Rotating Brush Adhesive Transfer for Foam Core Sandwich Panels
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Solution Overview
Problem
The adhesion of foam to the upper metal sheet in PIR/PUIR/PUR foam cored sandwich panels is weaker compared to the adhesion to the lower metal sheet, limiting the bonding strength of the foam to the upper sheet in continuous double belt production processes.
Innovation Solution
A rotating brush is used to transfer a portion of the adhesive applied to the lower metal sheet onto the upper metal sheet, ensuring consistent and improved adhesion of the foam to both metal sheets by distributing the adhesive evenly across the width and length of the upper sheet, with the adhesive being applied over a complete width and a substantial portion of the adhesive from the lower sheet being transferred.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied only to the lower metal sheet, then the adhesion of foam to the lower metal sheet is improved, but the adhesion of foam to the upper metal sheet becomes weaker
Solution Approach 1:
The patent applies adhesive locally to specific areas: the lower metal sheet receives full adhesive application, while the upper metal sheet receives adhesive only at its lower edge portion through the rotating brush. This localized application strategy ensures strong bonding where most needed while maintaining adequate bonding elsewhere, resolving the contradiction between maximizing lower sheet adhesion and ensuring upper sheet adhesion consistency.
Solution Approach 2:
The rotating brush applies adhesive to the upper metal sheet's lower edge portion before the foam core material is inserted. This preliminary action ensures that the adhesive is already in position to create strong bonding when the foam is inserted, preventing the adhesion weakness that would occur if adhesive application were delayed or insufficient.
2Strength
If adhesive is applied to both metal sheets, then the adhesion to both sheets is improved, but the adhesive consumption increases
Solution Approach 1:
Instead of applying adhesive uniformly to both metal sheets, the patent applies adhesive to the lower metal sheet fully and only to the lower edge portion of the upper metal sheet. This localized application strategy maintains strong bonding performance while significantly reducing overall adhesive consumption compared to full-bias application to both sheets.
Solution Approach 2:
The patent uses partial action by applying adhesive to only the critical lower edge portion of the upper metal sheet rather than the entire surface. This partial application is sufficient to achieve the required bonding strength while minimizing adhesive usage, effectively resolving the contradiction between strength improvement and consumption reduction.
3Strength
If a rotating brush is used to apply adhesive to the upper metal sheet, then the adhesion of foam to the upper metal sheet is improved, but the device complexity increases
Solution Approach 1:
The rotating brush acts as an intermediary device between the adhesive supply and the upper metal sheet. It efficiently transfers adhesive from the lower sheet area to the upper sheet's lower edge portion through rotation, providing a simple mechanical solution that improves adhesion without requiring complex multi-component application systems.
Solution Approach 2:
The rotating brush is designed to be self-regulating in its adhesive transfer function. As it rotates between the adhesive-coated lower sheet and the upper sheet, it automatically picks up and distributes the appropriate amount of adhesive without requiring complex control systems, maintaining simplicity while achieving the desired adhesion improvement.
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 method enhances the adhesion strength of the upper metal sheet to the foam core material, making it comparable to the adhesion strength of the lower metal sheet, thereby improving the overall bonding quality and consistency in the production of PIR/PUIR/PUR foam cored sandwich panels.
Implementation Method 1
a rotating brush, wherein the rotating brush is adapted to apply a portion of the adhesive applied to the lower metal sheet to the upper metal sheet
Data Source
AI summary
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.