Abstract: A method of filling a seam of a structural panel assembly utilizes a non-foaming, thixotropic, two-component polyurethane elastomeric material. The thixotropic, elastomeric material is prepared by rapidly mixing and initiating the reaction of a first thixotropic component comprising an isocyanate-terminated compound having at least two reactive isocyanate groups and a second thixotropic component comprising a hydroxyl-terminated compound having at least two reactive hydroxyl groups. Each of the first and second thixotropic components include from about 3% to 8% by weight fumed silica. The second thixotropic component also includes from about 10% to about 50% filler. The thixotropic elastomeric material is applied over the seam of a panel assembly. The method then includes fluidizing the thixotropic elastomeric material and driving the thixotropic elastomeric material into the seam of the panel assembly.

Abstract: A control for dispensing foam into hollow body cavities includes an index hole positioned adjacent to a dispense hole to receive the foam. The index hole carries information that is read by a sensor associated with a foam spray gun, wherein the information is selected to correspond to the desired amount of foam for the particular body cavity. With the inventive foam spray gun and method, an operator merely inserts the dispense nozzle into a dispense hole, and the sensor reads the information from the index hole. The sensor signal then allows control of the amount of foam dispensed into the dispense hole. This eliminates problems that have been experienced in the past wherein operators were forced to remember the amount of "shots" of fixed volumes of foam for each hole. In the past, operators may sometimes have dispensed too little foam or too great an amount of foam for a particular hole. Further, in the past, operators may sometimes have dispensed foam into a hole that should not have received any foam.

Abstract: 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.

Abstract: A clamp holds a wall panel against an adhesive bead on a wall frame support assembly as the adhesive bead cures. The clamp is actuated to secure the clamp to the support assembly adjacent the panel and hold the panel against the adhesive bead as the bead cures. In a preferred embodiment, the clamp includes a clamping portion having vacuum chambers and a reference surface. A vacuum is drawn on the vacuum chamber, thereby pulling the edges of abutting panels against the reference surface, drawing adjacent panel edge portions of the panels in the parallel relation. The clamping portion also includes a mechanical control which secure the clamping portion to the support assembly holding the panels against the adhesive in coplanar relation. In a method according to this invention polymer adhesive is applied to coplanar surfaces of support members. A clamp is placed adjacent a panel and actuated to hold the panel against the first surface of the clamp.

Abstract: 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.

Abstract: A clamp holds a wall panel against an adhesive bead on a wall frame as the adhesive bead cures. The clamps are automatically actuated to first secure the clamp to the structure adjacent the panel, and then hold the panel against the adhesive bead as the bead cures. In a first embodiment, the clamp is placed across the abutting edges of two adjacent panels, and a vacuum is drawn on both of the panels to draw edges of the panels against a reference surface. The reference surface insures that the edges of the panels an in abutting aligned relationships as the adhesive cures. In other embodiments of this invention the clamp may include a pusher member that receives a fluid pressure to drive the pusher member against the panel and hold the panel as the adhesive cures. With these embodiments there is also securement structure for holding the clamp against the panel. The securement members may be threaded screws driven by motors into the floor and ceiling.

Abstract: This invention relates to a flame-retardant polyurethane spray system prepared by mixing at an isocyanate index of from 90 to 120(A) an isocyanate composition containing(a) an organic polyisocyanate, and(b) 0 to 50 wt. %, relative to the organic polyisocyanate, of a halogen-containing organic flame retardant; and(B) an isocyanate-reactive composition containing(a) 10 to 80 wt. % of an isocyanate-reactive compound having a molecular weight of 400 to 10,000 and functionality of 2 to 7;(b) 1 to 50 wt. % of an isocyanate-reactive compound having a molecular weight less than 399 and functionality of 2 to 6;(c) 0 to 15 wt. % of an isocyanate-reactive tertiary amine polyether having a molecular weight of 100 to 1000;(d) 5 to 55 wt.

Abstract: A cap for sealing waste in a landfill is prepared by disposing a fill layer atop the waste and applying a fast-curing elastomeric material to the fill layer to provide a monolithic, continuous, elastomeric coating thereupon. The elastomeric material is derived from the reaction of an isocyanate-terminated compound having at least two reactive isocyanate groups and an amine-terminated compound having at least two reactive amine groups. The elastomeric layer is preferably covered with a porous drainage layer which is in turn covered with a layer of soil.

Abstract: 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 gypboards, fiberboards, plywood or OSB boards and trusses to ceiling panels. A preferred 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. Where the bead is applied to the side faces of the support members, the support members may be turned to orient the foam beads opposite the fibrous panel, which is preferably supported on a flat support surface, most preferably a vacuum plate which draws the panel flat.

Abstract: A foam delivery system includes a pump for delivering a pressurized flow of material to a dispenser through a flexible hose. The hose is encased in a flexible, expansible sheath which contains any material which may leak along the hose. The sheath expands in the region of the leak to accommodate the released material and to indicate the presence of the leak. The system also includes a monitor which senses a leak condition and then terminates the pressurized flow of material.

Abstract: The method of forming rigid panel assemblies of this invention eliminates the requirement for mechanical fasteners and clamps 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.

Abstract: This invention relates to a method of repairing existing manholes and similar structures by applying a fast-curing elastomeric material using spray techniques whereby a homogeneous, non-porous, and monolithic coating or lining is formed. The fast-curing elastomeric material can be applied directly to existing substrates, which may comprise of concrete, brick, tile, mortar, and metal surfaces normally found in sewer manholes and catch basins, sewer and drainage pipes, parking decks, bridge piers and footings, holding ponds, bridge trusses, culverts, gratings, and the like and does not require any formwork. More preferably, the substrate surfaces are first cleaned and primed to improve the bond of elastomeric coating to the substrate. The most preferred primer is an aqueous solution of silane, preferably containing 10% to 30% silane.

Abstract: This invention relates to a method of repairing existing manholes and similar structures by applying a fast-curing elastomeric material using spray techniques whereby a homogeneous, non-porous, and monolithic coating or lining is formed. The fast-curing elastomeric material can be applied directly to existing concrete, brick, tile, mortar, and metal surfaces normally found in sewer manholes and catch basins, sewer and drainage pipes, parking decks, bridge piers and footings, holding ponds, bridge trusses, culverts, gratings, and the like and does not require any formwork. The elastomeric coatings provide effective surface protection against wear, corrosion, and water infiltration and can be applied in a single operation to horizontal, vertical, and overhead surfaces.

Abstract: The foam application apparatus or gun of this invention is particularly adapted to prevent leakage of the gun through the nozzle while assuring repeated use without seizure. The foam application apparatus includes a cylindrical mixing chamber having two inlet passages and an outlet passage through which mixed foamable resin is sprayed or discharged under pressure. A cylindrical valve rod having a free end is reciprocated in the mixing chamber from an "off" position, wherein the rod free end blocks the communication from the inlet passages to the outlet passage, and "on " position, wherein the rod is retracted, providing unrestricted communication between the inlet and outlet passages. In one preferred embodiment, a pair of closely spaced radial grooves are provided on the free end of the valve rod. The grooves receive fluid resin to form in situ resin seals which are replenished each time the rod is reciprocated in the chamber.

Abstract: A method of substantially completely filling elongated channels with foam, such as the channels in an extruded lineal used by the window industry. The method includes first orienting the channel in an upwardly angled orientation preferably greater than 30 degrees and less than 90 degrees, with a preferred angle of about 60 degrees. Where the channel has open ends, the lower end may be temporarily sealed. A thin, relatively high-pressure high-velocity stream of liquid foamable resin is then directed into the elongated channel open end generally parallel to the inside walls, such that the high-pressure liquid stream is carried at least partially down the length of the elongated channel, prior to contacting the channel inside walls and creaming. The liquid foamable resin then rises upwardly through the elongated channel, substantially completely filling the channel with resin foam.

Abstract: A method of bonding rigid structural support members to a gypsum or fiberboard panel to form a structural building module. The method involves applying a polyurethane adhesive as a liquid by high pressure stream into a space formed at the junction of the support members and the panel. The space is established by providing a plurality of spaced feet on one planar side of the support members. The support members includes either integrally formed feet, which are placed on the panel, or non-integral feet that are inserted between the support members and the panels. The support members may include holes on the surface bonded to the panel in a face to face relationship or on vertical surfaces in close proximity to the panel through which foam may expand and form a mechanical interlock with the support members. The support members may be metal channels or wood members. The structural building module provides an increased strength bonded structure without the use of nails or other fasteners.

Abstract: A structural building module and a method of bonding rigid structural support members to a gypsum or fiberboard panel to form a structural building module. The method involves applying a polyurethane adhesive as a liquid by high pressure stream into a space formed at the juncture of the support members and the panel. The space is established by providing a plurality of spaced feet on one planar side of the support members. The support members include either integrally formed feet, which are placed on the panel, or non-integral feet that are inserted between the support members and the panels. The support members may include holes on the surface bonded to the panel in a face to face relationship or on vertical surfaces in close proximity to the panel through which foam may expand and form a mechanical interlock with the support members. The support members may be metal channels or wood members.

Abstract: A method of surface bonding elements with a two component polyurethane foam, particularly where one of the surfaces to be joined is relatively porous, including contoured fiberglass panels, carpet, foam and fibrous paneling and the resultant bonded structure. The method includes spraying the liquid foamable polyurethane in a fine mist under pressure on one of the surfaces to be bonded to form dispersed discrete liquid polyurethane droplets; permitting the polyurethane droplets to foam and expand in discrete foam pods; applying the second surface to be joined while said polyurethane foam pods are between 20% and 60% of full cure; and, completing the cure of the polyurethane foam, preferably under moderate heat and pressure.

Abstract: A prefabricated structural element and a method of bonding wallboard to structural elements such as trusses for use in construction or prefabrication of ceilings or walls. The method involves applying a resilient polyurethane foamable liquid by a high pressure impingement mixing spray gun onto areas of a clean, dry wallboard substrate which have wood trusses or studs placed upon them. The foam is sprayed on the drywall at the juncture with the wood members on both sides of the wooden members. The resulting bonded structure permits the unit to be used without further nailing or other attachment means. The foam also permits the combined product to present a flat surface regardless of irregularities in the wood trusses.