GB2305636A

GB2305636A - Embossing or impressing a design or pattern into a cladding panel or lining board

Info

Publication number: GB2305636A
Application number: GB9620224A
Authority: GB
Inventors: Andrew Wilson
Original assignee: Individual
Current assignee: Individual
Priority date: 1995-09-27
Filing date: 1996-09-27
Publication date: 1997-04-16
Anticipated expiration: 2016-09-27
Also published as: GB9620224D0; GB2305636B

Abstract

One or both faces of a lining board 10 having a foam core sandwiched between sheets of foil or paper is impressed with a design or pattern of longitudinal ridges or grooves 27 by passage beneath pattern roller 22 whilst supported on a flat rest 25 or a further pattern roller. An external cladding panel may be formed by cutting longitudinal slits 67 (Fig 6) in the non-patterned rear face 15 (Fig 11) of the board, prior to impressing troughs (71, Fig 8) between the slits. A corrugated metal sheet 51 is then adhesively bonded to the rear face of the board.

Description

A Cleddilng Panel The invention relates to a method and apparatus for post treating a lining board.

The invention particularly relates to rigid foam cored lining boards such as are currently used in building interiors as wall and ceiling lining elements. Such lining boards typically have a foam core of expanded rigid polyurethane or phenolic foam or the like material, sandwiched and bonded between two flexible facing sheets thus forming a flat composite board. The facing sheets may comprise for example of pairs of or combinations of metal foils, kraft paper or coated papers and fabrics. An outer facing sheet provides a flat decorative surface on the lining board. The lining boards are generally manufactured on a continuous production line with cut length facility.

It is an object of the present invention to further process such lining or boards in a suitable and efficient manner to make a viewed surface of the board more attractive and decorative in appearance.

It is a further object of the invention to convert the other surface of the lining board in such a manner as to enable it to be intimately bonded to existing structures or have further facings pressurised onto it converting into a surface suitable to resist the elements when exposed to outside climatic conditions, thus effectively producing a cladding panel suitable for external application.

According to the invention there is provided a method for post treating a lining board, comprising the steps of delivering a preformed lining board to a forming station, and at the forming station impressing a desired pattern or design into a face of the lining board.

In another embodiment of the invention the method further includes the step of impressing a selected design or pattern into both faces of the lining board.

In a particularly preferred embodiment, the method includes roll forming the pattern or design into the or each face of the lining board.

In a further embodiment the method includes the step of cutting a plurality of slits in the lining board defining said pattern or design prior to impressing said pattern or design into the lining board. In another embodiment the method includes applying an adhesive to the rear face of the board.

In another embodiment the method includes the step of bonding an outer cover sheet on to a face of the lining board. Preferably, the bonding is carried out by applying an adhesive between the face of the lining board and the cover sheet and then pressing the lining board and cover sheet together.

Conveniently, the adhesive is applied to indentations impressed in a face of the lining board. A suitable adhesive may be used. Butyl rubber strips have been found to be particularly convenient for many applications.

Conveniently, the roll forming is carried out by passing the lining board between a rotatably pattern roller and an associated rest, the pattern roller carrying a desired pattern on an outer surface of the roller for impressing the pattern into a roller-engaging face of the lining board as it is being delivered between the pattern roller and the rest.

In a further embodiment the method includes the step of cutting the slits in the lining board by feeding the lining board between a cutter head and an associated rest, engaging a plurality of spaced-apart cutter blades on the cutter head with the face of the lining board as the lining board is being delivered between the cutter head and the rest.

Preferably the method includes the step of engaging each cutter blade with the lining board while maintaining the cutter blade in an inclined orientation relative to the lining board. This advantageously facilitates smooth cutting of the lining board without tearing the outer facing sheets of the lining board.

Ideally, the pattern roller and/or the rest is movable for adjustment of the relative spacing between the pattern roller and the rest.

In a particularly preferred embodiment, the rest is fixed on a support frame and the pattern roller is slidably mounted on the support frame for adjustment of the relative spacing between the roller and the rest. Conveniently, the slide blocks at each end of the roller slide along associated tracks on the frame. A screw rotatably mounted on the frame engages each slide block for movement of the slide block on the support frame.

In another embodiment, a guide means is provided for feeding the panel to the pattern roller. Conveniently, the guide means may be provided by rails mounted on the support frame and extending outwardly from the pattern roller, the rails engaging and supporting side edges of the panel.

It will be appreciated that the forming station may be provided as a stand-alone unit or may be mounted at the end of a production line for forming the preformed panel.

It is envisaged that in some cases the method may include adhering a cover sheet onto the preformed panel prior to delivery of the preformed panel to the forming station for impressing the desired pattern onto the cover sheet.

In another aspect, the invention provides a cladding panel formed according to the method. The cladding panel thus formed may be mounted on a metal backing panel such as a steel roof sheet for example. The cladding panel may be bonded to the metal panel using strips of double-sided adhesive tape such as butyl rubber tape, for example.

In another aspect the invention provides apparatus for post-treating a lining board according to the method, the apparatus comprising a support frame, a pattern roller rotatably mounted on the support frame and an associated rest mounted on the support frame spaced-apart from the pattern roller, the pattern roller carrying a desired pattern on an outer surface of the roller for impressing said pattern on to a face of the lining board delivered between the pattern roller and the rest.

Preferably, guide means is provided at an inlet side of the pattern roller for feeding a lining board in a desired orientation between the pattern roller and the rest.

Conveniently, one or both of the pattern roller and the rest are moveable on the frame for adjusting the - space in between the pattern roller and the rest.

Preferably the rest is fixed and the pattern roller is carried between a pair of slide blocks which are slidable on the frame for adjusting the space in between the pattern roller and the rest.

In a further embodiment the apparatus further includes a cutting station comprising a support frame, a cutterhead rotatably mounted on the support frame and an associated rest on the support frame spacedapart from the cutterhead, the cutterhead having a number of cutter blades for engagement with a lining board passed between the cutterhead and the rest to cut slits in said lining board.

In another embodiment the relative space in between the cutterhead and the rest is adjustable, one or both of the cutterhead and associated rest being moveable mounted on the support frame.

The invention will be more clearly understood by the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which: Fig. 1 is a perspective view of a preformed panel; Fig. 2 is a perspective view of a cladding panel formed according to the method of the invention; Fig. 3 is a perspective view of a forming station used in the method; Fig. 4 is a detail end elevational view of the forming station; Fig. 5 is an underneath perspective view showing the cladding panel in use forming a ceiling, Fig. 6 is a detail perspective view of a cutting station used in the method; Fig. 7 is an end view of the cutting station; Fig. 8 is a perspective view of a pressing station used in the method; Fig. 9 is an end partially sectioned elevational view of the pressing station;; Fig. 10 is a perspective view of a portion of a roof assembly of panels manufactured according to the method; and Fig. 11 is a detail end elevational view of a pair of abutting panels formed according to the method.

Referring to the drawings1 a method and apparatus for forming cladding panels according to the invention will be described.

lining board Fig. 1 shows a known type of preformed/panel 10 generally rectangular in shape having a foam core 11 sandwiched between flexible thin flat facing sheets 12, 13 to form a laminated insulating panel. The facing sheets 12, 13 are of a reel stock flexible material such as aluminium or other metallic foils and/or treated papers such as kraft paper. In certain cases special fire resistant fabrics or inorganic coated materials may be used. The outer face 12 of the panel 10 forms a flat finished surface on the panel 10.

According to the invention, a patterned surface 15 is impressed into the outer surface 12 to form a more decorative finish on the viewed outer surface 12 of the panel 16.

Referring to Figs. 3 and 4, according to the method of the invention, the preformed panel 10 is delivered to a forming station 20 at which the patterned surface 15 is impressed into the outer surface 12 of the panel 10. The forming station 20 has a support frame 21. A pair of pattern rollers 22 are rotatably mounted on end supports 23 of the frame 21. Mounted beneath the rollers 22 is an associated flat rest 25. As can be seen from the drawings, an outer surface of each roller 22 is shaped such that it impresses a number of spaced-apart channels 27 into the outer surface 12 of the panel 10 to form a pattern of linear ridges and grooves extending along the length of the panel.

Guide rails 28 engage side edges of the panel 10 and feed the panel 10 to the rollers 22. Each roller 22 is vertically slidably on the end supports 23 by means of slide blocks slidable on the end supports 23 and adjustable by means of screws 29. Thus, the relative spacing between each roller 22 and the rest 25 can be adjusted.

It will be appreciated that instead of a flat rest 25, the rest may be provided by a roller having a smooth outer surface. Alternatively, if it is desired to decorate both faces of the panel 10 the rest may also impress a pattern onto a bottom face of the panel 10.

Referring now to Fig. 5, the panel 16 is shown mounted on supports 40 to form a ceiling. Prior to mounting the panel 16 in position, the panel 16 may be bonded to a corrugated steel roofing sheet 42 by a solid state adhesive.

Referring now to Figs. 6 to 11 a method for forming a further panel.

indicated generally by the reference 50 (Fig. 10), according to the method of the invention will be described. In this case in addition to having the patterned surface 15 on an inner face of the panel 50 a thin metal outer skin 51 is bounded to a rear or exterior face of the panel 50. Thus advantageously a panel suitable for external application is provided according to the method of the invention.

The external metal sheet 51 is applied prior to forming the patterned surface 15. First the preformed panel 10 is delivered to a cutting station 60 (Figs. 6 and 7). At the cutting station 60 the panel 10 is delivered between a cutter head 61 and an associated rest 62 mounted beneath the cutter head 61. The cutter head 61 is mounted on a support frame 63. The space in between the cutter head 61 and the rest can be adjusted in any suitable fashion for accommodation of panels of different thickness or for cutting slits of different depth in the panel 10.

The cutter head 61 comprises a beam 64 having a number of downwardly extending spaced-apart cutter blades 65 for engagement with the panel 10 to cut longitudinal slits 67 along the panel 10 as it is delivered between the cutter head 61 and the rest 62. It will be noted that the blades 65 are inclined relative to the face 12 of the panel 10. Thus advantageously the blades 65 are less likely to rip the facing sheet 12 on the panel 10 as the blades 65 are drawn through the panel 10.

Guides 68, 69 are provided on each side of the cutter head 61 for guiding the panel 10 in the correct orientation beneath the cutter blades 65.

Downstream of the cutting station 60 a pressing station 70 is provided. The pressing station 70 is generally similar to the forming station described previously except in this case the pressing station is arranged for forming deeper groves 71 into a surface of the panel 10 than the pressing station 70. The pressing station 70 has a pair of pressing rollers 73 arranged in series. Each pressing roller 73 is mounted spaced-apart above an associated rest roller 74. The rollers 73, 74 are mounted on a support frame 75. Each of the pressing rollers 73 is vertically adjustable on the support frame 75 for adjusting the spacing between each pressing roller 73 and its associated rest roller 74.

Each pressing roller 73 comprises a shaft 77 with a number of spacedapart shaped rollers 78 thereon for engaging and compressing the panel 10 between pairs of associated slits as shown in Fig. 8. The rollers 73 progressively compress the panel 10 between the slits to form the grooves 71 to a desired depth.

Having formed the grooves 71 the outer sheet 51 is bonded to the face of the panel 10, the metal sheet 51 having corrugations corresponding to the grooves 71. Bonding of the metal sheet 51 to the panel 10 is achieved by the use of butyl rubber tape which is applied between the panel 10 and the metal sheet 51. Various other types of solid state adhesives may be used as an alternative to butyl rubber adhesive tape.

The panel is then delivered to the forming station 20 as previously described for forming the patterned surface on an inside viewing face 15 of the panel 50. As the panel 50 is delivered through the forming station 20 the adhesive is compressed to provide a more effective bond between the metal sheet 51 and the external face of the panel.

In some cases adhesive is simply applied to the rear face of the board after pressing. Then the board can be mounted directly onto an existing wall or roof surface. Conveniently, the adhesive may be applied in the troughs or grooves 71.

Fig. 11 shows the overlap of metal sheets 51 at opposite sides of adjacent panels 50.

It is envisaged that a lining board of foam material without facing sheets may also be treated according to the method of the invention.

It will be appreciated that the invention provides a decorative cladding panel in a simple and efficient manner.

Claims

1. A method for post-treating a lining board, comprising the steps of delivering a preformed lining board to a forming station, and impressing a desired pattern or design into a face of the lining board at the forming station.

2. A method as claimed in claim 1 wherein the method further includes the step of impressing a selected design or pattern into both faces of the lining board.

3. A method as claimed in claim 1 or 2 wherein the method includes the step of roll forming the pattern or design into the or each face of the lining board.

4. A method as claimed in any preceding claim wherein the method includes the step of cutting a plurality of slits in the lining board defining said pattern or design prior to impressing said pattern or design into the lining board.

5. A method as claimed in any preceding claim, wherein the method includes the step of bonding an outer cover sheet onto a face of the lining board.

6. A method as claimed in claim 5 wherein the bonding is carried out by applying an adhesive between the face of the lining board and the cover sheet and then pressing the lining board and cover sheet together.

7. A method as claimed in claim 6 wherein the adhesive is applied into indentations impressed in a face of the lining board.

8. A method as claimed in any of claims 3 to 7 wherein the method includes roll forming the pattern or design into a face of the lining board by passing the lining board between a rotatably pattern roller and an associated rest, the pattern roller carrying a desired pattern on an outer surface of the roller for impressing said pattern into a roller-engaging face of the lining board as the lining board is being delivered between the pattern roller and the rest.

9. A method as claimed in any of claims 4 to 8 wherein the method includes the step of cutting the slits in the lining board by feeding the lining board between a cutter head and an associated rest, engaging a plurality of spaced-apart cutter blades on the cutter head with a face of the lining board as the lining board is being delivered between the cutter head and the rest.

10. A method as claimed in claim 9 wherein the method includes the step of engaging each cutter blade with the lining board while maintaining the cutter blade in an inclined orientation relative to the lining board

11. A method for post treating a lining board substantially as hereinbefore described with reference to the accompanying drawings.

12. A cladding panel comprising post-treated lining board whenever produced according to the method.

13. Apparatus for post-treating a lining board according to the method as claimed in any claims 1 - 11, the apparatus comprising a support frame, a pattern roller rotatably mounted on a support frame and an associated rest mounted on the support frame spaced-apart from the pattern roller, the patter roller carrying a desired pattern on an outer surface of the roller for impressing said pattern onto a face of a lining board delivered between the pattern roller and the rest.

14. Apparatus as claimed in claim 13, wherein guide means is provided at an inlet side of the pattern roller for feeding a lining board in a desired orientation between the pattern roller and the rest.

15. Apparatus as claimed in claim 13 or 14 for in one or about of the pattern roller and the rest are moveable on the frame for adjusting the relative spacing between the pattern roller and the rest.

16. Apparatus as claimed in claim 15 wherein the rest is fixed and the pattern roller is carried between a pair of slide blocks which are slidable on the frame for adjusting the spacing between the pattern roller and the rest.

17. Apparatus as claimed in any of claims 13 - 16 further including a cutting station comprising a support frame, a cutterhead rotatably mounted on the support frame and an associated rest on the support frame spaced-apart from the cutterhead, the cutterhead having a number of cutter blades for engagement with a lining board passed between the cutterhead and the rest to put slits in said lining board.

18. Apparatus as claimed in claim 17 wherein the relative spacing between the cutterhead and the rest is adjustable, one or both of the cutterhead and associated rest being movable mounted on the support frame.

19. Apparatus as claimed in claim 17 or 18 wherein guide means is provided for feeding a lining board to the cutterhead.

20. Apparatus for post-treating a lining board, substantially as hereinbefore described with reference to the accompanying drawings.