Mechanically reinforced foam insulation panel and methods of making the same

Patent metadata

Field	Value
Publication number	US-10179428-B2
Application number	US-201615354725-A
Country	US
Kind code	B2
Filing date	Nov 17, 2016
Priority date	Nov 17, 2016
Publication date	Jan 15, 2019
Grant date	Jan 15, 2019

Abstract

A formation assembly for use in manufacturing a reinforced insulation panel including a foam material and a reinforcing structure includes a back plate including a first surface configured to receive the foam material, and a first support sheet spaced from the first surface to form a gap therebetween, wherein the first support sheet supports the reinforcing structure. The formation assembly also includes a second support sheet spaced from the first support sheet, wherein the second support sheet defines an upper boundary of the reinforced insulation panel. A rigid structure is coupled to the second support sheet, wherein the rigid structure restricts movement of the reinforced insulation panel.

First claim

What is claimed is:

1. A formation assembly for use in manufacturing a reinforced insulation panel including a foam material and a reinforcing structure, said formation assembly comprising:
a back plate comprising a first surface configured to receive the foam material;
a first support sheet spaced from said first surface to form a gap therebetween, wherein said first support sheet supports the reinforcing structure;
a plurality of spacers coupled between said first surface and said first support sheet to define said gap;
a second support sheet spaced from said first support sheet, wherein said second support sheet defines an upper boundary of the reinforced insulation panel; and
a rigid structure coupled to said second support sheet, wherein said rigid structure restricts movement of the reinforced insulation panel.

2. The formation assembly in accordance with claim 1 , wherein said first support sheet and said second support sheet are configured to be deformed by expansion of the foam material.

3. The formation assembly in accordance with claim 1 , wherein said first support sheet and said second support sheet are formed from one of a woven metal mesh, a perforated plate, or an expanded metal mesh.

4. The formation assembly in accordance with claim 1 , wherein said rigid structure is formed from at least one of a foam material and a metallic material.

5. The formation assembly in accordance with claim 1 , further comprising a plurality of sidewalls configured to support at least one of said rigid structure and said second support sheet.

6. The formation assembly in accordance with claim 1 , further comprising a second rigid structure coupled to said first support sheet and spaced from said first surface to define said gap between said first surface and said second rigid structure.

7. The formation assembly in accordance with claim 1 wherein said first support sheet comprises a first plurality of through-holes, said second support sheet comprises a second plurality of through-holes, and said rigid structure comprises a third plurality of through-holes, wherein the foam material expands through said first, second, and third pluralities of through-holes such that the reinforcing structure is encased in substantially void-free foam material.

8. A method of manufacturing a reinforced insulation panel using a formation assembly, said method comprising:
positioning a reinforcing structure between a second support sheet and a first support sheet, wherein the second and first support sheets include a plurality of through-holes;
positioning a back plate below the first support sheet to define a gap therebetween;
positioning a plurality of spacers between the back plate and the first support sheet to define the gap;
positioning a rigid structure above the second support sheet to restrict movement of the reinforcing structure, the rigid structure including a plurality of through-holes;
depositing foam precursors on the back plate into the gap; and
allowing the foam precursors to expand through the pluralities of through-holes in the first support sheet, the second support sheet, and the rigid structure, such that the reinforced insulation panel includes the reinforcing structure encased in substantially void-free expanded foam material.

9. The method in accordance with claim 8 , further comprising removing the rigid structure from the expanded foam material.

10. The method in accordance with claim 9 , wherein removing the rigid structure includes simultaneously grinding a portion of the expanded foam material and the rigid structure.

11. The method in accordance with claim 8 , further comprising coupling the first support sheet to a second rigid structure spaced above the back plate to define the gap between the back plate and the second rigid structure.

12. The method in accordance with claim 8 , further comprising coupling the second support sheet to the rigid structure to secure the second support sheet.

13. The method in accordance with claim 8 further comprising positioning a plurality of sidewalls between the back plate and the rigid structure to limit expansion of the foam material.

14. The method in accordance with claim 8 further comprising removing the insulation panel from between the second and the first support sheets.

15. A formation assembly for use in manufacturing a reinforced insulation panel including a foam material and a reinforcing structure, said formation assembly comprising:
a back plate comprising a first surface configured to receive the foam material;
a first support sheet spaced from said first surface to form a gap therebetween, wherein said first support sheet supports the reinforcing structure;
a second support sheet spaced from said first support sheet, wherein said second support sheet defines an upper boundary of the reinforced insulation panel;
a first rigid structure coupled to said second support sheet, wherein said rigid structure restricts movement of the reinforced insulation panel; and
a second rigid structure coupled to said first support sheet and spaced from said first surface to define said gap between said first surface and said second rigid structure.

16. A formation assembly for use in manufacturing a reinforced insulation panel including a foam material and a reinforcing structure, said formation assembly comprising:
a back plate comprising a first surface configured to receive the foam material;
a first support sheet spaced from said first surface to form a gap therebetween, wherein said first support sheet supports the reinforcing structure, said first support sheet comprising a first plurality of through-holes;
a second support sheet spaced from said first support sheet, wherein said second support sheet defines an upper boundary of the reinforced insulation panel, said second support sheet comprising a second plurality of through-holes; and
a rigid structure coupled to said second support sheet, wherein said rigid structure restricts movement of the reinforced insulation panel, said rigid structure comprising a third plurality of through-holes, wherein the foam material expands through said first, second, and third pluralities of through-holes such that the reinforcing structure is encased in substantially void-free foam material.

17. A method of manufacturing a reinforced insulation panel using a formation assembly, said method comprising:
positioning a reinforcing structure between a second support sheet and a first support sheet, wherein the second and first support sheets include a plurality of through-holes;
positioning a back plate below the first support sheet to define a gap therebetween;
positioning a rigid structure above the second support sheet to restrict movement of the reinforcing structure, the rigid structure including a plurality of through-holes;
positioning a second rigid structure below the first support sheet and spaced from the back plate to define the gap between the back plate and the second rigid structure;
depositing foam precursors on the back plate into the gap; and
allowing the foam precursors to expand through the pluralities of through-holes in the first support sheet, the second support sheet, and the rigid structure, such that the reinforced insulation panel includes the reinforcing structure encased in substantially void-free expanded foam material.

18. A method of manufacturing a reinforced insulation panel using a formation assembly, said method comprising:
positioning a reinforcing structure between a first support sheet and a second support sheet,

Assignees

• Boeing Co

Inventors

• Roper Christopher S
• Page David
• Schubert Randall
• Chong Keith Y
• Clough Eric
• Iler Angela M
• Barnes Faizal K

Classifications

• B64D37/30

  Fuel systems for specific fuels · CPC title

• B64D37/02

  Tanks (tanks constructed integrally with aircraft wings B64C3/34) · CPC title

• B29C44/1228

  Joining preformed parts by the expanding material · CPC title

• B29K2025/06

  PS, i.e. polystyrene · CPC title

• B29L2007/002

  Panels; Plates; Sheets · CPC title