GB2540793A - Building panel and method of manufacture - Google Patents

Building panel and method of manufacture Download PDF

Info

Publication number
GB2540793A
GB2540793A GB1513268.1A GB201513268A GB2540793A GB 2540793 A GB2540793 A GB 2540793A GB 201513268 A GB201513268 A GB 201513268A GB 2540793 A GB2540793 A GB 2540793A
Authority
GB
United Kingdom
Prior art keywords
sheet
board
sheets
grooves
panel
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
GB1513268.1A
Other versions
GB2540793B (en
GB201513268D0 (en
Inventor
Anthony Clark Dennis
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.)
THERMOTEC ROOFING SYSTEMS Ltd
Original Assignee
THERMOTEC ROOFING SYSTEMS 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 THERMOTEC ROOFING SYSTEMS Ltd filed Critical THERMOTEC ROOFING SYSTEMS Ltd
Priority to GB1513268.1A priority Critical patent/GB2540793B/en
Publication of GB201513268D0 publication Critical patent/GB201513268D0/en
Publication of GB2540793A publication Critical patent/GB2540793A/en
Application granted granted Critical
Publication of GB2540793B publication Critical patent/GB2540793B/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/046—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/04—Punching, slitting or perforating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/10—Removing layers, or parts of layers, mechanically or chemically
    • B32B38/105—Removing layers, or parts of layers, mechanically or chemically on edges
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/7608—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising a prefabricated insulating layer, disposed between two other layers or panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/78—Heat insulating elements
    • E04B1/80—Heat insulating elements slab-shaped
    • 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
    • E04C2/02—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
    • E04C2/296—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 non-metallic or unspecified sheet-material
    • 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
    • E04C2/32—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 formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material
    • E04C2/328—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 formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material slightly bowed or folded panels not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/02—Bending or folding
    • B29C53/04—Bending or folding of plates or sheets
    • B29C53/06—Forming folding lines by pressing or scoring
    • B29C53/063—Forming folding lines by pressing or scoring combined with folding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/04—Punching, slitting or perforating
    • B32B2038/045—Slitting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0221—Vinyl resin
    • B32B2266/0228—Aromatic vinyl resin, e.g. styrenic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/022—Foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/546—Flexural strength; Flexion stiffness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1284—Application of adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/18—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
    • B32B37/182—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only one or more of the layers being plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/18—Handling of layers or the laminate
    • B32B38/1825—Handling of layers or the laminate characterised by the control or constructional features of devices for tensioning, stretching or registration
    • B32B38/1833—Positioning, e.g. registration or centering
    • B32B38/1841—Positioning, e.g. registration or centering during laying up
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/14—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements being composed of two or more materials

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Mechanical Engineering (AREA)
  • Panels For Use In Building Construction (AREA)

Abstract

A method of manufacturing a building panel comprising, forming a board 30 of insulative material, forming a first sheet 10 comprising a first set of groove lines 12 defining first fold lines in the first face and a second set of grooves 14 forming second fold lines in the first face, the second set of fold lines defining outwardly projecting flanges 18, applying adhesive to the first face of the first sheet 10, laying the first sheet over the board 30, repeating the previous steps for a second sheet 20, folding the first and second sheets around the board 30 and bonding projecting flanges 18 28 of the first and second sheets 10 20 together, pressing the two sheets towards each other around the board 30; and removing the projecting flanges 18. The first and second sheets 10 20 may be laid over the board 30 simultaneously. The insulative material may be an expanded foam material. The first and second sheets 10 20 may be a deformable material which may be metal, preferably aluminium or plastic preferably PVC. The grooves 12 14 may be routed in the respective sheets, the adhesive may be a contact adhesive, the bonding of the flanges may be by crimping. A plurality of opening and tongues may be formed in opposing sides of the panels and building panels to join sequential panels to one another. Also included is a claim to the panel produced by such a method.

Description

BUILDING PANEL AND METHOD OF MANUFACTURE Field of the Invention
The present invention relates to building panels, in particular their method of manufacture.
Background to the Invention
Insulated panels are well known in the construction industry. They can be made structural in order to take vertical loads, or can be provided in a relatively flexible form for insertion in wall, ceiling or roof cavities.
Examples of structural insulated panels (SIP’s) generally comprise a layer of insulation which is sandwiched between two layers of orientated strand wooden board (OSB). The panels are manufactured in any size to order. The wood is adhered to the insulation so that it doesn’t separate under vertical loading. The edges of the board are generally sealed using further pieces of wooden board. The edges may also be made with a projection in order that they may be overlapped against a neighbouring SIPs panel and movement inwards and outwards is prevented.
Other forms of insulated panel use plywood, plastic or composite in place of the OSB boarding. This has the advantage of being lighter, and because the composite or plastic is mouldable, then rapid machine construction is possible. In most cases the panels consist of two half shells of plastic surrounding a foam core. The plastic is adhered to the foam core. However there are a number of problems associated with these panels and the methods used to manufacture them.
The plastic or composite used in these sorts of panels requires moulding and because a relatively thin layer (1-3mm thick) is used compared to the OSB equivalent, they are not considered suitable for vertical structural loading. Also, in order to make the plastic fit around the foam, or incorporate a particular shape, it has to be moulded. The costs of making the moulds means that panels of only regular sizes can be manufactured and still make the process commercially viable. Furthermore, when pressure is applied to the two half shells in order to bind the adhesive on the inside between the plastic and the foam, it is common for the edges of the plastic or composite to separate from one another and from the foam around the edges of the foam.
There has now been devised a method of manufacturing building panels which overcomes and/or substantially mitigates the above referenced disadvantages associated with the prior art.
Summary of the Invention
In an aspect of the invention there is provided a method of manufacturing a building panel comprising the steps of: a) forming a board of insulative material, b) forming a first sheet, the first sheet comprising a first set of grooves scored in a first face, the first set of grooves defining fold lines in the first sheet, a second set of grooves scored in the first face, the second set of grooves defining outwardly projecting flanges of the first sheet, c) applying adhesive to the first face except the outwardly projecting flanges, d) laying the first sheet over the board, the first face being in contact with the board and positioned with the edges of the board corresponding with the first set of grooves in the first face, e) repeating steps b)-d) for a second sheet, f) folding the first and second sheets around the board and bonding the projecting flanges of the first and second sheets together, g) pressing the two sheets towards each other around the board; and h) removing the projecting flanges.
The method according to the invention is advantageous primarily in two ways. Firstly by introducing grooves into the sheets to define fold lines, means that the plastic does not have to be pre-moulded to the shape of the board and can be utilised flat. As long as the grooves fall in line with the edges of the board when the sheets are laid on to the board, the edges of the board will form a natural pivot point for the sheets to fold around. Thus the sheets form a tight fitting enclosure around the board without any pre moulding for shape. Secondly, the step of bonding the projecting flanges of the first and second sheets are together means that sheet material on the sides of panel does not separate from the board, when the two sheets are pressed together around the board.
The board according to the invention comprises two opposing faces and sides each having a surface area equal to or less than one of the faces. Thus the board may be cuboidal or have a square cross section, but generally will have a rectangular cross section. The faces may be square, rectangular, triangular or any quadrilateral shape.
In the method of the invention, the first sheet and the second sheet may be laid over the board simultaneously. This speeds up the manufacturing process.
Insulative according to the invention means acoustically insulative or thermally insulative. Therefore the insulative material may be any material which has these properties. Preferably, the insulative material is an expanded foam material. Examples of suitable materials include expanded foam polystyrene, Styrofoam, or Celotex®. Expanded foam materials, otherwise known as rigid foams, have high compressive strength and are able to support weight. As well as strength and durability, rigid foam insulation also provides additional properties such as fire resistance and acoustic insulation to minimise the level of sound travelling through the panel.
The grooves in the first sheet and the second sheet create natural fold lines for the sheets to bend round. The material of the sheets may be elastic in nature, and therefore resist bending. Even if this is the case when force is applied to the sheets to bend them around the edges of the board, the adhesive will then hold the sheets in place. It is recognised though, that by forming grooves on the sheets to create the fold lines, the elastic forces are reduced, and therefore the glue is less likely to fail. All this being said it is preferable that the first sheet and the second sheet are deformable. This has the benefit that when the sheets are bent around the edges of the board they remain substantially in place. It will be recognised that there may be some flexing of the sheets brought about by some elastic components, but in general the sheets will preferably hold their shape when bent.
The first sheet and/or the second sheet may be metal. This has the benefit that the panel can be manufactured to have structural qualities and resist forces applied to the faces or the sides, i.e forming a so called “structural panel”. Thus the panel may be classed as a structurally insulated panel (SIP), and can be used for structural bearing purposes rather than just for filling spaces.
When the first sheet or the second sheet is metal, preferably the metal is aluminium. This is because aluminium is easy to form into sheets, light, deformable, thin and strong, easy to score and does not rust.
The first sheet and/or the second sheet may a plastics material. Plastics materials provide the right deformability characteristics, are insulative in themselves, commercially viable and available, and lightweight. Other types of material may be used for the sheets, such as fibre board, composite, or cardboard.
Preferably the plastics material is PVC (polyvinylchloride). The PVC may be unplasticised. Other examples of suitable materials include nylon, rubber, polystyrene, polyethylene terephthalate, polyethylene, or polypropylene.
The grooves in the first sheet and the second sheet are preferably routed into the respective sheets. Both the first and second set of grooves define fold lines in the respective sheet, however necessarily the first set is inward from the second set which defines the projecting flanges of the first sheet. In this invention, inward from the first set means towards the centre of the face of the sheet. The first set of grooves defining fold lines in the first sheet are such that when overlaid the board correspond with the edges of the board. Thus the first set of grooves may be continuous around the face of the sheet. In order for the sheets to cover the sides of the board evenly when bent around the board, there may be necessarily gaps cut within the corners of the sheets so that when the sheets are bent over the edges the material at the corners contacts each other. Due to these gaps, the second set of grooves are therefore not continuous around the sheet, and extend only in the portions where the sheet would extend around the sides.
The first set of grooves and/or the second set of grooves may be in single lines scored into the respective sheets. Alternatively, the first set of grooves and/or the second set of grooves may be in multiple lines scored into the respective sheets. Preferably, the first set of grooves are scored as single lines and the second set of grooves are scored as double lines running parallel with one another. This provides greater flexibility to the second set of grooves than the first set, and means that the outwardly projecting flanges can be bent away from the first face more easily (ie projecting outwards from the panel).
The adhesive may be any adhesive suitable for bonding metal or plastics to insulative board. Preferably the adhesive is a contact adhesive. The adhesive may be sprayable. Examples of suitable adhesive are epoxy based and poly-chloroprene based. This provides the correct flowability. Furthermore, the time to cure can be altered so that it can either work instantaneously or with a delayed curing to allow for positional rearrangement of the sheets.
The outwardly projecting flanges project outwards from the side of the panel. The outwardly projecting flanges of the first sheet and the second sheet may be bonded together by riveting, welding, or clamping. Preferably the outwardly projecting flanges of the first sheet and the second sheet are bonded together by crimping. Non limiting examples of suitable welding include spot type welding, heat welding, or ultrasonic welding.
Preferably the second set of grooves define frangible portions for removal of the projecting flanges. In use, by twisting the flanges with respect to the panel, they will separate at the frangible portion from the remainder of the panel. This action of breaking off the flanges, leaves a clean side to the board. The parts of the sheet at the side of the panel still adhere to the board because by now the pressing step has caused good bonding of the adhesive applied to the inside of the sheets to the board. Once the flanges are removed there is no further manufacturing pressure applied, and so the sides of the panel remain clean and attached.
Preferably, the step of pressing the two sheets toward each other around the board is performed in a membrane press. This provides even pressure around the whole surface area of the panel. As the flanges are bonded together the sides of the panel do not bulge outwards during this process. A normal lateral press (ie applying force just to the faces of the panel). This has a similar effect to a membrane press but no force is applied to the sides.
The method according to the invention may further comprise the step of forming a plurality of openings in at least one side of a first panel and a plurality of tongues mutually engageable with the openings in at least one side of a second panel. The tongues and openings are designed so that neighbouring panels may be coupled together. Thus, there may be a plurality of building panels coupled by engaging the tongues of the second panel with the openings of the first panel. It will be appreciated that a plurality of panels could be coupled in the same manner and as part of the present invention if the first panel just had openings and a second and third panel on either side, just had tongues. And this pattern was repeated along the wall. This feature of the invention is advantageous because it allows the user to form a wall structure, rather than an infill structure for a ceiling or the like. The wall can be made to any dimensions, as panels can be added on laterally and longitudinally.
The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
Brief Description of the Drawings
Figure 1 is a three dimensional exploded view of a panel manufactured according to an embodiment of the method of the invention.
Figure 2 is a cross sectional view of a panel manufactured according to an embodiment of the method of the invention, prior to removal of the outwardly projecting flanges.
Figure 3 is a cross sectional view of a panel manufactured according to an embodiment of the method of the invention, after removal of the outwardly projecting flanges.
Figure 4 is a three dimensional view of one panel with tongues and one with mutually engageable openings.
Detailed Description of the Illustrated Embodiment
An example of the method of manufacturing a building panel according to the invention is provided below. a) forming a board of insulative material,
In this step the board 30 is formed as shown in Figure 1. The board 30 is a styrofoam board, having a rectangular cross section. The board has opposing faces 32a, 32b, edges 34 (12 number in total), and sides 36 (4 number in total). The board 30 is manufactured using conventional techniques for forming Styrofoam. The foam board used in the present example is Styrofoam block foam LBH-X, manufactured by Dow chemicals, Ltd.. b) forming a first sheet, the first sheet comprising a first set of grooves in a first face, the first set of grooves defining fold lines in the first sheet, a second set of grooves in the first face, the second set of grooves defining outwardly projecting flanges of the first sheet,
In this step the first sheet 10 (see figure 1) is a generally planar sheet of PVCu approximately 1.5 mm thick. The sheet 10 is scored on its under surface (the face of the sheet facing the board) using a router to create a first set of grooves 12 and a second set of grooves 14. The first set of grooves 12 are positioned so that they align with the edges 34 of the board 30. The first set of grooves are the innermost set from the edges of the sheet. The face of the first sheet 10 is of greater surface area than the surface area of one face of the board. In this way the first sheet over hands the edges of the board. The overhanging portions 16 extend half the width of each side. In order that the overhanging portions 16 can extend completely and neatly around the side of the board there are gaps 17 cut into the sheet 10. In the example shown these are right angle gaps, so that when the overhanging portions 16 are folded around the edges 34, they meet up. At the outward edge of each overhanging portion 16 is an outwardly projecting flange 18, which is defined by the second set of grooves 14. In the example shown the flange 18 is bent at right angles to the overhanging portion, so that when the overhanging portion is in contact with the sides of the board, it projects out parallel with the face of the sheet and/or the board. c) applying adhesive to the first face except the outwardly projecting flanges,
In this step, a moisture cure contact adhesive is sprayed onto the first face (inside face) of the first sheet 10. All areas of the face of the first sheet 10 are covered except the flanges 18. The adhesive used is a high grade polychlo-roprene based sprayable adhesive which combines excellent resistance to creep at high temperatures with good flexibility at very low temperatures. d) laying the first sheet over the board, the first face being in contact with the board and positioned with the edges of the board corresponding with the first set of grooves in the first face,
In this step the first sheet 10 is laid over the board 30, adhesive side down (ie in contact with the board). The position of the sheet 10 is such that the edges of the board 34 mate with the first set of grooves e) repeating steps b)-d) for a second sheet,
In this step the steps b)-d) above are repeated for a second sheet 20 (see figure 1). The second sheet is substantially the same as described above for the first sheet. The second sheet 20 thus has a first set of grooves 22, a second set of grooves 24, overhanging portions 26, outwardly projecting flanges 28 and gaps 27. The grooves are applied as above using a router. Adhesive is also applied as described above. The sheet 20 is laid on the board 30 on the remaining half of the board not covered by the first sheet 10. As the dimensions of the second sheet are the same as the first sheet, the laying over of the two sheets results in the whole surface area of the board being covered. f) folding the first and second sheets around the board and bonding the projecting flanges of the first and second sheets together,
In this step, the two sheets 10, 20 are bent around the edges 34of the board. The first set of grooves 12, 22 in each sheet form natural pivot/fold lines. As the overhanging portions 16, 26come down onto the board 30 the gaps 17 close and because the dimensions of the second sheet are the same as the first sheet, the laying over of the two sheets results in the whole surface area of the board being covered. The adhesive on the inside of the two sheets begins to adhere the sheets to the board. The projecting flanges 18, 28 align parallel and overlapping with each other and are spot crimped together at intervals around the perimeter of the panel. The area of the crimp is indicated as 40 in figure 2 in both sides of the cross section. g) pressing the two sheets towards each other around the board;
In this step the whole panel is placed in a membrane press and a vacuum pressure applied across the whole surface area of the board. Because the flanges are bonded together, the overhanging portions of the sheets do no disassociate from the sides of the board. After the pressing process the panel has a cross section as shown in figure 2. h) removing the projecting flanges.
This is the final step in the method and involves twisting the projecting flanges back and forth until they break away from panel. The second set of grooves provide frangible fold lines in order to facilitate this process. After the flanges have been removed the panel is ready for use, and has a cross section as shown in figure 3.
In a further example of the method of the invention, the second sheet 20 is an aluminium sheet and the first sheet 10 a PVC sheet. A plurality of panels are coupled together to form a wall. The coupling is achieved by adding openings 60 into one side of each panel, and tongues 62 in the other opposing side of each panel. The tongues 62 and openings 60 are staggered slightly as in figure 4. The tongues 62 are designed to engage with the openings 60 in a sliding action. When engaged, further lateral and longitudinal movement is prevented. A wall is created by coupling consecutive panels together. The wall can be made to any dimensions by adding on panels laterally and/or longitudinally.
In a further example of the method of the invention, the second sheet is an aluminium sheet and the first sheet a PVC sheet, and a plurality of panels are coupled together to form a wall as substantially described above. The coupling is achieved by adding openings (as described above) into both sides of one set of panels, and tongues (as described above) into both sides of a second set of panels. The tongues are designed to engage with the openings in a sliding action. When engaged, further lateral and longitudinal movement is prevented. A wall is created by coupling panels from the first set with panels from the second set and so on.

Claims (17)

1. A method of manufacturing a building panel comprising the steps of: a) forming a board of insulative material, b) forming a first sheet, the first sheet comprising a first set of grooves scored in a first face, the first set of grooves defining fold lines in the first sheet, a second set of grooves scored in the first face, the second set of grooves defining outwardly projecting flanges of the first sheet, c) applying adhesive to the first face except the outwardly projecting flanges, d) laying the first sheet over the board, the first face being in contact with the board and positioned with the edges of the board corresponding with the first set of grooves in the first face, e) repeating steps b)-d) for a second sheet, f) folding the first and second sheets around the board and bonding the projecting flanges of the first and second sheets together, g) pressing the two sheets towards each other around the board; and h) removing the projecting flanges.
2. A method according to claim 1, wherein the first sheet and the second sheet are laid over the board simultaneously.
3. A method according to claim 1 or claim 2, wherein the insulative material is an expanded foam material.
4. A method according to any preceding, wherein the first sheet and the second sheet are deformable.
5. A method according to any preceding claim, wherein the first sheet and/or the second sheet is metal.
6. A method according to claim 5, wherein the metal is aluminium.
7. A method according to any preceding claim, wherein the first sheet and/or the second sheet is a plastics material.
8. A method according to claim 7, wherein the plastics material is PVC.
9. A method according to any preceding claim, wherein the grooves in the first sheet and the second sheet are routed into the respective sheets.
10. A method according to any preceding claim, wherein the adhesive is a contact adhesive.
11. A method according to any preceding claim, wherein the bonding of the projecting flanges is by crimping.
12. A method according to any preceding claim, wherein the second set of grooves define frangible portions for removal of the projecting flanges.
13. A method according to any preceding claim, wherein the step of pressing the two sheets toward each other around the board is performed in a membrane press.
14. A method according to any preceding claim, further comprising the step of forming a plurality of openings in at least one side of a first panel and a plurality of tongues mutually engageable with the openings in at least one side of a second panel.
15. A method according to claim 14, wherein a plurality of building panels are coupled by engaging the tongues of the second panel with the openings of the first panel.
16. A building panel manufactured according to the method according to any preceding claim.
17. A building panel substantially as described, with reference to and/or as shown in figures 1 -4.
GB1513268.1A 2015-07-28 2015-07-28 Building panel and method of manufacture Expired - Fee Related GB2540793B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB1513268.1A GB2540793B (en) 2015-07-28 2015-07-28 Building panel and method of manufacture

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB1513268.1A GB2540793B (en) 2015-07-28 2015-07-28 Building panel and method of manufacture

Publications (3)

Publication Number Publication Date
GB201513268D0 GB201513268D0 (en) 2015-09-09
GB2540793A true GB2540793A (en) 2017-02-01
GB2540793B GB2540793B (en) 2017-09-06

Family

ID=54106723

Family Applications (1)

Application Number Title Priority Date Filing Date
GB1513268.1A Expired - Fee Related GB2540793B (en) 2015-07-28 2015-07-28 Building panel and method of manufacture

Country Status (1)

Country Link
GB (1) GB2540793B (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20180124486A1 (en) * 2016-10-28 2018-05-03 Mitek Corp., Inc. Covered plastic acoustic enclosure
US10477292B2 (en) * 2016-10-28 2019-11-12 Mitek Corp., Inc. Plastic acoustic enclosure
EP3725493A1 (en) * 2019-04-17 2020-10-21 Unionprofili S.r.l. Method for forming a composite element preferably for furniture or building, and composite element so obtainable

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1358345A (en) * 1971-04-01 1974-07-03 Johns Manville Insulating material and methods of manufacture
DE3347619A1 (en) * 1983-01-24 1984-07-26 Grünzweig + Hartmann und Glasfaser AG, 6700 Ludwigshafen Thermal insulating board with a covering and a particulate, highly disperse thermal insulating material compressed in the covering, as well as process for the production thereof and device for carrying out the process
JP2001234598A (en) * 2000-02-22 2001-08-31 Tokuyama Corp Heat insulation member for building, method for installing construction board, and wall structure
AU2012201247A1 (en) * 2012-03-01 2013-09-19 Joolca Pty Ltd High Temperature Reflective Insulation Sheeting
WO2015087150A1 (en) * 2013-12-09 2015-06-18 Franco Paulon Process for manufacturing a honeycomb structured panel and product obtained therefrom

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1358345A (en) * 1971-04-01 1974-07-03 Johns Manville Insulating material and methods of manufacture
DE3347619A1 (en) * 1983-01-24 1984-07-26 Grünzweig + Hartmann und Glasfaser AG, 6700 Ludwigshafen Thermal insulating board with a covering and a particulate, highly disperse thermal insulating material compressed in the covering, as well as process for the production thereof and device for carrying out the process
JP2001234598A (en) * 2000-02-22 2001-08-31 Tokuyama Corp Heat insulation member for building, method for installing construction board, and wall structure
AU2012201247A1 (en) * 2012-03-01 2013-09-19 Joolca Pty Ltd High Temperature Reflective Insulation Sheeting
WO2015087150A1 (en) * 2013-12-09 2015-06-18 Franco Paulon Process for manufacturing a honeycomb structured panel and product obtained therefrom

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20180124486A1 (en) * 2016-10-28 2018-05-03 Mitek Corp., Inc. Covered plastic acoustic enclosure
US10477292B2 (en) * 2016-10-28 2019-11-12 Mitek Corp., Inc. Plastic acoustic enclosure
EP3725493A1 (en) * 2019-04-17 2020-10-21 Unionprofili S.r.l. Method for forming a composite element preferably for furniture or building, and composite element so obtainable

Also Published As

Publication number Publication date
GB2540793B (en) 2017-09-06
GB201513268D0 (en) 2015-09-09

Similar Documents

Publication Publication Date Title
US10525685B2 (en) Methods and apparatus to couple a decorative composite having a reinforcing layer to a panel
KR20140136866A (en) Folded core panel
US10202799B2 (en) Double backbone core for automated door assembly line, door comprising same and method of using same
WO2009121016A3 (en) Engineered molded fiberboard panels, methods of making the panels, and products fabricated from the panels
US20070169432A1 (en) Panel structure
GB2540793A (en) Building panel and method of manufacture
US20150121799A1 (en) Rigid insulating panel and rigid insulation panel assembly
CN102257222A (en) Nail-plated composite structural system
US8597768B2 (en) Laminated foams with mating peaks and grooves
CN112140640A (en) Honeycomb bionic core plate with folded groove openings and manufacturing method thereof
US20110036042A1 (en) Bamboo open web joist
JP2016166500A (en) Sealant and foundation structure
CA2956657A1 (en) Structural insulated sheathing
EP2750883B1 (en) Composite panel combination, method of producing the same and use of it
JP5130064B2 (en) Manufacturing method of building panel material
WO2008137339A1 (en) Joint for connecting wood members
US20220314559A1 (en) Rv and trailer composite panel manufacturing process with interlocking connections assembly system
US20170321359A1 (en) A method of producing a sandwich panel core of mineral wool fibres
CN108527945A (en) A kind of flexible honeycomb and manufacturing method of heart cell
CA3051181C (en) Building material, stacked body of building materials, and building-material construction method
JP5130108B2 (en) Manufacturing method of building panel material
EP2457480A1 (en) Multilayer structure and method to produce a multilayer structure
CN219276111U (en) Arc plate structure and arc composite board
JP4958198B2 (en) Veneer
JP4872039B2 (en) Veneer

Legal Events

Date Code Title Description
PCNP Patent ceased through non-payment of renewal fee

Effective date: 20200728