Process for manufacturing resin-based composite material

Details Process for manufacturing resin-based composite material Process for manufacturing resin-based composite material

2001-11-30

2004-06-29

Davis, Robert (Department: 1722)

Plastic article or earthenware shaping or treating: apparatus

Building forms or construction engineering type mold with...

Including mold charging means

C425S096000, C425S099000, C425S103000, C425S107000, C425S073000, C425S173000, C425S213000, C198S465200, C198S465300

Reexamination Certificate

active

06755633

ABSTRACT:

TECHNICAL FIELD
The subject application relates to a method and apparatus for the manufacture of resin based, fiber-reinforced panels.
BACKGROUND OF THE INVENTION
It is commonplace in the recreational vehicle business to use glass fiber-reinforced wall panels for the exterior surface of the recreational vehicle. These wall panels vary in widths up to, and including, dimensions from 2.4 to 3 meters (8 to 10 feet), and can have a length as long as 12 meters (40 ft.) or more. While the composite material from which the panels are made provides an adequate material for the recreational vehicle side walls, the presently utilized processes and equipment for manufacturing the composite material invariably may emit VOCs, both within the facility, as well as that which may be exhausted to atmosphere.
The process of making the composite material first begins with use of an elongate mold. The mold is somewhat larger than the panels to be made, but large enough to accommodate the 3×12 meter (10×40 ft.) panels. The upper surface is a finished surface to provide a substantially flat and smooth surface, as it is this surface that forms the visible exterior surface of the panels to be made.
The prepared mold is first sprayed with a coating known as a gel coating, which cures to form a high gloss exterior surface for the panel. Once cured, a resin and fiberglass are applied to the top surface of the gel coating, and then a plurality of panels, typically hard board (such as luan panels) are positioned side by side on top of the fiberglass. The seams between the panels are covered with a seam material, and a vacuum bag is then placed over the top of the panels and a slight vacuum is introduced which draws resin into the luan panels to form a finished product. The completed product is then pulled off of the mold and cut and trimmed to the proper size.
One method of applying the gel coating is to maintain the elongate mold in a stationary fashion, and move the gel coating sprayer longitudinally along rails and spray the entire length of the elongate mold. While this provides for an excellent layer of gel coating on the mold, due to the movement of the sprayer, capturing the fumes of the gel coating can be difficult. Furthermore, as maintenance of the molds is required, the molds are moved into and out of their various positions by way of an overhead crane, which due to the size of the elongate mold, can be a difficult operation. The objects of the invention are therefore to overcome the shortcomings of the prior art.
SUMMARY OF THE INVENTION
The objects of the invention have been accomplished by providing an apparatus for manufacturing fiberglass-reinforced panels, comprising a plurality of molds for receiving the components of the panels, a spraying apparatus for applying an exterior coat for the panels, an applicator mechanism for applying the fiberglass to the panels, a guide mechanism for guiding the molds through the spraying apparatus and applicator mechanism, and a drive mechanism for independently driving individuals ones of the plurality of molds.
In a preferred embodiment of the invention, the drive mechanism is comprised of a plurality of drive rollers. The molds each comprise an elongate support surface, having an upper finished surface, and a lower sub-frame, the lower sub-frame including a horizontally projecting, longitudinally extending drive surface, whereby the drive rollers engage the drive surface. The sub-frame includes at least one longitudinally extending I-beam, and the lower drive surface is provided by a lower surface thereof. The drive rollers are preferably driven by variable speed motors which are individually controllable.
The guide mechanism is comprised of a plurality of guide rollers. The guide rollers comprise a first plurality of rollers, each having a rotational axis along a horizontal axis, to guide the molds in a horizontal sense. The molds each comprise an elongate support surface having an upper finished surface, and a lower sub-frame, where the sub-frame includes horizontally projecting, longitudinally extending first reference surfaces, whereby the first plurality of rollers engage the first reference surfaces. The guide rollers further comprise a second plurality of rollers, each having a rotational axis along a vertical axis, to guide the molds in a lateral sense. The molds further comprise vertically projecting, longitudinally extending second reference surfaces, whereby the second plurality of rollers engage the second reference surfaces. The molds each comprise an elongate support surface, having an upper finished surface, and a lower sub-frame comprises I-beam members extending longitudinally below the elongate support surface and adjacent to lateral side edges thereof, the first reference surfaces are defined by lower sections of the I-beam members, and the second reference surfaces are defined by exterior channels formed by the I-beams. The lower sub-frame further includes a longitudinally extending central I-beam, and a lower surface of the central I-beam provides a drive surface. The drive mechanism is comprised of drive rollers positioned beneath the central I-beam, drivingly engaging the drive surface.
Preferably, the spraying apparatus flanks the guide mechanism, whereby the molds are driven relative to, and through, the spraying apparatus, and has an enclosure surrounding the spraying apparatus. Enclosure further includes a ventilation system to vent fumes within the enclosure. An oven extends longitudinally from the enclosure, whereby the molds, after passing through the spraying apparatus, are driven through the oven.
In another embodiment of the invention, an apparatus for manufacturing fiberglass-reinforced panel, comprises a plurality of molds for receiving the components of the panels, a spraying apparatus for applying an exterior coat for the panels, an applicator mechanism for applying the fiberglass to the panels, a guide mechanism for guiding the molds through the spraying apparatus and applicator mechanism, and an enclosure surrounding the spraying apparatus and applicator mechanism.
In a preferred embodiment of the invention, the enclosure further includes a ventilation system to vent fumes within the enclosure. The enclosure is defined as a curing oven intermediate the spraying apparatus and applicator mechanism. The apparatus further comprises an operator viewing station, for viewing moving molds within the enclosure, from a position exterior of the enclosure. The apparatus also further comprises an operator enclosed area, downstream of the applicator mechanism. The operator enclosed area is preferably down-drafted to improve the air quality within the operator enclosed area.
Preferably, the apparatus further comprises a drive mechanism comprised of a plurality of drive rollers, to propel individual molds through the enclosure. The molds each comprise an elongate support surface, having an upper finished surface, and a lower sub-frame, the lower sub-frame including a horizontally projecting, longitudinally extending drive surface, whereby the drive rollers engage the drive surface. The lower sub-frame includes at least one longitudinally extending I-beam, and the lower drive surface is provided by a lower surface thereof. The drive rollers are driven by variable speed motors which are individually controllable.
In a preferred embodiment of the invention, the guide mechanism is comprised of a plurality of guide rollers. The guide rollers comprise a first plurality of rollers, each having a rotational axis along a horizontal axis, to guide the molds in a horizontal sense. The guide rollers further comprise a second plurality of rollers, each having a rotational axis along a vertical axis, to guide the molds in a lateral sense. The molds each comprise an elongate support surface, having an upper finished surface, and a lower sub-frame comprised of an I-beam structure, comprising I-beam members extending longitudinally below the elongate support surface and adjacent to lateral side edges thereof, whereby the first plura

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