GB2413569A

GB2413569A - Shingled panel

Info

Publication number: GB2413569A
Application number: GB0409288A
Authority: GB
Inventors: Raymond Alfred Merrit
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-04-26
Filing date: 2004-04-26
Publication date: 2005-11-02
Anticipated expiration: 2024-04-26
Also published as: GB2413569B; GB0409288D0

Abstract

A construction panel 10 comprises a plurality of overlapping adjacent rows of tiles 11, each row being laterally offset relative to each adjacent row and tiles 11 of each row being secured to tiles 11 of each adjacent row to form an integral structure. The tiles 11 are preferably timber and are preferably secured together by pairs of staples 12, 13, each tile 11 being secured by a corresponding one 12, 13 of a pair of staples to one of a pair of tiles 11 located in one of the adjacent rows. Also disclosed is a method of manufacturing such panels 10 by arranging a first row of tiles 11, advancing the first row of tiles 11 and arranging a second row of tiles 11 overlapping and laterally displaced with respect to the first row and securing the tiles 11 of the second row to those of the first row using a securing means. Also disclosed is an apparatus for carrying out the method comprising securing means, a feed table, a hopper for holding tiles, means for advancing tiles from the hopper towards the securing means and means for laterally displacing subsequently advanced tiles relative to previously advanced tiles.

Description

A Construction Panel This invention relates to a construction panel and to

a method of and apparatus for manufacturing such a panel.

In US-A-3 807 1 13 there is disclosed a roofing pane! with interlocking side edges. The pane! comprises sheet material, for example polyvinyl chloride (PVC), which is formed to simulate shingles, slates or clapboards.

A disadvantage of such a panel is that, generally, it is not formed of naturally occurring material and, being in sheet form, it does not have a realistic appearance of overlapping shingles, slates or clapboards.

According to the present invention, there is provided a construction panel comprising a plurality of rows of tiles, each row overlapping or being overlapped by an adjacent row and each row being offset laterally in relation to each adjacent row and tiles of each row being secured to tiles of each adjacent row thereby providing an integral structure.

Also according to the present invention, there is provided a method of manufacturing a construction panel of the kind specified above including the steps of arranging tiles in a first row, advancing the first row to a first position relative to securing means, arranging further tiles in a second row displaced laterally relative to the first row, advancing the second row to a second position relative to the securing means and in overlapping relation to the first row and operating the securing means to secure tiles of the second row to tiles of the first row.

Also according to the present invention, there is provided apparatus for carrying out the method the apparatus including the securing means, a feed table locatable adjacent the securing means, a hopper for receiving stacks of tiles, means for advancing tiles from the hopper towards the securing means and means for effecting transverse movement of subsequently advanced tiles relative to previously advanced tiles.

Following is a description, by way of example only and with reference to the accompanying drawings, of one method of carrying the invention into effect.

In the drawings: Figure 1 is a plan view of one embodiment of a construction panel in accordance with the present invention, Figure 2 is a diagrammatic cross section of the panel shown in Figure 1 when in use, Figure 3 is a side elevation of a feed table of apparatus for manufacturing the panel shown in Figure 1, Figure 4 is an end elevation of the table shown in Figure 3, Figure 5 is a plan view of the table shown in Figures 3 and 4, Figure 6 is a feed side elevation of stapling station of the apparatus, Figure 7 is an exit side elevation of the stapling station, and Figure 8 is a diagrammatic cross section of the stapling station.

Referring to Figures 1 and 2 the drawings, there is shown a construction panel 10 comprising an array of rectangular tiles 11 of equal area arranged in rows, each row being offset laterally in relation to each adjacent row by a distance corresponding to half the transverse dimension of each of the tiles but alternate rows being aligned one with another at edge margins so that the panel 10 is of substantially rectangular configuration. The tiles 11 are cut from sheets of timber and each tile 11 is stapled, by means of a pair of staples 12, 13, to two adjacent tiles 11 of the row below which it overlaps, the staples 12, 1 3 being inserted in the tiles 11 in a line extending mid-way from a top edge to a bottom edge of the corresponding tile 11 and the staples 12,13 of each pair each being inserted in a corresponding one of the two adjacent tiles 11 of the row below.

In use, the panel 10 is secured, by means of galvanized nails 14, to battens 15 of a timber structure and other panels 10 are also secured to the structure such that longitudinal and transverse margins of the panels 10 overlap one another thereby providing cladding and/or roofing for the structure.

A fillet 16 may be provided at a lower position of each lower panel 10 forming a cladding or a roofing so as to accommodate the slant caused by the shingle effect of the overlapping tiles 11. It may be also be necessary to carry out a faishing procedure with regard to lower edges of lower tiles 11 of a construction. In Figure 2, for example, tiles 11 in a lowermost row have been sawn so that their lower marginal edges align with the lower marginal edges the tiles 11 immediately above. This arrangement, together with the spacing provided by the fillet 16, ensures that there is a continuous longitudinal edge 17 spaced from a corresponding wall of a structure to shed rainwater away from the wall.

It will be appreciated that, instead of providing a structure having battens 15, the panels 10 may be secured to a backing board.

It will also be appreciated that the tiles 1 l may be formed of material other than timber but penetrateable by the staples 12, 13.

Furthermore, it will be appreciated that not all of the edges of the tiles l l need be rectilinear.

For example, the lower edges of the tiles 11 may be scalloped.

Referring to Figures 3 to 8 of the drawings, there is shown apparatus for manufacturing construction panels 1 0. The apparatus comprises a feed table 18 and a stapling station 1 9.

The feed table 18 includes a rectangular frame 20 supported at the four corners thereof by legs 21. The frame 20 includes spaced parallel front and rear members 22, 23, an intermediate member 24 extending between and parallel to the front and rear members 22, 23 and spaced parallel side members 25, 26. The front and rear members 22 and 23 and the intermediate member 24 are provided with apertures (not shown) each having a bearing (not shown) located therein in which is received a corresponding end portion of a shaft (not shown) of a corresponding one of a plurality of rollers 27 whereby the rollers 27 are rotatable on their longitudinal axes relative to the frame 20, the axes extending parallel to the side members 25, 26. The side members 25, 26 each have secured thereto a corresponding one of a pair of elongate guides 28, 29. The guide 28 is provided with an elongate slot 30.

The rollers 27 support a rectangular table 31, which is located between the guides 28, 29, the transverse dimension of the table 31 being less than the distance between the guides 28,29 so that the table 31 is moveable on the rollers 27 transversely of the frame 20. Transverse movement of the table 31 is effected by means of an hydraulic ram 32, the piston 33 of which extends through the slot 30 of the guide 28. A remote end portion of the piston 33 is attached to the table 31. The feed table 18 also includes an apron 34 adjacent the table 31, the apron 34 having a surface which is contained in the plane of the table 31, being stationery relative to the table 31 and being located adjacent the rear member 23 of the feed table 18.

The table 31 has located thereon a hopper 35 in the form of an elongate rectangular box having a front wall 36, a rear wall 37, side walls 38, 39 and a plurality of equi-spaced parallel partitions 40 extending parallel to the side walls 38, 39. The side walls 38, 39 are of greater depth than the front and rear walls 36,37 thereby providing a gap 41 between lower portions of the front and rear walls 36,37 and the upper surface of the table 31. The partitions 40 of the hopper 35 are of greater depth than the front and rear walls 36, 37 such that lower portions of the partitions 40 extend downwardly beyond the lower edge portions of the front and rear walls 36, 37. The partitions 40, together with the front, rear and side walls 36, 37, 38 and 39, define a series of compartments 42 each for receiving corresponding stacks of tiles 11. The gap 41 has vertical and transverse dimensions which are slightly in excess of corresponding dimensions of a row of tiles 11. The front wall 36 of the hopper 35 is provided with cut-outs 43 to facilitate loading of tiles l l into the compartments 42. The lower portions of the side walls 38,39 of the hopper 35 are secured to the table 31. s

The table 31 has located thereon a rectangular plate 44 which is slidable on the table 31, forwardly and rearwardly, such that a forward portion thereof passes through the gap 41. The plate 44 is provided with spaced parallel grooves 45 in each of which is received a corresponding one of the lower edges of the partitions 40 of the hopper 35. The front wall 36 of the hopper 35 has attached thereto an end portion of an hydraulic ram 46 the piston 47 of which is supported by a bracket 48 located on an upper surface of the plate 44. The arrangement is such that operation of the ram 46 causes the plate 44 to move longitudinally of the table 31 and parallel to the guides 28, 29, the movement, when in a forward direction, causing a leading edge of the plate 44 to slide through the gap 41.

When the compartments 42 of the hopper 35 contain stacks of tiles 11, lower-most tiles 11 of the stacks seat on the upper surface of the table 31. Operation of the ram 46 to effect forward movement of the plate 44 longitudinally of the table 31 causes the leading edge of the plate 44 to pass through the gap 41 and engage lower-most tiles 11 of the stacks contained in the compartments 42 of the hopper 35 such as to push those tiles forwardly in a row outwardly from the hopper 35. When the ram 46 is operated to effect rearward movement of the plate 44 relative to the table 31 and the leading edge of the plate 44 clears the stacks of tiles 11 contained in the compartments 42, the next lower- most tiles 11 in the stacks then seat on the upper surface of the table 3 l.

The piston 47 of the ram 46 extends outwardly of the cylinder thereof in a direction away from the hopper 35 and beyond the bracket 48 and the remote end portion of the piston 47 is provided with a stop 49 having an abutment 50. A helical compression spring 51 is located between the bracket 48 and the stop 49 and is coaxial with the piston 47. The bracket 48 is provided with a limit switch 52 which is arranged to be tripped when engaged by the abutment 50. The switch 52 is connected in an electrical circuit for controlling operation of the ram 46. If the switch 52 should be tripped, the control circuit operates to shut down operation of the ram 46.

The stapling station 19 comprises a vertical rectangular main frame 53 having spaced parallel side members 54, 55 formed integrally with legs 56, 57, a transverse anvil 58 extending between the side members 54, 55 and a platen 59 end portions of which are located in the side members 54, 55 so that the platen 59 is slidable vertically in the side members 54, 55 towards and away from the anvil 58. Movement of the platen 59 is effected by operation of rams 60, 61 mounted on the frame 53.

The platen 59 comprises a rectangular board 62 having a plurality of spaced rectangular openings 63 extending along a lower edge thereof, the lower edge being provided with a flange 64 on which is mounted a series of transverse saddles 65, each located adjacent a corresponding one of the openings 63, for receiving staples (not shown) such that the staples, if moved along the corresponding saddles 65 towards the board 62, will pass through corresponding openings 63. On a reverse side of the board 62, the feed side, there is provided a plurality of guides 66 for guiding a series of plates 67 such that the plates 67 move vertically relative to the board 62. Each of the plates 67 is provided with depending fingers 68, these also being guided in respective guides 69 adjacent corresponding openings 63. The platen 59 carries a plurality of rams 70, each for operating a corresponding one of the plates 67. The arrangement is such that, when the rams 70 operate to effect downward movement of the plates 67 relative to the board 62, the fingers 68 engage and apply downward pressure to staples advanced along saddles 65 through corresponding openings 63.

The side of the board 62 carrying the saddles 65, the exit side, is provided with a plurality of tension devices 71, each located adjacent a corresponding one of the saddles 65. Each tension device 71 comprises an endless belt 72 extending around pulleys 73, 74, 75 such that a portion of the belt 72 is rectilinear, is aligned longitudinally with a corresponding saddle 65 and engages staples mounted on the corresponding saddle 65. Each pulley 75 is secured to a shaft (not shown) to which is also secured a toothed wheel (not shown). Each of the plates 67 is provided with link means (not shown) each of which engages a corresponding toothed wheel of a corresponding tension device 71 such that, when the plates 67 are moved downwardly, the staples on the saddles 65 are advanced successively through the openings 63 in the board 62.

The legs 56, 57 of the frame 53 may be provided with height adjustment devices 76.

It will be appreciated that the rams 32,46, 60,61 and 70 are double acting.

The frame 53 is positioned between the guides 28,29 ofthe feed table 18 such that the anvil 58 is located adjacent the edge of the upper surface of the table 31 remote from the bracket 48 and the vertical position of the frame 53 relative to the table 31 is adjusted so that the anvil 58 is located below the plane of the upper surface of the table 31 at a depth corresponding approximately to the thickness of a tile 11. It may be necessary to secure the frame 53 to the guides 28, 29, for example by means of screws.

In operation, a sufficient number of tiles 11 for manufacturing a panel l O are stacked in the compartments 42 of the hopper 35. A switch (not shown) is then operated as a result of which the control system of the apparatus effects operation of the ram 46 to cause the plate 44 to be moved forwardly of the table 31 towards the anvil 58 causing the lowermost tiles 11 in the stacks located in the compartments 42 of the hopper 35 to be pushed forwardly out of the hopper 35. The platen 59 is in a raised position. When the piston 47 of the ram 46 has reached the end of its throw, it is reversed causing the plate 44 to be drawn rearwardly of the table 31. The tiles 11 which were formerly lower-most in the stacks located in the compartments 42 are now deposited in a row at a location at which their leading edges overhang the apron 34 and rest on the anvil 58. Tiles 11 which were previously immediately above the now deposited tiles 11 are now the lower-most tiles 11 in the stacks in the hopper and these seat on the upper surface of the table 31 as the leading edge of the plate 44 clears the hopper 35. However, before the ram 46 is again operated, the control circuit effects operation of the ram 32 thereby moving the table 3 l laterally a distance corresponding to half the width of a tile 11. The ram 46 is then operated causing the plate 44 again to move towards the anvil 58, the leading edge of the plate 44 engaging tiles 11 which now are the lower-most tiles 11 in the stacks in the hopper 35 pushing them forwardly such that they engage the already deposited tiles 11, the leading edges of which are supported on the anvil 58, and pushing those already deposited tiles 11 such that the trailing edges thereof move off the apron 34 and drop onto the anvil 58. As the plate 44 continues its forward, the advancing row of tiles 11 slide over the already deposited tiles 11 located on the anvil 58, the remaining one third of the area of the tiles 11 being located on the apron 34.. The arrangement is such that the plate 44 reaches the limit of its forward movement when the advanced tiles 11 overlap some two thirds of the area of the tiles 11 located on the anvil 58. The ram 46 is then controlled to reverse movement of the plate 44 with a result that the advanced tiles 11 are deposited in a position where they form a row of tiles 11 overlapping the row of tiles 11 already located on the anvil 58 and are displaced laterally relative to the row of tiles I 1 already located on the anvil 58 by a distance corresponding to half the width of a tile 11.

Before the ram 46 is again operated, the ram 32 is operated thereby moving the table 31 laterally to the initial position prior to previous operation of the ram 32.

Also before the ram 46 is again operated, the control circuit causes the rams 60, 61 to operate resulting in lowering of the platen 59 in the frame 53 such that flange 64 of the platen 59 engages the overlapping row of tiles 11 and applies downward pressure on the tiles 11. The control circuit then causes the rams 70 to operate such that the plates 67 and their associated depending fingers 68 are abruptly forced downwardly causing the fingers 68 to strike staples 12, 13 extending from corresponding saddles 65 and drive the staples 12, 13 into the tiles 11 so as to unite each of the tiles 11 of the overlapping row with a corresponding pair of tiles 11 of the row below.

The control circuit then causes the rams 70 to operate so as to raise the plates 67 and their associated fingers 68 relative to the platen 59, the movement resulting in ratcheting of the tension devices 71 so as to move succeeding staples 12, 13 longitudinally of their respective saddles 65 ready for being struck by corresponding fingers 68 of the plates 67 in a subsequent operation of the rams 70. The control circuit also causes the rams 60, 61 to operate so as to lift the platen 59 and permit further movement of the plate 44.

The control circuit includes means for timing the number of operations of the ram 46, which would correspond to depletion of tiles 11 contained in the hopper 35, and the procedure continues until time-out, when the control circuit causes the apparatus is shut down. At that stage, a panel 10 should have been constructed and should have issued from the anvil 58.

It will be appreciated that the provision of the limit switch 52 ensures that, if jamming of the tiles 11 should occur, the control circuit will operate to shut down the apparatus. Such jamming will result in arresting of forward movement of the plate 44. However, operation of the ram 46 will continue which will result in shortening of the distance between the bracket 48 and the stop 49 until, eventually, the abutment 50 contacts the limit switch 52 and trips the switch 52.

Claims

Claims 1. A construction panel comprising a plurality of rows of tiles,

each row overlapping or being overlapped by an adjacent row and each row being offset laterally in relation to each adjacent row and tiles of each row being secured to tiles of each adjacent row thereby providing an integral structure.
2. A panel as claimed in claim 1 wherein the tiles are secured one to another by pairs of securing devices, each tile being secured by a corresponding one of a pair of the devices to one of a pair of tiles located in a row below.
3. A panel as claimed in claim 2 wherein the devices are staples and the tiles are formed of a material penetrateable by the staples.
4. A panel as claimed in claim 3 wherein the material is timber.
S. A method of manufacturing a construction panel as claimed in any one of the preceding claims including the steps of arranging tiles in a first row, advancing the first row to a first position relative to securing means, arranging further tiles in a second row displaced laterally relative to the first row, advancing the second row to a second position relative to the securing means and in overlapping relation to the first row and operating the securing means to secure tiles of dhe second row to tiles of the first row.
6. Apparatus for carrying out the method as claimed in claim 5, the apparatus including die securing means, a feed table locatable adjacent the securing means, a hopper for receiving stacks of tiles, means for advancing tiles from dhe hopper towards the securing means and means for effecting transverse movement of subsequently advanced tiles relative to previously advanced tiles.
7. Apparatus as claimed in claim 6 wherein the securing means includes a surface for receiving rows of tiles, one row overlapping anodher; a platen for lowering on to and for applying pressure to the overlapping tiles; a series of saddles extending longitudinally of the platen each for receiving staples, and a series of operating devices, also extending longitudinally of the platen, adapted to engage staples from respective saddles to cause the staples to be removed from their respective saddles and to penetrate the tiles and thereby secure tiles of one row to tiles of the other row.
8. Apparatus as claimed in claim 7 wherein the securing means includes a series of tensioning devices extending longitudinally of the platen at locations corresponding to the saddles, each tensioning device being adapted to engage staples located on a corresponding saddle so as to ensure that staples located on saddles are successively engageable by successive operations of corresponding operating devices.
9. A construction panel substantially as hereinbefore described and as illustrated in Figures 1 and 2 of the accompanying drawings.

I 0. Apparatus for manufacturing construction panels substantially as hereinbefore described and as illustrated in Figures 3 to 8 of the accompanying drawings.