IE69262B1

IE69262B1 - A method and apparatus for forming a laminated panel

Info

Publication number: IE69262B1
Application number: IE337091A
Authority: IE
Inventors: Patrick Beirne; Michael Joseph Fenelon
Original assignee: Modular Erectors Ltd
Priority date: 1991-09-25
Filing date: 1991-09-25
Publication date: 1996-08-21
Also published as: GB9220179D0; GB2259887B; IE913370A1; ZA917812B; GB2259887A

Abstract

A laminated panel (1) comprises an inner sheet (4) of heat insulating material sandwiched between a pair of outer sheets (5) of sheet metal. Side edges (8, 9) of the outer sheets are folded to form tongues (14) and grooves (15) for engaging corresponding tongues (14) and grooves (15) of abutting panels. The panel (1) is cut from a continuous laminated sheet by cutting blades which make transverse cuts in the outer sheets (5) and a hot wire cutting element which makes the transverse cut in the insulating sheet (4). Prior to folding the edges (8, 9) of the outer sheets (5) to form the tongues (14) and grooves (15), lead-in slots (145, 146) are formed in the sheet metal for forming the outer sheets (5) to prevent burrs being formed on the outer sheets (5) by the cutting blades.

Description

The present invention relates to a method and apparatus for forming a laminated panel, and in particular,, for forming a laminated panel for use in the construction of an insulated building. The invention also relates to a laminated panel formed according to the method and on the apparatus.

Cold stores may be constructed within a building, or indeed may be constructed externally. In the construction of cold stores, laminated panels are commonly used. Such panels are constructed from an inner sheet of insulating material, generally, expanded polystyrene or the like, sandwiched between a pair of outer sheets, generally of sheet metal. The panels are joined by abutting one panel along its side edge against a corresponding side edge of the next adjacent panel. The side edges may be relatively plane, or provided with Interengagable complementary formations. However, in general, the longitudinal joints between side edges of adjacent panels require a ceiling strip which extends longitudinally of the panels for sealing each joint. In the mass production of such panels, the panels are formed from continuous sheets of sheet metal which are fed from a roll and which form the outer sheets ox the panel. The inner sheet of insulating material is inserted between the two outer sheets and bonded together. Panels are then cut from the continuous laminated sheet by a transverse cut from one side edge of the panel to the other. Unfortunately, no satisfactory method or apparatus for the production of such panels is known.

There is therefore a need for & method and apparatus 5 for producing such laminated panels, and there is also a need for a laminated panel produced according to the method and from the apparatus.

The present invention is directed towards providing such a method and apparatus and a laminated panel.

According to the invention, there is provided a method for forming a laminated panel comprising an inner sheet of insulating material sandwiched between a pair of outer sheets of sheet metal material, the method comprising the steps of drawing from respective rolls a pair of continuous sheets of sheet metal material parallel to and spaced apart from each other to form the outer sheets, feeding a sheet of insulating material between the outer sheets, bonding the outer sheets to the inner sheet to form a combined elongated continuous laminated sheet, folding each outer sheet along a first fold line adjacent one elongated side edge thereof, each first fold line being parallel to and spaced apart from the adjacent side edge so that portion of each outer sheet between the first fold line and the said adjacent side edge overlaps the corresponding outer sheet to form an elongated tongue, each first fold line defining an edge of the respective sheet, folding each outer sheet along second and third fold lines adjacent the other elongated side edge thereof to form an elongated groove for receiving a corresponding tongue of an adjacent panel, the second and third fold lines of each outer sheet being parallel to and spaced, apart from the adjacent side edge and being spaced apart from each other, the third fold line of each outer sheet being intermediate the second fold line and the adjacent side edge, so that a first portion of each outer sheet between the second and third fold line overlays the outer sheet and a second portion of each outer sheet between the third fold line and the adjacent side edge overlays the first portion to form with the first portion the elongated groove, transversely parting a portion of the laminated sheets from the continuous laminated sheet to form the laminated panel by cutting the continuous laminated sheet transversely thereof, wherein the method further comprises the step of forming first and second transverse lead-in slots adjacent respective side edges of each outer sheet prior to folding the outer sheets about the first, second and third fold lines, each first and second lead-in slot being formed in a location corresponding to the location where a transverse cut is to be made for parting off a laminated panel, and each first lead-in slot being located in a position adjacent where the first fold line is to be formed and extending on each side thereof, each second lead-in slot being formed adjacent where the second fold line is to be formed and extending on each side thereof.

In one embodiment of the invention, the first lead-in slot extends an equal distance on each side of the first fold line, and extends on one side of the first fold line to the adjacent side edge.

In another embodiment of the invention, the second lead-in slot extends on one side of the second fold line from the second fold line to the adjacent side edge, and on the other side of the second fold line for a distance equal to the distance between the second and third fold lines.

Additionally, the invention provides apparatus for carrying out the method according to the invention for forming a laminating panel comprising an inner sheet of insulating material sandwiched between a pair of outer sheets of sheet metal material, the apparatus comprising a main framework defining a passageway therethrough in which the sheets are laminated to form a continuous laminated sheet, a pair of support means for rotatably supporting respective rolls of sheet metal material for forming the outer sheets, means for drawing the outer sheets from the rolls of sheet metal through the passageway, feeding means for feeding the inner sheet between the two outer sheets prior to the outer sheets passing through the passageway, pressing means for pressing the sheets together in the passageway for bonding thereof, folding means for folding the outer sheets adjacent their side edges about the respective first, second and third fold lines for forming the respective tongues and grooves, punching means for punching the first and second leadin slots prior to the inner and outer sheets entering the folding means, and cutting means for making a transverse cut in the continuous laminated sheet for parting off a laminated panel from the continuous laminated sheet.

Further, the invention comprises a laminated panel formed according to the method of the Invention, the laminated panel comprising an inner sheet of insulating material sandwiched between a pair of outer sheets of sheet metal material.

Furthermore, the invention provides the laminated panel when formed in the apparatus according to the invention.

The invention will be more clearly understood from the β following description of a preferred embodiment thereof, given by way of example only, with reference to the accompanying drawings, in which: Fig. 1 is a perspective view of a panel according 5 to the invention.

Fig. 2 is a sectional view of portion of a pair of panels of Fig. 1 illustrated joined together, Fig. 3 is a perspective view of portion of a pair of panels according to the invention also joined together, Fig. 4 is a plan view of a sheet of sheet metal prior to being formed for the panel of Fig. 1, Fig. 5 is a side elevational view of apparatus according to the invention for forming the panel of Fig. 1, Fig. 6 is an enlarged side elevational view of portion of the apparatus of Fig. 5, Fig. 7 is a sectional end view of the apparatus of Fig. 5 on the line VI-VI of Fig. 5, Fig. 8 is a perspective view of another portion of the apparatus of Fig. 5, Fig. 9 is a side elevational view of the portion of the apparatus of Fig. 8, Fig. 10 is a perspective view of another portion 5 of the apparatus of Fig. 5, Fig. 11 is a side elevational view of the portion of the apparatus of Fig. 10, Fig. 12 is a perspective view of a further portion of the apparatus of Fig. 5, Fig. 13 is a plan view of a further portion of the apparatus of Fig. 5, Fig. 14 is a plan view also of a further portion of the apparatus of Fig. 5, Fig. 15 is a plan view of a sheet of sheet metal 15 partly formed, for forming the panel of Fig. l? and Fig. 16 is a view similar to Fig. 15 of another sheet of sheet metal for forming the panel of Fig. 1.

Referring to the drawings, there is illustrated a laminated panel according to the invention indicated generally by the reference numeral 1 produced according to a method of the invention on apparatus also according to the invention which. Is indicated generally by the reference numeral 2„ Before describing the apparatus 2 In detail, the laminated panel will first be described with reference to Figs. to 4. The laminated panel 1 is particularly suitable for use in the construction of a cold store (not shown). The panel 1 comprises an inner sheet 4 of heat insulating material, in this case expanded polystyrene sandwiched between a pair of outer sheets 5 of sheet metal. The outer sheets 5 are bonded, as will be described below, to the inner sheet 4. The panel 1 defines an inner surface 6 and an outer surface 7 which, in use, correspond to the inner and outer surfaces, respectively, of a wall of the cold store. The inner and outer surfaces 6 and 7 terminate in longitudinal sides 8 and S joined by top and bottom ends 10 and 11, respectively, which correspond to the top and bottom of the panel 1 when used in the construction of a cold store. The panels 1 are joined side by side to adjacent panels 1 by abutting the side 8 of one panel 1 against the side 9 of an adjacent panel 1. The bottom end 11 of each panel 1 rests on the base slab of the cold store while the top end 10 is provided with a recess 12 for receiving a roof panel 13. Each roof panel 13 is substantially similar to the panel 1 with the exception that both ends are similar to the bottom end 11. A roof panel 13 would normally extend horizontally between opposite panels 1 of side walls of the cold store, see Fig., 3.

Each outer sheet 5 terminates at the longitudinal side edge 8 in an elongated tongue 14, and each outer sheet 5 terminates in the longitudinal side 9 in an elongated groove 15. The tongues 14 and grooves 15 are formed so that the tongues 14 of one panel 1 engage the corresponding groove of the next adjacent panel 1 for securing adjacent panels 1 together, see Fig. 2. Each tongue 14 is formed by folding the outer sheet 5 along a first fold line 17 which extends parallel to and is spaced apart from an adjacent side edge 18 of the outer sheet 5, see Figs. 1 and 4. The outer sheet 5 is folded around the first fold line 17 so that a portion 19 of the sheet 5 extending between the first fold line 17 and the side edge 18 overlays the outer sheet 5 to form the tongue 14. Each groove 15 is formed by folding the outer sheet 5 about a pair of fold lines, namely, a second fold line 20 and a third fold line 21. The second and third fold lines 20 and 21 are parallel to and spaced apart from a side edge 23 of the outer panels 5. The second and third fold lines 20 and 21 are further spaced apart from each other, and the third fold line 21 Is provided intermediate the second fold line 20 and the side edge 23 of each outer sheet 5. Thus, on folding of each outer sheet 5 about the second fold line 20 a first portion 24 of the outer sheet 5 overlays the outer sheet 5, and on folding of the outer sheet 5 about the third fold line 21, a second portion 25 of the outer sheet 5 overlays the first portion 24, thereby defining with the first portion 24 the groove 15.

The inner sheet 4 extends on the side 8 to a position 10 co-ineiding with the first fold lines 17 of the outer sheets 5. The inner sheet 4 terminates at the side 9 at a position co-inciding with the third fold lines 21 of the outer sheets 5 to accommodate engagement of the tongues 14 in the grooves 15 of the next adjacent panel 1. The side 8 of the inner sheet 4 is relieved at 2S to form recesses 27 for accommodating the tongues 14. The tongues 14 and grooves 15 are sised so that when the tongues 14 are tightly engaged in the grooves 15 the side 8 of the inner sheet 4 tightly abuts the corresponding side 9 of the inner sheet 4 of an adjacent panel 1.

The outer sheets 5 are also bent along fold lines 29 and 30 adjacent the tongues 14 so that when the tongues 14 engage the grooves 15 the inner and outer surfaces δ and 7, respectively, of adjacent panels lie relatively flush with each other.

In the construction of a cold store, front, rear and side walls of the cold store are constructed of the panels 1 which are mounted with the bottom end 11 of the panels 1 standing on a base slab 32 of the cold store, see Fig. 3. Adjacent panels 1 are engaged by engaging the tongues 14 in the grooves 15 of adjacent panels, see Fig. 2. Prior to engagement of the tongues 14 in the grooves 15, an elongated bead 31 of an epoxy resin material is provided in the grooves 15, extending the length of the grooves 15 for bonding and sealably engaging the tongues 14 and grooves 15 of the adjacent panel 1. On the tongues 14 being fully engaged, in the grooves 15, the bead 31 is spread between the respective tongues 14 and grooves 15.

The roof panels 13 as mentioned above are substantially similar to the panels 1 with the exception that both ends 33 of the roof panels 13 are both identical to the bottom end 11 of the panel 1.

The roof panels 13 extend between panels 1 of opposite side walls and engage the recesses 12 of the panels 1, see Fig. 3. An elongated sealing member 35 seals the joint formed in the recess 12 between the roof panels 13 and the panels 1. The sealing member 35 is of plastics material and of L-shape cross section having a leg 37 which overlays the roof panels 13 and a leg 38 which overlays the panels 1» A leg 39 extending the length of the sealing member 35 from the leg 37 extends parallel to the leg 38 and defines with the leg 38 an elongated groove 40 for sealably engaging a portion 41 of the panel 1.

Reinforcing channels 42 are provided in the outer sheets 5 for strengthening the panel 1. Similar reinforcing channels 42 are provided on the outer sheets 5 in the roof panel 13.

Referring now to Figs. 5 to 12, the apparatus 2 for forming the panel 1 and the roof panel 13 will now be described. The apparatus 2 comprises a main framework 45 which is rigidly mounted on a floor 44 of a building (not shown). The main framework 45 defines a main passageway 46 which extends through the main framework 45 for accommodating the inner sheet 4 and outer sheets 5 as they pass through the main framework 45 to be laminated as will be described below. The main passageway 46 has an upstream end 47 and a downstream end 48. The inner sheets 4 and outer sheets 5 are fed into the main passageway 46 through the upstream end 47 and a continuous laminated sheet 43 from which the panels 1 and 13 are parted is delivered through the downstream end 48 of the main passageway 46. The outer sheets 5 are formed by sheets 51 and 52 fed from rolls 49 and 50, respectively, of sheet metal.

Roll support means for supporting the sheet metal rolls 49 and 50 comprise mounting frames 53 and 54, respectively, each of which carry a spindle 55 rotatably mounted in bearings 56. The spindles 55 engage cores 59 in the rolls 49 and 50. The mounting frame 54 is mounted at the upstream end of the main framework 45 and is slidable on rails 62 (see Fig. 12) in a direction transversely of the main passageway 45 for aligning the sheet 52 from the roll 50 in the main passageway 46. The rails 62 are mounted on the floor 44. A pneumatic ram 57 connected to the mounting frame 54 and anchored to the floor 44 slides the mounting frame 54 on the rails 62 for aligning the sheet 52 from the rolls 50. The mounting frame 53 is mounted on the top of the main framework 45 and is also slidable on transverse rails 80 on the main framework 45 transversely of the main passageway 46 by a pneumatic ram 81 to facilitate alignment of the sheet 51 from the roll 49 relative to the main passageway 46, see Fig. 7.

Photosensors 58 shown in block representation are mounted on the framework 45 downstream of the mounting frames 53 and 54 for monitoring a side edge 18 or 23 of the sheets 51 and 52 from the rolls 49 and 50. A signal from the photosensors 58 is fed to suitable control apparatus (not shown) which operates the corresponding pneumatic ram 57 for sliding the mounting frames 53 or 54 on the rails 52 to correct misalignment of the sheets 51 and 52 in the main passageway 46. Drums 60 and 61 rotatably mounted on the main framework 45 direct the sheet 51 from the roll 49 into the main passageway 46.

A deck 63 supports and guides sheets 64 of insulating material into the main passageway 46 between the sheets 51 and 52 from the rolls 49 and 50. The sheets 64 of insulating material form the Inner sheet 4 of the laminated panel 1. Feeding means comprising a pair of pneumatic rams 65 feed the sheets 64 into the upstream end 47 of the main passageway 46 so that the forward end of a following sheet 64 tightly abuts the trailing end of the next adjacent leading sheet 64. Furthermore, the rams 55 feed the sheets 64 of insulating material so that the forward ends of adjacent side by side sheets are staggered for strengthening the panels 1 and 13. The rams 65 are anchored to a suitable sub-framework (not shown).

Turning now to the main framework 45, pressing means for pressing and bonding the outer sheets 51 and 52 and the inner sheets 64 together comprise a plurality of pressure rollers, namely, upper pressure rollers 67 and lower pressure rollers 68. The pressure rollers 67 and 68 are rigidly mounted on shafts 66 which are rotatably mounted in the main framework 45 in bearings 74. The upper and lower pressure rollers 67 and 68 define between them the main passageway 46. A pair of longitudinal support members 69 extending on both sides of the main framework 45 carry the bearings 74 which rotatably support the lower pressure rollers 68. A frame 70 comprising a pair of side members 71 joined by cross members 82 carry the bearings 74 which rotatably carry the upper rollers 67. Only one cross member 82 is shown in Fig. 7. The frame 70 is adjustable vertically in the direction of the arrows C and D (see Fig. 6) for varying the pressure between the upper and lower pressure rollers 67 and 58, and also for accommodating panels with inner sheets 4 formed from sheets 64 of insulating material of different thickness. The frame 70 is supported on four threaded rods 73 which are rotatably carried in bearings (not shown) mounted on the main framework 45 at 83, see Fig. 7. Two threaded rods 73 are provided on opposite sides of the frame 70 and engage threaded bores (not shown) in brackets 75 extending from the side members 71 of the frame 70 for raising and lowering the frame 70. An electrically powered motor 76 mounted on the main framework 45 rotates one of the rods 73 for raising and lowering the frame 70. A chain 77 around sprockets 78 on the rods 73 operatively interconnect the rods 73 for even raising and lowering of the frame 70.

IS Means for drawing the sheets 51 and 52 from the rolls 49 and 50 and through the main passageway 46 comprises drive means for rotatably driving the upper and lower pressure rollers 67 and 68. The drive means comprises an electrically powered motor (not shown) which drives the rollers 67 and 68 through a drive transmission (not shown) θ Such drive transmissions will be well known to those skilled in the art. Although only three upper pressure rollers 67 and three lower pressure rollers 68 are illustrated, in practice, many more pressure rollers 67 and 68 will be provided.

Means for applying adhesive to the sheets 51 and 52 of sheet metal from the rolls 49 and 50 for bonding the sheets 51 and 52 to the inner sheets 64 comprise two pairs of similar manifolds 85 and 86 which extend transversely of the main framework 45 for dispensing adhesive over the entire width of the sheets 51 and 52. In this embodiment of the invention, a two part adhesive is used, one part of the adhesive is dispensed by the manifold 85 and the other part of the adhesive is dispensed by the manifold 86. One pair of manifolds 85 and 86 is provided at the top of the main frame 45 adjacent the mounting frame 53. The second pair of manifolds 85 and 86 is provided adjacent the mounting frame 54. The manifolds 85 and 86 adjacent the mounting frame 54 can clearly be seen in Fig. 12.

A plurality of jets (not shown) for delivering the parts of the adhesive onto the sheets 51 and 52 is provided in the manifolds 85 and 86. Pipes 87 feed the respective parts of the adhesive to the manifolds 85 and 86. Spreaders 88 each comprising a spreader flap 84 of flexible material are mounted on frames 89 and extend across the width of the sheets 51 and 52 for wiping the sheets 51 and 52, and accordingly, mixing and spreading the parts of the adhesive on the sheets 51 and 52, see Fig. 12. The spreader 88 adjacent the mounting frame 53 is similar to the spreader illustrated in Fig. 12. Reciprocating mechanisms (not shown) are provided for reciprocating the frames 89 and in turn the spreader flaps 84 transversely across the sheets 51 and 52 for mixing and spreading the adhesive. Such reciprocating mechanisms will be well known to those skilled in the art and the reciprocating mechanisms will not be described further in this specification.

Swaging means for forming the reinforcing channels 42 in the sheets 51 and 52 comprise two pairs of swaging rollers 90 in mounting brackets 91 mounted on the framework 45. One pair of swaging rollers 90 is mounted adjacent the mounting frame 53 for swaging the sheet 51. The other pair of swaging rollers 90 is mounted adjacent the mounting frame 54 for swaging the sheet 52.

Trimming means comprising a pair of milling cutters 92 driven by electrically powered motors 93 mounted at the upstream end of the main framework 45 form the recesses 27 in the insulating sheets 64 which subsequently form the recesses 27 In the inner sheet 4 for accommodating the tongues 14 of the outer sheets .

Folding means for folding the sheets 51 and 52 around the first, second and third fold lines 17, 20 and 21, respectively, to form the tongues 14 and grooves 15, and the fold lines 29 and 30 comprise a plurality of pairs of folding rollers (not shown) mounted in housings 96. The housings 96 are mounted on the main framework 45 in series on each side of the main passageway 46. The housings 96 comprising the folding rollers (not shown) for forming the tongue and groove on the sheet 51 are mounted on the side members 71 of the frame 70. The housings 96 comprising the folding rollers (not shown) for forming the tongue and groove on the sheet 52 are mounted on the side members 69 of the main framework 45, The folding rollers (not shown) engage portions of the sheets 51 and 52 adjacent the side edge 18 and 23 as the sheets 51 and 52 are drawn through the main passageway 46. The folding rollers (not shown) sequentially bend the sheets 51 and 52 in increments about the fold lines 17, 20 and 21, 29 and 30 to form the tongues 14 and grooves 15, respectively, as the sheets 51 and 52 are drawn through the main passageway 46. Such folding rollers will be well known to those skilled in the art and it is not intended to describe them further.

The continuous laminated sheet 43 is delivered at the downstream end 48 of the main passageway 46 into a first framework 100 which carries cutting means (described below) for transversely cutting the sheets 51 and 52 to facilitate subsequent parting of a laminated panel 1 or a laminated panel 13 from the continuous laminated sheet 43. The first framework 100 is rigidly mounted on the floor 44 relative to the main framework 45. An internal framework 103 is movablv mounted in the first framework 100 in a longitudinal direction relative to the longitudinal direction of the main passageway 46. Four bearing members 104 extending from the internal framework 103 slidably engage rails 105 on each side of the first framework 100 to facilitate longitudinal movement of the internal framework 103» Two spaced apart bearing members 104 engage each rail 105 to stabilise the internal framework 103. A shaft 108 rotatable in bearings (not shown) on the internal framework 103 rigidly carries pinions 107 which engage gear racks 109 on each side rail 105 for maintaining the internal framework 103 transversely aligned during longitudinal movement of the internal framework 103.

The cutting means for making the transverse cuts in the sheets 51 and 52 comprise three cutting blades 117, 118 and 119 which are mounted on and rotatably driven by electrically powered motors 122 mounted on the internal framework 103. The cutting blade 117 forms the transverse cut in the top sheet 51, while the cutting blades 118 and 119 form two transverse cuts in the lower sheet 52. The motors 122 which drive the cutting blades 118 and 119 are mounted on a platform 124. The platform 124 is carried on carrier brackets 125 which are slidably mounted on transverse carrier bars 126 extending transversely from side to side of the internal framework 103. A pneumatic ram (not shown) drives the platform 124 .from side to side in the internal framework 103 along the carrier bars 126 for making transverse cuts in the sheet 52. The motor 122 driving the cutting blade 117 is mounted on a platform 127 similar to the platform 124 which is slidably mounted on carrier bars 128 by carrier brackets 129. The carrier bars 128 extend between a pair of plate members 130 at opposite sides of the internal framework 103. The plate members 130 are carried on a pair of threaded rods 131 for vertical adjustment of the carrier bars 128 and in turn the platform 127 and the cutting blades 117 for accommodating laminated sheets 43 of different thickness. A pneumatic ram (not shown) drives the carrier platform 127 from side to side in the internal framework 103 along the carrier bars 128 for making the transverse cut in the sheet 51.

Clamping means comprising a clamp 134 clamps the internal framework 103 onto the laminated sheet 43 so that the internal framework 103 moves with the laminated sheet 43 while the cutting blades 117, 118 and 119 are making the transverse cuts in the sheets 51 and 52. The clamp 134 comprises a stationary clamping member 135 and a movable clamping member 136. The stationary clamping member 135 is rigidly mounted on the internal framework 103. Pneumatic rams 137 mounted on the internal framework 103 carry the movable clamping member 136 and operate the movable clamping member 136 for clamping the internal framework 103 onto the laminated sheet 43.

Counterweight (not shown) slidable in tubular members 140 in the first framework 100 is connected to the internal framework 103 by chains 141 around sprockets 143 mounted on the first framework 100 for returning the internal framework 103 towards the downstream end of the main framework 45 on release of the laminated sheet 43 by the clamp 134.

In order that the blades 117,, 118 and 119 form a clean transverse cut in the sheet 51 and 52, in other words, in order to avoid burrs being formed adjacent the first and second fold lines 17 and 20, respectively, of the outer sheets 5 of the laminated panels 1 and 13 first and second lead-in slots 145 and 146, respectively, see Figs. 15 and 16, are formed in the sheets 51 and 52 prior to forming the tongues 14 and grooves 15. One first lead-in slot 145 and one second lead-in slot 146 is formed in the sheet 51 in each location where a transverse cut 155 is to be made by the cutting blade 117. For convenience, the position where the transverse cut 115 is to be made is illustrated by the broken lines 115 in Figs. 15 and 16. Two adjacent first lead-in slots 145 and two adjacent second lead-in slots 146 are formed in the sheet 52 in each location where a transverse cut 155 is to be made. This is illustrated in Fig. 16.

Each first lead-in slot 145 is formed adjacent the side edge 18 of each sheet 51 and 52 and extends on both sides of the first fold line 17. Each first lead-in slot 145 extends on one side of the first fold line 17 to the adjacent side edge 18 and on the other side of the first fold line 17 a distance equal to the distance between the first fold line 17 and the side edge 18. In this embodiment of the invention, as can be seen, the first lead-in slots 145 extend inwardly from the side edge 18.

Each second lead-in slot 146 is formed in a location where each transverse cut 155 is to be made. Each second lead-in slot 146 extends from the second fold line 20 across the third fold line 21 to the side edge 23. The second lead-in slot 146 also extends a distance on the other side of the second fold line 20 which is similar to the distance between the second and third fold lines 20 and 21. In this embodiment of the invention, the second lead-in slots 146 extend inwardly from the side edge 23.

Accordingly, by providing the first and second lead-in slots 145 and 146 the cutting blades 117 to 119 only have to cut through the sheet metal 51 and 52 extending between the tongues and grooves 14 and 15, respectively. This avoids the cutting blades 117 to 119 having to cut through more than a single layer of sheet metal. It has been found that by providing the first and second lead-in slots 145 and 146, the danger of burrs being formed in the tongues or grooves 14 or 15 is virtually eliminated.

Punch means for forming the first and second lead-in slots 145 and 146 comprise pneumatically operated punches 148, 149, 150 and 151 mounted on the main framework 45. One pair of punches 148 and 149 are mounted at the top of the framework 45 downstream of the mounting frame 53 for respectively forming the first and second lead-in slots 145 and 146 in the sheet 51, see Figs. 13 and 14. Two pairs of punches 150 and 151 are mounted at the upstream end ox the main framework 45 just downstream of the mounting frame 54 for forming the adjacent respective first and second lead-in slots 145 and 146 in the sheet 52. The punches 148, 149, 150 and 151 of each pair are mounted on opposite sides of the main framework 45 for punching the first and second lead-in slots 145 and 146, respectively, on adjacent opposite side edges 18 and 23 of the sheets 51 and 52 which correspond to the outer sheets 5. Each punch 148, 149, 150 and 151 comprises a suitable punching member (not shown) for forming the respective first and second lead-in slots 145 and 146, respectively. Pneumatic rams (not shown) are provided in the punches 148 to 151 for operating the punch members.

Sensing means comprising a photosensor (not shown) is mounted in the internal frame 103 for detecting the first and second lead-in slots 145 and 146 so that on the first and second lead-in slots 145 and 146 being aligned with the cutting blades 117, 118 and 119 the internal framework 103 is clamped on to the laminated sheet 43 and the cutting blades 117 to 119 are moved transversely across the laminated sheet 43 for transversely cutting the sheets 51 and 52.

On the sheets 51 and 52 of the laminated sheet 43 having been transversely cut hy the cutting blades 117 to 119, the clamp 134 disengages the laminated sheet 43, which passes from the first framework 100 into a second framework 160 which comprises a further portion of the cutting means for cutting the insulating panels 64. The second framework 160 is mounted downstream of the first framework 100 and is longitudinally movable on a pair of rails 162 which are rigidly mounted on the floor 44. Eight pulley wheels 163 rotatably mounted on the second framework 160 rollablv engage the rails 162. The cutting means for cutting the sheet 64 of polystyrene material comprises a hot wire element 165 transversely stretched between a pair of anchor members 167 mounted on a carrier framework 169. The carrier framework 169 is slidably carried on vertical guide rods 171 by linear bearings 172 mounted on the carrier framework 169 which slidably engage the guide rods 171. The vertical guide rods 171 are carried on an intermediate framework 174 which is in turn longitudinally slidable on horisontal guide rods 175 which are carried on the second framework 160. Linear bearings 179 mounted on the intermediate framework 174 slidably engage the guide rods 175. A pneumatic ram 180 mounted between the intermediate framework 174 and the carrier framework 169 moves the carrier framework 169 vertically on the vertical guide rods 171 for passing the hot wire element 165 transversely through the sheet 64 perpendicularly to the plane of motion of the laminated sheet 43 for cutting the sheet 64 as will be described in more detail below. A pneumatic ram 182 mounted between the second framework 160 and the intermediate framework 174 moves the intermediate framework 174 horizontally on the guide rods 175 for moving the hot wire element 165 in a plane parallel to the direction of motion of the laminated sheet 43 for cutting the sheet 68 along a plane parallel to the direction of motion of the laminated sheet 43.

Clamping means is provided on the second framework 160 for clamping the second framework 160 onto the laminated sheet 43 so that the second framework 160 moves with the laminated sheet 43 during cutting of the sheet 64 with the hot wire element 65. The clamping means comprises a fixed clamping plate 184 and a movable clamping plate 185 mounted on the secondary framework 160. The fixed clamping plate 184 is rigidly mounted on the second framework 160. A pair of pneumatic rams 187 mounted on the second framework 160 and connected to the movable clamping plate 185 operate the movable clamping plate 185 for clamping the second framework 160 onto the laminated sheet 43.

Sensing means (not shown) comprising a photoelectric sensor Is mounted in the carrier framework 159 for detecting the transverse cut 155 formed in the sheet by the blades 117 for aligning the hot wire element 165 with the transverse cut 155. This enables the hot wire element 165 to pass through the transverse cut 155 in the sheet 51 into the sheet 64 for cutting thereof. On the photosensor (not shown) sensing the transverse cut 155 in the sheet 51 being aligned with the hot wire element 165, the second framework 160 is clamped onto the laminated sheet 43 by the clamping plates 184 and 185 so that the second framework 160 moves with the laminated sheet 43. A pneumatic ram (not shown) connected between the rails 162 and the second framework 160 returns the second framework 160 to a position adjacent the first framework 100 on the clamping plates 184 and 185 releasing the laminated sheet 43.

The rams 57, 65, 137, 180, 182 and 187 are supplied with high pressure air through pneumatic valves (not shown) the operation of which is controlled by control circuitry (not shown). The operation of the drive motors and punches are also controlled by the control circuitry. Such control circuitry will be well known to those skilled in the art and it is not intended to describe the control circuitry further here. However, the operation of the apparatus 2 under the control of the control circuitry will now be described.

Measuring means (not shown) for measuring the length of the laminated sheet 43 passing through the main passageway 45 engages the laminated sheet 43. Signals from the measuring means are relayed to the control circuitry which in turn activates the punches 148 to 151 for punching the lead-in slots 145 and 146 at appropriately spaced apart intervals. Such measuring means will be well known to those skilled in the art. For example, the measuring means may comprise a rotatably mounted wheel in rollable engagement with the laminated sheet.

Xn use, sheets 51 and 52 of metal are drawn from the sheet metal rolls 49 and 50 by the action of the upper and lower pressure rollers 67 and 68, The sheets 64 of insulating material are fed between the sheets 51 and 52 by the rams 65. Once the sheets 64 are provided between the sheets 51 and 52, the rotational action of the pressure rollers 67 and 68 on the sheets 51 and 52 draws the sheets 51 and 52 from the sheet metal rolls 49 and 50. As the sheets 51 and 52 are drawn from the sheet metal rolls 49 and 50, the swaging rollers 90 form the re-inforcing channels 42 in the sheets 51 and 52. The punches 148, 149, 150 and 151 form the first and second lead-in slots 145 and. 146 in the sheets 51 and 52. Where only one transverse cut is required in the sheet 52, for example, in the case of forming a panel with straight top and bottom ends, such as, for example, a roof panel, only one pair of punches 150 and 151 are operated for punching first and second lead-in slots 145 and 146 in the sheet 52. Where two cuts are to be provided in the sheet 52, the two pairs of punches 150 and 151 are operated. The pairs of punches 150 and 151 are spaced apart a distance similar to the spacing of the cutting blades 118 and 119. Two transverse cuts are required for forming the recess 12 in the top end 10 of the panel 1. Although not described, means for varying the longitudinal spacing between the cutting blades 118 and 119 and the longitudinal spacing between the pairs of punches 150 and 151 adjacent the mounting framework 54 are provided to accommodate different spacings between the two cuts in the sheet 52. Although only one set of cutting blades 117 for cutting the sheet 51 is provided, two spaced apart cutting blades could be provided for making two spaced apart cuts in the sheet 51. In such a case, two pairs of punches 148 and 149 would be mounted on the top of the framework 45 downstream of the mounting frame 53.

The two part adhesive is sprayed onto the sheets 51 and 52 as the sheets 51 and 52 are drawn beneath the manifolds 86. The spreaders 88 mix and spread the two part adhesive transversely over the sheets 51 and 52. As the sheets 51 and 52 are drawn through the main passageway 46 by the upper and lower pressure rollers and 68, the folding rollers in the housings 96 forra the tongues and grooves 14 and 15 on opposite sides of the sheets 51 and 52» The milling cutters 92 form the recesses 27 in the sheets 64. The control apparatus is set so that the pairs of punches 148 and 149 and 150 and 151 punch first and second lead-in slots 145 and 146, respectively, at locations where transverse cuts are to be made in the sheets 51 and 52» As the sheets 51 and 52 and 64 pass through the main passageway 46, the action of the pressure rollers causes the adhesive to bond the sheets 51 and 52 to the sheet 64» If desired, the rollers 67 and 68 may be heated to accelerate curing of the adhesive. The laminated sheet 43 passes from the main passageway 46 of the main framework 45 into the first framework 100» On the photosensor (not shown) mounted on the internal framework 103 detecting the first and second lead-in slots 145 and 146 in the sheets 51 being aligned with the cutting blade 117, the clamping member 136 is operated by the control circuit (not shown) for clamping the internal framework 103 onto the laminated sheet 43. The internal framework 103 then moves with the laminated sheet 43. With the blades 117, 118 and 119 rotating, the pneumatic rams (not shown) move the platforms 124 and 127 and in tum the cutting blades 117, 118 and 119 transversely relative to the laminated sheet 43 for making the transverse cuts. On the transverse cuts having been made, the clamping members 135 and 136 release the laminated sheet 43 and the internal framework 103 returns towards the downstream end 48 of the main passageway 46 for reengaging the laminated sheet 43 for making the next transverse cuts. The laminated sheet 43 continues through the second framework 160. On the photosensor (not shown) in the carrier framework 169 detecting the transverse cut in the sheet 51 being aligned with the hot wire element 165, the clamping plates 184 and 185 clamp the second framework 160 onto the sheet and the pneumatic ram 180 moves the carrier framework 169 vertically downwardly relative to the intermediate framework 174 for forming a cut for cutting into the sheet 64 of insulating material through a plane perpendicular to the direction of motion of the laminated sheet 43. In this embodiment of the invention, it is desired to form the recess 12 in rhe top end 10 of the panel 1 and accordingly, the pneumatic ram 180 moves the carrier framework 169 vertically until the hot wire element 1S5 is In a position halfway between the sheets 51 and 52 With the carrier framework 169 stationary relative to the intermediate framework 174, the pneumatic ram 182 then moves the intermediate framework 174 in an upstream direction relative to the second framework to form a cut in a plane parallel to the motion of the laminated sheet 43, in other words, parallel to the sheets 51 and 52 until the hot wire element is aligned with one of the transverse cut in the sheet 52, at which stage the pneumatic ram 182 holds the intermediate framework 174 in a fixed position relative to the second framework ISO and the pneumatic ram 180 moves the carrier framework 159 vertically downwardly to form a transverse cut which extends to the corresponding transverse cut in the sheet 52. On the sheet 64 being cut from the side adjacent the sheet 51 to the side adjacent the sheet 52 by the hot wire element 165, the clamping plates 184 and 185 release the second framework 160 from the laminated sheet 43, The ram (not shown) returns the second framework 160 to a position adjacent the first framework 100 for clamping on to the laminated sheet 43 to make the next cut in the sheet 64 for forming the next panel.

The panel 1 parted from the continuous laminated sheet 43 is removed. The bottom end of the panel 1 is formed with a remaining portion which was removed from the continuous sheet for forming of the recess 12 in the top end of another panel 1. This portion is separately removed by any suitable means, for example, a separate hot wire element or any other appropriate cutting tool. The cut through the sheet 64 is aligned with the other transverse cut in the sheet 52.

Pressure being imparted to the laminated sheets 51 and and 64 by the upper and lower pressure rollers 67 and 68 is adjusted by raising and lowering the framework 70. Should laminated panels 1 be required with the insulating sheet 64 of a different thickness, the relative position of the upper pressure rollers 67 is varied by raising or lowering the framework 70 as desired.

During operation of the apparatus 2,, should the photosensors 58 detect the sheets 51 or 52 becoming misaligned, the mounting frameworks 53 and 54 are transversely moved to compensate for the misalignment by the rams 57.

While the means for applying pressure to the laminated sheets has been described as being provided by pressure rollers, and the pressure rollers are used for drawing the sheet metal sheets through the passageway of the main framework, other suitable pressure means and other suitable drawing means may be provided. It will also be appreciated that other suitable feeding means for feeding the insulating sheet material may be used besides a pneumatic ram.

Needless to say, while the panels have been described as being provided with reinforcing channels, these are not essential. Further, any other suitable bonding means besides a two part adhesive may be used for bonding the sheets of sheet metal to the insulating material.

While it is preferable, it is believed that in manycases, it will not be essential to form the recesses in the inner panel to accommodate the tongues, and while the inner panel has been described as terminating at a position corresponding to the first fold line of the tongue, if desired, the panel may terminate at the tongue and extend on the other side edge to co-incide with the second fold line of the groove.

While the first and second lead-in slots have been described as extending a specific distance, the lead in slots may extend any distance from the first and second fold lines respectively.

Claims

1. , A method for forming a laminated panel comprising an inner sheet of insulating material sandwiched between a pair of outer sheets of sheet metal 5 material, the method comprising the steps of drawing from respective rolls a pair of continuous sheets of sheet metal material parallel to and spaced apart from each other to form the outer sheets, feeding a sheet of insulating material between the outer sheets, 10 bonding the outer sheets to the inner sheet to form a combined elongated continuous laminated sheet, folding each outer sheet along a first fold line adjacent one elongated side edge thereof, each first fold line being parallel to and spaced apart from the adjacent 15 side edge so that portion of each outer sheet between the first fold line and the said adjacent side edge overlaps the corresponding outer sheet to form an elongated tongue, each first fold line defining an ί edge of the respective sheet, folding each outer sheet 20 along second and third fold lines adjacent the other elongated side edge thereof to form an elongated groove for receiving a corresponding tongrie of an adjacent panel, the second and third fold lines of each outer sheet being parallel to and spaced apart 25 from the adjacent side edge and being spaced apart from each other, the third fold line of each outer sheet being intermediate the second fold line and the adjacent side edge, so that a first portion of each 3S outer sheet between the second and third fold line overlays the outer sheet and a second portion of each outer sheet between the third fold line and the adjacent side edge overlays the first portion to form with the first portion the elongated groove, transversely parting a portion of the laminated sheets from the continuous laminated sheet to form the laminated panel by cutting the continuous laminated sheet transversely thereof, wherein the method further comprises the step of forming first and second transverse lead-in slots adjacent respective side edges of each outer sheet prior to folding the outer sheets about the first, second and third fold lines, each first and second lead-in. slot being formed in a location corresponding to the location where a transverse cut is to be made for parting off a laminated panel, and each first lead-in slot being located in a position adjacent where the first fold line is to be formed and extending on each side thereof, each second lead-in slot being formed adjacent where the second fold line is to be formed and extending on each side thereof.

2. A method as claimed in Claim 1 in which the first lead-in slot extends an equal distance on each side of the first fold line, and extends on one side of the first fold line to the adjacent side edge.

3. A method as claimed in Claim 1 or 2 in which the second lead-in slot extends on one side of the second fold line from the second fold line to the adjacent side edge, and on the other side of the second fold 5 line for a distance equal to the distance between the second and third fold lines.

4. A method as claimed in any preceding claim in which the inner sheet extends on one side of the laminated panel to a position defined by the first or 10 second fold lines and on the other side of the panel to a position just short of the tongue or groove.

5. A method as claimed in Claim 4 in which the inner sheet extends to a position co-inciding with the first fold lines on one side of the laminated panel and to a 15 position co-inciding with the third fold lines on the other side of the laminated panel.

6. A method as claimed in any preceding claim in which the method further comprises the step of relieving an elongated longitudinal portion of the 20 inner sheet adjacent each tongue of a respective outer sheet.

7. A method as claimed in any preceding claim in which the laminated panel is parted from the continuous laminated sheet by cutting the outer sheets with a cutting blade movable transversely across the laminated sheet.

8. » A method as claimed in Claim 7 in which a pair of cutting blades are provided on opposite sides of the 5 continuous laminated sheet for making a transverse cut in the respective outer sheets.

9. A method as claimed in Claim 8 in which the blades are mounted on a platform movable in the direction of motion of the laminated sheet, the method comprising 10. The step of clamping the platform to the continuous laminated sheet during cutting.

10. A method as claimed in any preceding claim in which the location of the first and second lead-in slots are detected prior to making the transverse cuts 15 for aligning the cutting blades with the respective first or second lead-in slots.

11. A method as claimed in any preceding claims in which the inner sheet is cut by a heated wire.

12. A method as claimed in Claim 11 in which the 20 heated wire extends transversely of the continuous laminated sheet and is moved through the inner sheet from a position adjacent one of said outer sheets to a position in the inner sheet intermediate the inner and outer sheets, the heated wire being then moved through the inner sheet in a generally longitudinal direction relative to the direction of motion of the continuous laminated sheet, and the heated wire is then moved to 5 the other outer sheet.

13. A method as claimed in Claim 11 or 12 in which the inner sheet is cut after the outer sheets have been cut.

14. A method as claimed in Claim 13 In which the 10 heated wire is aligned with one of the transverse cuts in one of the outer sheets.

15. A method for forming a laminated panel, the method being substantially as described herein with reference to and as illustrated in the accompanying 15 drawings. IS. Apparatus for carrying out the method of any of Claims 1 to 15 for forming a laminated panel comprising an inner sheet of insulating material sandwiched between a pair of outer sheets of sheet 20 metal material, the apparatus comprising a main framework defining a main passageway therethrough in which the sheets are laminated to form a continuous laminated sheet, a pair of support means for rotatably supporting respective rolls of sheet metal material for forming the outer sheets, means for drawing the outer sheets from the rolls of sheet metal through the main passageway, feeding means for feeding the inner sheet between the two outer sheets prior to the outer sheets passing through the main passageway, pressing means for pressing the sheets together in the main passageway for bonding thereof, folding means for folding the outer sheets adjacent their side edges about the respective first, second and third fold lines for forming the respective tongues and grooves, punching means for punching the first and second slots prior to the inner and outer sheets entering the folding means, and cutting means for making a transverse cut in the continuous laminated sheet for parting off a laminated panel from the continuous laminated sheet.

16. 17. Apparatus as claimed in Claim 16 in which each punching means comprises a punch.

17. 18. Apparatus as claimed in Claim 17 In which each punch is mounted on the main framework upstream relative to the folding means.

18. 19. Apparatus as claimed in Claim 17 or 18 in which four punches are provided, two for punching the respective first and second slots on one outer sheet and the other two for punching the respective first and second slots on the other outer sheet.

19. 20. Apparatus as claimed in any of Claims 16 to IS in which each support means comprises a spindle rotatably mounted in a mounting framework adjacent the main 5 framework, each mounting framework being movable transversely relative to the main passageway for aligning the outer sheets with the main passageway.

20. 21. Apparatus as claimed in any of Claims IS to 20 in which trimming means are provided for relieving 10 portion of the insulated sheet adjacent the elongated tongues of the outer sheets, the trimming means being mounted intermediate the feeding means and the main passageway.

21. 22. Apparatus as claimed in any of Claims IS to 21 in 15 which means for applying an adhesive to the outer sheets are provided intermediate each roll support means and the main passageway.

22. 23. Apparatus as claimed in any of Claims 16 to 22 in which the pressing means comprises a plurality of 20 spaced apart upper and lower pressure rollers defining the main passageway therebetween.

23. 24. Apparatus as claimed in Claim 23 In which the means for drawing the sheets through the main passageway comprises drive means for rotating the pressure rollers for drawing the inner and outer sheets through the main passageway.

24. 25. Apparatus as claimed in any of Claims 14 to 24 in 5 which each folding means comprises a plurality of folding rollers arranged in series along the main passageway.

25. 26. Apparatus as claimed in any of Claims 16 to 25 in which the feeding means comprises a ram for urging the 10 inner sheet in a downstream direction in the main passageway between the outer sheets.

26. 27. Apparatus as claimed in any of Claims 16 to 26 in which the cutting means comprises a pair of spaced apart cutting blades, one of said cutting blades for 15 making a transverse cut in one of said outer sheets and the other of said cutting blades for making a transverse cut in the other of said outer sheets.

27. 28. Apparatus as claimed in Claim 27 in which the cutting blades are mounted in an internal framework, 20 the internal framework being movable relative to the main framework in a longitudinal direction relative to the direction of motion of the continuous laminated sheet, and clamping means are provided on the internal framework for releasably clamping the internal framework onto the continuous sheet of laminated material.

28. 29. Apparatus as claimed in Claim 27 or 28 in which the cutting means further comprises an elongated hot 5 wire element, the hot wire element being mounted in a carrier framework and extending transversely of the main passageway, the carrier framework being movable transversely of the main passageway for moving the hot wire element across the inner sheet from one outer 10 sheet to the other.

29. 30. Apparatus as claimed in Claim 29 in which the carrier framework is movable longitudinally relative to the main passageway for moving the hot wire element through the inner sheet at a position intermediate the 15 outer sheets in a generally longitudinal direction relative to the direction of motion of the continuous laminated sheet through the main passageway.

30. 31. Apparatus for forming a laminated panel, the apparatus being substantially as described herein with 20 reference to and as illustrated in the accompanying drawings.

31. 32. A laminated panel formed according to the method of any of Claims 1 to 15, the laminated panel comprising an inner sheet of insulating material sandwiched between a pair of outer sheets of sheet metal material.

32. 33. A laminated panel as claimed in Claim 32 in which the laminated panel is formed in apparatus according 5 to any of Claims 16 to 31»

33.

34. A laminated panel substantially as described herein with reference to and as illustrated in the accompanying drawings.