GB2257086A

GB2257086A - Manufacturing an insulated panel

Info

Publication number: GB2257086A
Application number: GB9115327A
Authority: GB
Inventors: Patrick Mcdonald
Original assignee: Kingspan Research and Developments Ltd
Current assignee: Kingspan Research and Developments Ltd
Priority date: 1991-06-25
Filing date: 1991-07-16
Publication date: 1993-01-06
Anticipated expiration: 2011-07-16
Also published as: GB2257086B; IE65213B1; GB9115327D0; BE1003153A6; IE912202A1

Abstract

An insulated panel 1 comprising a profiled external skin 2, an internal tray 3 and a foam core 4 is formed in a substantially continuous manner by a method which comprises automatically cutting the backing tray and part of the core using a circular saw 20 and subsequently automatically cutting the remainder of the foam core through to the external skin by using guillotine blades 25. The saw 20 and blades 25 are mounted on a carriage 14 which moves on tracks 12, 13, 15, 16 to align the saw 20 and blades 25 in cutting alignment as the panel 1 advances. <IMAGE>

Description

The invention relates to a method and apparatus for manufacturing an insulating panel of the type comprising a profile external skin and an internal backing tray having an insulating core therebetween.

According to one aspect of the invention provides a method for manufacturing an insulating panel of the type comprising a profiled external skin and an internal backing tray having an insulating core therebetween, the method comprising the steps of: conveying a profiled external skin along a flat bed with the outer surface of the skin lowermost, applying liquid insulating foam reactants onto the external skin, leading a backing tray continuously over the external skin, heating the assembly in an oven to allow the liquid foam reactants to expand to form an insulating core between the internal tray and external skin to form an insulating panel, automatically cutting at least the backing tray in a first cutting step, and automatically cutting the foam core substantially through to the external skin in a second cutting step.

In a particularly preferred embodiment of the invention the first cutting step comprises sawing through the backing tray and preferably portion of the foam core at a desired location of the panel.

Preferably the saw is extended transversely across the panel to cut through the backing tray and preferably portion of the foam core.

The first cutting step is preferably effected while the insulating panel is travelling along a cutting bed.

In a preferred embodiment of the invention the second cutting step comprises inserting a guillotine blade means through the foam core to cut the core substantially up to the level of the external skin of the panel. In this case preferably there is a second cutting step comprising inserting a plurality of guillotine blade means into the core, the blade means being spaced-apart to substantially follow the contour of the profile of the external skin on insertion of the blade means into the core. Ideally the second cutting step includes rocking the guillotine blade means to effect close cutting of the foam core.

The second cutting step is preferably effected while the insulating panel is travelling along a cutting bed.

In a particularly preferred embodiment of the invention the external skin is cut to length and releasably attached to a following external skin prior to application of the backing tray. Preferably adjacent pre-cut lengths of external skin are overlapped longitudinally prior to application of the liquid foam reactants. Ideally the lengths of external skin are overlapped and attached by an adhesive tape. Preferably the trailing edge of one external skin is overlapped onto the leading edge of a following external skin.

In a particularly preferred arrangement the backing tray and portion of the foam core are cut at the joint between over lapping panels so that on separating of the overlapping panels a clean transverse joint between overlapping panels in use from external skin to external skin may be made. In a particularly preferred arrangement after cutting, adjacent panels are at least partially separated by applying a longitudinal pushing force to push the panel longitudinally partially away from another.

Typically the cutting steps are initiated by a control system comprising a means for sensing a desired cutting portion, the cutting means activated on actuation of the sensing means.

In one arrangement the sensing means comprises a photoelectric sensor for sensing the position of an indicating mark at a desired location on a panel. In this case preferably the indicating mark is marked on the trailing edge of each external skin.

In another arrangement the sensing means comprises thickness sensing means for sensing the increased thickness at the overlap of the external skins.

Preferably the backing tray and external skin are pre-heated prior to application of the liquid foam reactants.

In a particularly preferred arrangement side sealing means are provided between the external skin and the backing tray.

Particularly the side sealing means comprises a sealing tape extending along at least one longitudinal edge of the panel.

Usually the side sealing tape is applied at the joint between the external skin and the backing tray at or prior to injection of the liquid foam reactants. Preferably the backing tray and insulating core terminate inwardly of one of the longitudinal side edges of the external skin to accommodate longitudinal overlapping of adjacent panels, in use.

In a preferred arrangement the external skin is of a metal material such as steel or aluminium. Preferably a backing tray is also of a metal material such as steel or aluminium.

Typically at least those surfaces of the skin and/or backing tray which are exposed in use are coated for corrosion resistance.

Preferably the core is of a rigid closed cell polyurethane or polyisocyanurate foam material. The invention also provides an insulating panel prepared by the method of the invention.

In another aspect the invention provides an apparatus for cutting and insulating panel of the type comprising a profiled external skin and an internal backing tray having an insulating core therebetween, the apparatus comprising; a bed along which the panel is led; a carriage which is longitudinally movable relative to the bed; cutting means mounted on the carriage to cut the backing tray and foam core as the panel is travelling along the bed; the cutting means comprising a first cutting means which is movable to pass transversely across the bed to cut through at least the backing tray; and a second cutting means which is moved into the cut formed by the first cutting means to cut through the foam core substantially to the external skin.

In a preferred embodiment of this aspect of the invention the first cutting means comprises a saw which is extended transversely across the backing sheet to cut through at least the backing sheet of the panel. Preferably the first cutting means comprises a circular saw.

In a preferred arrangement the second cutting means comprises a guillotine blade means.

Preferably the cutting means comprises a plurality of guillotine blade means which are spaced-apart to substantially follow the contour of the external skin of the panel.

Preferably the apparatus includes means for rocking the guillotine blade means on insertion into the foam core. The rocking means may comprise a vibration imparting means.

In one arrangement the guide blade means is mounted in advance of the first cutting means, the carriage advancing to align the guillotine blade means with the cut formed by the first cutting means.

Ideally the apparatus includes clamp means for clamping the panel in position during cutting.

In a particularly preferred arrangement the apparatus includes means for applying a separating force to the panels, upper cutting to separate one cut panel for the adjacent panel.

Preferably the means for applying a separating force comprises a ram means associated with an outlet clamp means.

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 flow chart of the method of the invention; Fig. 2 is a perspective view of an apparatus according to the invention used in the method of the invention; Fig. 3 is a front view of the apparatus in one position of use; Fig. 4 is a side elevational view of the apparatus in the position of use of Fig. 3; Fig. 5 is a front view of the apparatus in another position of use; Fig. 6 is a side elevational view of the apparatus in the position of use of Fig. 5; Fig. 7 is a perspective view of part of the apparatus in use; Fig. 8 is a perspective view of another part of the apparatus in use; Fig. 9 is a plan view of another part of the apparatus; Fig. 10 is a side elevational view of portion of the apparatus; and Figs. 11 and 12 are cross-sectional views of a pane'. in positions of use of the portion of the apparatus of Figs.

9 and 10; and Fig. 13 is a cross-sectional view of a panel formed by the method and apparatus of the invention.

Referring to the drawings, the method and apparatus of the invention is for forming an insulated panel of the type which is illustrated in Fig. 13 and indicated generally by the reference numeral 1. The panel 1 comprises a profiled external skin 2 of steel or aluminium material, an internal backing tray 3 also of steel or aluminium material and an insulating core 4 of polyurethane or polyisocyanurate foam material which fills the space between the external skin 2 and backing tray 3. The insulated panel 1 is typically used for roofing or cladding systems, adjacent panels being overlapped both longitudinally and transversely to clad or roof a particular area.

Referring particularly to Fig. 1 the method according to the invention for forming the panel 1 in a substantially continuous manner comprises the step of forming a desired profile of external skin which is then cut to length. Cut lengths of external skin 2 are laid down and marked to indicate the desired longitudinal overlap between adjacent panels in use. When a panel 1 has been marked up, the trailing edge of the external skin of a first leading panel in the line is lifted up and placed down on the leading edge portion of the external skin of a following panel 1. A joint between the skins is made by a releasable fasting means such as an adhesive tape which is laid down across the joint between the skins. The external skins are preheated prior to application of liquid foam reactants.A profiled backing tray 3 is also preheated and applied over the external skin and liquid foam reactants. The backing tray is maintained in spaced-apart relationship from the external skin by appropriate spacer blocks which retain the tray and skin in spaced-apart relation until the liquid foam reactants have expanded to a desired thickness to fill the space between the external skin 2 and backing tray 3. As the backing tray 3 is applied a longitudinally extending sealing tape 5 is also applied between the backing tray 3 and the skin 2 to confine the foam core 4 in the desired space. The liquid foam reactants are then allowed to expand to fill the space between the external skin 2 and 3 by passing the assembly through an oven where the reactants are heated and allowed to expand to the desired thickness of foam insulating core 4.The output from the oven is a continuous longitudinal sheet of insulating panels comprising backing trays, external skins and intermediate foam cores 4. This continuous assembly is passed to a first cutting stage which will be described in more detail below where the backing tray 3 and part of the foam 4 is cut at the location of the overlap between the external skins. The partially cut assembly then undergoes a second cutting stage where the remainder of the foam core is cut down to the internal face of the external skins 2. The panels are then separated.

In more detail, and referring to Figs. 2 to 12 there is illustrated a cutting apparatus comprising a bed 10 along which a panel is led, the bed 10 as will be particularly apparent from Fig. 3 having a profile corresponding to the profile of the external skin 2 of the panel. The bed is mounted in a frame 11 having longitudinally extending tracks 12, 13. A carriage 14 includes guides 15, 16 which run in the tracks 12, 13 as the carriage 14 moves longitudinally with respect to the bed 10.

Cutting means are mounted on the carriage 14 to cut the backing tray 3 and foam core 4 as the panel 1 is travelling along the bed 10. The cutting means comprises a first cutting means, in this case in the form of a circular saw 20 which is movable transversely across the panel to cut the backing tray 3 and part of the foam core 4 as the panel is moving along the bed 10. In addition to moving transversely across the panel 1 the saw 20 also moves longitudinally with the carriage 15, the forward movement being synchronised with the forward movement of the panel along the bed 10.

The cutting means also comprises a second cutting means which is moved into the cut formed by the saw 20 to cut through the remainder of the foam 4 substantially through to the inner surface of the external skin 2. In this case the second cutting means comprises a plurality of guillotine blades 25 which are mounted on a frame 26 supported on the carriage 15.

The frame 26 is movable by rams 27. The guillotine blades 25 are spaced-apart transversely to substantially follow the contour of the external skin 2 of the panel 1. The frame 26 is movable longitudinally forwardly with the panel 1 on the bed 10, the movement being synchronised with that of the panel 1. To ensure a clean cut through the remainder of the foam core 4, after insertion, the guillotine blades 25 are vibrated by a vibration unit 30 to rock the blades to and fro in the cut to complete the cut of the foam core 4.

Clamping means for clamping the panel 1 during cutting is in this case provided by a front transverse clamping plate 35 operated by rams 36 and a rear clamping plate 37 operated by rams 38.

When an overlap between adjacent external skins 2 is detected by a sensing means (not shown) the clamping plates 35, 37 are automatically extended by the rams 36, 38 to clamp the panel sections in position for cutting. The sensing means may comprises a photoelectric sensor for sensing the mark made on overlapping of the external skins. Alternatively, or additionally the sensing means may comprise a laser type sensor for sensing the increase in thickness of the external skin at the overlap.

When the cutting operations are complete a clean cut 40 is formed between adjacent panels as illustrated in Fig. 11.

Longitudinally extending rams 46, 47 are then extended at the clamp 37 to spread apart the adjacent panels as illustrated in Fig. 12.

In operation, when an overlap between adjacent external skins is sensed by the sensing means the clamps 35, 37 are operated.

When the overlap location is under the blade of the saw 20 the saw 20 is operated and extended transversely across the panel at the overlap to cut through the backing tray 3 and portion of the foam core 4. The clamps 35, 37 are then released and the carriage 14 is advanced forwardly over the first cut until the guillotine blades 25 are in line with the cut. The clamps 35, 37 are operated again to fix the panel in position during the second cut. The guillotine blades 25 are then extended downwardly into the first cut and through the remainder of the foam core to the internal surface of the external skin 2. The guillotine blades are rocked back and forward in the cut by the operation of the vibrator 30 to complete the cut of the foam core 4.

The carriage 14 is then advanced again until the clamp 37 is just ahead of the cut between adjacent panels. The clamp 37 is then operated to engage the leading panel and the rams 45, 46 are extended to push the clamp frame and hence the leading panel forwardly away from the trailing panel to separate the panels at the overlapping joint therebetween as illustrated in Fig. 12.

The method and apparatus of the invention offers very considerable advantages as insulated panels comprising profiled external sheets, backing trays and insulated foam cores may be manufactured substantially continuously with a minimum of operator intervention.

Many variations on the specific embodiment of the invention will be readily apparent and accordingly the invention is not limited to the embodiments hereinbefore described which may be varied in both construction and detail.

Claims

1. A method for manufacturing an insulating panel of the type comprising a profiled external skin and an internal backing tray having an insulating core therebetween, the method comprising the steps of: conveying a profiled external skin along a flat bed with the outer surface of the skin lowermost, applying liquid insulating foam reactants onto the external skin, leading a backing tray continuously over the external skin, heating the assembly in an oven to allow the liquid foam reactants to expand to form an insulating core between the internal tray and external skin to form an insulating panel, automatically cutting at least the backing tray in a first cutting step, and automatically cutting the foam core substantially through to the external skin in a second cutting step.

2. A method as claimed in claim 1 wherein the first cutting step comprises sawing through the backing tray and preferably portion of the foam core at a desired location of the panel.

3. A method as claimed in claim 2 in which the saw is extended transversely across the panel to cut through the backing tray and preferably portion of the foam core.

4. A method as claimed in any preceding claim wherein the first cutting step is effected while the insulating panel is travelling along a cutting bed.

5. A method as claimed in any of claims 1 to 4 wherein the second cutting step comprises inserting a guillotine blade means through the foam core to cut the core substantially up to the level of the external skin of the panel.

6. A method as claimed in claim 4 wherein the second cutting step comprises inserting a plurality of guillotine blade means into the core, the blade means being spaced-apart to substantially follow the contour of the profile of the external skin on insertion of the blade means into the core.

7. A method as claimed in claim 4 or 5 in which the second cutting step includes rocking the guillotine blade means to effect close cutting of the foam core.

8. A method as claimed in any preceding claim wherein the second cutting step is effected while the insulating panel is travelling along a cutting bed.

9. A method as claimed in any preceding claim wherein the external skin is cut to length and releasably attached to a following external skin prior to application of the backing tray.

10. A method as claimed in claim 9 wherein adjacent pre-cut lengths of external skin are overlapped longitudinally prior to application of the liquid foam reactants.

11. A method as claimed in claim 10 wherein the lengths of external skin are overlapped and attached by an adhesive tape.

12. A method as claimed in any of claims 9 to 11 wherein the trailing edge of one external skin is overlapped onto the leading edge of a following external skin.

13. A method as claimed in any of claims 9 to 12 wherein the backing tray and portion of the foam core are cut at the joint between overlapping panels so that on, separating of the overlapping panels, a clean transverse joint between overlapping panels in use from external skin to external skin may be made.

14. A method as claimed in claim 13 wherein, after cutting, adjacent panels are at least partially separated by applying a longitudinal pushing force to push the panels longitudinally partially away from another.

15. A method as claimed in claim 13 or 14 wherein the cutting steps are initiated by a control system comprising a sensing means for sensing a desired cutting portion, the cutting means being activated on actuation of a sensing means.

16. A method as claimed in claim 15 wherein the sensing means comprises a photoelectric sensor for sensing the position of an indicating mark at a desired location on a panel.

17. A method as claimed in claim 16 wherein the indicating mark is marked on the trailing edge of each external skin.

18. A method as claimed in any of claims 15 to 17 wherein the sensing means comprises thickness sensing means for sensing the increased thickness at the overlap of the external skins.

19. A method as claimed in any preceding claim wherein the backing tray and external skin are pre-heated prior to application of the liquid foam reactants.

20. A method as claimed in any preceding claim wherein side sealing means are provided between the external skin and the backing tray.

21. A method as claimed in claim 20 wherein the side sealing means comprises a sealing tape extending along at least one longitudinal edge of the panel.

22. A method as claimed in claim 21 wherein the side sealing tape is applied at the joint between the external skin and the backing tray at or prior to injection of the liquid foam reactants.

23. A method as claimed in claim 21 or 22 wherein the backing tray and insulating core terminate inwardly of one of the longitudinal side edges of the external skin to accommodate longitudinal overlapping of adjacent panels, in use.

24. A method as claimed in any preceding claim wherein the external skin is of a metal material such as steel or aluminium.

25. A method as claimed in any preceding claim wherein the backing tray is of a metal material such as steel or aluminium.

26. A method as claimed in claim 24 or 25 wherein at least those surfaces of the skin and/or backing tray which are exposed in use are coated for corrosion resistance.

27. A method as claimed in any preceding claim wherein the core is of a rigid closed cell polyurethane or polyisocyanurate foam material.

28. A method substantially as hereinbefore described with reference to the drawings.

29. An insulated panel whenever prepared by a method as claimed in any preceding claim.

30. Apparatus for cutting an insulating panel of the type comprising a profiled external skin and an internal backing tray having an insulating core therebetween, the apparatus comprising; a bed along which the panel is led; a carriage which is longitudinally movable relative to the bed; cutting means mounted on the carriage to cut the backing tray and foam core as the panel is travelling along the bed; the cutting means comprising a first cutting means which is movable to pass transversely across the bed to cut through at least the backing tray; and a second cutting means which is moved into the cut formed by the first cutting means to cut through the foam core substantially to the external skin.

31. An apparatus as claimed in claim 30 wherein the first cutting means comprises a saw which is extended transversely across the backing sheet to cut through at least the backing sheet of the panel.

32. An apparatus as claimed in claim 31 wherein the first cutting means comprises a circular saw.

33. An apparatus as claimed in any of claims 30 to 32 wherein the second cutting means comprises a guillotine blade means.

34. Apparatus as claimed in any claims 30 to 33 wherein the second cutting means comprises a plurality of guillotine blade means which are spaced-apart to substantially follow the contour of the external skin of the panel.

35. Apparatus as claimed in claim 33 or 34 including means for rocking the guillotine blade means on insertion into the foam core.

36. Apparatus as claimed in claim 33 where the rocking means comprising a vibration imparting means.

37. Apparatus as claimed in any of claims 33 to 36 wherein the guillotine blade means is mounted in advance of the first cutting means, the carriage advancing to align the guillotine blade means with the cut formed by the first cutting means.

38. Apparatus as claimed in any of claims 30 to 37 including clamp means for clamping the panel in position during cutting.

39. Apparatus as claimed in any of claims 30 to 38 including means for applying a separating force to the panels, upper cutting to separate one cut panel for the adjacent panel.

40. Apparatus as claimed in claim 39 wherein the means for applying a separating force comprises a ram means associated with an outlet clamp means.

41. Apparatus substantially as hereinbefore described with reference to the accompanying drawings.

42. A panel whenever produced using an apparatus as claimed in any of claims 30 to 41.