초록 ▼

A dual platen molding machine for constructing a plurality of pre-insulated structural panels is disclosed that includes multiple safety features. The molding machine produces one or more panels that may include one or more c-channels or profiles embedded in expandable polystyrene (EPS) foam to prov

A dual platen molding machine for constructing a plurality of pre-insulated structural panels is disclosed that includes multiple safety features. The molding machine produces one or more panels that may include one or more c-channels or profiles embedded in expandable polystyrene (EPS) foam to provide structural integrity to the panels, and resulting wall. A chase may be formed horizontally in the panels to provide a wiring conduit through the panel. The molding machine is electrically operated to control the movement of a movable molding portion when closed upon a stationary molding portion. Steam may be controlled to fuse insulating material such as expandable polystyrene (EPS) in cavities formed between the movable mold and the stationary mold. No hydraulics is required to operate the dual platen molding machine, thus improving operating and maintenance costs. Moreover, steam hoses may be avoided, thereby improving overall safety.

대표청구항 ▼

1. An apparatus for molding a pre-insulated building component, comprising: a stationary mold having a first vertical wall and a second vertical wall, the first and second vertical walls extending an entire length of the stationary mold and spaced apart by two first end caps positioned at opposite e

1. An apparatus for molding a pre-insulated building component, comprising: a stationary mold having a first vertical wall and a second vertical wall, the first and second vertical walls extending an entire length of the stationary mold and spaced apart by two first end caps positioned at opposite ends of the stationary mold, the first vertical wall and the second vertical wall each comprising a plurality of adjacent individual vertical hollow core tubes to create a surface of the first vertical wall and a surface of the second vertical wall, each vertical hollow core tube having a plurality of vent holes;a movable mold having a top cap, a first side wall spaced apart from a second side wall by two second end caps positioned at opposite ends of the movable mold, the top cap connected to each of the side walls and the two end caps, the movable mold configured to move in a vertical direction to engage the stationary mold to create a plurality of cavities within the movable mold including a first cavity positioned between the first vertical wall and the first side wall and a second cavity positioned between the second vertical wall and the second side wall, each cavity configured to receive fusable insulating material,wherein the first sidewall and the second sidewall each comprising a plurality of adjacent individual tubes with a plurality of steam vents;a base attached perpendicular to the first vertical wall, the second vertical wall and the two end caps, and the base configured to engage with the movable mold to enclose the first cavity and second cavity, wherein the base is configured with steam holes to vent steam into the plurality of vertical hollow core tubes;wherein the plurality of vent holes are configured to provide steam into the plurality of cavities to fuse the fusable insulating material to create a building panel with fused insulating material. 2. The apparatus of claim 1, wherein the stationary mold is configured with the plurality of vent holes on two opposing surfaces, the opposing surfaces each forming a wall of a separate cavity of the plurality of cavities. 3. The apparatus of claim 1, wherein the movable mold is configured with the plurality of steam vents on two opposing sides, the two opposing sides forming a wall of a separate cavity of the plurality of cavities, and the movable mold and the stationary mold each configured to provide at least one wall for each of the plurality of cavities. 4. The apparatus of claim 1, further comprising a source of fusable insulating material to fill the plurality of cavities, the source connected to the movable mold. 5. The apparatus of claim 1, wherein the fusable insulating material comprises expandable polystyrene (EPS). 6. The apparatus of claim 1, further comprising a frame for guiding the movable mold to engage the stationary mold, the movable mold propelled using electric motors. 7. The apparatus of claim 1, further comprising means to configure a horizontal chase in the building panel. 8. The apparatus of claim 1, further comprising means to configure a vertical support element in the building panel. 9. The apparatus of claim 1, further comprising valves to control venting of the steam into the stationary and movable molds. 10. The apparatus of claim 1, further comprising at least one insert for reducing a size of the cavity. 11. The apparatus of claim 1, further comprising means for configuring a vertical chase in the building panel. 12. The apparatus of claim 1, wherein the stationary mold and the movable mold each comprises the plurality of individual tubes, the steam vents configured in the plurality of individual tubes. 13. An apparatus for molding a pre-insulated building component, comprising: a stationary mold having a first vertical wall and a second vertical wall, the first and second vertical walls each comprising a plurality of individual vertical hollow core tubes arranged adjacent to one another to form at least two walls of the stationary mold, each vertical hollow core tube configured with a plurality of vent holes, and the stationary mold having a base;a movable mold configured with a first side wall and a second side wall and the movable mold configured to move in a vertical direction to engage the base of the stationary mold and to enclose the plurality of hollow core tubes of the stationary mold and to create a plurality of cavities within the movable mold including a first cavity created between the first vertical wall and the first side wall and a second cavity created between the second vertical wall and the second side wall, each cavity configured to receive fusable insulating material, wherein the first sidewall and the second sidewall each comprising a plurality of adjacent individual tubes with a plurality of steam vents; anda hopper configured to store the fusable insulating material for supplying the fusable insulating material to the plurality of cavities, the hopper configured to be in operational proximity with the movable mold and configured to move vertically along with the movable mold,wherein the base is configured with a plurality of steam holes to vent steam into the plurality of vertical hollow core tubes for directing steam into the plurality of cavitiesto create a plurality of insulated building panels during a molding cycle. 14. The apparatus of claim 13, wherein the insulating material comprises expandable polystyrene (EPS). 15. The apparatus of claim 13, further comprising means to construct a horizontal chase in the plurality of insulated building panels. 16. The apparatus of claim 13, further comprising means to construct contours on at least one edge of the plurality of building panels. 17. The apparatus of claim 13, further including an optical safety curtain to detect a safety violation and to stop movement of the movable mold. 18. The apparatus of claim 13, further comprising a magnetic retaining mechanism to hold one or more vertical support elements in place along the surface of the movable mold and the stationary mold during the molding cycle. 19. The apparatus of claim 1, wherein the stationary mold comprises four sides with at least two of the four sides being configured with the plurality of vertical hollow core tubes, each vertical hollow core tube configured with the plurality of vent holes, wherein the movable mold comprises four sides that create a hollow cavity, and the movable mold being configured to engage the stationary mold to create the plurality of cavities, wherein the stationary mold is configured to engage the hollow cavity to create the plurality of cavities by dividing the hollow cavity. 20. The apparatus of claim 1, wherein the stationary mold comprises the plurality of vertical hollow core tubes arranged adjacent to one another to form at least two walls of the stationary mold, and each core tube extending from the base forming one side of the stationary mold to a top cap of the stationary mold, each core tube configured with a plurality of steam vents. 21. The apparatus of claim 20, further comprising the base, the base configured with a plurality of steam holes to provide steam to the plurality of core tubes. 22. The apparatus of claim 21, wherein the base is configured to provide steam to the movable mold. 23. The apparatus of claim 1, wherein the movable mold comprises the plurality of vertical hollow core tubes arranged adjacent one another to form at least two of four walls of the movable mold, the plurality of core tubes each configured with the plurality of steam vents, the four walls and a top cap of the movable mold defining a movable cavity. 24. The apparatus of claim 23, wherein the stationary mold comprises a plurality of vertical hollow core tubes arranged adjacent to one another to form at least two walls of the stationary mold, and each vertical hollow core tube extending from the base forming one side of the stationary mold to a top cap of the stationary mold. 25. The apparatus of claim 23, wherein the stationary mold is configured to divide the movable cavity, in a mated configuration. 26. The apparatus of claim 1, wherein at least one of the stationary mold and the movable mold are configured to magnetically retain at least one vertical support channel within the plurality of cavities for holding the at least one vertical support channel during a molding process. 27. The apparatus of claim 13, wherein at least one of the stationary mold and the movable mold are configured to magnetically hold a vertical channel in place during a molding cycle steam to create the plurality of insulated building panels. 28. The apparatus of claim 13, further comprising: a first male tongue configured to be placed along the horizontal extent of the movable mold, the first male tongue configured to form a first bevel feature on one corner of the building panel; anda second male tongue configured along the horizontal extent of the stationary mold, the second male tongue configured to form a second bevel feature on another corner of the building panel. 29. The apparatus of claim 20, wherein said plurality of vertical hollow core tubes are configured with a magnetic retaining mechanism therewithin to magnetically hold a vertical channel in place during a molding cycle. 30. The apparatus of claim 1, wherein the plurality of cavities are each configured to create a building panel that may have a length of one of: about 4 foot, about 8 foot, about 10 foot and about 12 foot. 31. The apparatus of claim 13, wherein the plurality of cavities are each configured to create a building panel that may have a length of one of: about 4 foot, about 8 foot, about 10 foot and about 12 foot. 32. The apparatus of claim 13, wherein the plurality of insulated building panels are ejectable away from the stationary mold in a horizontal direction. 33. The apparatus of claim 1, further comprising a steam chest located below the stationary mold to provide steam to the plurality of vertical hollow core tubes through the base. 34. The apparatus of claim 1, further comprising a hopper configured to store the fusable insulating material for supplying the fusible insulating material to the plurality of cavities, the hopper configured to be in operational proximity with the movable mold and configured to move vertically along with the movable mold.