AU603362B2 - Composite building panel and manufacture thereof - Google Patents

Description

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FORM s J vuej COMMONWEALTH OF AUSTRALIA S F Ref: 17660 n A VC1m1o AI t~ .4 nn COMPLETE SPECIFICATIO FEE STAMP Tn. ALUE OF MAI O~;C6 L~ ATTACHED -1 sw 8*)

(ORIGINAL)

FOR OFFIfCEU~SE: Class Int. Class Application Number: Lodged: LODGED AT 3"UB-OFFICE 2 6 MAY 1987 S:Yctnev PH6102 26 May 1986 Accepted: Publ ished: Priority: Related Art: Name and Address of Applicant: -R&&1a;cG-Du n~lopLA4 m ted ~2-3rd-F.oor 650-Bourk-e-St-ree t Me-)bou r-n e-V-i-ctor1a-3O0-

AUS-TRA'L-IA

0B e\ acr P+ 1 L,(4IA*~ 18H d~ ooiq VDOCk Atf Actual Inventor: Address for Service: John Patrick Holden, Malcolm Bruce O'Brien, jqM~~vRS C.JIU7r Coc. s1~t~Je) Sp~ru-s o aLEe.r-g Li son.,_Rat entttorney s, .Le~e-V.-33-StMart i.-rvs=-Towe rl-3.l -Marke t S-tree-t~- -Sydeyr-N -o-~-W~---.200.,,A~tstral~ia, Complete Specification for the invgntion entitled: COMPOSITER BUILDING PANEL AND MANUFACTURE THEREOF The following statement is a full description of this Invention, including the best method of performing It known to me/us 5815/2 The present invention relates to composite building panels, and in particular to inter-engaging panels and the apparatus for manufacturing such panels.

Generally such composite building panels have an inner core of material having a high thermal resistance sandwiched between outer protective skins. The thickness and compositlon of the inner core primarily determines the thermal conductivity and rigidity of the panel.

Panels made in this way are excellent for the construction of refrigerated rooms as well as for general building requirements.

The outer skins may be sheet metal, plywood, plastics or any other suitable material.

The inner core may be foamed plastics such as polystyrene or polyurethane; synthetic honeycomb type papers; cork or other suitable material.

S 15 Panels using a foamed plastic core can be formed by either: bonding the outer skins to a prefolned sheet of foamed plastics; or (ii) holding the two outer skins parallel and apart the desired distance and injecting liquid plastics into the cavity between the skins so that as it foams it expands to fill the cavity.

The second method requires more complex equipment than the first and is generally a less desirable process.

Generally, an adhesive is applied to the inner surfaces of the metallic skins. A two-part adhesive is "dropped" onto the surface and mixed together with a spreader arm. This means that in order for the adhesive to be "dropped" i.e. with the aid of gravity, onto the inner surface of the top skin (if a horizontal arrangement is used), the skin must then have its roll direction reversed. This reversal causes problems if a pattern is to be pre-rolled into or onto the metallic skins.

Another disadvantage of the prior art apparatus is the fact that the j foam must be manually fed into the machine. Also, there has been no means by which the end surfaces of the foam cores could be secured together. If a weakness is present in the finished panel it is inevitably at the "non-secured" join. Therefore a continuous and automatic feed system would be most advantageous.

A continuous system would also allow the speed of the conveying T, apparatus to be increased, thereby Increasing output. However, problems in the production line occur with increased speed. Firstly, the length of the K' curing press is not suitable and any increased length would require an DG/0613t -2 Ih ni rMh r7increased number of rollers within the press.

The means by which the panel is held within the curing press has also lead to problems. In the past the upper and lower rollers have been pre-positioned with a separation distance slightly less than the thickness of thq foam. This was so that the foam itself would act as the force by which the outer skins are clamped to the inner foam. However, this method has resulted in undesirable undulations being pressed into the panel due to the pressure of the rollers.

At the end of the process it is necessary to cut the panel to the required lengths. At present this is a two stage process requiring two operators. Firstly the metallic skins are cut by way of a double hatchet apparatus on both the top and bottom. This double hatchet travels across the panel severing the metallic skins and a few millimetres of the foam only. Due to the differing natures of the foam and the skins, it is not possible to cut through the entire panel thickness with this action. Also, as can be appreciated, the battering of the hatchet blades on the metallic skins generates a considerable noise, which requires the operators to wear hearing protection and is environmentally difficult to contain.

Traditional sheet metal cutting means, such as a guillotine, cannot be used due to the lack of a hard surface beneath the sheets. Also, improved laser cutting methods cannot be utilised, again for the reason of the different natures of the materials.

The second cutting stage requires a hot wire cut to be made through the foam. The cut may be made staggered with the help of a template, and also the original metal cuts should be staggered to accommodate this. This staggered cut is particularly useful in coldroom applications.

The means by which the panels themselves are joined together has, in the past, relied on indents being made in the profile of the foam, these inda-its accommodating an form joining member on both sides of the panel. This leaves a somewhat "messy" appearance on th panel surface.

4f It is therefore an object of the present invention to overcome or "ubstantially ameliorate the abovementioned disadvantages.

There is disclosed herein an apparatus for manufacturing a composite building panel comprising: conveyor means to move preformed sheet core material, having two

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major faces, two end faces and two side faces, along a predetermined path; i l adhesive applying means located at a predetermined position on said path and adapted to apply an adhesive onto both main faces of said core material as said core material passes said predetermined position; DG/0613t -3 sheet applying means positioned on said path downstream of said adhesive applying means and adapted to bring a first and a second outer sheeting material into contact with said major surfaces of said core; a press positioned on said path at a position downstream of said sheet applying means and adapted to apply pressure to said sheeting whilst the adhesive is at least partly cured; and cutting means located at a position downstream of said press and adapted to cut discreet panels from the core and sheeting delivered thereto.

j Preferably the subsequent sheets of core material are fed in abutting end to end relationship into the apparatus from a magazine type feeder and means are provided to apply adhesive to abutting ends so as to glue them together.

In its broadest form the present invention comprises an apparatus for manufacturing a composite building panel comprising: conveyor means to move preformed sheet core material, having two major surfaces, two end faces and two side surfaces, along a predetermined path; adhesive applying means io'ated at a predetermined l position on said path and adapted to apply an adhesive onto both major surfaces of said core material as said core material JP passes said predetermined position; sheet applying means positioned on said path downstream of said adhesive applying meaiLs and adapted to bring a first and a second outer sheeting material into contact with said major surfaces of said core; 0198j 4 a;,l a press positioned on said path at a position downstream of said sheet applying means and adapted to apply pressure to said sheeting whilst the adhesive is at least Iartly cured; cutting means located at a position downstream of said press and adapted to cut discreet panels from the core and sheeting delivered thereto; said cutting means comprising a cutting arrangement having a blade carrier and at least one circular blade, said sheeting material being pre-profiled along one edge prior to being applied to cover material to facilitate mating with an adjacent panel on completion of said panel.

It is also desirable that there is provided a means by S which a profile is cut into the sides of the core material.

i *Preferably the core is an expanded foam plastics material and said outer skins are of metallic sheeting fed from a roll.

I\ Another preferred feature is that of a means by which a notch is made in the sheeting prior to the cutting stage.

M Also, the press should be closed by way of deflating air bags which are supporting the top section of the press.

According to another form the present invention provides a cutting arrangement comprising a blade carrier, and at least one circular blade.

Preferably there should be two blades which are positioned so as to be at an angle to each other and to the vertical.

Another preferred feature is the provision of a shavings catcher provided between and after the two blades.

There is further disclosed herein a building panel to be j 0 9--O g8j 4a en Vmatingly associated with like panels, said panel comprising a core of expanded foam material, said core having two major surfaces, two longitudinal side surfaces, and two end faces, said core also having a longitudinal recess in one side surface a metal sheet fixed to each major surface so as to cover at least a substantial portion thereof; and wherein one of the metal sheets has a first longitudinal edge portion located in said recess, said first edge portion being folded back upon itself to define a longitudinal groove extending inwardly of the panel from the associated longitudinal side surface, and a second longitudinal edge portion folded back upon itself to define a longitudinally extending projection extending at If S outwardly from the other side surface of the core and spaced from the adj.cent major surface so as to be received within the groove of an adjacent like panel.

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In a preferred embodiment there is provided a double angled plate to fit within the respective recesses of the male and female joint.3 of one I edge of one panel and to which may be provided a fastening means to attach said panel to another member.

5 Some embodiments of the present Invention will now be described, by way of example only, with reference to the accompanying drawings in which: FIG. 1 is a schematic elevation of the apparatus of the present invention used to manufacture the building panels of the Invention; FIG. 2 is a schematic plan view of the apparatus of FIG. 1; FIG. 3 is a perspective of a section of one embodiment of the building panel of the pre,',ent Invention; FIG. 4 is another perspective of a section of a building panel showing a recess to accommodate fixing of the panel to another member; FIG. 5 is a sectional view of two mating panels showing their fixing bolt; FIIG. 6 is another sectional view of two mating panels; FIG. 7 Is a schematic plan view of a section of the curing press of the present invention; FIG 8 is a schematic elevation of a section of the press of FIG, 7; FIG, 9 is an end view of the press of FIG, 7; FIG. 10 is a detailed section, of the press of FIG, 7, showing the minimum setting drive arrangement; FIG. 11 Is a schematic elevation of the cu~tting blade arrangement of the present invention; FIG, 12 is an end view of the blade arrangement of FIG. 11 showing the blades; FIG, 13 Is the upper end view of the cutting arrangement of FIG. 11, not showing the. blades; FIG. 14 Is a front elevation of the blade of the present invention; 3 FIG. 15 is an end elevation of the blade; FIG, 16 Is a schematic elevation of the blade carrier member; FIG, 17 Is an end elevation of the carrier member of FIG. 16; FIG, 18 Is a schematic elevation of the shavings catcher of the blade arrangement; and FIG. 19 k. an end elevation of the catcher of FIG. 18.

In FIG. I there Is depicted a building panel production line apparatus 1Q, This apparatus comprises a set of rolls 11 of metallic sheeting 12. The sheeting 12 Is fed through the tensioning rollers 13 and travels to a location on the line where it Is to be joined to the foam tDG/ 061 3t interior. A magazi,,ie 14 of polystyrene foam blocks 15 automatically and continuously feeds the foam blocks 15 to the adhesive spraying station 16.

The blocks 15 have longitudinally extending recesses 44 (see FIGS. 5 and 6) to be used in joining adjacent panels in use. Before the spraying station 16 is an adhesive applicator 17 by which an adhesive is applied to the ends of the blocks 15 and pressure i s appl ied to thereby secure the ends of the blocks 15 together. The desired foam profile is also cut into the block at 26, before it enters the spraying station 16.

W'hlst In the spraying station 16 the blocks 15 are sprayed with a one-part adhesive on both the top and bottom surfaces. The spray nozzles are arranged so as to avoid areas of over-spraying.

The coated blocks 15 are then brought into contact with the metallic sheeting 12 which form the two outer skins of the panel 18, The means by which this contact is arranged comprises a roll forming section 20. The continuous composite panel 18 is notched to the desired lengths at 19, prior to entering the roil forming section The notched, continuous panel then enters the insulated press chamber 21. The press 21 Is a three stage press, due to the length required to II maintain the conveyor speed and retain the panel 18 in the press 21 for a time sufficient for the adhesive to fully cure to a stage whereby the panel may be further handled without fear of it delaminating, The press 21 is seen in greater detail in FIGS. 7 to 10. The press 21 is arranged so that the upper section 22 of each stage is in a raised position as the start of the continuous panel 18 enters the press 21, Upon entering, the paneL1 18 is detected by sensors (not shown) and the upper section 22 of the first stage is lowered, Tills process continues for the next two stages of the press 21 Similarly, when the final section of the panel 18 is leaving the press 21 the three sections will be raised.

In order to avolkd the roller indents of the press of the prior art, this press 21 does not apply a pressure by setting the rollers of the two halves of the press 21 at a fixed distance apart. In this case the upper sections 22 are supported by means such as air bags 24, although hydraulic rams would also suffice. The Oir bags 24 are shown in greater detail In FIGS. 7 and 8, Therefore, upon. deflating these bags 24 a predetermined amount, the upper section 22 of the press 21 is gently lowered onto the panel 18. In this way the rollIers 25 of the press 21 merely hold the panel 18 together for the curing process. It Is therefore not necessary for all the rollers 25 to be driven,, especially as they do not need to pull the panel 18 through, as within the prior tart. The automatic core dl~spensinq DG/061 3t -6 apparatus 14 is acting so as to help in pushing the continuous panel through the system. A minimum setting drive arrangement 39 is situated on the press 21 and prevents the upper sactin 22 of the press 21 from being lowered too far. This is seen in greater detail in FIG. The cured panel 18 thien travels past the notch tracking panel 27 which registers whenever a notch is detected so as to initiate the cutting apparatus 28. The cut panel lengths 29 are then fed out of the apparatus A preferred form of the panel 30 to be constructed in this manner is shown in FIGS. 3 to 6. The metallic sheets 12 are preformed so as to incorporate matching male 31 and female 32 joints. In thi s way, the "H" form joining section of -the prior art is not required. The profile 33 of the foam blocks 15 is formed on the production line apparatus 10 at station 26 so as to accommodate the female joint 32. FIG. 6 shows how two panels 30 are joined together. This gives a sealed join particularly suitable for coldroom applications. W~hen the foam block 15 passes through the spraying station 16 it is possible to also apply adhesive to the side profile 33 of the foam block 15 so as to provide a means by which the joints 31 and 32 11 are secured to the foam.

FIG. 3 also shows the means by which the panels 30 may be fixed to another member 34. This entails providing a double angled plate 35 to fit within recesses 36 and 37 provided in the male 31 and female 32 joints respectively, on the same panel 30. A bolt 38, or other fastening means, is then passed through both the plate 35 and the male member 31 and attached to the other member 34.

Both the foam and the female joint 32 is notched on site to clear the fastener 38 as is seen In FIGS. 4 and The preferred method of cutting the composite panel 30 is depicted in FIGS. 11 to 19. The outer skins 12 of the panel 30 have previously been J 30 notched so as to avoid damaging the formed male and female joints.

The cutting arrangement 40 comprises mainly of a carrier 41 which travels across the panel 30, and to which is attached two circular bladesI 42 on either side of the carrier 41. Also attached to the carrier 41 is a shavings catcher 43, which travels between and behind the blades 42 and ro~lfs up '6e metal shavings to be disposed of at the other side. The blades 42 are arranged so as to be angled to the vertical, and tapering to a point at the catcher 43. The blades 42 rotate and thus create a situation similar to a double sided can opener. The blade itself may bej seen In FIGS. 14 and 15 and the assembled configuration is seen In FIGS. 11 DG/061 3t -7 to 13.

The foregoing describes only some embodiments of the present invention and modifications, obvious to those skilled in the art, can be made thereto without departing from the scope of the present invention.

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Claims (8)

1. An apparatus for manufacturing a composite building panel comprising: conveyor means to move preformed sheet core material, having two major surfaces, two end faces and two side surfaces, along a predetermined path; adhesive applying means located at a predetermined position on said path and adapted to apply an adhesive onto both major surfaces of said core material as said core material passes said predetermined position; sheet applying means positioned on said path downstream of said adhesive applying means and adapted to bring a first and a second outer sheeting material into contact with said major surfaces of said core; a press positioned on said path at a position downstream of said sheet applying means and adapted to apply pressure to said sheeting whilst the adhesive is at least partly ctt cutting Mean~ located at a posithn downstrei. press and adapted tc. cut discreut panels from thG za nd sheeting delivered thereto; said cutting means comprising a cutting arrangement having a blade carrier and at least one circular blade, said sheeting material being-pre-profiled along one edge prior to being applied to core material to facilitate mating with an adjacent panel on completion of said panil,

2. The apparatus of claim 1 further includinq -t means, to transversely notch each sheet prlV- thereof, arnd said cutting means Is adapted id sheeting along the notches formed therein, a aut said 0198j 9 P A~ 4j~ core in order to form discreet panels.

3. The apparatus of claim 2 further including magazine means located upstream of said adhesive applying means to feed discreet lengths of core material onto said path to enable joining thereof to form a continuous length of said core material to be fed to said adhesive applying means.

4. A building panel to be matingly associated with like panelgs, said panel comprising a core of expanded foam material, said core having two major surfaces, two longitudinal side surfaces, and two end faces, said core also having a longitudinal recess in one side surface; a metal sheet fixed to each major surface so as to cover at least a substantial portion thereof; and wherein one of the metal sheets has a first longitudinal edge portion located in said recess, and first edge portion being folded back upon itself to define a longitudinal groove extending inwardly of the panel from the associated longitudinal side surface, and a second longitudinal edge portion folded back upon itself to define a longitudinally extending projection extending outwardly from the other side i surface of the core and spaced from the adjacent major surface so as to be received within the groove of an adjacent like Spanel, i:

5. The building panel of claim 4, wherein the core is provided with two recesses which are located at opposite corners of the core, and each sheet is provided with one said longitudinal edge portion, and one said second longitudinal edge portion, so that adjacent panels are sealingly joined by two mating co-operating pairs of recesses and projections. 0198J 10 A e' '4 ny a 4s nrr~ n i r

6. A wall comprising a plurality of panels, according to claim 5, wherein each panel is joined to a supporting structure by means of an L-shaped bracket having a first leg abutting a major surface of an associated panel, and a second leg secured to the supporting structure.

7. An apparatus to manufacture building panels, substantially as hereinbefore described with reference to the accompanying drawings.

8. A building panel substantially as hereinbefore described with reference to the accompanying drawings. DATED this 8th day of August, 1990. PACIFIC DUNLOP LIMITED By Its Patent Attorneys ARTHUR S. CAVE CO. I 8 i O198j j 11 IP pt~ ih