Systems and apparatus for manufacturing multiple large-sized sandwich panels

Abstract

Systems and associated methods for manufacturing multiple sandwich panels are provided. In some embodiments, the system can include (1) a control unit; (2) a surface processing module configured to prepare a rolled material by at least one surface treatment process; (3) an environmental management module configured to control and management environmental factors during the surface treatment process and a pressing process; (4) a sealant module configured to apply sealants in sealant patterns on surfaces of flat portions of the rolled material and insulation layers; (5) a pressing module including a top mold, an intermediate mold, a bottom mold and configured to press multiple pairs of the flat portions and insulation layers so to form multiple sandwich panels in the pressing process.

I/We claim: 
     
         1 . A system for manufacturing multiple sandwich panels, comprising:
 a control unit;   a surface processing module configured to prepare a rolled material by at least one surface treatment process;   an environmental management module configured to control and management environmental factors during the surface treatment process and a pressing process;   a sealant module configured to apply sealants in sealant patterns on surfaces of flat portions of the rolled material and insulation layers; and   a pressing module including a top mold, an intermediate mold, a bottom mold and configured to press multiple pairs of the flat portions and insulation layers so to form multiple sandwich panels in the pressing process.   
     
     
         2 . The system of  claim 1 , wherein the intermediate mode include an upper mold and a lower mold. 
     
     
         3 . The system of  claim 1 , wherein the sealant patterns are formed in recesses on the insulation layers. 
     
     
         4 . The system of  claim 1 , wherein the multiple sandwich panels include six sandwich panels. 
     
     
         5 . The system of  claim 1 , wherein at least one of the multiple sandwich panels includes an opening. 
     
     
         6 . The system of  claim 5 , wherein at least one of the sealant patterns are formed in accordance with the opening. 
     
     
         7 . The system of  claim 5 , wherein the at least one of the multiple sandwich panels having the opening is configured to be a side panel of a statable trailer system. 
     
     
         8 . The system of  claim 1 , wherein at least one of the multiple sandwich panels includes a dimension of “40 feet×10 feet×2 inches.” 
     
     
         9 . The system of  claim 1 , wherein at least one of the top mold, the intermediate mold, the bottom mold includes a surface formed by a laser carving process. 
     
     
         10 . The system of  claim 1 , wherein the pressing module further includes a power module configured to apply a force on the top mold and the bottom mold. 
     
     
         11 . A method for manufacturing multiple sandwich panels, comprising:
 positioning a first flat portion on a bottom mold;   forming a first sealant pattern on the first flat portion;   positioning a first insulation layer on the first flat portion;   forming a second sealant pattern on the first insulation layer;   positioning a second flat portion on the first insulation layer;   positioning an intermediate mold on the second flat portion;   positioning a third flat portion on the intermediate mold;   forming a third sealant pattern on the third flat portion;   positioning a second insulation layer on the third flat portion;   forming a fourth sealant pattern on the second insulation layer;   positioning a fourth flat portion on the second insulation layer;   positioning a top mold on the fourth flat portion; and   pressing the top mold toward the bottom mold under a predetermined temperature profile during a predetermined time period.   
     
     
         12 . The method of  claim 11 , wherein the first sealant pattern and the second sealant pattern are vertically aligned. 
     
     
         13 . The method of  claim 11 , wherein the first sealant pattern and the third sealant pattern are vertically aligned. 
     
     
         14 . The method of  claim 11 , wherein the predetermined temperature profile includes a temperate range from 40 degrees Celsius to 50 degrees Celsius. 
     
     
         15 . The method of  claim 11 , wherein the predetermined time period ranges from 3 hours to 5 hours. 
     
     
         16 . The method of  claim 11 , wherein the first predetermined pattern includes sealant lines in parallel with one another. 
     
     
         17 . The method of  claim 11 , wherein the first predetermined pattern includes sealant lines perpendicular to one another. 
     
     
         18 . The method of  claim 11 , wherein the first predetermined pattern includes curved sealant lines. 
     
     
         19 . The method of  claim 11 , wherein the first predetermined pattern includes diagonal sealant lines. 
     
     
         20 . A system for manufacture multiple sandwich panels, comprising:
 a control unit;   a memory;   a surface processing module configured to prepare a rolled material by at least one surface treatment process;   an environmental management module configured to control and management environmental factors during the surface treatment process and a pressing process;   a sealant module configured to apply sealants in sealant patterns on surfaces of flat portions of the rolled material and insulation layers;   a pressing module including a top mold, an intermediate mold, a bottom mold and configured to press multiple pairs of the flat portions and insulation layers so to form multiple sandwich panels in the pressing process,   wherein the at least one surface treatment process and the pressing process are monitored and controlled by the control unit; and   wherein the sealant patterns are formed in accordance with a predetermined pattern stored in the memory.