AU2004201164A1 - A Laminated Panel - Google Patents

Description

A LAMINATED PANEL FIELD OF THE INVENTION This invention is directed to a laminated panel and is particularly directed to a laminated panel which contains an expanded core (typically polystyrene) which is laminated at least on one side with a flexible sheet material. The sheet material may comprise a woven plastic sheet such as woven polyethylene sheet material.

BACKGROUND ART Laminated polystyrene panels are known in the art and are typically used to provide insulation, and also used as building panels. These panels comprise a core of expanded polystyrene which is sandwiched between a pair of metal sheets.

The sheets may be profiled or substantially plain. An advantage of these panels is that they provide extremely good insulation against temperature/sound/vibration etc.

Such metal panels however suffer from many disadvantages. One disadvantage is that the metal panels are quite heavy and this places a limit on the size of each panel especially if the panels are to be assembled by manual labour. Another disadvantage is that the cost of manufacture of a laminated metal panel is quite high.

Yet a further disadvantage is that it can be somewhat difficult to cut or shape the metal panel. Also, the cutting action can create a sharp edge which is a hazard. Often, 2 0 it is necessary to cut the panel down to size or to a particular shape and this cannot be readily achieved except with the use of metal cutting tools. Yet a further disadvantage is that a metal panel cannot be bent into a particular desirable shape. Therefore, if it is desirable to manufacture a box like shape, it is necessary to use a number of panels which need to be attached at their edges to form the box like shape. A single panel cannot be used. Another disadvantage with metal panels is the difficulty and effort required to join adjacent panels together. The panels must typically be joined using a separate post member and the like; however it is not possible to join the panels together using a tape or other more readily usable materials. Sometimes, the panel members must be connected in such a way that the connection is vapour tight.

Typically, this will be an advantage in a coldroom where vapours should not leave the cold room. This will also be an advantage to ensure maximum installation efficiency.

With metal panels, the join does not often achieve the desired level of sealing and this reduces the efficiency of the assembly. Yet another disadvantage with metal laminated panels is that the panels are susceptible to corrosion. This limits the use of such panels in a marine environment. This also limits the use of such panels to store corrosive chemicals and especially oxidative chemicals which will quickly cause corrosion of the metal. Such chemicals can include bulk fertiliser. Galvanic corrosion can also occur especially if the panels are attached to a metal post of a dissimilar metal. Another disadvantage with metal panels is that the panels typically have a tongue and groove edge profile which allows adjacent panels to be fitted together.

However, the metal tongue and groove joint is easily damaged during transportation and the damage is difficult to repair and if not prepared, can result in adjacent panels.

not fitting together properly. Another disadvantage with metal panels is that the metal expands and contracts with changes in temperature. Therefore, if this type of panel is used in extreme environments, the expansion and contraction can damage the structure and can also jeopardise or compromise any vapour seal present between adjacent panels.

In relation to the transportation of metal panels, the weight of the panels is a significant problem when unloading as a forklift is usually required on site, or if a forklift is not available, a fairly large number of workers are required to lift and transport the panels. This would be difficult if the panels arc used as an emergency shelter in a disaster zone, and there would be many other circumstances where the weight of the panels would present a problem. Moreover, when the panels are packed on top of each other, the tongue and grooved joints are exposed and can be damaged by the forklift.

In the marine industry, there is a great need for temporary "on location" refrigerated buildings that are easily installed and removed and which are not susceptible to corrosion in the marine environment. Such buildings can be used to maintain the freshness of a marine catch such as fish, prawns etc. After the season has finished, the building should be dismounted and removed. Presently, there is no building system that can fulfill all these requirements cost effectively and efficiently.

In the chemical and fertiliser industry it is sometimes necessary to provide a temporary building which may need to be cooled or refrigerated. The building will temporarily store bulk material which means that the material contacts the side of the building. Presently, metal panels are not entirely suitable as they are susceptible to corrosion, difficult to erect, difficult to remove and are quite expensive.

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Therefore, there is presently no building system that can fulfill this requirement cost effectively and efficiently.

In the building industry, it is often necessary to trim/cut/shape/profile panel members to make them suitable for the particular building. This is particularly the case if the panel members are used in a frame structure or if the building must have a particular height/length/width etc. Sometimes, there is an advantage in using laminated polystyrene panels and presently these panels comprise the metal sheeted panels. It is difficult and slow to cut the metal panels to shape and to ensure that the cutting edge remains neat and that the polystyrene core is not damaged during the cutting/shaping process. Therefore, there would be an advantage if it were possible to provide a panel member which could be cut and shaped much more easily while still providing sufficient strength/ insulation properties etc. to the panel.

There are many situations where it is necessary to provide an insulated duct or conduit. As a particular example, is often necessary to lag or otherwise insulate an air-conditioning duct particularly when used in a high-rise building. These air-conditioning ducts can have a cross-section of between 20-200 cm. Similarly, pipes conveying hot/cold water often need to be insulated. Conventionally, insulating material is wound about the duct/pipes. Other times, insulating material can be sprayed onto the outer or even inner surface of the duct/pipes. In each case, the insulation process is laborious and the insulation does not have a relatively protected outer skin and is therefore quite easily damaged or corroded resulting in a reduction in the insulating properties. It is difficult to provide a duct which is made of insulating material. For instance, if the duct was manufactured from metal clad polystyrene panels, the duct would need to be made of long straight panels connected at their edges to form a rectangular duct. There would be a distinct advantage if it were possible to manufacture an insulating duct from a single sheet of material which could be readily bent into a rectangular or other desirable shape and there would be a especially distinct advantage if it were possible to achieve this while still providing the outer surface of the duct with a relatively robust and damage resistant skin or surface.

In the packaging industry it is often necessary to provide a box or carton which is insulated. Such boxes are used to transport fresh produce. Polystyrene boxes are well-known and provide good installation to produce. However, the boxes are very susceptible to damage making them less suitable for reuse. Another disadvantage is that the boxes cannot be "flat stacked" when not required or when returned to base. This makes the boxes, quite cumbersome. If a polystyrene carton is damaged it is generally scrapped and sent to landfill which creates an environmental problem. Conventional insulated boxes or cartons cannot be quickly assembled from a substantially flat position into an erected use position.

Demountable temporary shelters are often required. Such shelters can be used in disaster zones, war zones, but can also be used as temporary animal shelters, and machinery shelters especially in extreme environments of heat and cold.

The shelters should be lightweight to enable them to be transported quickly and easily, should be easy to erect (often manually) and need to be sufficiently strong for the duration that the shelter is required. The shelters should also be properly insulated.

Metal laminated panels are currently being used for such shelters but have the disadvantages described above. Therefore, there would be a great advantage if it were possible to provide a demountable temporary shelter which improved on the currently available shelters.

It is sometimes necessary to provide inground insulation and especially insulation under concrete slabs. This type of insulation is required in areas which have permafrost. It is also sometimes necessary to provide a moisture barrier underneath concrete slab, floor etc. Presently, plastic sheet is used but the plastic sheet does not provide any insulation and is also quite easily damaged. Polystyrene blocks are sometimes used underneath a concrete slab but these blocks are generally used to provide voids in the slab particularly on reactive soils. Metal insulated panels would not be suitable to provide underground insulation as the metal is susceptible to corrosion. Moreover, it would be difficult to seal adjacent metal panels together to form a strong moisture barrier and the inevitable corrosion would ultimately result in loss of the moisture barrier.

It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.

OBJECT OF THE INVENTION The present invention is directed to a laminated panel which uses a flexible sheet, and particularly a woven plastic sheet instead of a metal sheet and which can at least overcome some of the above-mentioned disadvantages.

It is an object of the invention to provide a laminated panel which may overcome at least some of the above-mentioned disadvantages or provide the public with a useful or commercial choice.

In one form, the invention resides in a laminated panel, the panel comprising an insulating member and a laminating member, the laminating member comprising a flexible sheet.

Suitably, the flexible sheet comprises a plastic sheet and it is particularly preferred that the flexible sheet comprises a woven plastic sheet.

Suitably, the woven plastic sheet comprises a woven polyethylene sheet laminated to the laminating member.

The insulating member is suitably an expanded plastics material.

Expanded polystyrene comprises a suitable insulating member.

The laminating member may be laminated to at least one side or zone or area of the insulating member, but may also be laminated to opposed sides of the insulating member.

The size and shape of the panel can vary. Typically, the panel will be substantially rectangular and may have a length of from less than 1 m up to 10 m. The panel may have a width which can vary and can typically vary from about 100 cm up to 4 m. The panel may have a thickness which can vary and can typically vary from between 10 mm- 100 mm. The panel may have a shape which is other than rectangular and may include an oval panel, circular panel, triangular panel, panels having other polygonal shapes, irregularly shaped panels and the like.

The insulating member may comprise an expanded plastics, and a widely used insulating member is expanded polystyrene. The polystyrene may have different densities. Other types of insulating members can be used such as other types of foamed or expanded plastics. Combinations of plastics may be used. The insulating member may comprise other components/compositions including wool, fibres including natural and artificial fibres, and other types of insulating products.

The insulating member may comprise natural materials such as vermiculite, combination of natural and artificial materials and the like. The thickness of the insulating material can vary depending on the desired properties.

Typically, the panel will comprise a single sheet of insulating material however it is envisaged that the panel may comprise a plurality of insulating materials which may be attached directly or indirectly to each other or otherwise formed into a panel.

The laminating member is typically a flexible plastic sheet. The plastic sheet is preferably woven plastic sheet material to provide strength to be laminated panel. A particularly desirable woven plastic sheet material comprises a woven polyethylene sheet. However, it is envisaged that the woven plastic sheet material may comprise other plastics such as polypropylene, nylon, mixtures of plastics materials The woven plastic sheet material may comprise a mixture of plastic filament members and non plastic filaments members. The non plastic filament members may comprise metal members, canvas members, cotton members, members made of other materials such as fibreglass, resin, wool, and the like. It is envisaged that the flexible sheet material may comprise a woven mesh of metal such as steel (however this may not be entirely suitable where corrosion presents a problem although it will reduce the weight of the panels). It is preferred that the woven plastic sheet material is substantially continuous and does not present prominent and multiple openings. Thus, it is preferred that the woven plastic sheet material extends substantially continuously over the insulating material and does not form a open weave or grid like covering.

The thickness of the plastic sheet can vary but will typically be between 0.1-5 mm and preferably between 0.5-2 mm. multiple sheets may be used to increase the strength of the panel.

The flexible sheet typically extends substantially over one side of the insulating material. Suitably, the flexible sheet extends over each opposed sides of the insulating material such that the insulating material is sandwiched between a pair of flexible sheets. It is also envisaged that the sheet can extend over parts or zones of the insulating material.

The flexible sheet will typically be laminated directly to the insulating material, however it is also envisaged that panel member will contain at least one intermediate member which may comprise a flexible sheet member to provide specific properties to the panel member. For instance, the intermediate member may comprise a fine metal mesh to insulate the panel against radiofrequency passage etc.

The panel member may contain additional components. For instance, it is envisaged that the surface of the panel member may be coated/covered or may otherwise contain a reflective material which may be positioned over or under the flexible sheet.

The panel member may be provided with at least one fold means which may be a recess or groove to allow the panel member to fold or hinge about the recess or groove. Suitably, the recess or groove extends through substantially all the intermediate member but not through or entirely through the laminating member. As the laminating member has a degree of flexibility, the panel member can be folded about the fold means without requiring a separate post or attachment member.

It is envisaged that the panel member can be provided with a plurality of such fold means to allow the panel member to be folded from a substantially fat position to a L-shaped position, a U-shaped position or even a substantially closed rectangular position. For instance, a single fold line will allow the panel member to fold into a L-shaped position. A pair of spaced apart parallel fold lines will allow the panel member to fold into a U-shaped position. Three spaced apart parallel fold lines will allow the panel member to fold into a rectangular position. Other arrangements of fold lines are envisaged.

If a groove or recess is provided, the groove or recess may be shaped to facilitate the folding action. For instance, if the groove or recess has a V shape, this 2 0 will facilitate folding of the panel into a L-shape. Alternatively, if the angle in the groove is different, the resulting fold angle will also be different. As an example, the panel may be provided with five fold lines to allow the panel to form a hexagonal shape, and each fold line may be profiled into a groove having an internal angle of approximately 70 to facilitate the formation of the hexagonal shape. Alternatively, 2 5 the groove or recess may be quite large which will allow the panel to fold about a range of angles for instance from between 45'-135'. It is envisaged that fold means may be provided along different parts of the panel member and the fold means need not be parallel to each other and may be at right angles to each other and the like.

The fold means may be manufactured into the panel member during the manufacturing process or may be machined or otherwise formed into the panel member after the panel member has been manufactured.

In another form, the invention resides in an assembly of panel members, each panel member being as described above, adjacent panel members being attached to each other via a flexible adhesive tape.

Suitably, the tape is applied to each side of the panel members such that the panel members are attached to each other by two lengths of flexible adhesive tape one on the outside and one on the inside.

The flexible adhesive tape may be of any suitable manufacture. It is found that the flexible adhesive tape will particularly adhere to the flexible plastic sheet of the panel member which is an advantage over metal sheet members which cannot be properly connected together using adhesive tape. Suitably, the tape is a poly woven ethylene tape.

The adhesive tape may be attached over the entire join length of the adjacent panel members or alternatively the adhesive tape may be attached only parts of the join length. Multiple lengths of adhesive tape may be used which may be spaced apart from each other if desired. The width of the adhesive tape can vary but should be sufficient to form a good attachment to each panel member.

The adhesive tape can also be used to assist in assembly of a panel member which contains fold means. For instance, the panel member can be folded about the fold means and adhesive tape can be used to hold the panel member in the folded position. The tape can also be used to provide additional strength along the fold line, installation and the like.

The panel member may be provided with an edge profile to facilitate assembly of one panel member to another panel member or of one panel member to another member such as a post and the like. In one form, the edge profile may comprise a "tongue-and groove" profile where the edge of one panel is provided with a tongue and the edge of an opposed panel is provided with a groove. Typically, each panel is provided with a tongue on one edge and the groove of the other edge. Other types of profiles are envisaged to facilitate attachment of an assembly of the panel members.

The adhesive tape can be used to attach panel members together where the panel members are provided with the tongue and groove profile or other type of profile, In this manner, the profile can facilitate attachment of the panel members together, and the adhesive tape can further facilitate in the attachment of the panel members together. Thus, there is no need for separate fasteners such as screws, bolts, rivets and the like.

If desired, said panel member may be attached to a post or other type of support member. Such an arrangement may be desirable to provide better loadbearing characteristics to the panel member. Suitably, the panel member is profiled and can be folded in such a manner that a spacing is provided for the post or other type of support member. The post or other type of support member can be attached to the panel member using the adhesive tape or other type of suitable attachment means.

BRIEF DESCRIPTION OF THE DRAWINGS Embodiments of the invention will be described with reference to the following drawings in which: Figure 1. Illustrates a section view of a first panel member and a second panel member about to be joined together.

Figure 2. Illustrates a section view of a first panel member and a second panel member joined together and about to be taped together using adhesive tape.

Figure 3. Illustrates a cold room made from panel members.

Figure 4. Illustrates a wall to ceiling joint of the cold room of Figure 3.

Figure 5. Illustrates a floor joint of the cold room of Figure 3.

Figure 6. Illustrates a box blank made of a single panel member which has been cut and grooved to shape.

Figure 7. Illustrates a box formed from the box blank of Figure 6.

Figure 8. Illustrates a different type of box also formed from the box blank of Figure 6 but containing corner posts to make the box load-bearing.

Figure 9. Illustrates a panel member containing spaced apart parallel grooves to allow the panel member to be folded into a duct.

Figure 10. Illustrates a duct made from the panel member of Figure 9.

Figure 11. Illustrates a wall and part of a roof of a building containing a plurality of panel members.

Figure 12. Illustrates a suspended ceiling made of a plurality of panel members.

Figure 13. Illustrates a demountable shelter made of panel members.

Figure 14. Illustrates a curved roof cover made of panel members.

Figure 14A. Illustrates attachment details of the curved roof cover.

Figures 15-19. Illustrate a retracting awning made of panel members.

BEST MODE Referring to the drawings and initially to figures 1-2 there is illustrated a first panel member 10 and a second panel member 11. Each panel member is substantially rectangular and contains an insulating material in the form of an expanded polystyrene core 13. The polystyrene core in this particular embodiment is laminated on either side by a flexible sheet member which in the particular embodiment comprises a poly woven ethylene sheet 14. Each panel member has a tongue and groove edge profile comprising a tongue 15 on one edge and a groove 16 on the other each. This allows adjacent panels to be connected together as illustrated in figure 1 and figure 2.

Referring to figure 2, the two panels 10, 11 can be held together by an adhesive tape which in the embodiment comprises a poly woven ethylene adhesive tape 17, 18. The tape extends over the join between the 2 panels and adheres strongly to the poly woven ethylene laminating sheet on each side of core 13, due to the like nature of the material. It would be difficult if not impossible to achieve the same using a steel panel.

Figure 1 also co-illustrates a variation to the tape which is to have two flaps 17A fastened to each side of the panel. Each flap has a glue strip covered by a peel of layer. Thus, once the panels are butted together, the peel off layer is removed from each flap 17A and the flap is stuck to the next panel.

Referring to figure 3, there is illustrated (schematically) a cold room or other type of insulated area. The cold room can be quickly assembled from a plurality of panels as described above. For instance, in this particular embodiment, the cold room is formed from side panels 19-22, rear panel 23, and roof panels 24, 25. These panels can be easily joined by adhesive tape 26 extending over the joints and the various corners. The adhesive tape will seal the cold room and will cover any gaps.

The floor of the cold room can be made from aluminium grid material (or non slip sheet material 27) which can be on a ply which itself can be laid on top of a plurality of floor panel members (not illustrated). In this manner, a very well insulated cold room can be quickly and easily assembled. Moreover, the cold room can be very quickly disassembled merely by pulling the tape off the joins and simply pulling the panels apart.

Referring to figure 4, there is illustrated one preferred way to connect a roof panel 24 to a side panel 21. Side panel 21 is provided with a rebate 30 to support roof panel 24. The adhesive tape 26 is applied to the outer and the inner corners to connect the panels together and to seal the panels together. This again shows how easy it is to connect the panels together. Moreover, side panel 21 can quite readily be cut to form the rebate 30 which is something that would be difficult if not impossible with a steel clad panel.

Figure 5 illustrates a particular floor joint. The floor joint contains a side panel 19 and a floor panel 31. A bumper strip 32 is set in concrete 33. An aluminium flat part (not illustrated) is set in and taped to the panel. A plastic angle 34 extends on the outer corner and is fixed to the floor. Adhesive tape (not illustrated) is used to tape the plastic angle 34 to the outside of panel 19. Again, this illustrates how quick and easy it is to form this type of floor joint.

Figure 6-7 illustrates the use of a panel member to form an insulated box or container. In particular, there is illustrated how a single panel member can be used to form the box body. Referring initially to figure 6, panel member 35 is cut into the particular shape illustrated in figure 6. Grooves or channels 36 are cut into the panel member to form fold lines. Importantly, the grooves do not extend through the bottom laminated sheet. The outer edge 37 of the panel member is also angled. When the "blank" illustrated in figure 6 is folded about the various fold lines, a box is formed this being illustrated in figure 7. The corners of the box can be taped with adhesive tape 26. The box 38 will be protected on the outer surface by the outer laminated sheet and will be protected on the inside by the inner laminated sheet.

Thus, the box is much stronger and much more robust than the known polystyrene boxes. When not required, the adhesive tape can be removed and the box can be folded back to the "blank" position illustrated in figure 6. The hinge line comprises one of the plastic laminated sheets which is sufficiently strong to allow the box to be knocked up and knocked down many times. This type of box is suitable for a produce or seafood packaging, an insulated container for fishing or camping, a dry storage container or even as a coffin.

Box 38 can be provided with a lid 39 which may also be a panel member. Lid 39 can be taped to the top of box 38 to completely seal the box making it weatherproof.

Referring to figure 8, there is illustrated another type of box 40 which can be formed from a blank of material similar to that of figure 6 except that edges 37 are profiled differently. When the box is assembled, the corners are provided with a rebate 42 which can accommodate an insert in the form of a corner post 41. Post 41 is positioned in each rebated corner and is taped to the corner using adhesive tape 26.

The function of post 41 is to provide the box with load-bearing characteristics for multiple stacking and/or heavyweight produce. Each post 41 may be provided with an extending finger 43 on one end and corresponding recess (not illustrated) on the other end, to facilitate multi-stacking and interlocking of the boxes. Again, when not required, the tape can be removed, the posts 41 can be removed and the panel member can be knocked down to the "blank" position illustrated in figure 6.

Figures 9-10 illustrates a insulated duct which can be formed from the panel member. In figure 9, panel member 45 is formed with three longitudinal grooves 46, the grooves extending entirely through one face of the panel member, through the insulating material but not through the plastic laminating member of the other side of the panel. Therefore, this plastic laminating member forms the "hinge".

The panel member 45 can be folded from the flat position illustrated in figure 9 to the duct position illustrated in figure 10. The free edge can be taped using adhesive tape 26 to form a fully insulated duct. The duct has a robust outer wall (because of the outer plastic laminating member, and the robust inner wall (because of the inner plastic laminating member). Again, the duct can be very quickly converted back to the flat position simply by removing tape 26. A water-based glue or sealant can be brushed into the joins prior to folding to adhere and seal the joints.

Figure 11 illustrates a shed wall and part of a shed roof. In this particular embodiment, panel members 50 can be screwed or otherwise attached to the inside of purlins or frames on a shed to form an insulated skin which has the additional benefit of protecting the shed frame in caustic environments such as fertiliser or saltwater fish tanks or for clean storage environments for food products.

Figure 12 illustrates the use of panel members 51 as a suspended ceiling so that large shed areas can be air-conditioned or made dust free for food 3 0 storage or to provide a dust free work environments.

Figure 13 illustrates the use of panel members to provide an instant shelter application. The shelter is formed from a plurality of panel members. The panel members can be precut and a taped together as described above on-site to form the shelter. This type of shelter is lightweight and would be ideal for extreme environments of heat and cold. A plywood floor can be laid over the floor panel members. The shelter can be secured to the ground with webbing straps onto screw foundation bolts or other types of anchor members. The shelter can be easily relocated by removing the tape or cutting the tape and dismantling the panel members.

Figure 13 also illustrates how some panel members can be provided with window or door openings.

Referring to figure 14, this illustrates an igloo roof cover where the panels are made flexible by rolling through squeeze rollers in a factory so that it can be curved on-site to form an arch. The roof cover will be secured to hinged C section joints 55-58 illustrated in figure 14. The panel is secured to the C section via a steel plate 57 and bolts 56. These will all be secured to the ground by post 59 which sits within foundation 60. The panels illustrated in figure 14 will be joined together using adhesive tape or the pre-backed adhesive flap, both being illustrated in figure 1.

Referring to figures 15-19, these illustrate laminated panels used as a retractable awning. The panels can be hinged in two different methods. Referring initially to figure 18, there is illustrated laminated panels joined as hinge joints by vinyl welding the overlapping sheets and fixing eyelets to the joints adjacent to stainless cable. Referring to figure 17, there is illustrated a two-part aluminium extrusion clamp which attaches to the sheets to form flexible hinge joints 65, 68. The ends of extrusions 68 have an eye fitted to slide along a stainless cable 61. Each extrusion 68 will have a stop strap fitted to enable each joint to open to approximately 450 so that the awning can span large distances due to the truss design. Each of the bottom joints will become a gutter to discharge water. During heavy wind conditions, or when the cover is not needed, the awning can be retracted and secured with overlapping straps. The arrangements can be used as an insulated vertical retractable wall or door for cold room divisions, or doors for weather protection walls.

The panel members are extremely versatile and the above embodiment are illustrative only of the use of panel members but are not considered to the limiting on such use. The panel members can be manufactured for approximately half the cost of metal members, are lightweight, easy to handle, are impermeable to water and resistant to saltwater and corrosive chemicals, can be installed quickly and easily and can be disassembled easily and moved to different location and reassembled. The.

panel members may be provided with an edge profile (typically a tongue and groove profile) and this may be glued together with the use of adhesive tape strips to allow for very fast installation and to provide an excellent vapour and water seal. The panel members are easy to manufacture and the panel members can be easily cut and shaped to a finished product straight of the press with an existing band saw and fast wire cutting technologies adapted to the run out end of the machine which eliminates present-day manual handling and cutting. The panels do not have sharp steel edges and therefore handling injuries are reduced. The panel member can support its own weight over reasonable distances and additional strengthening ribs can be provided.

The panel member can be cleaned with basic detergents and can be easily repaired by cutting out the damaged area and installing a new piece and fixing all the edges with adhesive joint tape. A single skin panel member can be quite flexible and can be used as pipe lagging or insulating round vessels. Another advantage is that if the panel member has a tongue and groove joint, any damage can be readily fixed. The adhesive tape will also cover any damage joints. The weight reduction is also significant. A metal skin panel having a length of 6 m a width of 1.2 m and a thickness of 10 cm having a metal skin of 0.6 mm steel weighs 83 kg, while a panel member according to the invention of the same dimensions will weigh approximately 18 kg.

It should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the spirit and scope of the invention.

Claims (32)

1. A laminated panel comprising an insulating member and a laminating member, the laminating member comprising a flexible sheet.

2. The panel as claimed in claim 1, wherein the flexible sheet comprises a plastic sheet.

3. The panel as claimed in any one of the preceding claims, wherein the plastic sheet is a woven plastic sheet.

4. The panel as claimed in any one of the preceding claims, wherein the woven plastic sheet comprises a woven polyethylene sheet.

5. The panel as claimed in any one of the preceding claims, wherein the insulating member is an expanded plastics material.

6. The panel as claimed in any one of the preceding claims, wherein the insulating member comprises an expanded polystyrene.

7. The panel as claimed in any one of the preceding claims, wherein the laminating member is laminated to both sides of the insulating member.

8. The panel as claimed in any one of the preceding claims, wherein the panel is substantially rectangular and has a length of 1-10 m.

9. The panel as claimed in any one of the preceding claims, wherein the panel has a width of 0.1- 4 m.

10. The panel as claimed in any one of the preceding claims, wherein the panel has a thickness of between 10 mm-100 mm.

11. The panel as claimed in any one of the preceding claims, wherein the laminating member is substantially continuous and does not present prominent and multiple openings.

12. The panel as claimed in any one of the preceding claims, wherein the laminating member has a thickness of between 0.1-5 millimetres.

13. The panel as claimed in any one of the preceding claims, wherein a plurality of laminating members is provided.

14. The panel as claimed in any one of the preceding claims, wherein the panel contains reflective material. The panel as claimed in any one of the preceding claims, wherein the panel member is provided with at least one fold line.

16. The panel as claimed in claim 15, wherein the fold line is a recess or groove which extends through substantially the intermediate member but not through or entirely through the laminating member.

17. The panel as claimed in claim 15 or claim 16, comprising a plurality of fold lines.

18. The panel as claimed in any one of claims 15-17, wherein the fold line defines an internal angle to enable adjacent panels to be folded to define various angles relative to each other.

19. The panel as claimed in claim 1.8, wherein the fold line is a V shaped groove.

20. The panel as claimed in any one of the preceding claims, wherein the panel contains at least one flap which is adapted to overly an adjacent panel to enable the panels to be joined together, the flap being provided with an adhesive.

21. The panel as claimed in claim 20, wherein the adhesive is protected by a peel off layer.

22. The panel as claimed in claim 20 or claim 21, comprising a pair of flaps extending adjacent each side edge of a panel member.

23. The panel as claimed in any one of the preceding claims, comprising a plurality of said the panels which are attached to each other via an adhesive tape.

24. The panel as claimed in any one of the preceding claims, wherein one edge of the panel is provided with a tongue and the other edge of the panel is provided with a groove to enable panels to be joined together by inserting the tongue on one panel into the groove on another panel. A cold room comprising at least one panel as claimed in any one of the preceding claims.

26. The cold room as claimed in claim 25 and with reference to figures

27. A box comprising a panel as claimed in any one of claims 1-24.

28. The box as claimed in claim 27 with reference to figures 6-8.

29. A duct comprising a panel as claimed in any one of claims 1-24. The duct as claimed in claim 29, with reference to figures 9-10. 3 0 31. A building structure comprising a panel as claimed in any one of claims 1-24.

32. The structure as claimed in claim 31, with reference to figures 11-13. 17

33. A curved cover comprising a panel as claimed in any one of claims 1- 24.

34. The cover as claimed in claim 33, with reference to figures 14 and 14A. A retractable awning or wall comprising a panel as claimed in any one of claims 1-24.

36. The awning or wall as claimed in claim 35 with reference to figures 19.

37. A panel substantially as hereinbefore described with reference to the drawings. Dated this 2 2 nd day of March 2004 Van-Rich Pty Ltd By their Patent Attorneys CULLEN CO.