Method and apparatus for manufacturing building panels
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Solution Overview
Problem
Current methods for manufacturing building panels with foam insulation lack efficiency in ensuring consistent foam thickness and bonding to the frame, leading to variations in insulation quality and structural integrity.
Innovation Solution
A method involving a multi-panel consolidation device that applies a compressive force to limit foam expansion, using a frame with defined cavities and injection apertures, and injecting an expandable polymer to form stable expanded foam bonded to the frame, while maintaining precise control over foam thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional foam injection methods are used without consolidation device, then the manufacturing process is simpler, but foam thickness consistency deteriorates with tolerance greater than 2 mm
Solution Approach 1:
The consolidation device is divided into multiple shelves that can be independently positioned and adjusted. Each shelf can apply localized compressive force to the foam, allowing precise control over foam thickness across different regions of the building panel. This segmentation enables the system to achieve uniform foam thickness tolerance of less than 2 mm while maintaining a modular, manageable device structure.
Solution Approach 2:
The shelves are positioned and adjusted before foam injection to pre-establish the desired cavity volume and compression force distribution. This preliminary configuration ensures that when the expandable polymer is injected, the foam expands uniformly and achieves the target thickness consistency. The injection apertures are also pre-positioned in the frame members to align with cavities, enabling precise foam placement from the outset.
2Manufacturing precision
If foam is allowed to expand freely without compression, then the foam can fill the cavity completely, but foam thickness uniformity deteriorates with variations exceeding 2 mm
Solution Approach 1:
The consolidation device allows dynamic adjustment of compressive force parameters during the foam expansion process. By controlling the position and force applied by each shelf, the system can modify the compression parameters to achieve uniform foam thickness. The shelves can be positioned at different heights and apply different forces to compensate for variations in foam expansion, ensuring thickness uniformity within 2 mm tolerance while maintaining complete cavity filling.
3Productivity
If multiple building panels are manufactured individually, then each panel can be produced with simple equipment, but manufacturing efficiency deteriorates with longer production time
Solution Approach 1:
The consolidation device merges multiple building panel manufacturing operations into a single integrated system. Multiple panels are placed on different shelves within the same device, and the foam injection and compression processes are performed simultaneously on all panels. This combining of operations achieves significant productivity improvement while the modular shelf design keeps the device complexity manageable and the structure organized.
Solution Approach 2:
The consolidation device is designed with universal shelves and injection systems that can accommodate multiple building panels of the same type simultaneously. The device performs multiple functions: holding frames, injecting foam, applying compression, and maintaining force during curing. This multi-functionality increases manufacturing efficiency without requiring separate specialized equipment for each panel, balancing productivity gains with reasonable device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures consistent foam thickness with a tolerance of less than 2 mm, enhancing insulation quality and structural integrity of building panels by maintaining precise foam expansion within the frame's cavities.
Implementation Method 1
injecting an expandable polymer through the at least one injection aperture into the at least one cavity... permit the expandable polymer to form a stable expanded foam within the at least one cavity
Implementation Method 2
The forcing the shelves of the multi-panel consolidation device into the collapsed configuration includes applying a compressive force to the frame and constraining expansion of the expandable polymer
Data Source
AI summary
A method of manufacturing building panels includes assembling a frame of a building panel. The frame defines at least one cavity and at least one injection aperture in fluid communication with the at least one cavity. The method also includes positioning the frame on one of a base and a shelf of a multi-panel consolidation device having a plurality of shelves, with the shelves being in an expanded configuration, and at least substantially enclosing the at least one cavity. The method also includes forcing the shelves of the multi-panel consolidation device into a collapsed configuration, and injecting an expandable polymer through the at least one injection aperture into the at least one cavity. The method further includes forcing the shelves into an expanded configuration after a predetermined period of time selected to permit the expandable polymer to form a foam bonded to the frame.