EP4334130A1 - Procédé et appareil de fabrication d'un panneau isolé - Google Patents

Procédé et appareil de fabrication d'un panneau isolé

Info

Publication number
EP4334130A1
EP4334130A1 EP22798434.1A EP22798434A EP4334130A1 EP 4334130 A1 EP4334130 A1 EP 4334130A1 EP 22798434 A EP22798434 A EP 22798434A EP 4334130 A1 EP4334130 A1 EP 4334130A1
Authority
EP
European Patent Office
Prior art keywords
sheet
insulated panel
core
conveyor
polymer
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.)
Pending
Application number
EP22798434.1A
Other languages
German (de)
English (en)
Inventor
Daniel JUKIC
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.)
Pro9 Global Ltd
Original Assignee
Pro9 Global 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
Priority claimed from AU2021901354A external-priority patent/AU2021901354A0/en
Application filed by Pro9 Global Ltd filed Critical Pro9 Global Ltd
Publication of EP4334130A1 publication Critical patent/EP4334130A1/fr
Pending 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
    • B29C44/20—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
    • B29C44/30—Expanding the moulding material between endless belts or rollers
    • 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
    • B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0046—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by constructional aspects of the apparatus
    • B32B37/0053—Constructional details of laminating machines comprising rollers; Constructional features of the rollers
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B32B37/1027—Pressing using at least one press band
    • 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
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/005—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile
    • 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
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/046—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance 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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/88—Insulating elements for both heat and sound
    • E04B1/90—Insulating elements for both heat and sound slab-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2007/00—Flat articles, e.g. films or sheets
    • B29L2007/002—Panels; Plates; Sheets
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • 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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/7608—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising a prefabricated insulating layer, disposed between two other layers or panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/78—Heat insulating elements
    • E04B1/80—Heat insulating elements slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B1/86—Sound-absorbing elements slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8423—Tray or frame type panels or blocks, with or without acoustical filling
    • E04B2001/8442—Tray type elements
    • E04B2001/8447—Tray type elements with two facing trays
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8423—Tray or frame type panels or blocks, with or without acoustical filling
    • E04B2001/8452—Tray or frame type panels or blocks, with or without acoustical filling with peripheral frame members
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8457—Solid slabs or blocks
    • E04B2001/8461—Solid slabs or blocks layered
    • 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

Definitions

  • This invention relates to a method, apparatus and system for manufacturing an insulated panel.
  • Insulated panels are useful for building construction, for example for cladding and for the construction of internal walls of a structure. Insulated panels may also be used for other purposes. Though various insulated panel designs are available, a typical structure includes a laminate of two outer skins or sheets bonded about a core of insulation material such as polyurethane (PU) or polyisocyanurate (PIR) resin though a range of suitable insulation materials are available and selection may depend on density and thermal or acoustic insulation properties.
  • the core also typically contains a fire retardant and may be fibre reinforced.
  • a mixture of reagents which react to form polyurethane are introduced during the panel manufacturing process.
  • Such processes are typically continuous to promote output and a bottom sheet is typically fed along a conveyor with damming to contain the mixture of reagents when received from a feeding apparatus.
  • a top sheet is then brought into co-operation with the curing reagent mixture and pressed into position so that both the top and bottom sheets are bonded to the polyurethane foam once cured under high temperature and pressure.
  • the reagent mixture is desirably fed to the bottom sheet and damming as quickly as possible because curing time is a function of the reagent mixture feed time.
  • a method and apparatus for manufacturing an insulated panel which may optimise reagent mixture feeding time with benefits for curing time, overall insulation panel manufacturing time and, where possible, insulation panel installation lead times and costs.
  • a method for manufacturing an insulated panel including outer sheets and a polymer resin core disposed between the outer sheets.
  • the method may include the steps of:
  • the at least one further sheet is applied from the first direction. [0009] In some embodiments, the at least one further sheet is applied from a second direction that is different to the first direction.
  • the second direction may be perpendicular to the first direction.
  • the first sheet may be conveyed by the first conveyor with the at least one further sheet then being applied from the side of the conveyor, either manually or by second conveyor.
  • the second direction may be a different angle than perpendicular if necessary.
  • the first and second conveyors may comprise a system of conveyors if required.
  • Conveying may include pushing or pulling the sheets in the respective directions.
  • Pressure may be applied, by a press, to either sheet during conveying, such pressure being applied to promote bonding between the sheets and polymer resin core.
  • the second sheet may be prepared on a surface, or table, adjacent the first conveyor and may be fed manually from the side of the first conveyor if desired.
  • Sheets may be prepared from a range of suitable cladding materials, having reference to properties such as fire retardancy and applicable standards (e.g. building or fire standards). Ceramic sheets, for example of MgO, are preferred.
  • the product insulated panel may include one or more structural members.
  • the structural members may, for example form a frame of the panel.
  • the structural members may be disposed along any or all of the sides of the panel when produced.
  • the structural members are arranged as required on the first sheet and the polymer resin is deposited such that the structural members have portions embedded in the cured polymer core of the product insulated panel.
  • Structural members can be embedded in a manner to leave connection means for connecting structural members to complementary connection means of other structural members of other panels if required.
  • the first and further sheet (s) may be provided as a mould and/or is preferably provided with a containment or damming means (analogous to formwork) for containing the reagent composition, including selectively containing the reagent composition in selected locations, as it is deposited and the polymer core as this forms.
  • a containment or damming means analogous to formwork
  • Such mould or containment means may form part of the product insulated panel or be removed prior to dispatch of product insulated panels.
  • the polymer core (which typically expands as it forms) should rise to a level that facilitates bonding with the second sheet, conveniently a level about equal to the height of the mould or containment means.
  • Deposition may be done in a number of ways.
  • deposition may comprise one or more of injection, spraying and pouring of the reagent mixture.
  • polymer reagents could be otherwise delivered to the containment means as part of the method.
  • the product insulated panel may be used for a range of purposes, for example in the construction of a range of structures. Such structures typically include components such as doors, windows, cable ducts, gutters and so on; and accommodation for such components.
  • frames or accommodation for such components may be included within a pre-form, for example being a core structure of the insulated panel because such structural components are conveniently located within the core structure, or formed during the method.
  • the containment means may include further containment means which prevent reagent entering zones that may later be required for such components, or to accommodate such components.
  • a window frame may be included with a containment means to prevent polymer resin entering a zone that will later become a window.
  • Other like examples are readily apparent.
  • Structural components within the preform or core structure may act as containment means for the reagent composition and product polymer.
  • a product insulated panel may be a self-supporting building module for constructing a structure, for example as described in the Applicant’s co-pending Australian Provisional Patent Application No. 2017902629, filed 5 July 2017, the contents of which are hereby incorporated herein by reference.
  • either sheet may be applied in assembly with a frame, structural members or other building components forming part of the structure to be constructed.
  • a range of polymer resins, and corresponding reagent compositions, may be used to form the core.
  • Polyurethane and polyisocyanurate resins are particularly preferred with properties such as density and thermal and acoustic insulation properties being selected as required for the application in which product insulated panels are to be used.
  • reagent mixture is deposited selectively to ensure that polymer resin is formed only at required locations within the panel, for example where required for thermal or acoustic insulation purposes and not, for example, injected to locations to become doors, windows or other accommodation for building components.
  • an apparatus for manufacturing an insulated panel including outer sheets and a polymer resin core disposed between the outer sheets.
  • the apparatus may include:
  • (c) means for applying at least one further sheet to the first outer sheet as the reagent mixture reacts to form the polymer resin core.
  • the application means is oriented to apply the at least one further sheet from the first direction.
  • the application means is oriented to apply the at least one further sheet from a second direction different to the first direction.
  • a method for manufacturing an insulated panel including:
  • the product insulated panel may be used for a range of purposes, for example in the construction of a range of structures.
  • the insulated panel may have length of an entire wall section, for example being several metres in length and a few metres in width.
  • Such a wall section can therefore be manufactured continuously reducing the number of panels in the wall section and reducing installation cost.
  • Such structures typically include structural components such as doors, windows, cable ducts, gutters and so on; and accommodation for such structural components.
  • frames or accommodation for such components may be included within a pre-form or mould forming the insulated panel portion, for example being a core structure of the insulated panel because such components are conveniently located within the core structure, or formed during the method.
  • the term core structure is used below but it will be understood that the insulated panel portion is not limited to the core structure. In the case of a core structure, this may include a further or second sheet.
  • the core structure and sheet(s) are advantageously conveyed into the press at the same time.
  • the press is used to apply pressure to the first sheet and the core structure to ease bonding of the outer sheet to the core structure through the polymer resin core.
  • Locations for deposition may be actively or passively controlled, for example by a control unit controlling the deposition of reagent composition by a reagent composition delivery means.
  • containment means or damming may be used to confine deposited reagent mixture and product polymer to particular locations of the core structure and not in locations which do not require it, for example in locations for doors and windows. Single pass conveying of sheets and core structure through the press is expected to be sufficient.
  • a first conveyor conveys the first protective sheet into the press.
  • a second conveyor conveys the core structure into the press.
  • the first conveyor is conveniently disposed at an acute angle to the second conveyor with both conveyors delivering the core structure and first protective sheet to a feed end of the press.
  • the core structure and first sheet are advantageously fed to the press at the same feed rate.
  • the production rate may be different dependent on time required within the press.
  • the core structure may itself include a second protective sheet.
  • One embodiment of insulated panel produced by the method would include two outer sheets with a polymer resin core disposed between them.
  • the outer sheets would be of a suitable cladding material. Insulated panels could include a plurality of sheets disposed about a polymer resin core and laminated outer sheets could also be produced by the method. [0046]
  • the core structure, whether including a second protective sheet or not, may be formed in a mould in step (a).
  • an apparatus for manufacturing an insulated panel including:
  • a reagent deposition delivery system for selectively depositing a reagent mixture within the core structure to form a polymer resin core for the insulated panel
  • a desirable insulated panel portion is a core structure for the product insulated panel.
  • the term core structure is used below for ease of description and is not intended to be limiting.
  • the core structure may itself include a second protective sheet, conveniently as a base or top surface.
  • the second conveyor is conveniently disposed at an acute angle to the first conveyor with both conveyors delivering the core structure and first protective sheet to a feed end of the press.
  • One of the conveyors is preferably disposed substantially horizontally in alignment with a feed end of the press.
  • the first and second conveyors may include rotating rollers to assist travel of core structure and first sheet.
  • the apparatus may include guide means to assist travel of the first sheet, bending it where necessary, and to ensure the correct tension is maintained in the first sheet.
  • the guide means may include a set of opposed rollers between which the first sheet stock travels.
  • the press conveniently includes two conveyor portions spaced apart a sufficient distance to accommodate travel of the core structure and first sheet between them, desirably under pressure as this facilitates the bonding process.
  • the conveyor portions may be tracked or provided with any required profiled structure.
  • the first sheet which may form the top sheet or board, may be brought under pressure by the press prior to the polymer resin rising to contact the first sheet.
  • the core structure and first sheet are advantageously fed to the press at the same feed rate.
  • the apparatus includes driving means, preferably electric motors, for the first and second conveyors as well as the press.
  • Speed of the electric motor may be controlled by a control unit to synchronise speed of the first and second conveyors and the feed rate.
  • Electric motor(s) for controlling the speed of the conveyor portions of the press may be synchronised with first and second conveyor speed. However, once the core structure and first sheet have travelled past the feed end of the press, the press electric motor(s) may be controlled to a rate optimal for the bonding process.
  • the conveyor portions of the press may include heater and/or cooler means to enable control over press temperature, again optimally for the bonding process.
  • Reagent compositions typically including reactants for forming a polymer resin, conveniently as an expanded foam, are conveniently injected by a reagent mixture delivery system located above the first conveyor proximate the feed end of the press.
  • the reagent composition delivery system may include one or a plurality of injection, spraying and/or pouring heads manually or automatically movable to selected locations for injection of reagent mixture to selected locations of the core structure.
  • the plurality of injection heads may include a spare injection head as a backup, for example allowing maintenance of an injection head.
  • An automatic reagent composition delivery system may be controlled by a control unit to deliver reagent mixture delivery rate and deliver reagent composition from injection head(s) to the selected locations of the core structure.
  • the apparatus described herein may include a cutter for cutting insulated panels to size where operated continuously.
  • the apparatus may be operated batchwise or semi-batchwise rather than continuously depending on the complexity of customisation of the core structure.
  • An insulated panel as produced in the above method or apparatus forms a further aspect of the present invention.
  • a product insulated panel may be a self-supporting building module for constructing a structure, for example as described in the Applicant’s co-pending Australian Provisional Patent Application No. 2017902629, filed 5 July 2017, the contents of which are hereby incorporated herein by reference.
  • a range of polymer resins may be used to form the core.
  • Polyurethane and polyisocyanurate resins are particularly preferred with properties such as density and thermal and acoustic insulation properties being selected as required for the application in which product insulated panels are to be used.
  • Reagent compositions to form such polymer resins are well known and include suitable alcohols and isocyanates, the latter also being suitable as a blowing agent causing the polymer to foam and/or form a cellular insulating structure.
  • FIG. 1 is an orthogonal view of an apparatus for manufacturing an insulated panel according to one embodiment of the present invention.
  • FIG. 2 is a front orthogonal view of the apparatus of FIG. 1 during manufacture of an insulated panel according to the first embodiment of the present invention.
  • FIG. 3 is a top orthogonal view of the apparatus of FIGS. 1 and 2.
  • FIG. 4 is a front orthogonal view of the apparatus, similar to FIG. 2 but at a later stage in the manufacturing method.
  • FIG. 5 is a front view of the apparatus during the manufacturing method.
  • FIG. 6 is a front view of the apparatus, similar to FIG. 5 but at a slightly later stage in the manufacturing method.
  • FIG. 7 is a side section view of the first conveyor of the apparatus shown in FIGS. 1 to 6.
  • FIG. 8 is a top orthogonal view of the apparatus of FIGS. 1 to 6 showing production of an insulated panel according to the first embodiment of the present invention.
  • FIG. 9 is a front orthogonal view showing the apparatus in similar production state to that illustrated in FIG. 7.
  • FIG. 10 is a side section view of the first conveyor of the apparatus shown in FIGS. 1 to 6, 8 and 9 following production of an insulated panel according to the first embodiment of the present invention.
  • FIG 11 is a top perspective view of the apparatus of FIGS. 1 to 6, 8 and 9 following production of an insulated panel according to the first embodiment of the present invention.
  • FIG. 12 is an orthogonal view of a core structure to form part of an insulated panel formed according to a second embodiment of the method of the present invention.
  • FIG. 13 is a first orthogonal view of an apparatus for manufacturing an insulated panel according to a third embodiment of the present invention.
  • FIG. 14 is a second orthogonal view of the apparatus of FIG. 13.
  • FIG. 15 is a partial top view of the apparatus of FIGS. 13 and 14 showing the press and first conveyor.
  • FIG. 16 is a side view of the apparatus of FIG. 14.
  • FIG. 17 is a detail from Fig. 14 showing the feed end of the press and the relative angular disposition of the first and second conveyors.
  • FIG. 18 is a partial orthogonal view from above showing the feed end of the press, the first conveyor and the core structure portion of an insulated panel to be produced by the method and apparatus of the third embodiment of the present invention.
  • FIG. 19 is a detail from FIG. 11 showing a product insulated panel including accommodation for components to be included in the insulated panel in use.
  • FIG. 20 is a cutaway view of the product insulated panel of FIG. 19.
  • FIG. 21 is a detail of a product insulated panel similar to FIG. 19.
  • FIGS. 1 to 11 there are shown schematic views of an insulated panel manufacturing system 10 including a press 11 with upper and lower tracked conveyor portions 11 A and 11 B (each being traced and including a plurality of track elements 11C) spaced apart by a constricted zone 14 and having a feed end 11 a into which a first sheet 1 which may be of a lightweight cladding material, such as those exemplified below, though the material is not intended to be limiting, is continuously fed in a direction D1.
  • a first sheet 1 which may be of a lightweight cladding material, such as those exemplified below, though the material is not intended to be limiting, is continuously fed in a direction D1.
  • Possible reagent compositions are described below.
  • the first sheet 1 is fed into the press 11 at the feed end 11 a and pushed or pulled through the press 11 , or through some other downstream pulling device (not shown), in a first direction D1 , towards the discharge end 115 where product insulated panels 50 can be collected, ready for use in construction of structures for example.
  • System 10 includes a table 20, located at one side of press 11 , for preparing a portion of an insulated panel or preform 18 with a core structure including structural frame 52 for use in a structure to be constructed from product insulating panels 50.
  • Preform 18 is to be bonded to the first sheet 1 to form an insulated panel.
  • Table 20 includes rollers 21 to ease movement of the second sheet 2.
  • the rollers 21 may be actuated manually or by an electric motor (not shown) to deliver the preform 18 in a direction D2 perpendicular to D1 as schematically indicated by Figs. 3 to 5.
  • Curable, foamable resin composition is first deposited, by metering or pouring onto the preform 18 by an injection system such as described below, before second sheet 2 closes over preform 18.
  • Press 11 applies pressure, and if necessary heat, through the upper and lower conveyor portions 11A and 11 B to assist bonding of the preform 18 to first sheet 1 through the curable foamable resin composition through a constricted zone 14 as schematically indicated in Figs. 7 and 8.
  • the pressure is controlled by operating hydraulic jacks 150 to position the structural beams 140 to cause a force to be exerted on upper conveyor portion 11 A and, consequently the preform 18, by the structural I beams 140 disposed across it and connected to upper conveyor portion 11 A by structural members 145.
  • Structural members 146 fix the lower conveyor portion 11 B to the floor.
  • I beams 140 relative to lower conveyor portion 11 B also controls the dimension of constricted zone 14 and the degree of pressure applied.
  • An electronic control unit can be used to control position of the hydraulic jacks 150.
  • the speed of upper and lower conveyor portions 11 A and 11 B is controlled by controlling the speed of the electric motors 116 actuating them.
  • the electric motor speed is selected to optimise the production rate while ensuring that the requisite degree of bonding between preform 18 and first sheet 1 is achieved prior to the product insulated panel 50 discharging through the discharge end 115 of press 11 as schematically indicated by FIGS. 9 to 11.
  • the same electronic control unit as used for controlling the position of hydraulic jacks 150 and constricted zone 14 sizing may be used to control the speed of electric motors 116.
  • FIGS. 12 to 18 there is described a further embodiment of the method and apparatus of the invention which involves the insulated panel manufacturing system 110 which again includes a press 11 including upper and lower conveyor portions 11 A and 11 B, again being tracked and including a plurality of interconnected pivoting metallic track elements 11C. Pivoting of the track elements enables a substantially continuous surface to be maintained.
  • a first conveyor 100 is provided for feeding a preform including a core structure 118, the core structure 118 including a base sheet 1 of lightweight cladding material and structural frame 152 to form part of a structure constructed by a modular technique.
  • First conveyor 100 is disposed horizontally and feeds the core structure 118 towards the feed end 111 of the press 11.
  • Core structure 118 is pushed or pulled through the press 11 , or through some other downstream pulling device (not shown), in a first direction D1 , towards the discharge end 115 of the press 11 where product insulated panels 50 can be collected, ready for use in construction of structures for example.
  • a second conveyor 200 is disposed above, and at an acute angle to, first conveyor 100. The acute angle is controlled by operating the hydraulic jacks 205 and 210 to heights corresponding to the required angle. Second conveyor 200 feeds a first sheet 2 to be bonded to the preform 118 through a polymer composition.
  • Both first and second conveyors 100 and 200 include rollers 121 , 221 to ease movement of preform 118 and bend first sheet 2 towards the press 11.
  • rollers 121 , 221 are most conveniently actuated by electric motors (not shown) to deliver the preform 18 in the same direction and at the same speed or feed rate towards the feed end 111 of the press 11 as schematically indicated by Figs. 13 to 17.
  • Curable, foamable resin composition is first deposited onto the preform 118 as it travels along first conveyor 100.
  • a reagent composition to form a curable, foamable polymer resin for example as described below, can be deposited using a variety of types of dispensing equipment including types well- known in the art.
  • Suitable equipment includes, for example, a traversing hose, one or more stationary mix heads, one or more injection nozzles, or other suitable apparatus for dispensing a fluid.
  • insulated panel manufacturing system 110 includes a gantry 1150, here fixed but which could be movable, with two reagent composition injection heads 1152A and 1152B for spraying reagent composition to selected locations.
  • Gantry 1150 includes a manifold supplied with reagent composition, the manifold communicating with each injection head 1152A, 1152B through a duct 1152C.
  • One injection head 1152B is operated by a control unit, to deposit reagent composition in selected location A of preform 118. Selected location A will require acoustic and thermal insulation when the product insulated panel 50 is in place within a structure constructed from a plurality of such panels 50.
  • Second injection head 1152A is here in back up mode, to be used when injection head 1152B is being maintained.
  • both injection heads 1152A, 1152B could be operated simultaneously or in timed relation to each other at a rate selected with reference to the speed of first conveyor 100 and conveyor portions 11 A and 11 B.
  • injection head 1152A is deliberately not operated to deposit reagent composition in location B which corresponds with a window for the final structure including panels 50. Insulation is not required in this location.
  • the equipment for depositing the curable, foamable resin composition may also include various tanks or other containers for storing components of the resin composition, metering means for metering those components and/or the formulated resin composition; mixing means for mixing the components to form the resin composition, pumping means for transferring the components of the resin composition from their respective storage containers to and through the mixing means and/or through the dispensing apparatus.
  • Suitable equipment for mixing and dispensing the components of curable, foamable resin compositions are available commercially from, for example, Cannon, SAIP and Krauss Maffei.
  • the dispensed resin composition may be formed into a layer and/or gauged at this point in the process using equipment such as, for example, a set of nip rolls or a doctor blade. It is not desirable for polymer resin to expand beyond the top of the preform 118 as this may lead to wastage and cost.
  • Resin composition sprayed or poured by injection heads 1152a and 1152B typically begins to react and expand as soon as it is deposited, and may be expanding in some cases even as it is deposited. Accordingly, foamable resin composition may already be partially expanded when sheet 2 is applied.
  • the guide rollers 130 which guide, by bending, the sheet 2 towards the preform 118 and to ensure the correct tension is maintained in that sheet 2.
  • the guide rollers 130 guide the sheet 2 such that the sheet 2 is applied generally from the first direction D1. In other words, the sheet 2 is applied from the first direction. That is, the sheet 2 is applied from the same direction as the sheet 1.
  • first conveyor 100 and the second conveyor 200 are oriented with respect to each other at an acute angle, it will be appreciated that the sheet 2 is bent by the guide rollers 130 so that it contacts the preform 118 at an angle that is generally parallel to the first direction D1. In some embodiments, it may therefore be said that the sheet 2 is applied from the same direction as the sheet 1 , for at least this reason.
  • top sheet 2 may be brought under pressure by press 11 prior to resin composition expanding to contact it, making a more efficient bond.
  • the expanded resin composition may be somewhat compressed in this step, but the pressure should not be so great as to collapse the polymer foam or to create a large back-pressure. Heat may be applied through either or both surfaces if needed to drive the cure of resin composition.
  • the speed of upper and lower conveyor portions 11 A and 11 B is controlled by controlling the speed of the electric motors (not shown) actuating them.
  • the electric motor speed typically synchronised between the two electric motors (not shown) is selected to optimise the production rate while ensuring that the requisite degree of bonding between preform 118, polymer resin and first sheet 2 is achieved prior to the product insulated panel 50 discharging through the discharge end 115 of press 11.
  • the same electronic control unit as used for controlling the position of hydraulic jacks 150 and constricted zone 14 sizing may be used to control the speed of electric motors 116.
  • constricted region 14 The assembly including preform 118, sheet 2, and resin composition is passed continuously through constricted region 14 that extends the length of press 11. This step is performed before foamable resin composition has fully expanded.
  • Constricted region 14 has a height no greater than and preferably slightly (such as 2 to 25%) less than the combined height of the various layers immediately before they enter constricted region 14. Therefore, sheet 2 and resin composition 19 are compressed together in constricted zone 14 with pressure being controlled as described above.
  • resin composition Prior to applying sheet 2, resin composition is desirably only partially expanded and/or partially cured. Partial curing can help the expanding resin composition support the weight of sheet 2. The expansion can occur before, during and/or after sheet 2 is applied, as already described, though before application of sheet 2 is preferred.
  • the curing step typically proceeds simultaneously with the expansion and conveyor portion 11 A, 11 B should be controlled accordingly to synchronise this timing.
  • the product insulated panel 50 is continuously expelled from the discharge end 115 of press 11.
  • the product insulated panel 50 may have length of an entire wall section, for example being several metres in length and a few metres in width. Such a wall section can therefore be manufactured continuously reducing the number of panels in the wall section and reducing installation cost.
  • laminate type structural insulated panels may also be produced by manufacturing system 110. Such laminated panels may then be cut to any desired length (such as by knife or, preferably a band or circular saw), post-cured if necessary or desirable, and packaged for warehousing and/or shipment.
  • Sheets 181 and sheet 2 each are single or multi-layer materials that may include at least one metallic layer or a layer of a refractory lightweight cladding material such as MgO or MgS04 board.
  • a metallic layer is selected, preferred metals for this purpose are steel, stainless steel, aluminium, nickel, zinc, titanium, bronze, copper, brass, magnesium, and various alloys of any of these.
  • the metallic layer may be planar, but can also be profiled (for example, grooved or channelled along its length).
  • Product insulating panels 50 from manufacturing systems 10 or 110 are shown in FIGS. 19 to 21.
  • Product insulated panels 50 may include a core structure 50 (as shown in FIGS. 19 and 20) or simply a polymer resin core as indicated in FIG. 21.
  • Product insulation panels 50 preferably have a thickness of 80 to 250 mm.
  • the foam layer may have a thickness from 70 to 240 mm.
  • Curable, foamable resin composition is a mixture of polymer precursors and blowing agents and/or blowing agent precursors that react in the process to produce a cellular polymer foam.
  • Curable, foamable resin composition preferably is formulated to produce a foam having a free rise density of a specified kg/m 3 , for example, within a range of 24 to 80 kg/m 3 , or a value of about 45 kg/m 3 .
  • the cellular polymer foam so produced preferably is a rigid foam.
  • Isocyanate-based resin compositions may also be adopted because these compositions can be formulated to be low in initial viscosity and because isocyanate-based resin compositions can be formulated to expand and cure rapidly to form a polymer foam having useful properties.
  • the isocyanate-based resin compositions may be formulated to produce a polymer having urethane groups, urea groups and/or isocyanurate groups.
  • An especially preferred type of isocyanate-based resin composition is a polyisocyanurate or polyurethane-polyisocyanurate foam-forming composition, as foams of these types exhibit an excellent combination of high thermal and acoustic insulation and excellent strength-to-weight ratio.
  • the product insulation panels 50 can be used in a variety of structural, thermal insulation and/or decorative applications. They can be used as materials of construction for interior or exterior walls, ceilings and roofing materials for buildings; as decorative and/or facade materials, ducting system panels, walls and ceilings in buildings; as thermal insulation panels for buildings and various types of cold-storage facilities.
  • the laminates can be used as deckings for ships and other transport vehicles.
  • the product insulated panels 50 can in general be used in the same applications and in the same manner as conventional panels.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Architecture (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Fluid Mechanics (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un panneau isolé (50). Le panneau isolé (50) comprend des feuilles externes, des éléments structuraux (dans certains modes de réalisation, comprenant de l'acier) et un cœur de résine polymère disposé entre les feuilles externes. Le procédé comprend les étapes consistant à : transporter une feuille par un premier transporteur (100) pour former une première feuille externe d'un panneau isolé (50) dans une première direction ; déposer une composition de réactif pour former un cœur polymère pour le panneau isolé (50) sur la feuille externe pendant le transport ; et appliquer au moins une autre feuille sur la première feuille externe lorsque les réactifs réagissent pour former le cœur polymère.
EP22798434.1A 2021-05-06 2022-05-06 Procédé et appareil de fabrication d'un panneau isolé Pending EP4334130A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2021901354A AU2021901354A0 (en) 2021-05-06 Method and apparatus for manufacturing an insulated panel
PCT/AU2022/050430 WO2022232887A1 (fr) 2021-05-06 2022-05-06 Procédé et appareil de fabrication d'un panneau isolé

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EP4334130A1 true EP4334130A1 (fr) 2024-03-13

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AU (1) AU2022269676B2 (fr)
WO (1) WO2022232887A1 (fr)

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3560285A (en) * 1967-02-06 1971-02-02 Kaiser Aluminium Chem Corp Processes for producing composite panels
DE1729013B2 (de) * 1967-10-16 1972-09-28 Süllhöfer, Heinz, 4000 Düsseldorf Verfahren und vorrichtung zur fortlaufenden herstellung von kaschierten platten aus polyurethan-hartschaumstoff
US4581186A (en) * 1982-12-17 1986-04-08 Larson Roger E Method of making foam core building panels in a continuous operation
US20030082365A1 (en) * 2001-10-30 2003-05-01 Geary John R. Tough and durable insulation boards produced in-part with scrap rubber materials and related methods
US9862126B2 (en) * 2014-03-19 2018-01-09 Great Dane Llc Method and apparatus for forming objects having a core and an outer surface structure
EP3558665A1 (fr) * 2016-12-20 2019-10-30 Dow Global Technologies LLC Panneaux sandwich renforcés

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AU2022269676A1 (en) 2023-09-21
AU2022269676B2 (en) 2023-12-07

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