Patent Description:
Polymeric foams, in particular polyurethane foams, are well known. In general, the preparation of a polyurethane foam requires the mixing of reactive chemical components, such as a polyol and an isocyanate, in the presence of normally used additives such as a suitable catalyst, a surfactant or cell growth control agent, and a physical and/or chemical blowing agent which permits the blowing of the foam.

<CIT> discloses a production line and a method for manufacturing a multilayer foam panel member.

In a continuous process for producing a rigid foam, and particularly in the production of rigid foams for manufacturing a foam panel structure, as currently practiced on conventional machines, it is common practice to spread or pour, via a dispenser or dispensing device, a thin layer of a reactive mixture of the foam-forming components, in a liquid state, in between a bottom (or lower) sheet substrate (one outer layer) and a top (or upper) sheet substrate (another outer layer) while the substrates are moving for example in a lateral or horizontal direction.

Then, as the reactive mixture moves laterally with the bottom sheet substrate, the foam is allowed to start to rise freely, due to the reaction between the chemical components and the effect of the blowing agent, until the expansion of the foam reaches and contacts the top sheet substrate; and the foam forms a panel structure integrally attached to the top sheet substrate and the bottom sheet substrate. The foam in the panel structure is then allowed to cure; and thereafter, the panel structure is cross-sawn into panels. The foam composite panel structure typically includes, for example, a polyurethane resin (PUR) foam core or a polyisocyanurate resin (PIR) foam core. The foam core and outer layers of the panel often are also called sandwich elements or sandwich panels. A common process for the production of a composite panel structure composed of metallic outer layers with a core of foam, as generally described above, includes for example, a double band lamination (DBL) process. And, depending on the type of facing (one of the outer layers of the panel) on the panel, DBL can be distinguished in rigid-faced DBL (RF-DBL) and flexible-faced DBL (FF-DBL).

As aforementioned, the DBL process apparatus includes: (<NUM>) a lower moving sheet of a desired substrate; (<NUM>) an upper sheet of a desired substrate; and (<NUM>) a dispenser for applying a reactive foam-forming composition, which can be an emulsion, onto the lower moving sheet of the apparatus. And in general the DBL process includes the steps of: (I) providing a reactive foam-forming composition by mixing: (a) gases, i.e. blowing and nucleation agents, with (b) reacting liquids, for example, a mixture of a polyol and an isocyanate, to obtain a reactive emulsion wherein the reacting liquids in the emulsion ultimately react to form the final PUR foam or PIR foam inbetween the upper (top) and lower (bottom) sheet substrates; and
(II) distributing the above obtained emulsion onto the lower moving sheet of the DBL process equipment via a dispenser (this step (II) can also be referred to as a "laydown" step). As the emulsion is distributed on the lower sheet substrate, the gases (blowing and nucleating agents) nucleate and expand via bubbles leading to the formation of the final foam that fills the gap between the two sheets.

In general, a DBL process includes a dispenser means, which is typically a hard solid device with orifices; such dispensers are known in the art as a "poker" or a "rake". The dispenser is used to distribute the PUR or PIR emulsion mixture throughout the width of the lower moving sheet substrate where the foam continues to react and polymerizes between the lower and upper sheets. In a short time, the foam cures to form an integral multi-layer (e.g., a three-layer) foamed panel structure. Then, as is known in the art, the formed multi-layer foamed structure is cut into blocks or sections (or "panels") of the desired length to form the panel products.

Using a RFDBL process requires that the dispenser or dispensing device used in the process satisfy a strict set of requirements including, for example: (<NUM>) a good quality of the top surface wherein the dispenser has to provide a uniform distribution of the foam-forming reactive mixture through the panel width leading to a good aesthetic quality of the top facing sheet substrate; (<NUM>) a good working dispenser with a long operational life to provide fewer stops of a continuous process. In general, a normal operational life requirement for the dispenser is half a production shift, i.e. approximately (~) <NUM> hours (hr). The operational life of the dispenser is mainly driven by fouling of the reactive mixture that partially or completely obstructs the flow within the dispenser ducts or passageways; (<NUM>) a good flexibility wherein the dispenser can serve a broad range of emulsion viscosities and flow rates; and (<NUM>) a lower dispenser cost since the dispenser article is an additional cost and such cost needs to be kept low given the fact that these devices are disposable and the current lifetime is around <NUM> hr.

Heretofore, a rigid distribution dispenser (also referred to as a "rake") such as a hard, unflexible, solid block or structure (e.g., a rake made of a metal pipe with holes or of any rigid material); for example produced by a conventional injection molding process has been used to distribute a reactive mixture to form a foam product. Developments in the field of manufacturing a foam panel typically are directed only to the geometry of a dispensing device and not to technology directed to the fabrication of the dispensing device. In addition, the problem of dispenser lifetime is not addressed by the prior art. For example, it is known that a short operational life of a dispenser reduces the cycle time of the production line and process of a panel product. However, a main focus of the prior art is to achieve a good distribution of a reactive foam mixture or to decrease defects of the foam surface after the laydown step of the process. Thus, heretofore, the developments in the field of manufacturing a foam panel are not typically directed to improving the dispenser or the production line and process that includes the dispenser for producintg a panel structure. It is desired therefore to provide a production line and a process for manufacturing a multilayer foam panel member using a novel flexible film fluid-dispensing device suitable for dispensing a reactive fluid composition such a foam-forming fluid reaction composition.

The present invention is directed to a production line and a process for manufacturing a multilayer foam panel member (structure or article) using a novel flexible film fluid-dispensing device.

The present invention includes a production line for manufacturing a multilayer foam panel member as defined by claim <NUM>.

The present invention includes a process for manufacturing a multilayer foam panel member as defined by claim <NUM>.

The production line of the present invention provides a multilayer panel article wherein a least one layer of the panel article is a foam, such a polyurethane or polyisocyanurate foam. Some of the advantageous properties of the present invention include, for example: (<NUM>) using a flexible film fluid-dispensing device having a low affinity to polyurethane material advantageously increases the flexible film fluid-dispensing device's lifetime which, in turn, provides longer production cycles of panel articles; (<NUM>) fouling is reduced by the deformation of the ducts in the flexible film liner member of the flexible film fluid-dispensing device, which also leads to longer production cycles of panel articles; and (<NUM>) the flexible film fluid-dispensing device provides a uniform distribution of reactive fluid foam-forming mixture on the width of the bottom sheet substrate of the process equipment which leads to a foam layer of the panel article with fewer defects.

Generally, the production line for manufacturing a multilayer foam panel member includes a novel combination of the following apparatus components: (a) a storage system for components of a foam-forming fluid reactive mixture; (b) a dosing system for flowing the components of the foam-forming fluid reactive mixture to a chamber means (also referred to as a mixing head) for mixing the components of the foam-forming fluid reactive mixture to form the foam-forming fluid reactive mixture; (c) a flexible fluid dispensing device for receiving the foam-forming fluid reactive mixture; (d) a means for flowing the foam-forming fluid through the flexible fluid dispensing device to dispense the foam-forming fluid; (e) a moving or stationary bottom sheet substrate for receiving the foam-forming fluid dispensed from the flexible dispensing device; (f) a means for allowing the foam-forming fluid to react, as the fluid travels on the moving bottom sheet substrate, wherein a foam material forms inbetween the moving bottom sheet substrate and a top sheet substrate to form a panel structure, wherein the panel structure comprises the foam material disposed inbetween the top sheet and the bottom sheet; (g) a panel structure comprising the foam material disposed inbetween the top metal sheet and the bottom metal sheet; (h) a means for curing the foam material to form an integral part of the top and bottom sheet substrates and to form a cured panel structure; and in continuous production lines (i) a cutting means for cutting the panel structure into predetermined discrete panel member sections; and in a discontinuous process, (j) a demolding means for demolding a foam panel structure from a mold.

The production line of the present invention can be a continuous production line or a discontinuous production line. With reference to <FIG>, there is shown a continuous production line, generally indicated by reference numeral <NUM>, including a material feed section (or reaction mixture production section) generally indicated by reference numeral <NUM>; a foam-forming section (or foam production section) generally indicated by reference numeral <NUM>; and a cutting section (or panel production section) generally indicated by reference numeral <NUM>. In one embodiment, the present invention production line <NUM> of <FIG> can be used for manufacturing a rigid faced foam sandwich panel article or member generally indicated by reference numeral <NUM>. For example, the continuous production line <NUM> of the present invention can include a rigid faced double belt lamination (RFDBL) continuous production line. The continuous production line useful for producing a panel article can include, for example, a double band lamination (DBL) process used for producing PUR and PIR foam panels. And, depending on the type of facing (one of the outer layers of the panel) on the panel, the process for fabricating panels can include, for example, a rigid-faced DBL (RF-DBL) process and a flexible-faced DBL (FF-DBL) process. Some preferred embodiments of the continuous production line for fabricating panels include, the RF-DBL and the FF-DBL.

In one preferred embodiment, the multilayer foam sandwich panel member <NUM> produced using the production line <NUM> of the present invention includes, for example, a three-layer structure multilayer foam sandwich panel member <NUM> (see <FIG>) including a top sheet substrate (top layer) <NUM>, a bottom sheet substrate (bottom layer) <NUM> and a middle foam layer <NUM> disposed inbetween the top and bottom layers and integrally attached to the top and bottom layers forming the three-layer panel article <NUM>. While the production line <NUM> can include various pieces of equipment and steps known in the prior art for making panel articles, the present invention production line <NUM> differs from the prior art by incorporating a novel flexible film fluid-dispensing device generally indicated by reference numeral <NUM> in <FIG>.

In another embodiment, the production line of the present invention includes, for example, a discontinuous production line (not shown). The discontinuous production of panel members can be carried out using, for example, molds of defined shapes and sizes. A typical mold for making a rectangular shaped panel member has the following dimensions: a length of the mold is, for example, between <NUM> and <NUM>, the width of the mold can be in the range of from <NUM> and <NUM>, and the thickness of the mold can be between <NUM> to <NUM>. In this discontinuous process, the reacting mixture is usually injected in the mold and then the injection hole or holes are closed immediately after the injection. In some cases, the reacting mixture is poured and distributed with the mold opened through a casting rake and then the mold is closed. Afterwards the foaming mass fills the molds, while air is released through venting holes. The continuous process is less flexible but has a much lower cost per square meter of panel.

One of the objectives of the present invention is to provide a process of making a panel article using a novel flexible film dispenser design such that the design of the dispenser is technically superior in function to known prior art dispensers; and which provides an improved manufacturing process for making a panel member and an improved panel member made by the above process. The superior industrial design of the dispenser of the present invention is capable of readily dispensing an emulsion for PIR/PUR panel production using, for example, a RFDBL continuous process.

In a general embodiment, the flexible film dispenser <NUM> useful in the present invention has several advantageous over other known dispensers including, for example, the dispenser: (<NUM>) is made using a flexible film liner and not of a hard inflexible solid block or structure; (<NUM>) is made using a heat sealable flexible film liner material; (<NUM>) has dimensions such as to cover a panel width; (<NUM>) has a flow path that provides an appropriate clearance between the dispenser and the moving or stationary metal bottom sheet substrate on which the reactive fluid mixture from the dispenser has flowed thereon; (<NUM>) is made using a flexible film liner that can encompass one layer or multiple layers; and (<NUM>) is made using a flexible film liner that can be laminated or coextruded.

In a preferred embodiment, the dispensing device or dispenser <NUM> useful in the production line <NUM> of the present invention can include, for example, the dispenser described in <CIT>. An embodiment of the dispenser <NUM> is shown in <FIG> and described in the above patent application.

With reference to <FIG>, and as described in the above patent application, the fluid dispenser <NUM> includes: (a) a flexible film liner, generally indicated by reference numeral <NUM>;(b) a rigid frame member, generally indicated by reference numeral <NUM>; and (c) a connection means or connector generally indicated by reference numeral <NUM>. The flexible film liner <NUM> can include, for example, a liner made by a heat-sealing process wherein the heat sealing provides a flow path for the fluid to be dispensed; and the flow passages are defined by the negative impression of the sealing die. The rigid frame <NUM> of the dispenser <NUM> is used, for example, for holding the flexible film liner <NUM> in place during the operation of the dispenser <NUM>. And, the connection means or connector <NUM> of the dispenser <NUM> is used, for example, for connecting the liner <NUM> to the outlet pipe(s) of a fluid production line.

In one preferred embodiment, the flexible film liner <NUM> of the dispenser <NUM> useful in the present invention is, for example, a flexible film member described in <CIT>. For example the liner <NUM> can be made of multiple layers wherein at least one layer is made of heat-sealing material to be heat sealed by a heat-sealing process wherein the heat sealing provides a flow path in the form of a series of ducts or passageways <NUM> in liner <NUM> for fluid to be dispensed from the dispenser <NUM>. Typically, the flow passages <NUM> are defined by the negative impression of the sealing die when forming the flexible film liner <NUM>.

In a preferred embodiment, the flexible film liner <NUM>, which is held in place by the rigid frame <NUM>, includes at least two areas, (i) a heat-sealed area (<FIG> shows one side of the flexible film liner <NUM> showing the heat-sealed area 63A) and (ii) a flow path area in the form of a pattern of a series of inflatable ducts <NUM> for a fluid or emulsion to flow therethrough. The liner <NUM> and the frame <NUM> are connected to a production line by means of the connector <NUM> for feeding a flow of fluid into, and through, the dispenser <NUM>.

The rigid frame <NUM> of the dispenser <NUM> for holding the flexible film liner <NUM> in place can include any shape frame member such as square, triangular, reactangular, trapasoidal, and the like. The frame <NUM> can also include any size of the above shape as desired for applicability for a particular production line or application.

The connection means or connector <NUM> of the dispenser <NUM> for connecting the dispenser <NUM> to the outlet pipe of a fluid manufacturing line (not shown) can include any conventional connecting means such as nuts and bolts, threaded pipes and the like. In a preferred embodiment, the connector <NUM> is a hermetic connector. In one embodiment, a flexible film dispenser <NUM> is connected to a manufacturing line via the hermetic connector <NUM> such that a foam-forming fluid can be fed into the dispenser <NUM>, passed through the dispenser <NUM>, and dispensed or deposited onto a surface of a substrate.

With reference to <FIG>, the dispensing device or dispenser <NUM> useful in the present invention bridges the material feed section <NUM> and the foam-forming section <NUM> of the production line <NUM>. The material feed or reaction mixture production section <NUM> of the production line <NUM> includes, for example, a multi-component dosing unit comprising several vessels including for example vessels <NUM>, <NUM> and <NUM> which contain the foam-forming reactive components to be mixed and dispensed. The vessels <NUM>-<NUM> include supply lines <NUM>-<NUM>, respectively; the supply lines can be a series of pipes <NUM>-<NUM>, and pumps (not shown). The contents of the pipes <NUM>-<NUM> flow into a high-pressure mixing unit or mixing head <NUM> for receiving and mixing the fluid components from the vessels <NUM>, <NUM> and <NUM>. The three vessels <NUM>-<NUM>, and supply lines <NUM>-<NUM> from vessels <NUM>-<NUM>, respectively, of the reaction mixture production section <NUM> are used for supplying reactive components to the mixing head or unit <NUM> for forming a reactive foam-forming mixture fluid which is then sent to the dispensing device <NUM> connected to the mixing head or unit <NUM>.

The foam-forming or foam production section <NUM> of the continuous process <NUM> includes, for example, a top film sheet substrate <NUM> and the bottom film sheet substrate <NUM> which move through the foam production section <NUM> via a double band.

In a preferred embodiment shown in <FIG>, the dispenser <NUM> is incorporated into the continuous production line <NUM>; and the dispenser <NUM> receives a foam-forming fluid reactive mixture <NUM> from the mixing head <NUM> through at least one inlet <NUM> of ducts <NUM> in the liner <NUM> of the dispenser <NUM>; and the reactive fluid mixture <NUM> is flowed through the dispenser <NUM> through the duct system in the dispenser and then, the mixture exits the dispenser from a plurality of outlets <NUM> in the dispenser. The foam-forming reactive mixture <NUM> is fed from the dispenser <NUM> to the surface of a substrate as the fluid <NUM> exits the dispenser <NUM>. The liquid fluid <NUM> flowing and being dispensed from the dispenser <NUM> is "laid down" (i.e. poured) onto a substrate, for example, the substrate can be a moving bottom facing layer or bottom sheet substrate <NUM> of the foam-forming section <NUM> of the production line <NUM>.

In a preferred embodiment, the process of "laying down" the reactive mixture fluid <NUM> can be summarized in accordance with the following steps: (i) flowing the foam-forming fluid through the dispenser <NUM>; (ii) dispensing the foam-forming fluid from the dispenser <NUM> onto a moving, optionallyheated, bottom or lower sheet substrate <NUM>; (iii) allowing the foam-forming fluid <NUM> to react, as the fluid travels on the moving bottom sheet substrate <NUM>, typically in a horizontal direction, to form a foam <NUM> inbetween a top sheet substrate (top layer) <NUM> and the bottom sheet substrate (bottom layer) <NUM>; (iv) allowing the foam to contact the top layer <NUM> and bottom layer <NUM> and to fill in the gap between the top and bottom layers, such that the foam is integrally connected to the top and bottom layers forming a panel structure <NUM> comprising the foam material disposed inbetween the top and bottom facing layers <NUM> and <NUM>.

The dispenser <NUM>, connected to the mixing head <NUM>, is used for dispensing the mixed reactive fluid mixture <NUM> from the mixing head <NUM> onto the laydown surface area <NUM> of the moving bottom sheet substrate <NUM> in the form-forming section <NUM>. The dispenser <NUM> dispenses or distributes the reactive fluid <NUM> evenly, homogeneously, and uniformly across the full width of, and onto the laydown surface area <NUM> of the bottom sheet substrate <NUM>. The bottom sheet substrate <NUM> moves in the direction indicated by arrow A. Auxiliary equipment such as pumps (not shown) can also be included in the production line <NUM>.

Once the mixing head <NUM> mixes the components coming from the different lines <NUM>-<NUM> forming the reactive mixture <NUM>, the components in the reactive mixture <NUM> begin to react. Thereafter, the dispensing device <NUM> dispenses the reactive mixture <NUM> uniformly and homogeneously onto the surface of the moving bottom sheet substrate <NUM> and across the entire width of the moving bottom sheet substrate <NUM>. As the fluid mixture <NUM> moves across the foam production section <NUM>, the components in the reactive mixture <NUM> react to form a rigid foam material <NUM>.

The foam material <NUM> is allowed to contact the top and bottom layers <NUM> and <NUM>, respectively, to fill in the gap between the top layer, such that the foam is integrally connected to the top and bottom layers forming a panel structure comprising the top sheet substrate <NUM> which becomes the top layer <NUM>, the bottom sheet substrate <NUM> which becomes the bottom layer <NUM>, and the foam material <NUM> disposed inbetween the top and bottom sheet substrates or layers which becomes the middle layer <NUM> of the panel member <NUM> when the structure from the foam production section <NUM> is cut in the panel production section <NUM> with cutting tool <NUM>.

Generally, the free rising foam touches the top facing slightly before the gel time of the reacting mixture. In general, the difference between the gel time and the contact time is kept between <NUM> and <NUM> in one embodiment, between <NUM> and <NUM> in another embodiment and between <NUM> and <NUM> in still another embodiment. This permits the foam being formed to intimately adhere itself to the top and bottom sheet substrates. Once the foam expands and intimately adhere to the top and bottom layers toward the end of the process in section <NUM>, the formed foamed panel is cut using a cutting tool <NUM>. The panels are cut into predetermined discrete panel sections <NUM> as shown in <FIG>, <FIG>.

The reactive liquid fluid <NUM> deposited on the surface of the moving bottom sheet substrate <NUM> moves through the length of the foam production section <NUM> for a sufficient time and at a sufficient speed for the components in the reactive fluid <NUM> to sufficiently react to form the foam material <NUM> toward the end of the foam production section <NUM>. For example, a sufficient speed and time of the moving sheet <NUM> is used to allow the foam-forming fluid to react, as the fluid travels on the moving sheet <NUM> typically in a horizontal direction (shown by directional arrow A in <FIG>), to form a foam inbetween a top sheet substrate (top layer) <NUM> and the bottom sheet substrate (bottom layer) <NUM>. Typical line speeds for the moving sheet <NUM>, when using a RFDBL process, can be, for example, from <NUM>/min to <NUM>/min in one embodiment, from <NUM>/min to <NUM>/min in another embodiment, and from <NUM>/min to <NUM>/min in still another embodiment. When using a FFDBL process, the line speeds can be, for example, from <NUM>/min to <NUM>/min in one embodiment, from <NUM>/min to <NUM>/min in another embodiment, and from <NUM>/min to <NUM>/min in still another embodiment.

In another embodiment, the moving bottom sheet substrate <NUM> can be heated with a heat means (not shown), and also the reactive fluid <NUM> can be heated. The heat cures the foam-forming mixture <NUM> as the mixture is transported through the foam-forming section <NUM> to the cutting section <NUM> via the moving bottom sheet <NUM>.

After passing through section <NUM>, the panel structure <NUM> is passed to a panel cutting section <NUM>. In the cutting section <NUM> of the production line <NUM>, the foam panel structure <NUM> produced in section <NUM> is cut into discrete panel sections of a desired length using a cutting tool <NUM>. Cutting of the foam panel structure <NUM> into sections produces the cut foam panel article, generally indicated by reference numeral <NUM> in <FIG>, <FIG>. After cutting the panel structure <NUM> into panel members <NUM>, the produced panels <NUM> are cooled (not shown) to finalize the curing of the foam in the middle foam layer <NUM> of the panels <NUM> before the panels <NUM> are further processed.

After cutting the formed foamed panel into predetermined discrete panel sections, the panels can be subjected to additional processing steps. For example, although not shown in <FIG>, additional optional processing units or equipment can be added to the production line <NUM>. For example, the cut panels <NUM> can be stacked and packed by forwarding the panels <NUM> to further processing units or equipment such as an apparatus for cooling the cut discrete panel sections, an apparatus for stacking the cut discrete panel sections, and an apparatus for wrapping the cut discrete panel sections with shipping film to provide a stack of panel sections for shipping.

In other embodiments, such as in the case of a rigid-faced DBL at the beginning of, and prior to, the production line, the production line can also include a profiling section, a pre-heating section, and/or a pre-treating section (not shown). For example, the pre-treating section can include corona treatment of the sheet substrates such as metal sheet substrates; and/or an adhesion promoting layer can be deposited on the metal sheet substrates.

Foam panels members <NUM> can be produced via the production line <NUM> of the present invention which can be a continuous or a discontinuous process. The production line <NUM> shown in <FIG> is a continuous process. The process of the present invention for manufacturing a panel article includes the steps defined by claim <NUM>.

The temperatures used for processing a PUR foam and a PIR foam are different and can vary. In general, for example, when processing a PUR foam, the top and bottom sheet substrates such as metal sheets, can be at a temperature of from <NUM> and <NUM> in one embodiment, from <NUM> to <NUM> in another embodiment, and from <NUM> to <NUM> in still another embodiment. For the components used to make a PUR foam, for example, the temperature of the components can be from <NUM> and <NUM> in one embodiment, from <NUM> to <NUM> in another embodiment, and from <NUM> to <NUM> in still another embodiment. The pressure for operating the mixing head can be from <NUM> bar to <NUM> bar in one embodiment, from <NUM> bar to <NUM> bar in another embodiment, and from <NUM> bar to <NUM> bar in still another embodiment.

In another embodiment, the process for manufacturing a panel article using the production line <NUM> of the present invention can include, for example, the additional step of pre-treating the metal facings to be attached to the foam. The pre-treatment of the facings can include, for example, one or more of the following pre-treatments: decoiling, corona treatment, profiling, heating, and adhesion promoter layer laydown. After dosing the reactive components, the components reach the mixing chamber or mixing head, where a high-pressure mixing of the components can be performed to produce the foam-forming fluid reactive mixture (for example, normally all of components are mixed in two separate streams and then the two separate streams are combined to form the reactive mixture).

The use of the flexible film fluid-dispensing device <NUM> and the production line <NUM> of the present invention provides a panel member <NUM> with fewer defects and a more homogenous foam middle layer of the panel member <NUM> than using a conventional dispenser. For example, some of the advantageous properties exhibited by the panel member <NUM> made by the above-described process of the present invention can include, for example, the panel member <NUM> has: (<NUM>) a foam middle layer <NUM> that is homogeneous, and (<NUM>) a foam middle layer <NUM> that has a reduced density. For example, all the important properties of the foam middle layer, e.g. thermal conductivity, mechanical strength and density, can have a normalized standard deviation over the width of the panel from <NUM> % to <NUM> % in one embodiment, from <NUM> % to <NUM> % in another embodiment, and from <NUM> % to <NUM> % in still another embodiment. In addition, having a more uniform distribution of the foam-forming reactive mixture by the dispenser also allows a manufacturer the capability of reducing the overpacking, and therefore, the final applied density of the panel, which in turn has a beneficial impact on the final cost of the panel. Foam overpacking is described as the amount of PUR/PIR foam exceeding the minimum amount of foam needed to fill the panel thickness. For example, the overpacking of the foam middle layer can be from <NUM> % to <NUM> % in one embodiment, from <NUM> % to <NUM> % in another embodiment, and from <NUM> % to <NUM> % in still another embodiment.

Claim 1:
A production line for manufacturing a multilayer foam panel member comprising:
(a) a storage system for components of a foam-forming fluid reactive mixture;
(b) a dosing system for flowing the components of the foam-forming fluid reactive mixture to a chamber means for mixing the components of the foam-forming fluid reactive mixture to form the foam-forming fluid reactive mixture;
(c) a flexible fluid dispensing device for receiving the foam-forming fluid reactive mixture; wherein the flexible fluid dispensing device comprises
i) a flexible member having at least one fluid inlet aperture;
ii) a rigid frame member for receiving at least the edges of the flexible member and for holding the flexible member in place during the flow of fluid through the flexible member wherein the flexible member is held in place by the rigid frame member;
iii) a hermetic junction for connecting the at least one fluid inlet aperture of the flexible member to the outlet of the chamber means for mixing the components of the foam-forming fluid reactive mixture;
iv) a plurality of fluid outlet apertures; and
v) a series or pattern of flexible fluid flow path ducts of the flexible member for providing an even distribution of fluid exiting the plurality of fluid outlet apertures of the flexible member onto the surface width of a moving bottom sheet substrate;
(d) a means for flowing the foam-forming fluid through the flexible fluid dispensing device to dispense the foam-forming fluid;
(e) a moving first bottom sheet substrate for receiving the foam-forming fluid dispensed from the flexible dispensing device;
(f) a means for allowing the foam-forming fluid to react, as the fluid travels on the moving bottom sheet substrate, wherein a foam material forms inbetween the moving first bottom sheet substrate and a second top sheet substrate to form a panel structure, wherein the panel structure comprises the foam material disposed inbetween the top sheet and the bottom sheet;
(g) a panel structure comprising the foam material disposed inbetween the top sheet and the bottom sheet;
(h) a means for curing the foam material to form an integral part of the top and bottom sheet substrates and to form a cured panel structure; and
(i) a cutting means for cutting the panel structure into predetermined discrete panel member sections, characterized in that the flexible member is a flexible multilayer film member.