Mcdonnell Douglas Corporation

Harald E Karlson

William B Goldsworthy

A method and apparatus for continuously fabricating three-dimensional (3D) filament reinforced foam insulation slabs. Rows of X or longitudinal filaments are fed longitudinally into a machine in spaced, stacked horizontal planes. Rows of Y or transverse filaments are fed transversely into the machine in spaced, stacked horizontal planes. Z or vertical filaments are fabricated into units of four vertical spaced lengths of strands which fit into each of the vertical column squares formed by the X-Y filaments to form the continuous X-Y-Z orthogonal array. Urethane or equivalent foam is discharged onto a moving belt beneath the filamentary array which is moved in the same direction and at the same rate as the belt carrying the foam. The foam material froths or foams upwardly through the filamentary array as they move along to the next station for curing. After sufficient cure, the foamed array is cut from the frames and into desired length, forming planks.

Apparatus for continuously fabricating three-dimensional filament

Method for continuously fabricating three-dimensional filament

A method and apparatus for continuously weaving fibers or filaments, particularly glass fiber filaments, into a scrim cloth, to serve as reinforcement in the fabrication of filament reinforced foam insulation slabs. The scrim cloth consisting of uniformly spaced filaments in the X (longitudinal) direction and Y (transverse) direction is fabricated by traversing the Y filaments between hooks attached to long moveable oppositely spaced side panels and by paying off bands of spaced X filaments at various locations between the Y traversing mechanism. One layer of scrim cloth is fabricated at each station, the desired number of stations for the respective layers being located sequentially along the length of the machine. In fabricating a single layer of cloth at any station, a rotatable vertical tube through which a continuous Y filament is payed from a remotely mounted spool, is moved on a cross slide mechanism transversely back and forth between the hooks on the side panels of the machine, the filament from the lower end of the tube being initially tied to the first hook. The motion of the cross slide and an arm mounted on the rotatable tube orients the Y filament on one hook or set of hooks on one side panel as the cross slide changes direction, and after traversing the distance between the side panels the cross slide and arm on the tube orients the Y filament on an oppositely facing hook or set of hooks on the opposite side panel. The X filaments for each layer are inserted as a band of spaced filaments, each such X filaments moving in the direction of longitudinal side panel travel and resting on the Y filaments.

Method and apparatus for fabricating open weave scrim cloth

A method and apparatus are described for the making of a three dimensional filament reinforced foam insulation member. Generally parallel arrays of vertically stacked fabric or cloth having filaments running in an X-Y axis are reinforced by third axis Z directional filaments pre-cut to a desired length and inserted down through openings referred to as vertical columns hereinafter through the said array. The Z filaments are air directed through the stack of open weave. After the formation of the filament reinforced weave the assembly is impregnated with foam to form a unitary member. The apparatus to form the article and carry out the method above consists of a conveyor carrying stacked open weave fabric through an open ended enclosure wherein there are provided first vertical tubes and second vertical tubes. The second vertical tubes are injected into the stack or array of open weave. The first vertical tubes are telescopically inserted into the tops of the said second vertical tubes. A filament is fed vertically downwardly into the first vertical tube and cut to a predetermined length. Compressed air in a chamber surrounding the said first vertical tube assists in forcing the filaments into the said second vertical tube. The said second vertical tube may be vibrated to prevent hang up of the desired Z directional filament. The said second set of vertical tubes are retracted from the array after the array is completely reinforced with Z directional filament. Thereafter foam insulating may fill the reinforced array. Additional cutters may be provided for trim purposes to remove excess Z directional filaments extending above the array.

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Eugene, OR, United States of America

Harald E Karlson