Claim 6
Dependent Claim
23 words
The process as defined in claim 4 wherein the second pressure application is made by passing the hot panel between opposing rubber rollers.
Claim 7
Dependent Claim
25 words
The process as defined in claim 1 wherein the adhesive applied to said outer skins and edge members is a solvent based polychloroprene adhesive composition.
Claim 8
Dependent Claim
22 words
The process as defined in claim 6 wherein the adhesive applied to the foam core is a water dispersed polychloroprene adhesive composition.
Claim 9
Dependent Claim
153 words
A process for producing a building panel comprising the steps of: a. preparing outer skins and edge members and applying a solvent based polychloroprene adhesive to selected portions thereof; b. preparing a foam core and applying a water based polychloroprene adhesive thereto; c. drying said adhesives to a substantially non-tacky state; d. assemblying the outer skins, edge members and foam core to provide a panel; e. passing said assembled panel between a pair of rollers preset to impart pressure only to insure contact at all areas to be bonded while expelling any entrapped air therefrom; f. heating said panel on both sides at a temperature in the range of about 140° to about 150°F. for a time sufficient to cocure said adhesives; and g. immediately passing said panel through a pair of rubber covered rollers preset at a space to impart sufficient pressure to insure good bonding and expel any further air therefrom.
Claim 10
Dependent Claim
153 words
A process for producing a building panel comprising the steps of: a. preparing outer skins and edge members and applying a solvent based polychloroprene adhesive to selected portions thereof; b. preparing a foam core and applying a water based polychloroprene adhesive thereto; c. drying said adhesives to a substantially non-tacky state; d. assemblying the outer skins, edge members and foam core to provide a panel; e. passing said assembled panel between a pair of rollers preset to impart pressure only to insure contact at all areas to be bonded while expelling any entrapped air therefrom; f. heating said panel on both sides at a temperature in the range of about 140° to about 150°F. for a time sufficient to cocure said adhesives; and g. immediately passing said panel through a pair of rubber covered rollers preset at a space to impart sufficient pressure to insure good bonding and expel any further air therefrom.