Polyisocyanurate Panel Production with Heated Foil Bonding
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Solution Overview
Problem
Existing methods for producing polyisocyanurate insulation panels face challenges in achieving consistent quality, aesthetic appeal, and compressive strength, particularly in the thickness direction, during the production process.
Innovation Solution
A method involving the uninterrupted deposition of a liquid polyisocyanurate foam formulation on a foil supported by a heated table, where the foam reacts and bonds to the foil in the transverse direction, ensuring uniform fixation and controlled expansion, thereby orienting cells mainly in the thickness direction for improved compressive strength and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the liquid polyisocyanurate foam formulation is deposited on the foil without uninterrupted moistening, then the production process is simpler, but the foil surface shows folds and creases resulting in poor aesthetic appearance
Solution Approach 1:
The foil is pre-heated on the heated table before the liquid foam formulation is deposited. This preliminary heating action prepares the foil surface to immediately bond with the foam upon deposition, preventing folds and creases from forming during the moistening process, thus achieving smooth aesthetic appearance without complicating the overall production process
2Manufacturing precision
If the foam formulation flows in the width direction during deposition, then the application process is simpler, but folds and creases form in the foil reducing aesthetic quality
Solution Approach 1:
The temperature parameter of the foil is changed by pre-heating it on the heated table before foam deposition. This parameter change causes the foam to immediately react and bond with the heated foil upon contact, preventing the foam from flowing in the width direction and eliminating folds and creases, thereby improving aesthetic appearance while maintaining deposition simplicity
3Manufacturing precision
If the foam is not quickly fixed to the foil, then the bonding process is less intensive, but the foil surface develops folds and creases during production
Solution Approach 1:
The foil is pre-heated on the heated table before foam deposition, creating optimal bonding conditions in advance. This preliminary action enables the foam to quickly fix to the foil immediately upon contact without requiring excessive reaction intensity, preventing folds and creases while maintaining controlled power levels during the bonding process
4Strength
If the cells in the polyisocyanurate foam are not oriented in the thickness direction, then the foam expansion is more uniform in all directions, but the compressive strength in the thickness direction is reduced
Solution Approach 1:
The temperature parameter of the foil is pre-increased on the heated table before foam deposition. This parameter change creates a temperature gradient that directs the foam expansion primarily in the thickness direction, causing cells to orient vertically. This results in improved compressive strength in the thickness direction while maintaining controlled and stable foam composition
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 results in insulation panels with enhanced compressive strength and a pleasing aesthetic appearance, achieved through controlled chemical reactions and uniform bonding, facilitating a continuous production process.
Implementation Method 1
the foil is supported by a heated table, wherein, in the method, the liquid polyisocyanurate foam formulation reacts to form a polyisocyanurate foam which is bonded to the foil
Implementation Method 2
the polyol reacts with the di-isocyanate to form a rigid foam
Data Source
Figure 1~3
Figure 4~6
AI summary
Method for producing a polyisocyanurate panel, wherein the produced insulation panel comprises a polyisocyanurate foam (12) between two foils (14, 16). A liquid polyisocyanurate foam formulation (18) is deposited on a foil (14), so that, at the position where the liquid foam formulation is deposited on the foil (14), the foil is moistened in an uninterrupted manner in the direction at right angles to the direction of production. The foil (14) is supported by a heated table (20) at the position where the liquid foam formulation is deposited on the foil. The liquid polyisocyanurate foam formulation (18) reacts to form a polyisocyanurate foam (12) which is bonded to the foil (14).