GB2446521A - A composite cladding panel - Google Patents

A composite cladding panel Download PDF

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Publication number
GB2446521A
GB2446521A GB0802567A GB0802567A GB2446521A GB 2446521 A GB2446521 A GB 2446521A GB 0802567 A GB0802567 A GB 0802567A GB 0802567 A GB0802567 A GB 0802567A GB 2446521 A GB2446521 A GB 2446521A
Authority
GB
United Kingdom
Prior art keywords
panel
blocks
skin
external skin
adhesive
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.)
Granted
Application number
GB0802567A
Other versions
GB2446521B (en
GB0802567D0 (en
Inventor
James Carolan
David Cookson
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.)
Kingspan Research and Developments Ltd
Original Assignee
Kingspan Research and Developments 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
Application filed by Kingspan Research and Developments Ltd filed Critical Kingspan Research and Developments Ltd
Publication of GB0802567D0 publication Critical patent/GB0802567D0/en
Publication of GB2446521A publication Critical patent/GB2446521A/en
Application granted granted Critical
Publication of GB2446521B publication Critical patent/GB2446521B/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • 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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/88—Curtain walls
    • E04B2/90—Curtain walls comprising panels directly attached to the structure
    • E04B2/92—Sandwich-type panels
    • 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
    • E04C2/292—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 composed of insulating material and sheet metal
    • 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
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0801—Separate fastening elements
    • E04F13/0832—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements
    • E04F13/0833—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements not adjustable
    • E04F13/0835—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements not adjustable the fastening elements extending into the back side of the covering elements
    • E04F13/0837—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements not adjustable the fastening elements extending into the back side of the covering elements extending completely through the covering elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0862—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of a number of elements which are identical or not, e.g. carried by a common web, support plate or grid
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0864—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of superposed elements which overlap each other and of which the flat outer surface includes an acute angle with the surface to cover
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49616—Structural member making
    • Y10T29/49623—Static structure, e.g., a building component
    • Y10T29/49629—Panel

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Finishing Walls (AREA)
  • Laminated Bodies (AREA)

Abstract

A composite cladding panel 1 comprises a backing tray (fig.3, 2) and an external skin (fig.3, 3) with a layer of foam insulation material (fig.3, 4) such as a phenolic or polyurethane based foam material therebetween. One of the skins, in this case the external skin 3 has a plurality of tongue and mortise blocks (fig.3, 5) fastened to the panel 1 by fasteners 12, such as peel rivets. Pilot holes (fig.2, 13) are first drilled through the blocks 5 and the rivet 12 is inserted. On operation of a rivet gun the main body curls up (fig.3, 22) and is clamped against the in side surface of the external skin 3. The blocks 5 are thereby clamped to the external skin 3. A method of manufacture is also disclosed wherein an adhesive is applied to the inner surface of the external skin prior to the lay-down of liquid insulating foam reactants.

Description

"A composite panel"
Introduction
The invention relates to a composite cladding panel of the type comprising an inner skin and an external skin with insulation foam material therebetween.
Buildings comprising a steel frame on which pre-formed panels are mounted may be erected quickly and more cheaply than buildings with brick or block facades.
One of the problems with buildings constructed from pre-formed panels is that such panels can often be uninteresting aesthetically. It is known to form such panels with various profiles and in various colours, however, there is still a need to provide an aesthetically different façade in some cases.
This invention is directed towards providing a panel system which will address this need.
Statements of Invention
According to the invention there is provided a composite cladding panel comprising an internal skin and an external skin with insulation material therebetween, one of the skins having a plurality of tongue and mortise blocks mounted directly to the * ** 25 panel by a mounting means to form a cladding. * S * * S. * 511 * S
In one embodiment the blocks have mounting holes and the mounting means comprises a fastener for insertion through the hole to fasten the block to the panel. *IS * ** *. * * S * S *
* ..Sl* * S In one case the fastener comprises a clamping fastener.
The clamping fastener may comprise a peel rivet.
In one embodiment the external skin of the panel has an adhesive on the inner face thereof. The adhesive may be applied to the inner face of the external skin prior to lay-down of liquid insulating foam reactants.
The invention also provides a method for manufacturing a composite cladding panel comprising the steps of: -manufacturing a composite insulating panel comprising an internal skin, an external skin with insulation material therebetween; providing a plurality of tongue and mortise blocks with mounting holes through the blocks; providing a plurality of fasteners; placing the blocks along at least portion of the external face of a skin; and fastening the blocks to the skin by inserting the fasteners through the holes in the blocks. * *S * * * * ** * ..I
The method may comprise the step of fixing the blocks to the panel using the fasteners. The fasteners are preferably clamping fasteners, especially peel rivets. *
S * ** .* * * * * S * * * *
In one embodiment the method comprises boring holes through the blocks to provide the mounting holes.
In one embodiment the method comprises the steps of laying the external skin down with the outer side lowermost, applying an adhesive to the inner face of the external skin, applying liquid foam reactants over the adhesive, applying an internal skin over the liquid form reactants and heating the sandwich thus formed in an oven to form the composite insulating panel.
The invention further provides composite cladding panels when manufactured by a method of the invention.
Brief Description of the Drawings
The invention will be more clearly understood from the following description thereof given by way of example only, in which:-Fig. I is a cross-sectional view of a composite insulating cladding panel according to the invention with a plurality of tongue and mortise blocks attached; Fig. 2 is perspective view of one of the blocks of Fig. I; Fig. 3 is a perspective partially cut-away of the block of Fig 2 fastened to the *:*::* 25 panel; * .** * * Fig. 4 is a view of a rivet used to fasten the blocks to the panels;
S * * *
* *, Fig. 5 is a cross sectional view of the drilled block of Fig 2; ** ** * * S * * * *.S.** * S Fig. 6 is a perspective view showing a plurality of the drilled blocks with the panel omitted; Figs. 7(a) to 7(c) illustrate the mounting of the blocks to the panel; Figs. 8 and 9 are perspective views illustrating the mounting of the blocks to panels; Fig. 10 is a cross-sectional view of a composite panel with no blocks in place; and Figs. 11 to 14 are various views of a prior art tongue and mortise block used in the composite panel of the invention.
Detailed Description
Referring to the drawings there is illustrated a composite cladding panel I according to the invention. The panel I comprises a steel skin or backing tray 2 and an external steel skin 3 with a layer of foam insulation material 4 such as a phenolic or polyurethane based foam material therebetween. The panel may be of any suitable type such as that described in our UK2325678A, the entire contents of which are hereby incorporated by reference.
One of the skins, in this case the external skin 3 has a plurality of tongue and mortise * blocks 5 such as those available from Novabrick fastened to the panel 1 by fasteners * *** * 12. Each fastener 12 in this case is a clamping fastener and comprises a peel rivet *:*. having a mandrel, a stress plate, and a main body. We have found that such a clamping fastener is particularly efficient in fastening such blocks to the panel. ** ** * * * * * * * *
Pilot holes 13 are first drilled through the blocks 5 and the rivet 12 is inserted. On operation of a rivet gun the main body curls up as illustrated by reference 22 and is clamped against the inside surface of the external skin 3 as will be particularly apparent from Fig. 3. In this way the blocks 5 are fixed to the panels. The blocks 5 are thereby efficiently and effectively clamped to the external skin 3.
To enhance the peel strength of the composite panel a layer 30 of an adhesive is applied to the internal face of the external skin 3. The adhesive layer 30 is a pre-lay-down adhesive which is compatible with the material of the insulting core 4. We have found that the use of such an adhesive greatly enhances the peel strength of the panel and enables the panel to carry the additional load of the cladding tiles.
In manufacture, an external skin 3 is drawn from a reel and laid down in a lay-down bed with the internal face uppermost. The adhesive 30 is then uniformly applied over the internal face of the skin 3 prior to lay-down of liquid foam reactants. The inner skin 2 is then led from a reel and located above the liquid foam reactants.
The assembly is the passed through an oven in which the liquid foam reactants expand to form the insulating core 4. A desired length of panel is then cut. The blocks 5 are laid out across the external face of the skin 3 and the locations for fastening the receiving holes to be drilled in the panel are marked. The blocks 5 are then fitted as illustrated. The system is a mortarless cladding system.
The invention provides a composite panel of relatively simple but highly robust * ** 25 construction which facilitates easy on site cladding with tongue and mortise blocks.
The system creates a strong, water resistant brick finish with insulation built-in. The system combines proven composite insulated panel technology with an aesthetic and *:*. high performance mortarless brick cladding. * *.* ** ** * * * * * *
****** * S The system of the invention allows a weather proofed building to be fitted out much quicker than traditional blockwork. This is because the panels can be put up quickly and the building is then ready to fit out. The bricks can be applied to the outside of the panel at any stage. The panels of the invention do not need to cover the whole of the building. For example, they can be used at suitable locations such as for a height of one or two metres from the ground up much like a dado-wall. Such an arrangement is particularly suitable for retail parks, supermarkets and the like as the brick clad panel is more resistant to impact damage (for example from shopping trolleys) than an unclad panel.
The invention is not limited to the embodiments hereinbefore described which may be varied in detail.
*.. 25 * * * * ** * *** * ** * * * * * ** *
S * * .* 0 S * S
S
0.5*55 * .

Claims (15)

1. A composite cladding panel comprising an internal skin and an external skin with insulation material therebetween, one of the skins having a plurality of tongue and mortise blocks mounted directly to the panel by a mounting means to form a cladding.
2. A panel as claimed in claim I wherein the blocks have mounting holes and the mounting means comprises a fastener for insertion through the hole to fasten the block to the panel.
3. A panel as claimed in claim 2 wherein the fastener comprises a clamping fastener.
4. A panel as claimed in claim 3 wherein the clamping fastener comprises a peel rivet that clamps to the inside of the external skin.
5. A panel as claimed in any preceding claim wherein the external skin of the panel has an adhesive on the inner face thereof.
6. A panel as claimed in claim 5 wherein the adhesive is applied to the inner face of the external skin prior to lay-down of liquid insulating foam reactants.
7. A panel substantially as hereinbefore described with reference to the * * 25 accompanying drawings. * * S * ** * **S * *
8. A method for manufacturing a composite cladding panel comprising the steps of: -
S *** * ** .5 * * . * * *
*..*** * 5 manufacturing a composite insulating panel comprising an internal skin, an external skin with insulation material therebetween; providing a plurality of tongue and mortise blocks with mounting holes through the blocks; providing a plurality of fasteners; placing the blocks along at least portion of the external face of a skin; and fastening the blocks to the skin by inserting the fasteners through the holes in the blocks.
9. A method as claimed in claim 8 wherein the fastener comprises a clamping fastener for clamping to the inside of the external skin.
10. A method as claimed in claim 9 wherein the clamping fastener comprises a peel rivet.
11. A method as claimed in claim 10 comprising the step of fixing the blocks to the panel using the rivets.
12. A method as claimed in any of claims 8 to 11 comprising the steps of laying * * 25 the external skin down with the outer side lowermost, applying an adhesive to * the inner face of the external skin, applying liquid foam reactants over the adhesive, applying an internal skin over the liquid form reactants and heating *:*. the sandwich thus formed in an oven to form the composite insulating panel. * S.. S. * . S * .
*..*** * .
13. A method as claimed in any of claims 8 to 12 comprising boring holes through the blocks to provide the mounting holes.
14. A method for manufacturing a composite cladding panel substantially as hereinbefore described with reference to the accompanying drawings.
15. Composite cladding panels when manufactured by a method as claimed in any of claims 8 to 14. * .* * * . * ** *.* * * "Is II * * * * * I. I* * *, I. * S * *
S
*5*55I * *
GB0802567A 2007-02-12 2008-02-12 A composite panel Expired - Fee Related GB2446521B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
IE20070086 2007-02-12

Publications (3)

Publication Number Publication Date
GB0802567D0 GB0802567D0 (en) 2008-03-19
GB2446521A true GB2446521A (en) 2008-08-13
GB2446521B GB2446521B (en) 2011-11-16

Family

ID=39247507

Family Applications (1)

Application Number Title Priority Date Filing Date
GB0802567A Expired - Fee Related GB2446521B (en) 2007-02-12 2008-02-12 A composite panel

Country Status (6)

Country Link
US (1) US20100031592A1 (en)
EP (1) EP2126245A1 (en)
CA (1) CA2679630A1 (en)
GB (1) GB2446521B (en)
NZ (1) NZ578903A (en)
WO (1) WO2008099372A1 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011154929A3 (en) * 2010-06-08 2013-01-03 Kingspan Holdings (Irl) Limited A structural infill wall panel module
WO2015059009A1 (en) * 2013-10-21 2015-04-30 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Facade element and method for mounting same

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100095952A1 (en) * 2008-10-16 2010-04-22 Fmi Products, Llc Masonry structure
ES2657612T3 (en) 2010-05-28 2018-03-06 The Diller Corporation Laminate coating system for construction

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US4736560A (en) * 1986-12-01 1988-04-12 Engineered Construction Components (America) Peel rivet
GB2214204A (en) * 1988-01-11 1989-08-31 Hunter Douglas Ind Bv Sandwich wall panels with tongue and groove connection
GB2262753A (en) * 1991-12-24 1993-06-30 Hunter Douglas Ind Bv Curtain wall cladding system using metal-faced panels
US5678369A (en) * 1992-12-28 1997-10-21 Ig-Technical Research Inc. Refractory/heat insulating panels
US6108995A (en) * 1995-06-02 2000-08-29 Produits Alba, Inc. Block for the mortarless construction of a wall
WO2006072174A1 (en) * 2005-01-05 2006-07-13 Novabrik International Inc. A starter element for stackable inter-engaging bricks.

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US5031378A (en) * 1986-12-01 1991-07-16 Engineered Construction Components (America) Inc. Method of inserting a rivet into a roof structure
DE3837217A1 (en) * 1987-12-09 1989-06-22 Asta Ullrich Gmbh Annweiler Am Multilayered, prefabricated structural panel
DE4320190C2 (en) 1993-06-18 1996-07-11 Heinemann Herbert Building wall cladding
SE503917C2 (en) * 1995-01-30 1996-09-30 Golvabia Ab Device for joining by means of groove and chip of adjacent pieces of flooring material and a flooring material composed of a number of smaller pieces
ATE253153T1 (en) 1997-05-21 2003-11-15 Kingspan Res & Dev Ltd THERMALLY INSULATED PANEL
EP0990079A4 (en) * 1997-06-26 2002-07-10 Milton J Altenberg Metal sandwich panels
DE19804890A1 (en) * 1998-02-07 1999-09-02 Sonnleitner Holzwerk Gmbh Building wall for wooden houses
US6332733B1 (en) * 1999-12-23 2001-12-25 Hamberger Industriewerke Gmbh Joint
GB0006335D0 (en) 2000-03-17 2000-05-03 Thermaliner Insulation Sys Ltd Panel
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4736560A (en) * 1986-12-01 1988-04-12 Engineered Construction Components (America) Peel rivet
GB2214204A (en) * 1988-01-11 1989-08-31 Hunter Douglas Ind Bv Sandwich wall panels with tongue and groove connection
GB2262753A (en) * 1991-12-24 1993-06-30 Hunter Douglas Ind Bv Curtain wall cladding system using metal-faced panels
US5678369A (en) * 1992-12-28 1997-10-21 Ig-Technical Research Inc. Refractory/heat insulating panels
US6108995A (en) * 1995-06-02 2000-08-29 Produits Alba, Inc. Block for the mortarless construction of a wall
WO2006072174A1 (en) * 2005-01-05 2006-07-13 Novabrik International Inc. A starter element for stackable inter-engaging bricks.

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011154929A3 (en) * 2010-06-08 2013-01-03 Kingspan Holdings (Irl) Limited A structural infill wall panel module
US8769898B2 (en) 2010-06-08 2014-07-08 Kingspan Research And Developments Limited Structural infill wall panel module
WO2015059009A1 (en) * 2013-10-21 2015-04-30 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Facade element and method for mounting same

Also Published As

Publication number Publication date
US20100031592A1 (en) 2010-02-11
EP2126245A1 (en) 2009-12-02
GB2446521B (en) 2011-11-16
GB0802567D0 (en) 2008-03-19
IE20080100A1 (en) 2008-10-01
WO2008099372A1 (en) 2008-08-21
AU2008215835A1 (en) 2008-08-21
NZ578903A (en) 2012-03-30
CA2679630A1 (en) 2008-08-21

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PCNP Patent ceased through non-payment of renewal fee

Effective date: 20160212