US4252515A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Apparatus for the continuous fabrication of cellular products of a thermosetting resin
Assignee: Saint Gobain Industries SA
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Filing: 1978-09-22
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Granted: 1981-02-24
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Expires: 1998-09-22
Abstract
Abstract A method for the continuous fabrication of blankets or sheets of expanded phenolic resin displaying a hard skin on each of their sides, according to which a mixture, comprising in particular a resole resin, a blowing agent and a hardening catalyst is placed on an essentially flat surface of a moving conveyor, is completely expanded, and is conformed eventually between two parallel surfaces entrained in the same direction, the second surface being located above and substantially parallel to and able to move at the same speed as the moving surface, characterized in that, in a first stage, after having been distributed at the surrounding temperature and in the liquid state along the whole width of the surface of the transport component, in such a way so as to comprise a blanket of expandable liquid mixture essentially uniform in thickness, the expandable mixture is conveyed in the open air towards the conformation surfaces while being submitted to a heating so that it expands, the degree of heating and the length of the path in the open air being chosen in a way that the upper skin loses its stickiness before the complete expansion of the mixture and that after the complete expansion, the obtained expanded mass reaches an immediate hardening state, the upper skin remaining supple and unsticky; and then the expanded mass is formed by the exertion of pressure on its free side at the time of entry between the conformation surfaces, thus reducing the thickness of the mass to its definitive value; and finally the hardening of the resin is completed by maintaining the pressure and the heat during the passage between the conformation surfaces.
Inventors
- 👤 Jean P. Meunier
- 👤 Marie P. Barthe
- 👤 Serge Have
- 👤 Bernard Frumen
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-06 13:05
CPC Classifications
B; B29; B29C; B29C44/00; B29C44/20; B29C44/22; B29L; B29L2007/00; Y; Y10; Y10S; Y10S264/00; Y10S264/02
Claims Analysis
Total Claims: 28
Claim 1
Independent Claim
232 words
Apparatus for the continuous manufacture of blankets or sheets of expanded phenolic resin having a hard skin on each face, comprising: (a) a displaceable mixer gun; (b) a moving surface set below the mixer gun and on which the mixer gun deposits the expandable phenolic resin mixture, which moving surface is divided into a first cold zone, a second zone that is heated and is downstream of the first cold zone, and a third zone that is heated and is downstream of the second zone; (c) an upper movable surface which is placed in a substantially parallel position to the third zone of the moving surface and which has a length and width that are substantially equal to the third zone of the moving surface; (d) heating means for heating the upper movable surface and the second and third zones of the moving surface; (e) movable side belts placed on both sides of the lower surface along a length coinciding with the first and second zones of the moving surface and forming with the moving surface a tight contact with the expandable phenolic resin mixture; and (f) movable side rollers placed in alignment with the downstream end of the movable side belts and at the entrance of the third zone, which movable side rollers form with the moving surface and upper movable surface a tight contact with the expandable phenolic resin mixture.
Claim 2
Dependent Claim
232 words
Apparatus for the continuous manufacture of blankets or sheets of expanded phenolic resin having a hard skin on each face, comprising: (a) a displaceable mixer gun; (b) a moving surface set below the mixer gun and on which the mixer gun deposits the expandable phenolic resin mixture, which moving surface is divided into a first cold zone, a second zone that is heated and is downstream of the first cold zone, and a third zone that is heated and is downstream of the second zone; (c) an upper movable surface which is placed in a substantially parallel position to the third zone of the moving surface and which has a length and width that are substantially equal to the third zone of the moving surface; (d) heating means for heating the upper movable surface and the second and third zones of the moving surface; (e) movable side belts placed on both sides of the lower surface along a length coinciding with the first and second zones of the moving surface and forming with the moving surface a tight contact with the expandable phenolic resin mixture; and (f) movable side rollers placed in alignment with the downstream end of the movable side belts and at the entrance of the third zone, which movable side rollers form with the moving surface and upper movable surface a tight contact with the expandable phenolic resin mixture.
Claim 3
Dependent Claim
256 words
Apparatus for the continuous manufacture of blankets or sheets of expanded phenolic resin having a hard skin on each face, comprising: (a) a displaceable mixer gun; (b) a moving continuous conveyor belt wound upon two drums and set below the mixer gun and on which the mixer gun deposits the expandable phenolic resin mixture, which moving belt is divided into a first cold zone, a second zone that is heated and is downstream of the first cold zone, and a third zone that is heated and is downstream of the second zone; (c) an upper movable continuous conveyor belt wound upon two drums and placed in a substantially parallel position directly above the third zone of the moving belt and which has a length and width that are substantially equal to the third zone of the lower moving belt; (d) heating means for heating the upper movable belt and the second and third zones of the lower moving belt; (e) movable side belts placed on both sides of the lower moving belt along a length coinciding with the first and second zones of the lower moving belt and forming with the lower moving belt a tight contact with the expandable phenolic resin mixture; and (f) movable side rollers placed in alignment with the downstream end of the movable side belts and at the entrance of the third zone of the lower moving belt, which movable side rollers form with the lower moving belt and upper movable belt a tight contact with the expandable phenolic resin mixture.
Claim 4
Dependent Claim
256 words
Apparatus for the continuous manufacture of blankets or sheets of expanded phenolic resin having a hard skin on each face, comprising: (a) a displaceable mixer gun; (b) a moving continuous conveyor belt wound upon two drums and set below the mixer gun and on which the mixer gun deposits the expandable phenolic resin mixture, which moving belt is divided into a first cold zone, a second zone that is heated and is downstream of the first cold zone, and a third zone that is heated and is downstream of the second zone; (c) an upper movable continuous conveyor belt wound upon two drums and placed in a substantially parallel position directly above the third zone of the moving belt and which has a length and width that are substantially equal to the third zone of the lower moving belt; (d) heating means for heating the upper movable belt and the second and third zones of the lower moving belt; (e) movable side belts placed on both sides of the lower moving belt along a length coinciding with the first and second zones of the lower moving belt and forming with the lower moving belt a tight contact with the expandable phenolic resin mixture; and (f) movable side rollers placed in alignment with the downstream end of the movable side belts and at the entrance of the third zone of the lower moving belt, which movable side rollers form with the lower moving belt and upper movable belt a tight contact with the expandable phenolic resin mixture.
Claim 5
Dependent Claim
31 words
Apparatus according to claim 2 in which the speed of the movable side belts and movable side rollers is equal to that of the lower moving surface and upper movable surface.
Claim 6
Dependent Claim
74 words
Apparatus according to claim 2 in which the movable side rollers freely turn and have a height equal to the separation between the lower moving belt and upper movable belt and which movable side rollers have axes that are disposed vertically in the plane containing the horizontal axis of the anterior drum of the upper movable belt, the faces of these movable side rollers being aligned on the surfaces of the movable side belts.
Claim 7
Dependent Claim
33 words
Apparatus according to claim 2 wherein displaceable distributing combs are placed adjacent to the lower moving belt at a location in the first cold zone that is downstream of the displaceable mixer gun.
Claim 8
Dependent Claim
20 words
Apparatus according to claim 2 wherein the distance between the lower moving belt and uper movable belt can be adjusted.
Claim 9
Dependent Claim
25 words
Apparatus according to claim 2 wherein the interior drum of the upper movable belt has a radius of between about 25 cm and 50 cm.
Claim 10
Dependent Claim
17 words
Apparatus according to claim 2 wherein the movable side rollers are made of steel coated with polytetrafluoroethylene.
Claim 11
Dependent Claim
17 words
Apparatus according to claim 2 wherein the movable side belts and movable side rollers have heating means.
Claim 12
Dependent Claim
28 words
Apparatus according to claim 2 in which the displaceable mixer gun is equipped with means for activating a regular to-and-fro movement along the whole width of the belt.
Claim 13
Dependent Claim
33 words
Apparatus according to claim 2 in which the first cold zone is equipped with means for maintaining the temperature of the expandable phenolic resin mixture at a temperature of less than 23° C.
Claim 14
Dependent Claim
27 words
Apparatus according to claim 3 in which the second zone is equipped with means of heating the expandable phenolic resin mixture to a maximum of 60° C.
Claim 15
Dependent Claim
25 words
Apparatus according to claim 2 in which the movable side rollers have a height which corresponds to the greatest thickness of the expanded phenolic resin.
Claim 16
Dependent Claim
29 words
Apparatus according to claim 2 which further includes turning brushes to clear the particles of expandable phenolic resin mixture adhering to the upper movable belt and lower moving belt.
Claim 17
Dependent Claim
32 words
Apparatus according to claim 2 in which the third zone is equipped with means of heating the expandable phenolic resin to a temperature of between about 50° C. and about 70° C.
Claim 18
Dependent Claim
34 words
Apparatus according to claim 13 in which the lower moving belt, upper movable belt, movable side belts and movable side rollers each have a nonadhesive surface in contact with the expandable phenolic resin mixture.
Claim 19
Dependent Claim
19 words
Apparatus according to claim 16 in which the nonadhesive surface is a band of rubber material with polytetrafluoroethylene surfaces.
Claim 20
Dependent Claim
27 words
Apparatus according to claim 2 in which heating means maintain at approximately the same temperature, the lower moving surface and adjoining portions of the movable side belts.
Claim 21
Dependent Claim
32 words
Apparatus according to claim 2 in which heating means maintain at approximately the same temperature, the movable side rollers and the adjoining portions of the lower moving belt and upper movable belt.
Claim 22
Dependent Claim
23 words
Apparatus according to claim 2 further including means for cutting the material into panels after the material has passed through the third zone.
Claim 23
Dependent Claim
16 words
Apparatus according to claim 20 in which the means for cutting is a transversal sawing apparatus.
Claim 24
Dependent Claim
22 words
Apparatus according to claim 20 further including a means for drying the resin material after that material has been cut into panels.
Claim 25
Dependent Claim
40 words
Apparatus according to claim 22 in which the drying means consists of a heating means capable of heating the panels of resin material to a temperature of between about 70° C. and about 150° C. during this further drying step.
Claim 26
Dependent Claim
40 words
Apparatus according to claim 22 in which the drying means consists of a heating means capable of heating the panels of resin material to a temperature of between about 110° C. and about 120° C. during this further drying step.
Claim 27
Dependent Claim
22 words
Apparatus according to claim 2 in which the distance between the side rollers is less than the distance between the side belts.
Claim 28
Dependent Claim
18 words
Apparatus according to claim 2 in which the distance between the side belts and side rollers is adjustable.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1984-02-24 | 1984-08-25 | 1985-02-24 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1988-02-24 | 1988-08-25 | 1989-02-24 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1992-02-24 | 1992-08-25 | 1993-02-24 | $7700.00 | Window Closed / Lapsed |