IE20050417U1 - A method and apparatus for forming a laminated heat insulating panel - Google Patents

Abstract

applies the adhesive, which is a two- part adhesive, to a downwardly facing under surface

Description

“A method and apparatus for forming a laminated heat insulating panel" The present invention relates to a method and apparatus for forming a laminated heat insulating panel comprising an inner sheet of heat insulating material sandwiched between and bonded to first and second outer sheets of sheet metal material, and the invention also relates to the use of the apparatus in the production of laminated heat insulating panels, and the invention also relates to a heat insulating panel produced by the method, and to a heat insulating panel produced by the apparatus.

Such laminated heat insulating panels are well known, and are commonly used in the construction of cold rooms of the type used to store food at chilled and deep frozen temperatures. The panels are suitable for use in the construction of internal cold rooms and external cold rooms. internal cold rooms are cold stores which are located within a building and are formed by partitioning off part of the building using the laminated heat insulating panels. External cold rooms are located externally of a building, and in such cases the laminated heat insulating panels are suitable for use in all weather conditions. Such heat insulating panels are also used for roofing of both internal and external cold rooms. Additionally, such heat insulating panels are used as metal decking for external roofing of buildings, typically, industrial buildings, as well as external cladding of such buildings.

In general, such laminated heat insulating panels are formed by drawing two sheets of sheet metal material from corresponding rolls which form the outer sheets of the panel. The sheets are drawn from the respective rolls so that one sheet extends above the other sheet and is spaced apart therefrom. Sheets of heat insulating material, typically, expanded polystyrene or expanded polyurethane materials are urged between the upper and lower sheet metal sheets to form the inner sheet. An adhesive, typically, a two-part self-curing adhesive is ideally applied to the respective major surfaces of the upper and lower sheets which are to abut the inner sheet. The upper and lower sheets with the adhesive applied thereto are then urged into engagement with the inner sheet. With the inner sheet sandwiched between the upper and lower sheets, the sheets are passed through a press for pressing the sheets together until the adhesive has cured, so that the upper and lower sheets are securely bonded to the inner sheet of heat insulating material.

Continuous process apparatus for producing such panels typically comprise a plurality of stations through which the sheet metal sheets and the inner insulating sheet are drawn in order to form a continuous composite laminated sheet which comprises the inner sheet of the heat insulating material laminated between and secured to the outer sheet metal sheets. The laminated heat insulating panels are then sequentially parted off from the continuous composite laminated sheet.

Such continuous process apparatus suffer from a number of disadvantages. Firstly, in general, the two-part adhesive used for bonding the outer metal sheets to the inner insulating sheet is a liquid two-part adhesive, and the two parts of the adhesive are dispensed downwardly. This thus, in general, requires that the adhesive for bonding the upper sheet to the inner sheet is dispensed onto an upwardly facing top surface of the inner sheet of heat insulating material. Applying the two-part adhesive directly to the inner insulating sheet is unsatisfactory, since the inner insulating sheet has a capacity to absorb a substantial amount of the two liquid parts of the adhesive before the top surface of the inner insulating sheet can be brought into engagement with the upper metal sheet, and thus, much of the adhesive is lost by absorption into the inner insulating sheet. This is unsatisfactory, since in many cases there is insufficient adhesive remaining on the top surface of the inner insulating sheet for bonding the top surface of the inner insulating sheet to the upper metal sheet by the time the upper metal sheet is brought into engagement with the inner insulating sheet One method for overcoming this problem is to initially draw the upper metal sheet from the corresponding roll with the surface which is to be bonded to the top surface of the inner insulating sheet facing upwardly, and then draw the upper metal sheet around an idler roller for orienting the sheet through 180° so that the initially upwardly facing surface of the upper metal sheet after passing around the idler roller IE 050417 through 180° is facing downwardly. The adhesive is applied to the initially upwardly facing surface of the upper metal sheet prior to the sheet being drawn around the idler roller. in this way the adhesive can be dispensed downwardly onto an upwardly facing surface of the upper metal sheet, which after being drawn around the idler roller becomes a downwardly facing surface which is then bonded to the inner insulating sheet. However, a disadvantage of this method is that since the adhesive is a two—part self-curing adhesive, curing commences immediately the two parts of the adhesive are dispensed onto the upper metal sheet, and in many cases, by the time the adhesive coated surface of the upper metal sheet is brought into engagement with the top surface of the inner insulating sheet, the adhesive is either cured or partially cured to the extent that the bond strength between the upper metal sheet and the inner insulating sheet is insufficient.

There is therefore a need for a method and apparatus for forming a laminated heat insulating panel which comprises an inner sheet ofheat insulating material sandwiched between and bonded to first and second outer sheets of sheet metal material which addresses this problem.

The present invention is directed towards providing such a method and apparatus, and the invention is also directed towards providing a laminated heat insulating panel According to the invention there is provided a method for forming a laminated heat insulating panel comprising an inner sheet of heat insulating material sandwiched between and bonded to first and second outer sheets of sheet metal material, the method comprising the steps of drawing two sheets from respective rolls of sheet metal material for forming the first and second outer sheets of the panel, the sheets being drawn so that a first one of the sheets passes above and is spaced apart from a second one of the sheets with the first sheet having a downwardly facing under major surface facing an upwardly facing top major surface of the second sheet, and the linear speeds of the first and second sheets are similar, applying an adhesive to the downwardly facing under surface of the first sheet, and applying an adhesive to IE 050417 the upwardly facing top surface of the second sheet, sequentially urging sheets of heat insulating material between the first and second sheets to form the inner sheet between the first and second sheets, urging the first and second sheets into engagement with the inner sheet with the under surface of the first sheet and the top surface of the second sheet with the respective adhesives thereon abutting the inner sheet on respective opposite sides thereof, and subjecting the sheets to a pressing action for pressing the sheets together for laminating and bonding the first and second sheets to the inner sheet to form a composite laminated sheet from which the laminated heat insulating panel is formed.

In one embodiment of the invention the adhesive applied to each of the first and second sheets is a two—part adhesive having co—operating first and second liquid parts for facilitating curing thereof, the first and second liquid parts being applied adjacent but spaced apart from each other to the respective first and second sheets for facilitating blending of the first and second parts for curing thereof during the pressing of the sheets together.

Preferably, the first and second parts of the adhesives are applied to the first and second sheets in elongated lines extending along the first and second sheets in the general direction of movement of the sheets. Advantageously, a plurality of pairs of adjacent lines of the first and second parts of the adhesives are applied to the first and second sheets, the pairs of the adjacent lines of the first and second parts of the adhesives being spaced apart from each other on each first and second sheet. in one embodiment of the invention the first and second parts of the adhesive are applied to the downwardly facing under surface of the first sheet through respective first and second tubular members, the first and second tubular members terminating in respective first and second dispensing nozzles adapted for wiping along the downwardly facing under surface of the first sheet for applying the corresponding parts of the adhesive thereto.

Preferably, each first and second tubular member is of resilient material, and the tubular members are arranged for resiliently urging the corresponding dispensing nozzles into engagement with the downwardly facing under surface of the first sheet for wiping the dispensing nozzles along the first sheet as the first sheet is moving past the dispensing nozzles. in one embodiment of the invention each first and second tubular member is arranged to extend towards the under surface of the first sheet to define an angle with the first sheet of less than 90°, and preferably, each first and second tubular member defines an angle with the first sheet of less than 60°, and advantageously, each first and second tubular member defines an angle with the first sheet of less than 30°, and ideally, each first and second tubular member defines an angle with the first sheet of approximately 20°. in one embodiment of the invention each first and second tubular member extends towards the under surface of the first sheet in the general direction of movement of the first sheet. in another embodiment of the invention the first and second tubular members extend in a generally upwardly direction towards the downwardly facing under surface of the first sheet.

In one embodiment of the invention the first sheet is inclined downwardly in the direction of movement thereof at an angle to the horizontal of less than 60° adjacent the dispensing nozzles of the first and second tubular members, and preferably, the first sheet is inclined downwardly in the direction of movement thereof adjacent the dispensing nozzles at an angle to the horizontal of less than 30°, and advantageously, the first sheet is inclined downwardly in the direction of movement thereof adjacent the dispensing nozzles at an angle to the horizontal of approximately 20°.

Preferably, the respective first and second parts of the adhesives on the first and second sheets are blended by respective blending means. Advantageously, each IE 050417 blending means comprises a reciprocating blending blade extending transversely of the corresponding one of the first and second sheets, and is reciprocated in a direction transversely of the corresponding one of the first and second sheets for co- operating with the corresponding first and second parts of the adhesive on the corresponding one of the first and second sheets for blending thereof.

In one embodiment of the invention at least one longitudinally extending side edge of each of the first and second sheets is shaped for forming corresponding engagement edges for engaging respective first and second outer sheets of an adjacent laminated heat insulating panel. Preferably, both longitudinally extending side edges of each of the first and second sheets are shaped for forming respective engagement edges. Advantageously, one of the longitudinally extending side edges of each of the first and second sheets is shaped to form a male engagement edge for engaging a female engagement edge of a corresponding one of first and second sheets of an adjacent laminated heat insulating panel, and the other of each longitudinally extending side edge of each of the first and second sheets is shaped to form a female engagement edge for engaging a male engagement edge of a corresponding one of first and second sheets of an adjacent laminated heat insulating panel.

In one embodiment of the invention each longitudinally extending side edge of the first and second sheets which is to be shaped to form an engagement edge is shaped prior to subjecting the first and second sheets and the inner sheet to pressing for forming the composite laminated sheet.

Preferably, the laminated heat insulating panel is parted off from the composite laminated sheet.

In one embodiment of the invention the laminated heat insulating panel is parted off from the composite laminated sheet by initially cutting the first and second sheets transversely relative to the direction of movement thereof to form first and second outer sheets of the laminated heat insulating panel, and subsequently cutting IE 050417 through the inner sheet. Preferably, the first and second sheets are transversely cut by drawing respective first and second cutting means across the first and second sheets transversely relative to the direction of movement thereof, and the first and second cutting means form respective gaps between the first and second sheets and the portions thereof to be parted off during cutting thereof for facilitating cutting of the inner sheet. Advantageously, the inner sheet is cut using a third cutting means.

In one embodiment of the invention the respective shaped edges of the first and second sheets are punched prior to transverse cutting of the first and second sheets by the first and second cutting means.

In another embodiment of the invention a plurality of laminated heat insulating panels are formed from the composite laminated sheet, the laminated heat insulating panels being sequentially parted off from the composite laminated sheet.

The invention also provides apparatus for forming a laminated heat insulating panel comprising an inner sheet of heat insulating material sandwiched between and bonded to first and second outer sheets of sheet metal material, the apparatus comprising a means for drawing two sheets from respective rolls of sheet metal material for forming the first and second outer sheets of the panel, the sheets being drawn so that a first one of the sheets passes above and is spaced apart from a second one of the sheets with the first sheet having a downwardly facing under major surface facing an upwardly facing top major surface of the second sheet, the means for drawing the sheets from the respective rolls of the sheet metal material drawing the first and second sheets at similar linear speeds, a first dispensing means for applying an adhesive to the downwardly facing under surface of the first sheet, and a second dispensing means for applying an adhesive to the top surface of the second sheet, a first urging means for sequentially urging sheets of heat insulating material between the first and second sheets to form the inner sheet between the first and second sheets, a second urging means for urging the first and second sheets into engagement with the inner sheet with the under surface of the first sheet and the top surface of the second sheet with the respective adhesives lE050417 thereon abutting the inner sheet on respective opposite sides thereof, and a pressing means for subjecting the sheets to a pressing action for pressing the sheets together for laminating and bonding the first and second sheets to the inner sheet to form a composite laminated sheet from which the laminated heat insulating panel is formed.

In one embodiment of the invention each adhesive is a two-part adhesive having co- operating first and second liquid parts forfacilitating curing thereof, the first and second dispensing means being adapted for applying the first and second liquid parts adjacent but spaced apart from each other to the respective first and second sheets for facilitating curing of the adhesive during the pressing of the sheets together by the pressing means.

Preferably, the first and second dispensing means are each adapted for applying the first and second parts of the adhesives to the first and second sheets in elongated lines extending along the first and second sheets in the direction of movement of the sheets. Advantageously, the first and second dispensing means are each adapted for applying a plurality of pairs of adjacent lines of the first and second parts of the adhesive to the first and second sheets, the pairs of the adjacent lines of the first and second parts of the adhesive being spaced apart from each other on each of the first and second sheets. in one embodiment of the invention the first dispensing means comprises a plurality of first and second tubular members for applying the respective first and second parts of the adhesive, the first and second tubular members terminating in respective first and second dispensing nozzles, the first and second dispensing nozzles being adapted for wiping along the downwardly facing under surface of the first sheet for applying the corresponding parts of the adhesive thereto.

Preferably, the first and second tubular members of the first dispensing means are of resilient material, and the first and second tubular members are arranged for resiliently urging the corresponding first and second dispensing nozzles into engagement with the under surface of the first sheet for wiping the first and second iE@5@!ii2 dispensing nozzles along the first sheet as the first sheet is being moved past the first dispensing means. in one embodiment of the invention each first and second tubular member of the first dispensing means is arranged to extend towards the under surface of the first sheet to define an angle with the first sheet of less than 90°, and preferably, each first and second tubular member of the first dispensing means defines an angle with the first sheet of less than 60°, and advantageously, each first and second tubular member of the first dispensing means defines an angle with the first sheet of less than 30°, and ideally, each first and second tubular member of the first dispensing means defines an angle with the first sheet of approximately 20°. in one embodiment of the invention each first and second tubular member of the first dispensing means extends towards the under surface of the first sheet in the general direction of movement of the first sheet.

In a further embodiment of the invention the first and second tubular members of the first dispensing means extend in a generally upwardly direction towards the downwardly facing under surface of the first sheet. in one embodiment of the invention the second dispensing means comprises a plurality of first and second tubular members for applying the respective first and second parts of the adhesive, the first and second tubular members terminating in respective first and second dispensing nozzles, the first and second dispensing nozzles being adapted for wiping along the upwardly facing top surface ofthe second sheet for applying the corresponding parts of the adhesive thereto.

Preferably, the first and second tubular members of the second dispensing means are of resilient material, and the first and second tubular members are arranged for resiliently urging the first and second dispensing nozzles into engagement with the top surface of the second sheet for wiping the dispensing nozzles therealong. lE0504 Preferably, a blending means is provided associated with each of the first and second dispensing means downstream thereof for blending the adjacent first and second parts of the adhesive dispensed onto the corresponding one of the first and second sheets. Advantageously, each blending means comprises an elongated blending blade extending transversely of the corresponding one of the first and second sheets, and each blending blade is reciprocally driven in a direction transversely of the corresponding one of the first and second sheets for co—operating with the first and second paths of the adhesive on the corresponding one of the first and second sheets for blending thereof. in one embodiment of the invention a first guide means is provided for guiding the first sheet past the first dispensing means inclined downwardly in the direction of movement of the first sheet at an angle to the horizontal of less than 60°, and preferably, the first guide means guides the first sheet past the first dispensing means inclined downwardly in the direction of movement thereof at an angle to the horizontal of less than 30°, and advantageously, the first guide means guides the first sheet past the first dispensing means inclined downwardly in the direction of movement thereof at an angle to the horizontal of approximately 20°. in one embodiment of the invention a pair of first shaping means is provided for shaping one longitudinally extending side edge of each of the first and second sheets for forming corresponding engagement edges for engaging respective first and second sheets of an adjacent laminated heat insulating panel.

In another embodiment of the invention a pair of second shaping means is provided for shaping the other longitudinally extending side edges of each of the first and second sheets for forming corresponding engagement edges for engaging respective first and second sheets of an adjacent laminated heat insulating panel.

Preferably, the first shaping means are provided for forming male engagement edges, and the second shaping means are provided forforming female engagement edges. lE0504 in one embodiment of the invention the first and second shaping means are located upstream of the pressing means relative to the direction of movement of the first and second sheets.

In one embodiment of the invention first and second cutting means are provided for cutting the first and second sheets, respectively, the first and second cutting means being operable for cutting the first and second sheets transversely relative to the direction of movement of the first and second sheets for facilitating parting off of the laminated heat insulating panel from the composite laminated sheet.

Preferably, the first and second cutting means are adapted for forming respective gaps between the first and second sheets and portions thereof during cutting for facilitating cutting of the inner sheet.

Advantageously, the apparatus comprises a main stationary framework.

In one embodiment of the invention the first and second cutting means are located in A a first support means, the first support means being moveable relative to the main stationary framework with the composite laminated sheet between a first position and a second position downstream of the first position during cutting of the first and second sheets of the composite laminated sheet by the first and second cutting means.

Preferably, a first clamping means is provided for clamping the first support means onto the composite laminated sheet so that the first support means moves between the first and second positions thereof with the composite laminated sheet at the linear speed thereof.

Advantageously, a first return means is provided for returning the first support means from the second position thereof to the first position.

E 050417.

Ideally, the first return means comprises a first scissors linkage drive mechanism for returning the first support means from the second position thereof to the first position.

In one embodiment of the invention punching means are provided on the first support means for punching respective notches in the engagement edges of the first and second sheets prior to cutting of the first and second sheets with the first and second cutting means.

In another embodiment of the invention a third cutting means is provided for cutting the inner sheet.

Preferably, the third cutting means comprises an abrasive wire cutter.

Advantageously, the third cutting means is located in a second support means, the second support means being moveable relative to the main stationary framework with the composite laminated sheet between a first position and a second position downstream of the first position during cutting of the inner sheet of the composite laminated sheet by the third cutting means.

Preferably, a second clamping means is provided for clamping the second support means onto the composite laminated sheet so that the second support means moves between the first and second positions thereof with the composite laminated sheet at the linear speed thereof.

Advantageously, a second return means is provided for returning the second support means from the second position thereof to the first position.

Ideally, the second return means comprises a second scissors linkage drive mechanism for returning the second support means from the second position thereof to the first position. lEGL7@tM7 Preferably, the first, second and third cutting means are adapted for sequentially parting off a plurality of laminated heat insulating panels from the composite laminated sheet.

In one embodiment of the invention the second support means is located downstream of the first support means relative to the direction of movement of the first and second sheets.

Additionally" the invention provides use of the apparatus according to the invention for producing laminated heat insulating panels.

The invention also provides a laminated heat insulating panel produced using the method according to the invention, and the invention further provides a laminated heat insulating panel produced using the apparatus according to the invention.

Additionally, the invention provides a laminated heat insulating panel produced using the method according to the invention and the apparatus according to the invention.

The invention will be more clearly understood from the following description of a preferred embodiment thereof, which is given by way of example only, with reference to the accompanying drawings, in which: Fig. 1 is a perspective view of a laminated heat insulating panel according to the invention, Fig. 2 is a side elevational view in block representation form of apparatus according to the invention for producing the panel of Fig. 1, Fig. 3 is a diagrammatic side elevational view of a portion of the apparatus of Fig. 2, Fig. 4 is a diagrammatic side elevational view of another portion of the E 0504 apparatus of Fig. 2, Fig. 5 is a view similar to Fig. 4 illustrating portions of the apparatus in respective different positions, Fig. Bis a top plan view ofia portion of the apparatus of Fig. 2, Fig. 7 is a plan view of a portion of the panel of Fig. 1, Fig. 8 is a perspective view of a portion of the apparatus of Fig. 2, Fig. 9 is another perspective view of the portion of Fig. 8 of the apparatus of Fig. 2, Fig. 10 is another perspective view of the portion of Fig. 8 of the apparatus of Fig. 2, Fig. 11 is a perspective view of a detail of the portion of Fig. 8 of the apparatus of Fig. 2, Fig. 12 is a perspective view of another detail of the portion of Fig. 8 of the apparatus of Fig. 2, Fig. 13 is a side elevational view of a detail of the portion of Fig. 8 of the apparatus of Fig. 2, Fig. 14 is a perspective view of another portion of the apparatus of Fig. 2, Fig. 15 is another perspective view of the portion of Fig. 14 of the apparatus of Fig. 2, Fig. 16 is an end elevational view of the portion of Fig. 14 of the apparatus of IE 0504 Fig. 2, Fig. 17 is a perspective view of a detail of the portion of Fig. 14 of the apparatus of Fig. 2, Fig. 18 is a perspective view of another detail of the portion of Fig. 14 of the apparatus of Fig. 2, Fig. 19 is a diagrammatic end elevational view of another portion of the apparatus of Fig. 2, Fig. 20 is a diagrammatic side elevational view of the portion of Fig. 19 of the apparatus of Fig. 2, Fig. 21 is a diagrammatic end elevational view of another portion of the apparatus of Fig. 2, and Fig. 22 is a diagrammatic side elevational view ofa detail of the portion of Fig. 21 of the apparatus of Fig. 2.

Referring to the drawings, there is illustrated apparatus according to the invention, indicated generally by the reference numeral 1, for sequentially producing laminated heat insulating panels also according to the invention, and indicated generally by the reference numeral 2, see Fig. 1. Before describing the apparatus 1 in detail, one of the laminated heat insulating panels 2 will first be described.

Referring now to Fig. 1, the laminated heat insulating panel 2 is particularly suitable for use in the construction of a cold room (not shown) of the type hereinbefore described, and comprises first and second outer sheets 3 and 4, respectively, of sheet metal material laminated and bonded to an inner sheet 5 of heat insulating material, in this embodiment of the invention expanded polystyrene. The first and second outer sheets 3 and 4 are bonded by a two-part adhesive as will be described below to the inner sheet 5 to form the laminated heat insulating panel 2. Opposite side edges 8 and 9 of the respective first and second outer sheets 3 and 4 are shaped to form engagement edges for facilitating sealable inter-engagement of adjacent panels 2. The edges 8 of the first and second outer sheets 3 and 4 are formed into elongated longitudinally extending tongues 10, and the opposite side edges 9 of the first and second outer sheets 3 and 4 are shaped to form elongated longitudinally extending grooves 11 for engaging corresponding tongues 10 of an adjacent panel 2 so that adjacent panels 2 can be sealably secured by the tongues of one panel 2 engaging the grooves 11 of an adjacent panel 2. Shallow strengthening troughs 14 are formed in the first and second outer sheets 3 and 4 for strengthening the laminated panel 2.

Referring now to Figs. 2 to 22, the apparatus 1 for producing the panels 2 will now be described. The apparatus 1 comprises four main stations 20, 21, 22 and 23. The first station 20 comprises a main stationary framework 25 within which are housed two pairs of drawing rollers 26 and 27, see Fig. 3, for drawing first and second sheets 28 and 29, respectively, of sheet metal from first and second rolls 30 and 31 _ for forming the first and second outer sheets 3 and 4, respectively, of the panels 2.

The pairs of drawing rollers 26 and 27 are driven by a drive motor (not shown) and are driven at appropriate speeds, so that the first sheet 28 and the second sheet 29 are urged through the apparatus 1 at similar linear speeds. A roll support 32 rotatably supports the first and second rolls 30 and 31 of the sheet metal material.

The first and second sheets 28 and 29 are initially drawn from the first and second rolls 30 and 31 through a series of straightening rollers 35 and 36, respectively, to idler rollers 37 and 38, respectively.

A first shaping means comprising two series of pairs of first shaping rollers, illustrated in block representation by the block 40 in Figs. 3 and 6 are located in the main framework 25 to one side thereof for forming the tongues 10 on the side edges 8 of the first and second sheets 28 and 29 as the first and second sheets 28 and 29 are being urged through the first station 20. A second shaping means comprising two series of pairs of second shaping rollers, illustrated in block representation by IE 0504 the block 41 in Fig. 6 are located in the main framework 25 to the other side thereof for forming the grooves 11 on the side edges 9 of the first and second sheets 28 and 29 as the first and second sheets 28 and 29 are being urged through the first station , see Figs. 3 and 6. Such shaping rollers as the shaping rollers 40 and 41 will be well known to those skilled in the art, and further description of the shaping rollers 40 and 41 should not be required.

Upper and lower pairs of forming rollers illustrated in block representation by the blocks 42 and 43 are located after the corresponding pairs offirst and second shaping rollers 40 and 41 for forming the shallow troughs 14 in the first and second sheets 28 and 29, respectively. Such forming rollers as the forming rollers 42 and 43 will be well known to those skilled in the art, and further description should not be required.

A first guide means comprising a pair of first guiding idler rollers 45 and 46 incline the first sheet 28 in a generally downwardly downstream direction towards the second station 21 at an angle 0 of approximately 20° to the horizontal, see Fig. 3. A second guide means comprising second guiding idler rollers 47 and 48 direct the second sheet 29 inclined in a generally upwardly downstream direction towards the first sheet 28.

A first urging means, in this embodiment of the invention a roller conveyor 52 is located within the first station 20 for receiving and urging a plurality of sheets 53 of heat insulating material for forming the inner sheet 5 of the panel 2 between the first and second sheets 28 and 29 as the first and second sheets are entering the second station 21, see Fig. 3. Rollers 54 of the roller conveyor 52 co-operate with pinch rollers 49, all of which are driven at a constant speed, which is matched with the speed of the drawing rollers 26 and 27, so that the linear speed of the sheets 53 of heat insulating material is similar to the linear speed of the first and second sheets 28 and 29 as the first and second sheets 28 and 29 are entering the second station 21. An input conveyor 56 extending transversely of the first station 20 conveys the sheets 53 of heat insulating material onto the roller conveyor 52 at an upstream end IE 0504 55 thereof, see Fig. 6. A feed ram 44, see also Fig. 6, urges the sheets 53 from the input conveyor 56 onto the conveyor 52, until the sheets 53 are gripped between the rollers 54 of the conveyor 52 and the pinch rollers 49.

First and second adhesive dispensing means, namely, a first adhesive dispenser 57 and a second adhesive dispenser 58, respectively, are located in the first station 20 for applying adhesive to the first and second sheets 28 and 29, respectively, for bonding the first and second sheets 28 and 29 to the inner sheet 5 formed by the sheets 53 of heat insulating material, see Fig. 3. The first adhesive dispenser 57 applies the adhesive to a downwardly facing under major surface 50 of the first sheet 28, and the second adhesive dispenser 58 applies the adhesive to an upwardly facing top major surface 51 of the second sheet 29. The first and second adhesive dispensers 57 and 58 are described in more detail below. In this embodiment of the invention the adhesive is a two-part liquid adhesive, and‘ the adhesive is dispensed onto the first and second sheets 28 and 29 in respective spaced apart pairs of adjacent lines 59 and 60 of the respective parts of the adhesive, see‘ Fig. 7.

Blending means, namely, elongated blending blades 72 are located just upstream of the first and second guiding idler rollers 46 and 48 and downstream of each first and second adhesive dispenser 57 and 58 for blending the first and second parts ofthe adhesive in the adjacent lines 59 and 60. The blending blades 72 extend transversely of the first station 20, and are reciprocally driven by respective motors 33 in the direction of the arrows X and Y transversely of the first and second sheets 28 and 29, see in particular Fig. 7, for blending the first and second adhesives of the adjacent lines 59 and 60, respectively, thereof to form beads 78 of the mixed adhesive for bonding the first and second sheets 28 and 29 to the inner sheet 5.

Thus, as the first and second sheets 28 and 29 are urged towards each other by the first and second guiding idler rollers 45, 46, 47 and 48, and are urged into engagement with the inner sheet 5 by the first and second guiding idler rollers 46 and 48, which act as a second urging means, the parts of the adhesive in the respective adjacent lines 59 and 60 are blended, and curing of the adhesive commences. lE050-417 The second station 21 is a press station for pressing the first and second sheets 28 and 29 into tight engagement with the sheets 53, which form the inner sheet 5, for bonding and securing the first and second sheets 28 and 29 to the inner sheet 5.

The second station 21 comprises a first stationary framework 65, see Figs. 3 to 5.

Upper pressure rollers 61 in the first stationary framework 65 co-operate with lower pressure rollers 62 for urging the first and second sheets 28 and 29 into tight bonding engagement with the inner sheet 5. The lower pressure rollers 62 are driven rollers, and are rotatably carried on a lower framework 63, which is mounted in the first framework 65. The upper pressure rollers 61 are also driven, and are rotatably carried on an upper carrier framework 64, which is vertically moveable within the first framework 65, and is urged by appropriate hydraulic rams (not shown) downwardly towards the lower framework 63, for in turn urging the first and second sheets 28 and 29 into tight bonding engagement with the inner sheet 5. The upper and lower pressure rollers 61 and 62 are driven at a speed which matches the speed at which the first and second sheets 28 and 29 are being urged through the apparatus by the pairs of drawing rollers 26 and 27.

Heaters 66, in this embodiment of the invention electrically powered infrared heaters mounted in the lower framework 63 between adjacent pairs of some of the lower pressure rollers 62 accelerate the curing of the adhesive for bonding the first and second sheets 28 and 29 and the inner sheet 5. The first and second sheets 28 and 29 bonded to the inner sheet 5 are urged from the second station 21 into the third station 22 in the form of a continuous composite laminated sheet 67, where the first and second sheets 28 and 29 are transversely cut at predetermined intervals for commencing sequential parting off of the panels 2 from the composite laminated sheet 67.

The third station 22 comprises a second framework 68 which is moveable on a pair of spaced apart longitudinally extending tracks 69, with the composite laminated sheet 67. Track engaging wheels 77 rotatably carried on the second framework 68 rollably engage the tracks 69, which are secured to the ground. First and second cutting means comprising upper and lower metal cutters 70 and 71, respectively, are E 0504 located in the second framework 68 for forming respective transverse cuts 73 across the first and second sheets 28 and 29, respectively, see Figs. 4, 5, 19 and 20. The upper and lower metal cutters 70 and 71 and their operation is described in more detail below. In this embodiment of the invention the upper and lower metal cutters 70 and 71 form the cuts 73 in the form of gaps 74, see Fig. 20, for facilitating subsequent cutting of the inner sheet 5 in the fourth station 23, as will be described below. Two pairs of upper and lower punches 75 and 76 are also located in the third station 22 for punching the corresponding side edges 8 and 9 adjacent the tongues and grooves 11 formed in the first and second sheets 28 and 29 where the cuts 73 are to be formed by the upper and lower metal cutters 70 and 71 for facilitating entry and exit of the upper and lower metal cutters 70 and 71 into and out of the first and second sheets 28 and 29.

A first clamping means comprising a pair of first clamps 79 mounted at the upstream and downstream ends of the second framework 68 are selectively operable for clamping the second framework 68 onto the composite laminated sheet 67, so that the second framework 68 moves with the composite laminated sheet 67 during transverse cutting of the first and second sheets 28 and 29 of the composite laminated sheet 67 by the upper and lower metal cutters 70 and 71 while the composite laminated sheet 67 is being urged through the apparatus 1.

A first scissors linkage mechanism 80 couples the second framework 68 of the third station 22 to the first framework 65 of the second station 21, and permits the second framework 68 to move with the composite laminated sheet 67, when the second framework 68 is clamped onto the composite laminated sheet 67, from a first position illustrated in Fig. 5 adjacent the first framework 65 to a second position illustrated in Fig.4 adjacent the fourth station 23. Afirst return means provided by an hydraulic ram (not shown) operates the first scissors linkage mechanism 80 for returning the second framework 68 from the second position to the first position.

The fourth station 23 comprises a third framework 82, which is moveable on the tracks 69 with the composite laminated sheet 67. Track engaging wheels 30 IE 0504 rotatably carried on the third framework 82 rollably engage the tracks 69 for facilitating movement of the third framework 82 with the composite laminated sheet 67 from a first position illustrated in Fig. 4 to a second position illustratedtin Fig. 5. A third cutting means comprising an insulating material cutter 84 is located in the third framework 82 for cutting through the inner sheet 5, as will be described below for sequentially parting off the panels 2 from the composite laminated sheet 67. A second clamping means, namely, a second clamp 83 mounted in the third framework 82 selectively clamps the third framework 82 onto the composite laminated sheet 67 for moving the third framework 82 with the composite laminated sheet 67 during cutting of the inner sheet 5 by the insulating material cutter 84.

A second scissors linkage mechanism 86 couples the third framework 82 of the fourth station 23 to a take-off conveyor 87 for facilitating movement of the third framework 82 between the first and second positions. A second return means comprising an hydraulic ram (not shown) is provided for operating the second scissors linkage mechanism 86 for returning the third framework 82 from the second to the first position.

Driven rollers 92 of the take-off conveyor 87 sequentially convey parted off panels 2 from the apparatus 1 as the panels 2 are sequentially parted off from the composite laminated sheet 67.

Referring now to Figs. 3 and 8 to 13, the first adhesive dispenser 57 will now be described. The first adhesive dispenser 57 comprises a sub—framework 95 comprising a pair of end plates 96 which arejoined by a pair of spaced apart shafts 97. The shafts 97 are slideably carried in corresponding pairs of linear bearings 98 and 99. The linear bearings 98 and 99 are secured to the main framework 25 of the first station 20. First and second elongated tubular manifolds 100 and 101, respectively, extend between and are carried in the end plates 96 for delivering the respective liquid parts of the two—part adhesive. Flexible supply tubes 103 and 104 supply the respective liquid parts of the two—part adhesive to the first and second manifolds 100 and 101, respectively, through rotatable couplings 120 and 121, iEo5o4 respectively, see Fig. 10.

A plurality of resilient first dispensing tubes 105 extend from the first tubular manifold 100, and terminate in first dispensing nozzles 106 for engaging and dispensing one of the two liquid parts of the adhesive onto the downwardly facing under major surface 50 of the first sheet 28 to form the corresponding lines 59 of the one part of the adhesive on the under major surface 50 of the first sheet 28 as the first sheet 28 moves past the first adhesive dispenser 57, see also Fig. 7. A plurality of second resilient dispensing tubes 108 extend from the second tubular manifold 101 and terminate in second dispensing nozzles 109 for engaging and dispensing the other of the two liquid parts of the adhesive onto the under major surface 50 of the first sheet 28 in the corresponding lines 60 adjacent but spaced apart from the lines 59 of the adhesive for facilitating subsequent blending of the adjacent pairs of lines 59 and 60 by the blending blade 72, see also Fig. 7. The first and second dispensing tubes 105 and 108 extend from the first and second manifolds 100 and 101, respectively, towards the under major surface 50 of the first sheet 28 in the direction of motion of the first sheet 28 at an angle 0 to the under major surface 50 of approximately 20°, see Fig. 13.

The first and second manifolds 100 and 101 are rotatably mounted in the end plates 96, and are rotatable by a pneumatic ram 112 through a linkage mechanism 114, for selectively urging the first and second dispensing nozzles 106 and 109 of the first and second dispensing tubes 105 and 108 into and out of resilient engagement with the under surface 50 of the first sheet 28. The rotatable couplings 120 and 121 facilitate rotation of the first and second manifolds 100 and 101, respectively, relative to the supply tubes 103 and 104. When the first and second dispensing nozzles 106 and 109 are urged into engagement with the first sheet 28 by the ram 112, the dispensing nozzles 106 and 109 resiliently wipe the under surface 50 of the first sheet 28 for dispensing the two parts of the adhesive in the respective lines 59 and 60 onto the first sheet 28. Additionally, the ends of the first and second dispensing tubes 105 and 108 are cut at an angle forforming the corresponding dispensing nozzles 106 and 109 so that when the dispensing nozzles 106 and 109 are urged lE 0504 into engagement with the under surface 50 of the first sheet 28, the respective first and second parts of the adhesive are dispensed in the lines 59 and 60 on the under surface 50, see in particular Figs. 7 and 12. The ram 112 is operable for rotating the first and second manifolds 100 and 101 for selectively disengaging the dispensing nozzles 106 and 109 from the under surface 50 of the first sheet 28 should it be desired not to dispense adhesive onto the first sheet 28.

Valving members 116 located in the respective first and second manifolds 100 and 101 adjacent the first and second dispensing tubes 105 and 108, respectively, are provided for facilitating manual adjustment of the dispensing rate of the first and second adhesives through the dispensing tubes 105 and 108.

A drip tray 117 is carried on the first adhesive dispenser 57 and is secured by brackets (not shown) to the end plates 96.

Referring now to Figs. 14 to 18, the second adhesive dispenser 58 is illustrated and is substantially similar to the first adhesive dispenser 57, and similar components are identified by the same reference numerals. The main difference between the second adhesive dispenser 58 and the first adhesive dispenser 57 is that the first adhesive dispenser 57 is mounted in the first station 20 with the shafts 97 extending between the end plates 96 located above the first and second tubular manifolds 100 and 101, while in the second adhesive dispenser 58 is mounted in the first station with the shafts 97 extending between the end plates 96 located beneath the first and second tubular manifolds 100 and 101. The first and second tubular manifolds 100 and 101 of the second adhesive dispenser 58 are also rotatably mounted in the end plates 96, and are rotatable by a pneumatic ram 112 through a linkage mechanism 114 into and out of engagement with the top surface 51 of the second sheet 29. As in the case of the first adhesive dispenser 57, the first and second dispensing tubes 105 and 108 extend from the first and second manifolds 100 and 101 towards the second sheet 29 in the direction of motion of the second sheet 29 at an angle to the top surface 51 of approximately 20°, and dispense the respective parts of the adhesive downwardly onto the top surface 51 of the second sheet 29 in the lines 59 and 60. lE0504 A pair of pumps (not shown) pump the respective first and second parts of the adhesive to the first and second manifolds 100 and 101 of the first and second adhesive dispensers 57 and 58, respectively, through the supply tubes 103 and 104.

Rotatable couplings 120 and 121 also couple the first and second manifolds 100 and 101 of the second adhesive dispenser 58 to the supply tubes 103 and 104 for facilitating rotation of the first and second manifolds 100 and 101 of the second adhesive dispenser 58 by the rams 112.

The first and second adhesive dispensers 57 and 58 are coupled together by a coupling member 122, see Fig. 3, and are slideable between an operative position illustrated in full lines in Figs. 3 and 6 with the first and second adhesive dispensers 57 and 58 located for dispensing the adhesive onto the first and second sheets 28 and 29 and an inoperative position illustrated in broken lines in Fig. 6 withdrawn from the first station 20. As mentioned above, the shafts 97 of the first and second adhesive dispensers 57 and 58 are slideably mounted in linear bearings 98 and 99 which are in turn mounted in the main framework 25 of the first station 20. By sliding the shafts 97 through the bearings 98 and 99 the first and second adhesive dispensers 57 and 58 are slideable between the operative and inoperative positions.

A drive motor 123 is mounted on a carrier bracket 124, which is rigidly mounted to the main framework 25, and drives a pinion (not shown), which in turn engages a rack (also not shown) formed on one of the shafts 97, namely, the shaft 97a of the first adhesive dispenser 57, for urging the first adhesive dispenser 57, and in turn the second adhesive dispenser 58 between the operative and inoperative positions. The pairs of bearings 98 and 99, in which the shafts 97 are slideable, are carried on the carrier bracket 124.

Referring now to Figs. 19 and 20, the upper and lower metal cutters 70 and 71 in the third station 22 are carried in and are slideable in respective upper and lower tracks 125. The upper and lower metal cutters 70 and 71 are driven from a first position at a side 126 of the composite laminated sheet 67 to a second position at the opposite IE 0504 side 127 of the composite laminated sheet by respective linear pneumatic drives 128. Each linear pneumatic drive 128 comprises a double acting pneumatic cylinder 129 having a piston 130 slideably mounted therein. A drive wire 131 coupled to respective opposite ends of the piston 130, sealably extends through end caps 132 at respective opposite ends of the cylinder 129, and in turn extends around a corresponding pair of pulleys 133, which are rotatably mounted in the second framework 68. The upper and lower cutters 70 and 71 are coupled to the corresponding one of the drive wire 131 for driving the metal cutters 70 and 71 between the first and second positions on the respective opposite sides 126 and 127 of the composite laminated sheet 67. As the upper and lower metal cutters 70 and 71 are being urged from the first position to the second position, the upper and lower metal cutters 70 and 71 cut the upper and lower sheets 28 and 29 along the cut 73 to form the gap 74.

Referring now to Figs. 21 and 22, the insulating material cutter 84 in the fourth station 23 for cutting through the inner sheet 5 will now bedescribed. The insulating material cutter 84 comprises an endless abrasive wire 135 having a roughened surface. The abrasive wire 135 is carried on and extends around a pair of pulleys 136 and 137. The pulleys 136 and 137 are rotatably carried on a pulley carrier 139, which is in turn carried on a piston rod 140 of an hydraulic ram 141, which in turn is mounted in the third framework 82. The ram 141 is operable for urging the pulley carrier 135 from a first upper position with a lower leg 143 of the abrasive wire 135 located above the composite laminated sheet 67 to a second lower position with the lower leg 143 of the abrasive wire 135 below the composite laminated sheet 67 for cutting through the inner sheet 5. The pulley 136 is a driven pulley, and is driven by a motor (not shown) mounted on the pulley carrier 139 for driving the endless abrasive wire 135 around the pulley 136. The pulley 137 is an idler pulley.

In use, first and second rolls 30 and 31 of the first and second sheets 28 and 29 of sheet metal are mounted on the roll support 32. The first and second sheets 28 and 29 are fed through the straightening rollers 35 and 36 to the pairs of drawing rollers and 27, and in turn fed through the first and second shaping rollers 40 and 41 and EE @5841? 26 the upper and lower forming rollers 42 and 43, and in turn through the first and second adhesive dispensers 57 and 58 into the second station 21. The sheets 53 of the insulating material located on the roller conveyor 52 are urged between the first and second sheets 28 and 29 into the second station 21. The first and second sheets 28 and 29 and the sheets 53 are then inched fon/vard through the second station 21 and in turn through the third and fourth stations 22 and 23. initially the third and fourth stations 22 and 23 are located in their respective first positions.

Once the first and second sheets 28 and 29 and the inner sheet 5 of insulating material have been inched through the four stations 20, 21, 22 and 23, the apparatus 1 is ready for use. The adhesive pumps (not shown) are powered up for pumping adhesive to the upper and lower adhesive stations 57 and 58 and the upper pressure rollers 61 of the second station 21 are set to apply the appropriate pressure to the first and second sheets 28 and 29 and the inner sheet 5. The pairs of drawing rollers 26 and 27 are then powered up and the roller conveyor 52 and the pinch rollers 49 are also powered up. The sheets 53 are sequentially fed by the input conveyor 56 to the roller conveyor 52, and urged by the feed ram 44 onto the roller conveyor 52 and between the rollers 54 of the roller conveyor 52 and the pinch rollers 49. The first and second sheets 28 and 29 and the inner sheets 53 are thus continuously urged through the first, second, third and fourth stations 20 to 23.

Adhesive is applied in the continuous lines 59 and 60 to the under surface 50 and the top surface 51 of the first and second sheets 28 and 29, respectively, by the first and second adhesive dispensers 57 and 58. The parts of the adhesive in the respective adjacent pairs of lines 59 and 60 are blended by the reciprocating blending blades 72. The first and second sheets 28 and 29 and the inner sheets 53 are pressed together by the upper and lower pressure rollers 61 and 62 in the second station 21, and the adhesive is cured therein, thus bonding the first and second sheets 28 and 29 to the inner sheet 5 to form the composite laminated sheet 67.

After a predetermined length of the composite laminated sheet 67, which corresponds to the desired length of each panel 2, has passed through the third station 22 in its first position, and the position at which the cuts 73 are to be made in the first and second sheets 28 and 29 are aligned with the upper and lower cutters 70 and 71, the first clamps 79 in the third station 22 are operated for clamping the third station 22 to the composite laminated sheet 67, and the third station 22 commences to move from its first position to its second position towards the fourth station 23. With the third station 22 clamped onto the composite laminated sheet 67, the punches 75 and 76 are operated for punching through the tongues 10 and the grooves 11 on the respective opposite sides of the first and second sheets 28 and 29. The respective upper and lower metal cutters 70 and 71 are then operated for forming the transverse cuts 73 in the respective first and second sheets 28 and 29, for in turn forming the gaps 74. When the third station 22 has reached its second position, the first clamps 79 are released from the composite laminated sheet 67, and the third station 22 under the action of the ram (not shown) and the scissors mechanism 80 is returned to its first position. With the fourth station 23 in its first position, when the gaps 74 in the first and second sheets 28 and 29 align with the insulating material cutter 84 in the fourth station 23, the second clamp 83 in the fourth station 23 is activated for clamping the fourth station 23 onto the composite laminated sheet 67.

With the fourth station 23 clamped onto the composite sheet 67, the fourth station 23 commences to move from its first to its second position, and the insulating material cutter 84 is activated for urging the lower leg 143 of the abrasive wire 135 through the inner sheet 5 for in turn parting off a panel 2 from the composite laminated sheet 67. When the panel 2 has been parted off from the composite laminated sheet 67, the fourth station 23 is urged from its second to its first position by the second scissors linkage mechanism 86 and is ready to part the next panel 2 from the composite laminated sheet 67.

When a sufficient length of the composite laminated sheet 67 has passed through the third station 22 from the cuts 73 which have just been made in the first and second sheets 28 and 29, which corresponds to the desired length of the panel 2, the first clamps 79 are again clamped onto the composite laminated sheet 67 and the third station 22 again commences to move with the composite laminated sheet 67, and so the laminated heat insulating panels are sequentially produced by the apparatus 1.

The driven rollers 92 of the take—off conveyor 87 are continuously operated for taking off the panels 2 as they are sequentially parted from the composite laminated sheet 67.

While the laminated heat insulating panel according to the invention has been described as having tongues and grooves formed in the first and second outer sheets on respective opposite side edges thereof, it is envisaged in certain cases that the tongues and grooves may be omitted, and indeed, it is envisaged in certain cases that the panel may be provided with other suitable engagement means for engaging adjacent panels. It is also envisaged in certain cases that the panels may be provided without engagement means.

While the panels have been described as being provided with strengthening troughs in the respective first and second outer sheets, the strengthening troughs may be omitted.

While the heat insulating inner sheet has been described as being of expanded polystyrene material, it may be of any other suitable heat insulating material, for example, expanded polyurethane material, rock wool, fibre glass material, and the like.

Claims (5)

Claims

1. A method for forming a laminated heat insulating panel comprising an inner sheet of heat insulating material sandwiched between and bonded to first and second outer sheets of sheet metal material, the method comprising the steps of drawing two sheets from respective rolls of sheet metal material for forming the first and second outer sheets of the panel, the sheets being drawn so that a first one of the sheets passes above and is spaced apart from a second one of the sheets with the first sheet having a downwardly facing under major surface facing an upwardly facing top major surface of the second sheet, and the linear speeds of the first and second sheets are similar, applying an adhesive to the downwardly facing under surface of the first sheet, and applying an adhesive to the upwardly facing top surface of the second sheet, sequentially urging sheets of heat insulating material between the first and second sheets to form the inner sheet between the first and second sheets, urging the first and second sheets into engagement with the inner sheet with the under surface of the first sheet and the top surface of the second sheet with the respective adhesives thereon abutting the inner sheet on respective opposite sides thereof, and subjecting the sheets to a pressing action for pressing the sheets together for laminating and bonding the first and second sheets to the inner sheet to form a composite laminated sheet from which the laminated heat insulating panel is formed.

2. A method for forming a laminated heat insulating panel comprising an inner sheet of heat insulating material sandwiched between and bonded to first and second outer sheets of sheet metal material, the method being substantially as described herein with reference to and as illustrated in the accompanying drawings.

3. Apparatus for forming a laminated heat insulating panel comprising an inner sheet of heat insulating material sandwiched between and bonded to first and second outer sheets of sheet metal material, the apparatus comprising a means for drawing two sheets from respective rolls of sheet metal material for forming the first and second outer sheets of the panel, the sheets being drawn so that a first one of the sheets passes above and is spaced apart from a second one of the sheets with the first sheet having a downwardly facing under major surface facing an upwardly facing top major surface of the second sheet, the means for drawing the sheets from the respective rolls of the sheet metal material drawing the first and second sheets at similar linear speeds, a first dispensing means for applying an adhesive to the downwardly facing under surface of the first sheet, and a second dispensing means for applying an adhesive to the top surface of the second sheet, a first urging means for sequentially urging sheets of heat insulating material between the first and second sheets to form the inner sheet between the first and second sheets, a second urging means for urging the first and second sheets into engagement with the inner sheet with the under surface of the first sheet and the top surface of the second sheet with the respective adhesives thereon abutting the inner sheet on respective opposite sides thereof, and a pressing means for subjecting the sheets to a pressing action for pressing the sheets together for laminating and bonding the first and second sheets to the inner sheet to form a composite laminated sheet from which the laminated heat insulating panel is formed.

4. Use of the apparatus as claimed in Claim 3 for producing laminated heat insulating panels.

5. A laminated heat insulating panel produced using the method as claimed in Claim 1 or 2 and the apparatus of Claim 3 for forming a laminated heat insulating paneL F.F. GORMAN & CO.