Laminated foam product and methods for making laminated foam products

Patent metadata

Field	Value
Publication number	US-10500653-B2
Application number	US-201615078510-A
Country	US
Kind code	B2
Filing date	Mar 23, 2016
Priority date	May 22, 2012
Publication date	Dec 10, 2019
Grant date	Dec 10, 2019

Abstract

Thermally laminated foam boards, methods for making thermally laminated foam boards, apparatus for making thermally laminated foam boards, smaller foam pieces made from thermally laminated foam boards, methods for making smaller foam pieces from thermally laminated foam boards, parts made from thermally laminated foam boards, methods for making parts from thermally laminated foam boards, and tools for making parts from thermally laminated foam boards are disclosed. The thermally laminated foam boards are made by thermally bonding at least two polystyrene boards together.

First claim

We claim:

1. A rotary cutting tool for shaping insulation products, comprising:
an annular support having a concave, or a convex, exterior annular surface formed from sheetmetal;
a plurality of discrete, cutting elements permanently secured to the concave, or the convex exterior, annual surface; and
a base secured to the sheetmetal annular support for rotating the sheetmetal annular support and attached cutting elements,
wherein the rotary cutting tool has a closed, hollow interior space.

2. The rotary cutting tool of claim 1 wherein the annular support is made by spin forming.

3. The rotary cutting tool of claim 1 wherein the plurality of cutting elements include carbide, ceramic, or hardened steel.

4. The rotary cutting tool of claim 1 wherein each of the plurality of cutting elements are pointed teeth spaced apart from each other on the exterior surface of the annular support.

5. The rotary cutting tool of claim 4 wherein the plurality of cutting elements are uniformly spaced apart.

6. The rotary cutting tool of claim 4 wherein the insulation product is a foam insulation material and the plurality of cutting elements are spaced apart a sufficient distance that prevents the build-up and retention of foam insulation material on the rotary tool when cutting the foam insulation material.

7. The rotary cutting tool of claim 6 wherein the foam insulation material is polystyrene foam insulation.

8. The rotary cutting tool of claim 4 wherein the annular support has a proximal end attached to the base and a distal tip opposite the proximal end, wherein the plurality of pointed teeth are attached along the annular support from the proximal end to the distal tip.

9. The rotary cutting tool of claim 1 wherein the annular support and the base form a hollow cutting tool.

10. The rotary cutting tool of claim 1 wherein the annular support is shaped as a hemisphere facing away from the base.

11. The rotary cutting tool of claim 1 wherein the annular support has a proximal end attached to the base and a distal tip opposite the proximal end, wherein the plurality of cutting elements are attached along the annular support from the proximal end to the distal tip.

12. The rotary cutting tool of claim 1 wherein the cutting tool has a diameter of over 10 inches.

13. The rotary cutting tool of claim 1 wherein the cutting elements are thermally bonded onto the exterior surface of the annular support.

Assignees

• Owens Corning Intellectual Capital Llc

Inventors

• Budinscak Jr John F
• Van Sloun Jeffrey J

Classifications

• B32B5/32

  at least two} layers being foamed {and next to each other · CPC title

• B32B5/145

  Variation across the thickness of the layer · CPC title

• B29C66/91411

  of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account · CPC title

• B29C65/1432 Primary

  direct heating of the surfaces to be joined · CPC title

• B29C66/71

  characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125) · CPC title