EP1663602A1 - A panel - Google Patents

A panel

Info

Publication number
EP1663602A1
EP1663602A1 EP04770402A EP04770402A EP1663602A1 EP 1663602 A1 EP1663602 A1 EP 1663602A1 EP 04770402 A EP04770402 A EP 04770402A EP 04770402 A EP04770402 A EP 04770402A EP 1663602 A1 EP1663602 A1 EP 1663602A1
Authority
EP
European Patent Office
Prior art keywords
seal
panel
insulating panel
insulating
foam
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP04770402A
Other languages
German (de)
French (fr)
Inventor
James Carolan
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kingspan Research and Developments Ltd
Original Assignee
Kingspan Research and Developments Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kingspan Research and Developments Ltd filed Critical Kingspan Research and Developments Ltd
Publication of EP1663602A1 publication Critical patent/EP1663602A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B29C44/06—Making multilayered articles
    • B29C44/065—Making multilayered articles comprising at least one barrier layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/046—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
    • B29C44/32—Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements
    • B29C44/326—Joining the preformed parts, e.g. to make flat or profiled sandwich laminates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/16—Drying; Softening; Cleaning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/292—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and sheet metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/20—Inorganic coating
    • B32B2255/205—Metallic coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/302—Conductive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Definitions

  • the invention relates to a panel of the type comprising an external sheet and a backing sheet with an insulating foam core therebetween.
  • an insulating panel is manufactured to the required thickness to provide the desired insulating properties taking account of estimated the effects of ageing on the insulating properties of a panel when installed in a particular operational environment. This is generally inefficient and wasteful.
  • the present invention addresses these problems.
  • a method for manufacturing a composite insulating panel of the type comprising an external metal skin, an internal metal skin and an insulating core of foam material therebetween, the method includes the steps of: - conveying one of the metal skins continuously along a flat bed with an outer surface of the skin lowermost; laying down liquid insulating foam reactants onto the first skin; leading the second metal skin continuously over the liquid insulating foam reactants and the first metal skin; heating the assembly in an oven to allow the foam reactants to expand to form an insulating core between the metal skins; cutting the panel to a desired length, and applying a seal to at least one of the exposed foam edges of the panel.
  • the method comprises the step of removing dust from the exposed foam edge prior to application of the seal.
  • the dust may be removed from the exposed foam edge by the application of suction. Alternatively or additionally the exposed foam edge is brushed to remove dust.
  • the seal is applied in-line.
  • the seal comprises a gas and/or vapour barrier.
  • the method includes the step of applying a seal in the form of a strip of film, membrane or tape to the exposed edge of the panel.
  • a seal in the form of a strip of film, membrane or tape to the exposed edge of the panel.
  • the strip is retained in place by adhesive bonding.
  • the method includes the step of applying a seal forming liquid to the exposed edge of the panel.
  • a seal forming liquid is applied by spaying or by coating.
  • the seal comprises a polymeric material, preferably the polymeric material is polyvinylidene chloride or polyvinyl alcohol or polyvinyl chloride. In another embodiment the seal comprises a thermoplastics material.
  • the seal comprises a foil.
  • the seal may comprise a metallic foil.
  • the seal comprises an Aluminium foil.
  • the seal comprises a laminate foil comprising polymeric material with a metallic coating.
  • the metallic material is Aluminium.
  • an insulating panel comprising an external metal skin, an internal metal skin and an insulating core of foam material therebetween, the panel having at least one cut edge and the panel having a seal applied to the cut foam edge.
  • the panel has two opposed cut edges and a seal is applied to both cut edges.
  • the seal comprises a gas and/or vapour barrier.
  • the seal is in the form of a strip of film, membrane or tape.
  • the strip is retained in place by adhesive bonding.
  • the seal is comprised of a seal forming liquid.
  • the liquid is applied by spaying or by coating.
  • the seal comprises a polymeric material.
  • the polymeric material is polyvinylidene chloride or polyvinyl alcohol or polyvinyl chloride.
  • the seal comprises a foil.
  • the seal comprises a metallic foil.
  • the seal comprises an Aluminium foil.
  • the seal comprises a laminate foil comprising polymeric material with a metallic coating.
  • the metallic material is Aluminium.
  • the seal comprises a thermoplastics material.
  • Fig. 1 is a transverse cross sectional view of a panel of the invention
  • Fig. 2 is a side view of a part of an apparatus used in the method of the invention.
  • Fig. 3 is a side view of an alternative apparatus used in the method of the invention.
  • a composite insulating panel 1 comprises an external metal skin 2, an internal metal skin 3, and an insulating core 4 of foam between the skins 2, 3. Both skins 2, 3 may be of steel material and are usually profiled to a desired profile shape.
  • the insulated panel 1 is typically used for roofing and/or wall cladding, partitions, compartmental wall panels, cold store panels, clean room envelopes, food processing areas and the like applications, particularly where added fire resistance is required.
  • the insulating panels 1 are manufactured by first conveying one of the metal skins 2 continuously along a flat bed 30 with an outer surface of the skin 2 lowermost. Liquid insulating foam reactants including a blowing agent are then laid down through a lay down device such as a poker 20 onto the first skin 1.
  • the second skin 3 is laid continuously over the liquid insulating foam reactants and the first metal skin 2.
  • the assembly thus formed is then heated in an oven 21 to allow the foam reactants to expand to form an insulating core 4 between the metal skins 2,3.
  • the continuous panel thus formed is then cut to a desired length using an in-line saw 22.
  • the top and bottom edges 5 and 6 of the resulting cut panel are exposed.
  • any dust remaining on the cut edge is first removed in steps 25.
  • a suction may be applied to suck up the dust and/or the edge may be brushed.
  • These dust removal step(s) 25 may be carried out in-line. They ensure that the cut edge is prepared to receive and bond with the applied seal.
  • a seal 7 is applied to at least one of the exposed cut edges 5, 6 of the panel.
  • the seal 7 is a gas and/or vapour impermeable seal.
  • An in-line sealing means 23 may be used to apply the seal 7 to the exposed edges.
  • the seal 7 forms a gas or vapour barrier on the panel.
  • the seal 7 may comprise a membrane or film strip or tape, which is continually applied to the cut edge of the panel.
  • the seal 7 may alternatively be in the form of an aqueous emulsion applied by spraying or coating onto the edges onto the exposed panel edges.
  • Suitable seals include: Aluminium foil, or a foil of polymeric material coated with Al. Foils, membranes or emulsions comprising a polymeric material for example polyvinylidene chloride (PVDC) from Solvay or Dow, polyvinyl alcohol (PVOH), polyvinyl chloride (PVC), or laminated foils or membranes comprised of polymeric and metallic layers.
  • PVDC polyvinylidene chloride
  • PVH polyvinyl alcohol
  • PVC polyvinyl chloride
  • laminated foils or membranes comprised of polymeric and metallic layers laminated foils or membranes comprised of polymeric and metallic layers.
  • the panel comprises an insulating foam with high insulating properties.
  • Insulating foams with a closed cell structure are particularly suitable.
  • Polyisocyanurate for example has the desired closed cell structure for good thermal conductivity.
  • the choice of blowing agent used in the manufacturing process effects the thermal conductivity of the panel.
  • the blowing agent escapes from the foam and is replaced by air, with the effect of reduced thermal conductivity.
  • changes in the internal cell gas pressure result in reduced thermal conductivity.
  • the steel faced insulated polyisocyanurate panels thus produced have excellent structural properties and a high thermal conductivity.
  • Panels may be readily produced in any desired length, width or thickness.
  • the panels were of dimensions 500x500x80mm. Sections of dimensions
  • 250x250x25mm were cut from the middles of the panels and the thermal conductivity measured. The effect of different blowing agents use was also considered.
  • the panels with exposed edges sealed have superior thermal properties.
  • the sealed panels provide more stable K values irrespective of blowing agent used.
  • the invention provides a method of production of sealed panels with improved thermal conduction and K value.
  • the invention further provides for the provision of panels with the required levels of thermal conductivity which have a reduced thickness in comparison with panels that are currently in use.
  • the invention provides an extremely efficient factory scale process for manufacturing high quality composite Steel faced PIR panels on a continuous basis. Thus, the unit costs of production of such panels is minimised.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

A method for manufacturing a composite insulating panel of the type comprising an external metal skin (2), an internal metal skin (3) and an insulating core of foam material (4) therebetween, the method includes the steps of: conveying one of the metal skins continuously along a flat bed with an outer surface of the skin lowermost; laying down liquid insulating foam reactants onto the first skin; leading the second metal skin continuously over the liquid insulating foam reactants and the first metal skin; heating the assembly in an oven to allow the foam reactants to expand to form an insulating core between the metal skins; cutting the panel to a desired length, and applying a seal to at least one of the exposed foam edges of the panel. The seal which comprises a gas and/or vapour barrier is applied in-line.

Description

"A PANEL"
Introduction
The invention relates to a panel of the type comprising an external sheet and a backing sheet with an insulating foam core therebetween.
Over time diffusion of gas/vapour from insulating panels often results in decreased thermal conductivity. To cater for this in production, an insulating panel is manufactured to the required thickness to provide the desired insulating properties taking account of estimated the effects of ageing on the insulating properties of a panel when installed in a particular operational environment. This is generally inefficient and wasteful.
The present invention addresses these problems.
Statements of Invention
According to the invention there is provided a method for manufacturing a composite insulating panel of the type comprising an external metal skin, an internal metal skin and an insulating core of foam material therebetween, the method includes the steps of: - conveying one of the metal skins continuously along a flat bed with an outer surface of the skin lowermost; laying down liquid insulating foam reactants onto the first skin; leading the second metal skin continuously over the liquid insulating foam reactants and the first metal skin; heating the assembly in an oven to allow the foam reactants to expand to form an insulating core between the metal skins; cutting the panel to a desired length, and applying a seal to at least one of the exposed foam edges of the panel.
In one embodiment the method comprises the step of removing dust from the exposed foam edge prior to application of the seal.
The dust may be removed from the exposed foam edge by the application of suction. Alternatively or additionally the exposed foam edge is brushed to remove dust.
In one embodiment the seal is applied in-line.
In another embodiment the seal comprises a gas and/or vapour barrier.
In one embodiment the method includes the step of applying a seal in the form of a strip of film, membrane or tape to the exposed edge of the panel. Preferably the strip is retained in place by adhesive bonding.
In one embodiment the method includes the step of applying a seal forming liquid to the exposed edge of the panel. Preferably the liquid is applied by spaying or by coating.
In one embodiment the seal comprises a polymeric material, preferably the polymeric material is polyvinylidene chloride or polyvinyl alcohol or polyvinyl chloride. In another embodiment the seal comprises a thermoplastics material.
In a further embodiment the seal comprises a foil. The seal may comprise a metallic foil. In a preferred embodiment the seal comprises an Aluminium foil.
In another embodiment the seal comprises a laminate foil comprising polymeric material with a metallic coating. Preferably the metallic material is Aluminium.
According to another aspect of the invention there is provided an insulating panel comprising an external metal skin, an internal metal skin and an insulating core of foam material therebetween, the panel having at least one cut edge and the panel having a seal applied to the cut foam edge.
In one embodiment the panel has two opposed cut edges and a seal is applied to both cut edges.
In another embodiment the seal comprises a gas and/or vapour barrier.
In one embodiment the seal is in the form of a strip of film, membrane or tape. Preferably the strip is retained in place by adhesive bonding.
In one embodiment the seal is comprised of a seal forming liquid. Preferably the liquid is applied by spaying or by coating.
In another embodiment the seal comprises a polymeric material. Preferably the polymeric material is polyvinylidene chloride or polyvinyl alcohol or polyvinyl chloride.
In one embodiment the seal comprises a foil. Preferably the seal comprises a metallic foil. Most preferably the seal comprises an Aluminium foil. In another embodiment the seal comprises a laminate foil comprising polymeric material with a metallic coating. Preferably the metallic material is Aluminium.
In a further embodiment the seal comprises a thermoplastics material. Description of Drawings
The invention will be more clearly understood from the following description thereof given by way of example only with reference to the accompanying drawings, in which
Fig. 1 is a transverse cross sectional view of a panel of the invention;
Fig. 2 is a side view of a part of an apparatus used in the method of the invention; and
Fig. 3 is a side view of an alternative apparatus used in the method of the invention.
Detailed Description
Referring to Figs. 1 and 2 a composite insulating panel 1 comprises an external metal skin 2, an internal metal skin 3, and an insulating core 4 of foam between the skins 2, 3. Both skins 2, 3 may be of steel material and are usually profiled to a desired profile shape. The insulated panel 1 is typically used for roofing and/or wall cladding, partitions, compartmental wall panels, cold store panels, clean room envelopes, food processing areas and the like applications, particularly where added fire resistance is required. The insulating panels 1 are manufactured by first conveying one of the metal skins 2 continuously along a flat bed 30 with an outer surface of the skin 2 lowermost. Liquid insulating foam reactants including a blowing agent are then laid down through a lay down device such as a poker 20 onto the first skin 1. The second skin 3 is laid continuously over the liquid insulating foam reactants and the first metal skin 2. The assembly thus formed is then heated in an oven 21 to allow the foam reactants to expand to form an insulating core 4 between the metal skins 2,3. The continuous panel thus formed is then cut to a desired length using an in-line saw 22. The top and bottom edges 5 and 6 of the resulting cut panel are exposed. Referring to Fig. 3 in a preferred arrangement any dust remaining on the cut edge is first removed in steps 25. For example, a suction may be applied to suck up the dust and/or the edge may be brushed. These dust removal step(s) 25 may be carried out in-line. They ensure that the cut edge is prepared to receive and bond with the applied seal. A seal 7 is applied to at least one of the exposed cut edges 5, 6 of the panel. The seal 7 is a gas and/or vapour impermeable seal.
An in-line sealing means 23 may be used to apply the seal 7 to the exposed edges.
At least one of the top and bottom edges 5, 6 of the panels, which are exposed when the panel is cut, are sealed by the in-line sealing means 23 to prevent the diffusion out of the blowing agent used in the manufacture of the panel. The seal 7 forms a gas or vapour barrier on the panel. The seal 7 may comprise a membrane or film strip or tape, which is continually applied to the cut edge of the panel.
The seal 7 may alternatively be in the form of an aqueous emulsion applied by spraying or coating onto the edges onto the exposed panel edges.
Suitable seals include: Aluminium foil, or a foil of polymeric material coated with Al. Foils, membranes or emulsions comprising a polymeric material for example polyvinylidene chloride (PVDC) from Solvay or Dow, polyvinyl alcohol (PVOH), polyvinyl chloride (PVC), or laminated foils or membranes comprised of polymeric and metallic layers. It will be appreciated that seals of any suitable thermoplastics material may the used.
The panel comprises an insulating foam with high insulating properties. Insulating foams with a closed cell structure are particularly suitable. Polyisocyanurate for example has the desired closed cell structure for good thermal conductivity. The choice of blowing agent used in the manufacturing process effects the thermal conductivity of the panel. In addition, over time the blowing agent escapes from the foam and is replaced by air, with the effect of reduced thermal conductivity. During the ageing process changes in the internal cell gas pressure result in reduced thermal conductivity.
The steel faced insulated polyisocyanurate panels thus produced have excellent structural properties and a high thermal conductivity.
Panels may be readily produced in any desired length, width or thickness.
Example:
Comparative measurements of the thermal conductivity of polyisocyanurate steel faced panels were taken after ageing the panels for 25 weeks at 70°C. The edges of one set of panels were sealed with Aluminium foil. The edges of the second set were not sealed.
The panels were of dimensions 500x500x80mm. Sections of dimensions
250x250x25mm were cut from the middles of the panels and the thermal conductivity measured. The effect of different blowing agents use was also considered.
Blowing IInniittiiaall K value Aged K Value Aged K Value Agent W/mK (unsealed) (sealed) W/mK W/mK 141b 0.0184 0.0192 0.0188 365/227 0.0190 0.0201 0.0192 Water blown 0.0215 0.0232 0.0214
Thus the panels with exposed edges sealed have superior thermal properties. The sealed panels provide more stable K values irrespective of blowing agent used.
The invention provides a method of production of sealed panels with improved thermal conduction and K value. The invention further provides for the provision of panels with the required levels of thermal conductivity which have a reduced thickness in comparison with panels that are currently in use.
The invention provides an extremely efficient factory scale process for manufacturing high quality composite Steel faced PIR panels on a continuous basis. Thus, the unit costs of production of such panels is minimised.
The invention is not limited to the embodiments hereinbefore described which may be varied in detail.

Claims

Claims
1. A method for manufacturing a composite insulating panel of the type comprising an external metal skin, an internal metal skin and an insulating core of foam material therebetween, the method includes the steps of :- conveying a first metal skin continuously along a flat bed with an outer surface of the skin lowermost; laying down liquid insulating foam reactants onto the first skin; leading the second metal skin continuously over the liquid insulating foam reactants and the first metal skin; heating the assembly in an oven to allow the foam reactants to expand to form an insulating core between the metal skins; cutting the panel to a desired length, and applying a seal to at least one of the exposed foam edges of the panel.
2. A method as claimed in claim 1 comprising the step of removing dust from the exposed foam edge prior to application of the seal.
3. A method as claimed in claim 2 wherein dust is removed from the exposed foam edge by the application of suction.
4. A method as claimed in claim 2 or 3 wherein the exposed foam edge is brushed to remove dust.
5. A method as claimed in any preceding claim wherein the seal is applied inline.
6. A method as claimed in any preceding claim wherein the seal comprises a gas and/or vapour barrier.
7. A method as claimed in any preceding claim including the step of applying a seal in the form of a strip of film, membrane or tape to the exposed edge of the panel.
8. A method as claimed in claim 7 wherein the strip is retained in place by adhesive bonding.
9. A method as claimed in claims 1 to 6 including the step of applying a seal forming liquid to the exposed edge of the panel.
10. A method as claimed in claim 9 wherein the liquid is applied by spraying.
11. A method as claimed in claim 9 wherein the liquid is applied by coating.
12. A method as claimed in any preceding claim wherein the seal comprises a polymeric material.
13. A method as claimed in claim 12 wherein the polymeric material is polyvinylidene chloride.
14. A method as claimed in claim 12 wherein the polymeric material is polyvinyl alcohol.
15. A method as claimed in claim 12 wherein the polymeric material is polyvinyl chloride.
16. A method as claimed in claimed in any preceding claim wherein the seal comprises a thermoplastic material.
17. A method as claimed in any preceding claim wherein the seal comprises a foil.
18. A method as claimed in any preceding claim wherein the seal comprises a metallic foil.
19. A method as claimed in any preceding claim wherein the seal comprises an Aluminium foil.
20. A method as claimed in any preceding claim wherein the seal comprises a laminate foil comprising polymeric material with a metallic coating.
21. A method as claimed in claim 20 wherein the metallic material is Aluminium.
22. A method for manufacturing an insulating panel substantially as hereinbefore described with reference to the drawings.
23. An insulating panel whenever manufactured by a method as claimed in any preceding claim.
24. An insulating panel comprising an external metal skin, an internal metal skin and an insulating core of foam material therebetween, the panel having at least one cut edge and the panel having a seal applied to the cut foam edge.
25. An insulating panel as claimed in claim 24 wherein the panel has two opposed cut edges and a seal is applied to both cut edges.
26. An insulating panel as claimed in claims 24 or 25 wherein the seal comprises a gas and/or vapour barrier.
27. An insulating panel as claimed in any of claims 24 to 26 wherein the seal is in the form of a strip of film, membrane or tape.
28. An insulating panel as claimed in any of claims 24 to 27 wherein the strip is retained in place by adhesive bonding.
29. An insulating panel as claimed in any of claims 24 to 28 wherein the seal is comprised of a seal forming liquid.
30. An insulating panel as claimed in claim 29 wherein the liquid is applied by spraying.
31. A method as claimed in claim 29 wherein the liquid is applied by coating.
32. An insulating panel as claimed in any of claims 24 to 31 wherein the seal comprises a polymeric material.
33. An insulating panel as claimed in claim 32 wherein the polymeric material is polyvinylidene chloride.
34. An insulating panel as claimed in claim 32 wherein the polymeric material is polyvinyl alcohol.
35. An insulating panel as claimed in claim 32 wherein the polymeric material is polyvinyl chloride.
36. An insulating panel as claimed in any of claims 24 to 35 wherein the seal comprises a foil.
37. An insulating panel as claimed in any of claims 24 to 36 wherein the seal comprises a metallic foil.
38. An insulating panel as claimed in any of claims 23 to 36 wherein the seal comprises an Aluminium foil.
39. An insulating panel as claimed in any of claims 23 to 38 wherein the seal comprises a laminate foil comprising polymeric material with a metallic coating.
40. An insulating panel as claimed in claim 39 wherein the metallic material is Aluminium.
41. An insulating panel as claimed in any of claims 24 to 40 wherein the seal comprises a thermoplastics material.
42. An insulating panel substantially as hereinbefore described with reference to the drawings.
EP04770402A 2003-09-19 2004-09-20 A panel Withdrawn EP1663602A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IE20030689 2003-09-19
PCT/IE2004/000127 WO2005028179A1 (en) 2003-09-19 2004-09-20 A panel

Publications (1)

Publication Number Publication Date
EP1663602A1 true EP1663602A1 (en) 2006-06-07

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Application Number Title Priority Date Filing Date
EP04770402A Withdrawn EP1663602A1 (en) 2003-09-19 2004-09-20 A panel

Country Status (6)

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EP (1) EP1663602A1 (en)
AU (1) AU2004274252A1 (en)
GB (1) GB2418174B (en)
IE (2) IES20040637A2 (en)
NZ (1) NZ546130A (en)
WO (1) WO2005028179A1 (en)

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DE102010049294A1 (en) * 2010-10-22 2012-04-26 Kraussmaffei Technologies Gmbh Apparatus and method for producing sandwich elements with integrated seal
US9714511B2 (en) 2011-06-17 2017-07-25 Lenmak Exterior Innovations Inc. Apparatus and method for manufacturing insulated wall panels
KR20160117603A (en) * 2014-02-06 2016-10-10 바스프 에스이 Insulating assembly for a storage vessel and process for its preparation
EP4028607B1 (en) * 2019-09-12 2025-03-12 Tata Steel IJmuiden B.V. Sandwich panel and method of manufacturing such a sandwich panel

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BE734484A (en) * 1964-06-09 1969-12-12
GB1198393A (en) * 1967-05-26 1970-07-15 Hennecke G M B H Formerly Know Apparatus for the continuous production of rigid plastics foam panels, in particular based on polyurethane, laminated with rigid convering layers
DE1729013B2 (en) * 1967-10-16 1972-09-28 Süllhöfer, Heinz, 4000 Düsseldorf METHOD AND DEVICE FOR CONTINUOUS PRODUCTION OF LAMINATED PANELS FROM RIGID POLYURETHANE FOAM
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Also Published As

Publication number Publication date
IE20040635A1 (en) 2005-03-23
IES20040637A2 (en) 2005-03-23
IES20040636A2 (en) 2005-03-23
GB2418174A8 (en) 2006-03-29
GB2418174A (en) 2006-03-22
NZ546130A (en) 2009-03-31
GB2418174B (en) 2008-12-24
WO2005028179A1 (en) 2005-03-31
AU2004274252A1 (en) 2005-03-31
GB0420855D0 (en) 2004-10-20

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