Patent ID: 6117375
Filing Date: 2000-09-12
Classification: B29C,E04C,E04D

Abstract:
A continuous method of making a facerless insulation board comprising the steps of:feeding a first sheet of temporary facer material into a laminator;depositing a foamable polymer liquid onto the first sheet;feeding a second sheet of temporary facer material into said laminator above the foamable polymer liquid;allowing the polymer liquid to rise between the first and second sheets forming polymer foam of a pre-determined thickness;curing the polymer foam under heat to create the insulation board;removing the first and second sheets from the board prior to final curing and cooling;cutting the board to desired lengths; andstacking a plurality of said boards in a separator assembly for additional curing and subsequent stacking; wherein said separator assembly comprises a plurality of arm members attached at one end to a frame member, and wherein said step of stacking includesplacing a first board onto one of said arms;positioning a subsequent arm over said first board;repeating said steps of placing and positioning to form a bundle of said boards within said separator assembly; andstoring said boards in said bundle for a period of time sufficient to allow said boards to become dimensionally stable.