Patent EA-000941-B1 (EA)
Title: Apparatus and method for manufacturing foamed material
Inventor: UNGERLEIDER ANDREW
IPC: C03C11/00
Filed: 1997-02-07
Abstract: 1. An apparatus for the manufacture of a continuous bar or strip (16) of foamed glass material (16) using a furnace (14) at a temperature of at least 677 degree C (12500 degree F), characterized by mold means (11) that includes an upper portion (12) and a lower portion (13) that are each endless and cooperate with one another to form a closed and continuous mold cavity (23) within said furnace (14); and feed means (15) for introducing material (28) that is to be foamed to said mold means (11) upstream of said furnace (14). 2. An apparatus according to claim 1, characterized further by means (32), such as scrapers, disposed downstream of said furnace (14) to aid in separating foamed material (28) from said mold means (11), and in supporting such material. 3. An apparatus according to claim 1, characterized in that said upper portion (12) and said lower portion (13) of said mold means (11) are each an endless moving loop (17, 18) formed of a plurality of sections (20, 26), preferably of stainless steel, that are secured to at least one chain (21), and preferably to a plurality of continuous linked steel chains, disposed on an inner surface of said loop, in that each of said mold means loops (17, 18) is preferably disposed about respective driven and freely rotatable wheels (19) that are disposed externally of said furnace (14), in that downstream of said feed means (15), and throughout said furnace (14), said mold means loops (17, 18) cooperate with one another to form said closed mold cavity (23), and in that said mold means loops (17, 18), when viewed in a direction of travel thereof, have the respective portions thereof as they travel between separating means (32) back to said feed means (15) disposed externally of said furnace (14). 4. An apparatus according to claim 3, characterized in that each of said loop sections (20, 26) comprises at least one part and extends over the entire width of said loop (17, 18) as viewed in a direction perpendicular to a direction of movement of said loop. 5. An apparatus according to claim 3, characterized in that within said furnace (14), hold-down wheels (29) and support wheels (30) press respective portions of said loops (17,18) of said upper and lower portions (12, 13) of said mold means (11) toward one another, said wheels (29, 30) preferably pressing against said at least one chain (21) of each of said loops (17, 18). 6. An apparatus according to claim 3, characterized in that said upper portion loop (17) comprises a plurality of profiled corrugated sections (20) and said lower portion loop (18) comprises a plurality of flat sections (26), or in that both said upper portion loop (17) and said lower portion loop (18) comprise a plurality of profiled corrugated sections, or in that at least one of said upper and lower portion loops (17, 18) comprises a plurality of profiled corrugated sections, and wherein exchangeable inserts (40) are provided for installation in said corrugated sections. 7. An apparatus according to claim 1, characterized by cleaning means in the form of brushes (36, 37) for cleaning surfaces of said upper and lower portions (12, 13) of said mold means (11) after said foamed material (16) has been separated therefrom, and/or by means (33) for conveying separated foamed material (16) to a tempering or annealing furnace. 8. A method of manufacturing a continuous bar or strip of foamed glass material (16) using a furnace (14), characterized by the steps of providing a mold means (11) that includes an upper portion (12) and a lower portion (13) that are each endless and cooperate with one another to form a closed and continuous mold cavity (23) within said furnace (14); introducing material (28) that is to be foamed to said mold means (11) upstream of said furnace (14); moving said material (28) on said mold means (11) through said furnace (14) at temperatures of at least 1250 degree  F to foam said material; and separating a continuous bar or strip of foamed material (16) from said mold means (11) downstream of said furnace (14). 9. A method according to claim 8, characterized by the steps of forming each of said upper and lower portions (12, 13) of said mold means (11) as an endless loop (17, 18) formed of a plurality of sections (20, 26) secured to at least one chain (21), and moving each of said loops (17, 18) through said furnace (14) at the same speed in a continuous manner or in a batch-wise manner, wherein said loop sections (20, 26) are preferably exchangeable. 10. A method according to claim 9, characterized in that at least one of said upper and lower portion loops (17, 18) comprises a plurality of profiled corrugated sections, and characterized by the step of providing exchangeable inserts (40) for installation in said corrugated sections.