초록 ▼

The method of forming rigid panel assemblies of this invention eliminates the requirement for mechanical fasteners and may be used to bond wall boards to studs, floor joists to wood flooring such as plywood or OSB boards and trusses to ceiling panels. The method of this invention includes applying a

The method of forming rigid panel assemblies of this invention eliminates the requirement for mechanical fasteners and may be used to bond wall boards to studs, floor joists to wood flooring such as plywood or OSB boards and trusses to ceiling panels. The method of this invention includes applying a thin bead of a thoroughly mixed two-component liquid polyurethane foamable resin adhesive on the surface where the components are to be joined. The foamable resin is formulated to provide a long tack time or delay curing until the assembly is complete. The foamable resin is then allowed to cream and rise before bonding. Where the bead is applied to the side faces of the support members, the support members are preferably turned to orient the foam beads over the fibrous panel, which is preferably supported on a flat horizontal support surface. Finally, the beads are compressed against the fibrous panel, wetting the panel with liquid foam resin before the foam has gelled, permanently bonding the support members to the panel and forming the structural panel assembly. Where an enclosed panel assembly, such as a closed wall is desired, the structural members are attached to a first panel, orienting the support members for application of the polyurethane foam bead, as described.

대표청구항 ▼

[ I claim:] [1.] A method of forming a self-supporting structural panel assembly comprising a plurality of support members permanently bonded to a generally flexible fibrous panel, said support members being generally rectangular in cross-section each having a pair of opposed generally parallel side

[ I claim:] [1.] A method of forming a self-supporting structural panel assembly comprising a plurality of support members permanently bonded to a generally flexible fibrous panel, said support members being generally rectangular in cross-section each having a pair of opposed generally parallel side surfaces and a pair of opposed generally parallel edge surfaces, with said edge surfaces being narrower in width than said side surfaces, said method comprising:arranging a plurality of said support members in generally parallel relation to each other such that one of said edge surfaces of each of said plurality of support members is oriented upwardly to form a top surface of each of said support members with said top surfaces of said support members being generally co-planar;applying a bead of a liquid foamable polyurethane resin adhesive along the length of each of said top surfaces of each of said support members with said bead having a width substantially less than the width of each of said top surfaces of each of said support members;applying said flexible fibrous panels to said top surfaces of said support members under pressure thereby compressing said beads of said liquid foamable polyurethane resin adhesive and wetting the opposed surfaces of each of said top surfaces of said support members and the opposed surfaces of said flexible fibrous panels and said liquid foamable polyurethane resin adhesive foaming and rising and filling voids between said flexible fibrous panels and said top surfaces of said support members; andallowing said liquid foamable polyurethane resin adhesive to cure thereby permanently bonding substantially the entire said top surface of each of said support members to the opposed surfaces of said flexible fibrous panels and forming a self-supporting structural panel assembly.