Patent GB-1001566-A (GB)
Title: Improvements in or relating to plastic foam production
IPC: B32B27/00
Filed: 1961-11-16
Abstract: 1,001,566. Web coating apparatus. UNION CARBIDE CORPORATION. Nov. 16, 1961 [June 13, 1961], No. 41139/61. Heading D1L. [Also in Divisions B2 and B5] A machine for manufacturing a composite structure consisting of at least one facing sheet 24, 25 and a layer 23 of plastic foam theron, comprises means e.g. driven rolls 26, 27, for advancing a strip of sheet facing material through a coating zone 16, an intermediate zone 17, a metering zone 18, a heating zone 19, an expansion zone 20, a height controlling zone 21 and a product withdrawing zone 22 of the machine; an applicator 28 for coating the mixture of plastic foam on the advancing strip in the coating zone and means for supplying a mixture of components of foam-forming material to the applicator, the plastic foam forming a bank of the mixture in the intermediate zone adjacent the metering zone; and automatically monitoring apparatus in the intermediate zone to control the thickness of the bank of the mixture whereby the rate of flow of the mixture to the applicator and on to the advancing strip is regulated within a predetermined range to avoid accumulation of stale mixture in the bank. Ventilating means e.g. fans 38, may be provided adjacent each edge of the advancing strip. The machine may have a proportionating pump for supplying a stream of polyhydroxy organic compound; a proportionating pump for providing a regulatable stream of organic diisocyanate; a proportionating pump providing a regulatable stream of modifying agents comprising a catalyst; a mixing chamber 47 in which the diisocyanate, polyhydroxy compound and modifying agents are agitated to provide a foam-forming mixture; conduits directing the mixture from the mixing chamber to an applicator for coating the mixture onto an advancing strip of sheet material; thickness controlling means for regulating the thickness of the coating on the advancing strip of material, whereby there is provided a bank of polurethane foam forming mixture rearwardly of the controlling means, e.g. upper metering roll 29; monitoring apparatus responsive to the quantity of mixture in the bank to maintain the bank within a predetermined range, the apparatus regulating the flow of each of the components toward the mixing chamber, while maintaining the predetermined proportions of components; heating means e.g. lamps 36, in the heating zone for accelerating the chemical reaction whereby the mixture is transformed into a plastic foam; and withdrawal means in the product withdrawal zone for removing the polyurethane foam structure from the machine. The monitoring apparatus may comprise a master control which regulates the proportionating pumps for maintaining a predetermined relationship among the plurality of components while supplying a mixture of the components at a flow rate variable in response to the master control; a thickness regulating means spaced from the heating means; and advancing means beyond the thickness regulating means for advancing the coated strip sheet from a position adjacent the applicator to the withdrawal zone. The monitoring apparatus may comprise electric eyes 33, 35 and a connection between the electric eyes and the master control 48 for sending a signal when detecting an excess or a deficiency of coating material in the intermediate zone; a constant speed electric motor 49 driving the master control, the control being adjustable to transmit a range of speeds in response to signals from the electric eyes, the control actuating a master transmission to accelerate or decelerate the speed of component transmissions 51, 52, 53, 54, 55 and 56 each being driven by the master transmission, and each having a stabilized speed ratio by reason of the adjustment of the variable speed component transmission; a plurality of hydraulic pumps 61, 62, 63, 64, 65 and 66, each driven by each component transmission and each circulating hydraulic fluid through a closed path; a plurality of reciprocating hydraulic motors 71, 72, 73, 74, 75 and 76 each driven by the fluid circulated by its hydraulic pump; and a plurality of reciprocating bifunctional pumps 81, 82, 83, 84, 85 and 86, each pump being rigidly connected with its reciprocating hydraulic motor, each pump directing a flow of a component from a source of supply to the mixing chamber during each stroke of the reciprocating pump. The height of the foamed layer may be controlled by a pair of belts 45. The withdrawal zone may include a reciprocating circular saw 46 which slits the continuously produced structure. As shown in Fig. 2, applicator 128 deposits a film of polyurethane onto release coated endless belt 125, the film being metered by the rearward passage of the belt over roll 129 and the forward passage of the film on the belt over roll 130. Foaming, expansion and polymerization occurs in heating zone 119 and the foamed film is transferred from the belt to sheet material 124 e.g. textile fabric or carpet, laid thereon, when the bond therebetween is sufficiently strong. In Fig. 3, sheets 224, 225 are given a film of foam forming composition and are maintained apart at the spacing of the intended product as they are advanced through zones in which foaming occurs and the foams coalesce into an unitary core 223. In Fig. 4, sheet material 325 is heated by lamps 336 before the coating material is applied thereto by applicator 328 and metered by rolls 329, 330 and monitored by photo-cells 333, and 335. In Fig. 5, an orga-- nic hydroxy compound is sprayed from device 97 as spaced droplets on sheet material 425 e.g. of polyethylene, prior to the polyurethane foam forming composition being deposited thereon. In Fig. 6, shaped members 94 which may comprise glass fibres are introduced between coated sheets 524, 525 to form a honeycomb reinforcement, the edge of the product being strengthened by strips 96, the polyurethane coating being subsequently foamed and coalesced.