Wall panel machine and method

Abstract

The present invention is directed to a wall panel characterized by a plurality of individual wires having a sine wave configuration having an upper and lower apex, alternate wires being parallel to and out of phase with the adjacent wire, with the lower apexes of the individual wires welded to a lower wire mesh and the upper apexes of said individual wires welded to a upper wire mesh; and an insulation material formed of synthetic expandable resin in situ to surround and embed the individual wires between said lower and upper meshes. Further, the present invention is directed to a machine and method for making the panels of the present invention.

1 . A machine for making wall panels comprising: 
 a feed section including means for feeding a wire mesh and means for feeding a plurality of individual wires;    a wire forming/welding section including means to form the individual wires into a sine wave configuration having an upper and lower apex, alternate wires being parallel to and out of phase with the adjacent wire, and means for welding lower apexes of said individual wires to said wire mesh;    an insulation forming section including means to introduce the components of a synthetic expandable resin to form a foamed insulation material on top of the mesh, said insulation material as it foams surrounding and embedding said individual wires;    a top mesh feeding/welding section including means to feed a top wire mesh and means for welding top apexes of said individual wires to said top wire mesh; and    a cutter section including a saw to cut the panel made in said machine to a desired length.    
   
   
       2 . A machine according to  claim 1  further including: 
 at least one chain having means to move said lower wire mesh directionally from said feed section toward said cutter section.    
   
   
       3 . A machine according to  claim 2  further including: 
 means for moving said welding means during welding in the same direction and speed as said chain moves said lower wire mesh.    
   
   
       4 . A machine according to  claim 1  wherein said insulation material is polyurethane.  
   
   
       5 . A machine for making monolithic wall panels comprising: 
 means to feed a wire mesh and a plurality of individual wires;    means to form the individual wires into a sine wave configuration having an upper and lower apex, alternate wires being parallel to and out of phase with the adjacent wire, and to weld lower apexes of said individual wires to said wire mesh;    means to introduce the components of a synthetic expandable resin in situ to form a foamed insulation material on top of the mesh, said insulation material as it foams surrounding and embedding said individual wires; and    means to feed a top wire mesh and to weld top apexes of said individual wires to said top wire mesh thereby making a panel.    
   
   
       6 . A monolithic panel comprising: 
 a plurality of individual wires having a sine wave configuration having an upper and lower apex, alternate wires being parallel to and out of phase with the adjacent wire, most lower apex of said individual wires welded to a lower wire mesh and most upper apex of said individual wires welded to a upper wire mesh; and    an insulation material formed of synthetic expandable resin in situ to surround and embed the individual wires between said lower and upper meshes.    
   
   
       7 . A panel according to  claim 6  wherein said synthetic resin is polyurethane.  
   
   
       8 . A method for making wall panels comprising: 
 feeding a wire mesh into a machine for making wall panels;    feeding individual wires having a sine wave configuration, alternate wires being parallel to and out of phase with the adjacent wire;    welding the lower apexes of said individual wires to said wire mesh;    forming a synthetic expandable resin in situ to form a monolithic foamed insulation material on top of the mesh, said insulation material as it foams surrounding and embedding said individual wires; and    welding a top wire mesh to the top apexes of said individual wires.