GB2389558A

GB2389558A - Manufacture of insulating panels

Info

Publication number: GB2389558A
Application number: GB0213296A
Authority: GB
Inventors: Patrick Mcdonald
Original assignee: Kingspan Research and Developments Ltd
Current assignee: Kingspan Research and Developments Ltd
Priority date: 2002-06-10
Filing date: 2002-06-10
Publication date: 2003-12-17
Anticipated expiration: 2022-06-10
Also published as: GB0213296D0; GB2389558B

Abstract

A cleaning carriage 50 is mounted for vertical movement and is also movable transversely of separated panels 10, 12 along tracks 51 for movement of the carriage 50 across the gap between the separated panels 10, 12. The carriage 50 is moved from a raised inactive position to an extended or lowered active position and is then driven across the gap created between the panels 10, 12 to clean and de-burr the end faces 11, 13. Material removed on cleaning is collected in hoppers 52 to prevent contamination in the region of the panels. To clean the upper and lower faces 70, 71 of a panel 10, the panel is led over a lower face cleaning brush 80 and under an upper face cleaning brush 81 at a panel face cleaning station 85. The brushes 80, 81 are provided in the form of belts that brush across the faces 70, 71 of the panel 10 as the panel travels along a conveyer 86. Debris is brushed into inlets 87 of a vacuum removal system 88.

Description

- 1 "Manufacture of insulating panels" introduction

The invention relates to a method and apparatus for manufacturing and handling panels. In particular, the invention relates to insulating panels of the type comprisulg an external skin and an internal backing with an insulating core therebetween.

0 UK-A-22Z7712, UE(-A-2257086 and UK--2338448 describe methods and apparatus for manufacturing insulating panels. However, there is an increasing need to improve manufacturing and handling efficiency and to optimise product quality in a cost efficient manner to cut costs and maxantse the production rates for such panels.

5 This invention is therefore directed towards providing an improved method and apparatus for producing panels of high quality and for efficient manufacturing and handling of such panels.

20 Statements of Invention

According to the invention there is provided a method for manufacturing a composite Lnsulating panel of the type comprising an external skin. an internal backing tray and an insulating core therebetween, the method composing the steps of: 2s cutting a substantia11y continuous panel to a desired length, the cut defining a leading panel on one side and a trailing panel on the other side: clamping the leading panel adjacent to the cut using leading clamping means: clamping the trailing panel adjacent to the cut using trailing clamping means:

- 2 - after clamping, separating the leading and trailing panels by a preset distance; and after separation, cleaning the trailing end of the leading panel and the s leading end of the trailing panel.

in one embodiment the trailing end of the leading panel and the leading end of the trailing panel are cleaned substantially simultaneously.

lo Preferably the method comprises de-burring the external skin and/or internal backing tray. The de-burrlog may be carried out by drawing a blade across the face of the external skin and/or backing tray.

In one arrangement the external skin and/or backing tray is demurred while cleaning 5 of the trailing end of the leading pang and Me leading end of the trailing panel.

In a preferred embodiment the trailing end of the leading panel and the leading end of the trailing panel are cleaned by drawing brush means across the ends of the parcels.

The brush means may be provided on a Reading carriage and the method comprises 20 the step, after separation of the panels, of extending the carriage from a retracted position into an extended position in me gap between the trailing end of Me leading panel and the leading eras of We trailing panel. Preferably the method comprises driving *'e cleaning carriage across the gap between the trailing end of the leading panel and the leading end of the trailing panel. Ideally the method comprises raising 25 the carriage from the gap on traversing of the ends of the adjacent panels.

In a preferred embodiment the method comprises cleaning the upper and/or lower faces of the panel, Tile panel may be led over a lower face cleaning brush and leading the pang over an upper face cleaning brush. In one embodiment the panel is led over so the face cleaning brush means after end cleaning.

( - 3 In one arrangement die method comprises moving the upper face cleaning brush from a retracted disengaged position to an engaged position in which the brush is engaged with the upper face of the panel.

5 The invention also provides an insulated panel whenever manufactured by a method of the invention.

Brief Description of Drawings

The invention will be more clearly understood from the following description thereof

given by way of example only in which; Fig. is a side viev'of a cutting step in the method of die invention: Fig. 2 is an enlarged crosssectional view illustrating the cutting of a panel; Fig. 3 is a side view of a separatlag step in the method of the invention; 20 Fig. 4 is a crosssectional view of adjacent panels separated; Fig. 5 is a side view of a fiat stage step In panel edge cleaning; Fig. 6 is a cross-sectional view of adjacent panel ends, prior to cleaning; Fig. 7 is a side view of a panel end cleaning step in the method of the invention; Fig. 8 is an enlarged cross-sectional view of the panel ends being cleaned; Fig, is plan view clef a panel cleaning anti rie-hrnng step:

( Fig. 10 is a perspective view of an end cleaning apparatus used in the method of the invention; 5 Fig. It is a perspective view of panel face cleaning apparatus used in the method of the invention Fig. 12 is a side view of a panel face cleaning step used in the method of the invention: and Fig. 13 is a cross-sectional view of the panel face cleaning step.

Detailed Description

Referring to the drawings there is illustrated part of a method and apparatus used for manufacturing an insulated panel length I of the type having an external skin, an internal backing tray and an insulating core between the external skin and backing tray. Refemag initially to Figs 1 and 2 a continuous length nit panel 1 is formed and delivered to a cutting station 2 at which the panel 1 is cut to a desired length by a crosscut saw 4. The panel is cut to provide a leading panel 10 with a trailing end 11 and a trailing panel 12 having a leading erN] 13. A first clamp comprising a first upper as clamping head 20 arid a first lower clamping head 21 grips the leading panel 10. A second clamp comprising a second upper clamping head 22 and a second lower clamping head 23 grips the trailing panel 12. The first and second clamps are mounted on separate carriages 24, 25 which are moved apart as illustrated in Fig. 3 to separate the panels 10, 12 at the joint. The carriages 24, 25 on which the clamps are 30 mounted travel with Me panels Hey progress along the production line. This ensures am processing time is optimized = the panels are not stopped during the

- 5 - separation of the panels. At this stake the trailing end I 1 of the leading panel I O is separated from We leading end 13 of the trailing panel 13. The end faces have a rough finish after the cutting process and may be contaminated by metal shards, and dust of loam material.

Cleaning apparatus for simultaneously cleaning and de-burring the end faces I 1, 13 of the adjacent panels is illustrated in Figs. 5 to 10. The cleaning apparatus comprises a cleaning carriage 50 which is mounted for vertical movement in the direction of the amps A, for example by a ram. The carriage SO is also movable in the direction of lo the arrows B transversely of the panels lO, 12 along tracks Sl for movement of the carriage 50 across the gap between Me separated panels 10, 12. In use, the camage 50 Is moved firm the raised inactive position of Figs 5 and lO to the extended or lowered active position of Figs. 7 and 8 and is then driven across the gap created between the panels 10, 12 to clean the end foes 11, 13. Material removed on cleaning is collected I S in hoppers 52 to prevent contamination in the region of the panels.

The camage 50 carries a leading panel cleaning head 55 and a tlailmg panel cleaning head 56. The leading panel head 55 has pairs of upper and lower brushes 60, 61 and de-buring knives 63 between the pair of upper brushes fig. Similarly, the Mailing so panel cleaning head 56 has pairs of upper and lower brushes 63, 64 anal de-burong hives 65 between the upper brushes 63 As the camage 50 is moved across between the panels lo, 12 in the direction of the arrow B in Fig. 9 the brushes 60, 61, 63, 64 brush of debris from the ends 11, 13 of the panels 10, 12 and the knives 63, 65 drag on the uppermost metal edge of the panels, removing metal shards. The lowermost as metal edge of the panels may be similarly de- burred.

After end cleaning the carriage 50 is lifted back up to the inactive position, the panels 10, 12 travel to the next station and the cutting, cleaning, and de-burring station is ready for the next panel.

- 6 - Referring to Figs. 10 to 13 to clean Me upper and lower faces 70, 11 of a panel 10, the panel is led over a lower face clesng brush 80 and under an upper face cleaning brush 81 at a panel face cleaning station 85. In this case the brushes 80, 81 are provided in the form of belts that brush across the faces 70, 71 of the panel I O as the 5 panel travels along a conveyer 86. Debris is brushed into inlets 87 of a vacuum removal system 88. Both the upper and lower face cleaning brushes 80, 81 are movable front a raised to a lowered position by any suitable means such as a ram.

The invention provides a highly optimised process for producing insulating panels in lo which the panel is cut to a desired length or line, the end faces me cleaned and de burred and the panel faces are cleaned in-line without interrupting the production panel flow. Substantially clean faces are provided which assists in optimising use of the panels and preventing damage caused by loose metal shards or debris which may damage the panel faces or ends.

The invention is not limited to the embodiments hereinbefore described which may be varied in construction and detail.

Claims

/ Claims

1. A method for manufacturing a composite insulating panel of the type comprising an external SEA, internal backmg tray and an insulating core 5 therebetween, the method comprlsir the steps of: cutting a substantially contuuous panel to a desired length, the cur defining a leading panel on one side and a trailing panel on the other side; clamping the leading panel adjacent to Me cut using a leading clamping means; clamping the trailing panel adjacent to the cut using a trailing clamping 15 rnesus; after clamping, separatlog the leading and trailing panels by a pre-set distance: 20 and after separation, cleaning the trailing end of the leading panel and the leadlug end of the trailing panel.

2. A method as claimed in claim I wherein the trailing end of the leading panel and the leading end of the trailing panel are cleaned substantially 25 simultaneously

3. A method as claimed in claim 1 or 2 comprising deburring the external skin andior internal backing tray.

30

4. A method as claimed in claum wherein the de-burring is carried out by drawing a bluely across the face of the external skin andIor baclcin% tray.

(

5. A method as clowned in claim 3 or 4 wherein the extema1 skin and/or backup tray is de-burred while cleaning of the trailing end of the leading panel and the leading end of the trailing panel.

a

6. A method as claimed in any <if claims 2 to 5 wherein the trailing end of the leading panel and the leading end of the trailing panel are cleaned by drawing brush means across the ends of the panels.

10

7. A method as claimed In claim 6 wherein the brush mcarm are provided on a cleaning camage and the method comprises the step, after separation of the panels, of extending the carriage from a retracted position into an extended position in the gap between the trailing end of the leading panel and the leading end of the trailing panel t5

8. A method as claimed In claim 7 comprising driving the cleaning carriage across the gap between the trailing end of the leading panel and the leading end of the trailing panel.

20

9 A method as claimed in claun 8 comprising raising the carriage frown the gap on traversing of the ends of the adjacent panels.

10. A method as claumed in any preceding clann comprising cleaning the upper and/or lower faces of the panel.

11. A method as claimed us claim 10 comprising Icading the panel over a lower face cleaning brush and leading the panel over an upper face cleaning brush.

12. A method as claimed in clann 11 whereon the panel is led over the face so cleaning brush means after end cleaning,

( - g -

13. A method as claimed in clann It car 12 comprising moving the upper face cleaning brush from a retracted disengaged position to an engaged position in which the brush is engaged with the upper face of the panel.

5

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

15. An insulated panel whenever manufactured by a method as claimed in any proceedlag claim.