ALUMINIUM CHASSIS HAVING HEAT INSULATING FOAM FILLED IN OPENING PORTION, ITS MANUFACTURING METHOD AND APPARATUS

Abstract: The present invention relates to an aluminium chassis having heat insulating foam filled in an opening portion, its process and apparatus. There is provided a method for forming heat insulating foam in the opening portion of the aluminium chassis comprising: applying adhesives to the opening portion while the aluminium chassis is moved at a regular speed by an ordinary control unit; closing partially an upper part of an opening portion of the aluminium chassis applied with the adhesives; filling preliminary granular foam into the opening portion; supplying dry vapor directly to the preliminary granular foam; heating indirectly the aluminium chassis while it is transferred; discharging the aluminium chassis; and cooling the aluminium chassis. According to the present invention, the heat insulating foam is filled in the opening portion in accordance with the present invention, whereby enhancing soundproof capability and heat insulating capability. Furthermore, productivity and working efficiency is enlarged as the process for forming the heat insulating foam is carried out successively.

Description: TITLE ALUMINIUM CHASSIS HAVING HEAT INSULATING FOAM FILLED IN OPENING PORTION, ITS MANUFACTURING METHOD AND APPARATUS TECHNICAL FIELD The present invention relates to an aluminium chassis having heat insulating foam filled in an opening portion, its process and apparatus, and more particularly to a method for forming heat insulating foam comprising: closing partially an upper part of an opening portion while the aluminium chassis is moved along the line, filling preliminary granular foam obtained from a first foaming of foamable polystyrene into the opening portion, and supplying dry vapor to the preliminary granular foam for heating and foaming the preliminary granular foam in the opening portion, and an apparatus for carrying out continuously the foaming process. BACKGROUND ART Generally, an aluminium chassis has a free shaped structure formed on the outer surface of the pipe body according to its use, and an opening portion opened toward one side thereof and formed longitudinally. In such a conventional aluminium chassis, it contact with the outer wall of a window frame to form a spatial portion when it constructed on a window or a door. With this aluminium chassis, however, the opening portion of the aluminium chassis is closed, thus a heat insulting capability is weakened especially in winter. As a result, dew forms on the inner surface if the difference between the room temperature and the outdoor temperature is considerable. In addition, heat loss is numerous and sound absorption is insufficient. Therefore, it is necessary to carry out heat insulating treatment to the spatial portion when the aluminium chassis is constructed on the window frame. DISCLOSURE OF THE INVENTION It is an object of the present invention to eliminate the drawbacks in use of the conventional aluminium chassis. To accomplish the object of the present invention, there is provided a method for forming heat insulating foam comprising: closing partially an upper part of an opening portion with a supporting plate for supporting a forming mold to create a spatial portion; filling preliminary granular foam obtained from a first foaming of foamable polystyrene into the spatial portion; and supplying dry vapor to the preliminary granular foam for heating and foaming the preliminary granular foam in the opening portion, and an apparatus for carrying out continuously the foaming process. According to the present invention, in order to form heat insulating foam by foaming the preliminary granular foam in the opening portion of the aluminium chassis, the following steps are carried out: Applying adhesives to the opening portion while the aluminium chassis is moved at a regular speed by an ordinary control unit; closing partially an upper part of an opening portion of the aluminium chassis applied with the adhesives; filling preliminary granular foam into the opening portion; supplying dry vapor directly to the preliminary granular foam; heating indirectly the aluminium chassis while it is transferred; discharging the aluminium chassis; and cooling the aluminium chassis. BRIEF DESCRIPTION OF THE DRAWINGS The details of the present invention will be described in connection with the accompanying drawings, in which Fig. 1 is a side elevation view of the entire construction showing a preferred embodiment according to the present invention; Fig. 2 is a plan view of the entire construction showing a preferred embodiment according to the present invention; Fig. 3 is a perspective view of an adhesives applying means according to the present invention; Fig. 4 is a detailed side elevation view showing an preferred embodiment of a filling means for filling preliminary granular foam, a supplying means for supplying dry vapor, and a maturing means according to the present invention; Fig. 5 is a cross-sectional view of a supporting plate for supporting a forming mold; and Fig. 6 is a cross-sectional view of another preferred embodiment of a supporting plate for supporting a forming mold according to the present invention. BEST MODE FOR CARRYING OUT THE INVENTION Now, the present invention will be described in detail with reference to the accompanying drawings. Fig. 1 is a side elevation view of the entire construction showing a preferred embodiment according to the present invention, and Fig. 2 is a plan view of the entire construction showing a preferred embodiment according to the present invention, which show a method for forming heat insulating foam comprising: closing partially an upper part of an opening portion; filling preliminary granular foam in the opening portion; and supplying dry vapor directly to the preliminary granular foam for heating and foaming the preliminary granular foam in the opening portion, and an apparatus for carrying out continuously the foaming process. As shown in Fig. 1 and Fig. 2, an apparatus for forming heat insulating foam according to the present invention comprises a ' transferring means 10 for transferring an aluminium chassis 100 at a regular speed, an applying means 20 for applying adhesives to an opening portion 100a on the aluminium chassis 100 transferred by the transferring means 10, a filling means 30 for filling preliminary granular foam 110 in the opening portion 100a of the aluminium chassis 100 applied with the adhesives by the applying means 20 for applying adhesives, an supplying means 40 for supplying directly dry vapor to the preliminary granular foam 110 filled in the opening 100a by the filling means 30 for filling preliminary granular foam to heat the preliminary granular foam directly, a maturing means 50 for heating the aluminium chassis 100 such that the preliminary granular foam 110, which is filled by the filling means 30 for filling preliminary granular foam and heated by the supplying means 40 for supplying dry vapor, is foamed, a cooling means 60 for cooling the aluminium chassis 100 having heat insulating foam in the opening portion 100a through foaming of the preliminary granular foam by the maturing means 50, and a drying means 70 for drying the aluminium chassis 100 cooled by the cooling means 60. The transferring means 10, which is provided to transfer the aluminium chassis 100 at a regular speed, comprises a transferring die 13 having a plurality of rollers arranged continuously from on end to the other end, a fair of driving rollers 11 arranged vertically opposite to each other on either side at the front end, or arranged in the same direction as the rollers of the transferring die 13, for transferring successively the aluminium chassis 100 placed on the transferring die 13, and a guide for guiding the aluminium chassis 100 transferred by the driving rollers 11. The guide includes a plurality of guide rollers 12 arranged successively at regular intervals for guiding the aluminium chassis 100 to the rear of the driving rollers 11. Otherwise, the guide may include guiding plates arranged to the both sides of the aluminium chassis 100. The applying means 20 for applying the adhesives, which is provided to apply the adhesives to the aluminium chassis 100 so that heat insulating foam 120 obtained from foaming of the preliminary granular foam 110 is adhered to the aluminium chassis 100, comprises an applying nozzle 21 for applying the urethane or water-soluble adhesives which does not dissolve the preliminary granular foam filled in the opening portion, a control valve 22 for controlling the flow of the adhesives discharged through the applying nozzle 21, and a sensing plate 23 protruded downwardly at the axis of the valve, which is turned by the aluminium chassis 100 entered by the transferring means 10, for allowing the valve 22 to open or close . The filling means 30 for filling preliminary granular foam, which is provided to fill the preliminary granular foam 110 by closing partially an upper part of an opening portion 100a of the aluminium chassis 100, comprises a supporting plate 33 for supporting a forming mold, which close partially an upper part of an opening portion 100a of the aluminium chassis 100 to create a spatial portion, and a supply unit 31 for supplying the preliminary granular foam 110 from a hopper 130 into the spatial portion foamed by the supporting plate 33 for supporting a forming mold. The supporting plate 33 for supporting a forming mold has an inlet portion 33a for granular foam arranged in the central portion and connected to a vacuum pump for generate negative pressure in order that the preliminary granular foam 110 is filled through the supply unit 31 into the spatial portion. The supporting plate 33 for supporting the foaming mold is provided at both ends thereof with a clearance in order that it can not contact with the both side wall of the opening portion 100a to minimize the friction, and that the preliminary granular foam 110 can not passed through the clearance. The supply unit 31 is connected via the hopper 130 and a supplying tube 32 for supplying the preliminary granular foam. The supplying tube 32 for supplying the preliminary granular foam is provided with a valve 32a for controlling the flow of the preliminary granular foam. Meanwhile, another embodiment of the supporting plate 33 for supporting the foaming mold, as shown in Fig. 6, includes a sealing member 33b connected elastically to both sides thereof by the spring 33c. The sealing member 33b is made of a low-frictional material, such as graphite, to minimize the frictional resistance. The sealing member 33b has an inclined surface at the outside of the front end by which the aluminium chassis 100 can enter initially with ease. The supplying means 40 for supplying dry vapor, which is provided to blow by force the dry vapor of the temperature ranged between 110 °C to 140 °C for heating directly the preliminary granular foam 110 filled in the spatial portion by the filling means 30 for filling preliminary granular foam and inducing the filling process, includes a vapor supplying tube 41 connected to the upper portion of the supply unit 31 for supplying the dry vapor. The maturing means 50, which is provided to heat the aluminium chassis 100 under the temperature of 70 °C to 120 °C for 10 to 180 seconds for foaming the preliminary granular foam, the aluminium chassis 100 being filled with the preliminary granular foam 110 by the filling means 30 for filling preliminary granular foam and being transferred at the regular speed, includes a maturing chamber 51 for maturing the aluminium chassis 100 transferred at the regular speed for 10 to 180 seconds, a vapor nozzle 52 for supplying dry vapor of the temperature ranged between 70 °C to 120 °C at the upper part and the lower part of the maturing chamber 51 to heat the aluminium chassis 100, and a discharging tube 53 arranged at the lower part of the maturing chamber 51 for collecting and discharging water formed form cooling of the dry vapor. The cooling means 60, which is provided to cool the aluminium chassis 100 heated in the maturing chamber 51 of the maturing means 50, comprises a cooling chamber 61 through which the aluminium chassis 100 heated in the maturing chamber 51 is passed, water spraying nozzles 62 arranged at the upper part and the lower part of the cooling chamber 61 for spraying the cooling water, and a discharging tube 63 arranged at the bottom part of the cooling chamber 61 for collecting and discharging the cooling water sprayed by the water spraying nozzle 62. The drying means 70, which is provided to remove the water in the aluminium chassis 100 wetted with the cooling water from the cooling means 60, and thus to dry the aluminium chassis 100, includes an air nozzle 71 for blowing by force the pressurized air. Meanwhile, between the maturing means 50 and the cooling means 60 is arranged a coating means 80 for coating the exposed surface of the heat insulating foam. The supporting plate 33 for supporting the foaming mold is provided at the lower part thereof with a Teflon coating to minimize the friction between the preliminary granular foam filled and the heat insulating foam foamed. The heat insulating foam foamed on the cutting area of the aluminium chassis is cut by a cutting means transferred and returned at the same speed as the transferring speed of the aluminium chassis. The operation of the invention will be described below. As described above, with the apparatus for forming heat insulating foam according to the present invention comprising a transferring means 10, an applying means 20 for applying adhesives, a filling means 30 for filling preliminary granular foam, an supplying means 40 for supplying dry vapor, a maturing means 50, a cooling means 60, and a drying means 70, the end of the opening portion 100a of the aluminium chassis 100 which is supplied to the transferring die 13 for the first time is closed by synthetic resin so that the preliminary granular foam 110 supplied at the first stage is filled into the opening portion 100a. The aluminium chassis thus placed on the transferring die 13 is moved at the regular spped by the driving roller 11. The aluminium chassis 100 transferred as mentioned above turn the sensing plate 23 of the applying means 20 for applying adhesives to open the valve 22, whereby the adhesives are applied to the opening portion 100a through the applying nozzle 21. The supporting plate 33 for supporting the foaming mold closes partially the upper part of the opening portion 100a of the aluminium chassis 100 transferred, the aluminium chassis 100 being applied with the adhesives by the applying means 20 for applying adhesives to create the spatial portion. In the spatial portion is filled the preliminary granular foam 110 stored in the hopper 130 through the supply unit 31 by virtue of the negative pressure generated by the vacuum pump which discharges air through the inlet portion 33a for granular foam. At this time, the dry vapor of the temperature ranged between 110 °C to 140 °C is blowed by force from the upper part of the supply unit 31 by the supplying means 40 for supplying dry vapor. As a result, the preliminary granular foam filled in the spatial portion is heated directly, and thus foamed. The filling process of the preliminary granular foam and direct heating process of the preliminary granular foam by the dry vapor are carried out successively to the aluminium chassis 100 transferred at the regular speed. The aluminium chassis 100 passed through the above mentioned process is heated with the dry vapor of the temperature ranged between 70 °C to 120 °C sprayed from the vapor nozzle 52 at the upper part of the maturing chamber of the maturing means 50 when the aluminium chassis 100 passes the inlet portion 33a for granular foam of the supporting plate 33 for supporting the foaming mold. Consequently, the preliminary granular foam filled in the spatial portion is foamed to form the heat insulating foam 200 in the opening portion 100a. The aluminium chassis 100, which is passed through the maturing means 50, foamed finally, and discharged, is cooled by the cooling water sprayed from the water spraying nozzle 62 arranged at the upper part and the lower part of the cooling chamber 61 of the cooling means 60. Subsequently, the water created in the cooling process is removed by the pressurized air blowed from the air nozzle 71 of the drying means 70, thereby the aluminium chassis 100 being dried. Through the process as described above, the heat insulating foam is provided in the opening portion 100a of the aluminium chassis 100. INDUSTRIAL APPLICABILITY As described above, the heat insulating foam is filled in the opening portion in accordance with the present invention, whereby enhancing soundproof capability and heat insulating capability. Furthermore, productivity and working efficiency is enlarged as the process for forming the heat insulating foam is carried out successively. It is to be understood that the forms of the invention herewith shown and described are to be taken as illustrative embodiments of the same, and that various changes in the shape, size and arrangement of parts, as well as various procedural changes, may be resorted to without departing from the spirit of the invention.

Claims: WHAT IS CLAIMED IS: 1. A method for manufacturing an aluminium chassis having heat insulating foam filled in an opening portion comprising: applying adhesives to the opening portion of the aluminium chassis while the aluminium chassis is transferred at a regular speed by an ordinary control unit; closing partially an upper part of the opening portion of the aluminium chassis applied with the adhesives in a maturing chamber of the temperature ranged between 70 °C to 120 °C; filling preliminary granular foam into the opening portion; supplying dry vapor of the temperature ranged between 110 °C to 140 °C directly to the preliminary granular foam; heating indirectly the aluminium chassis for 10 to 180 seconds; discharging the aluminium chassis; and cooling the aluminium chassis. 2. An aluminium chassis having heat insulating foam filled in an opening portion manufactured by the steps of: filling preliminary granular foam 110 in the opening portion 100a of the aluminium chassis 100; supplying dry vapor of the temperature ranged between 110 °C to 140 °C directly to the opening portion 100a; and heating the aluminium chassis at the temperature of 70 °C to 120 °C, whereby the heat insulating foam 120 being filled in the opening 100a. 3. An apparatus for manufacturing an aluminium chassis having, heat insulating foam filled in an opening portion comprising: a transferring means 10 for transferring the aluminium chassis 100 at a regular speed, including a transferring die 13 having a plurality of rollers arranged continuously from on end to the other end, a fair of driving rollers 11 arranged in front of the transferring die 13 for transferring successively the aluminium chassis 100 by force, and a guide 12 for guiding the aluminium chassis 100 transferred by the driving rollers 11; an applying means 20 for applying adhesives such that the heat insulating foam 120 is adhered to the opening portion 100a of the aluminium chassis 100 transferred successively, the aluminium chassis 100 being placed on the front end of the transferring means 10; a filling means 30 for filling the preliminary granular foam 110 in the opening portion 100a of the aluminium chassis 100 applied with the adhesives by the applying means 20 for applying the adhesives, including a supporting plate 33 for supporting a forming mold to close partially an upper part of an opening portion 100a of the aluminium chassis 100, a supply unit 31 arranged at the front end of the supporting plate 33 for supplying the preliminary granular foam 110 into the opening portion 100a, said supporting plate 33 for supporting a forming mold having an inlet portion 33a for granular foam connected to a vacuum pump for allowing the preliminary granular foam 110 to be filled through the supply unit 31 into the opening portion 100a, said supply unit 31 being provided with a valve 32a for controlling the flow of the preliminary granular foam 110 from a hopper 130; a ' supplying means 40 for supplying dry vapor, which is provided to blow by force the dry vapor of the temperature ranged between 110 °C to 140 °C through the supply unit 31, for heating directly the preliminary granular foam 110 aw well as inducing the filling of the preliminary granular foam 110; a maturing means 50 for heating the aluminium chassis 100 having preliminary granular foam filled in the opening portion 100a by the filling means 30 for filling the preliminary granular foam, the aluminium chassis 100 being transferred successively, to foam the preliminary granular foam; a cooling means 60 for spraying the cooling water on the aluminium chassis 100 through a water spraying nozzle 62 arranged in a cooling chamber 61, the opening portion 100a of said aluminium chassis 100 being filled with the heat insulating foam 120 by foaming of the preliminary granular foam in the maturing chamber 51 of the maturing means 50; and a drying means 70 for removing the water in the aluminium chassis 100 wetted with the cooling water from the cooling means 60 by blowing by force the pressurized air through an air nozzle 71 to dry the aluminium chassis 100. 4. The apparatus for manufacturing an aluminium chassis having heat insulating foam filled in an opening portion as claimed in claim 3, wherein said supporting plate 33 for supporting the foaming mold includes a sealing member 33b connected elastically to both sides thereof, the sealing member 33b being made of a low-frictional material to keep airtightness between both sides of the supporting plate 33 and the both side walls of the opening portion 100a.

Inventors: YOON KYU TAE, YOON, KYU, TAE
Applicants: MIPO CHEMICALS CO LTD, YOON KYU TAE, MIPO CHEMICALS CO., LTD., YOON, KYU, TAE
Application year: 1999
Main classification: B62D
IPC codes: B29C44, E04C3, E06B1, E06B3