IE85804B1 - A composite insulating panel - Google Patents

A composite insulating panel Download PDF

Info

Publication number
IE85804B1
IE85804B1 IE2007/0411A IE20070411A IE85804B1 IE 85804 B1 IE85804 B1 IE 85804B1 IE 2007/0411 A IE2007/0411 A IE 2007/0411A IE 20070411 A IE20070411 A IE 20070411A IE 85804 B1 IE85804 B1 IE 85804B1
Authority
IE
Ireland
Prior art keywords
panel
overlap
portions
panel portions
insulating
Prior art date
Application number
IE2007/0411A
Other versions
IE20070411A1 (en
Inventor
Carolan James
Flynn Gregory
Original Assignee
Kingspan Research And Developments Limited
Filing date
Publication date
Application filed by Kingspan Research And Developments Limited filed Critical Kingspan Research And Developments Limited
Priority to IE2007/0411A priority Critical patent/IE85804B1/en
Publication of IE20070411A1 publication Critical patent/IE20070411A1/en
Publication of IE85804B1 publication Critical patent/IE85804B1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/046—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/292—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and sheet metal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
    • E04D3/351—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material
    • E04D3/352—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material at least one insulating layer being located between non-insulating layers, e.g. double skin slabs or sheets
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
    • E04D3/358—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation with at least one of the layers being offset with respect to another layer
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0875—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having a basic insulating layer and at least one covering layer
    • E04F13/0876—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having a basic insulating layer and at least one covering layer the covering layer comprising mutual alignment or interlocking means

Abstract

ABSTRACT An insulated panel 1 comprises a first panel portion 2 and a second panel portion 3 which are identical. Each panel portion 2, 3 comprises an outer profiled sheet 5 and an inner backing tray with a foam core 7 there between. The panel portions 2, 3 each have external sheet overlap parts 10, 11 and backing sheet overlap parts 23, 24. The corresponding overlap parts 10, ll, 23, 24 of adjacent panel portions 2, 3 are bonded together at the overlap. The bonding may be by an adhesive 15.

Description

A composite insulating panel Introduction The invention relates to composite insulation panels of the type comprising inner and outer skins with a body of insulating material therebetween.
Insulation panels of this type are widely known and used extensively, especially for roof and wall panels in buildings.
There are however limitations on the size of the panels that can be manufactured using known technologies.
There is therefore a need to provide an improved panel and associated manufacturing technique which will overcome at least some of these drawbacks.
Statements of Invention According to the invention there is provided a manufactured insulating panel comprising:- a first panel portion; and a second panel portion similar to the first panel portion the first and second panel portions each being of the type comprising a profiled metal external sheet and an internal metal backing tray having an insulating foam core therebetween, the panel portions each having an overlap part for receiving part of an adjacent like panel, on assembly, the first and second panel portions being bonded together at the overlap parts therebetween, wherein the overlap parts are side overlap parts, wherein the external sheet of the panel portions have a longitudinally extending recessed region along both side edges, the recess region along one side being filled with foam and defining a male side overlap part and i the recessed region along the opposite side being open to define a female overlap part for reception of the male overlap part of an adjacent panel portion; and wherein the recessed regions of the external sheets are bonded together at the side overlap, wherein the backing tray of the panel portions comprise a projecting part extending along one side edge and a recessed part extending along the opposite side edge, the projecting and recessed parts of the backing sheets of the panel sections being overlapped, and wherein the backing tray projecting part and recessed part of the panel portions are bounded together at the side overlap.
The recess regions may be of generally trapezoidal form.
In one case the panel portions are adhesively bonded.
In one embodiment at least one fiirther similar panel portion is bonded to the first or the second panel portion.
The manufactured insulated panel may have a width of from about 2 to 3 metres.
Preferably the manufactured panel has a width of about 2 metres.
In a preferred embodiment there are two panel portions and the width of each panel portion is half the width of the insulated panel.
The invention also provided a stack comprising a plurality of insulated panels of the invention.
The panels in the stack are preferably nested. Alternate panels in the stack are preferably in different orientations.
In another aspect the invention provides a method for manufacturing an insulating panel comprising the steps of:- providing a first insulating panel portion; providing a second insulating panel portion; the first and second panel portions each being of the type comprising a profiled external skin and an internal backing tray having an insulating core therebetween, the panel portions each having an overlap part for receiving part of an adjacent like panel portion, on assembly, the overlap parts comprise side overlap parts, the external sheet of the panel portions have a longitudinally extending recessed region along both side edges, the recess region along one side being filled with foam and defining a male side overlap part and the recessed region along the opposite side being open to define a female overlap part for reception of the male overlap part of an adjacent panel portion, and wherein the backing tray of the panel portions comprise a projecting part extending along one side edge and a recessed part extending along the opposite side edge, the projecting and recessed parts of the backing sheets of the panel sections being overlapped, placing the first and second panel portions such that corresponding overlap parts of the panel portions are engaged, and before, during or after the engagement of the overlap parts, bonding the panel portions at the joint therebetween to provide a manufactured insulating panel.
In one embodiment the method comprises the step, prior to engagement, of applying an adhesive to the overlap parts of the panel portions.
In one case, prior to application of the adhesive at least one of the side overlap parts are pre- treated. The pre-treatment may comprise heating.
In one embodiment the method comprises post-treating after joining of the panel portions. The post-treating may comprise pressing the panel portions together at the joint therebetween.
In one case the overlap parts are side overlap parts.
In one embodiment the method comprises the step of stacking the panels. The method may comprise the step of inverting alternate panels during stacking.
Brief Description of the Drawings The invention will be more clearly understood from the following description thereof given by way of example only, in which:- Fig. 1 is a cross sectional view of an insulating panel of the invention; Fig. 2 is a cross sectional view of one of the two panel portions which make up the panel of Fig. 1; Figs. 3(a) and 3(b) are cross sectional views illustrating the jointing of the panel portions to form the panel of Fig. 1; Figs. 4(a) to 4(b) are diagrams illustrating various steps in a method for manufacturing the panel of Fig. 1; and Figs. 5(a) to 5(b) are cross-sectional view illustrating anotherjointing of panel portions to form a panel.
Detailed Description Referring to the drawings and initially to Figs. 1 to 3 thereof there is illustrated a manufactured insulated panel 1 of the invention which comprises a first panel portion 2 and a second panel portion 3 which are identical. Each panel portion 2, 3 is approximately 1 metre wide and comprises an outer profiled metal sheet 5 and an inner backing tray 6 which is typically also of metal. A foam insulating core 7 which is a unitary body and may be, for example, of polyisocyanurate foam, is located between the inner and outer sheets 5, 6. The panel portions 2, 3 each have an overlap part, in this case a side overlap part 10, for receiving an overlap part I l of an adjacent panel portion 2, 3 on assembly.
The corresponding overlap parts 10, ll of adjacent panels 2, 3 are bonded together during — manufacture at the overlap therebetween. In this case adhesive 15 is applied to one or both of the overlap portions 10, 11 which may be pre-treated to receive the adhesive or post-treated (for example by pressing) after engagement to ensure positive bonding between the overlap parts of the panel portions 2, 3 and thereby forming a larger single panel I which is about 2 metres wide.
Adhesive may be applied in the form of beads l5(a), 15(b) as iilustrated in Figs. 5(a) and 5(b).
Such beads of adhesive can be readily applied in-line and provide particularly good sealing and bonding.
The external sheet 5 has a number of recesses which in this case are defined by trapezoidal shaped formations 20. One of the formations 20 is open to define a female overlap part 10 whilst the other formations 20 are filled with foam. The formation at the side of the panel section opposite to the side overlap part 10 defines a male side overlap part 1 1. When the panel sections are joined together during manufacture the male side overlap part I 1 of one section 3 is received in the female side overlap part 10 of an adjacent panel section 2 as shown for example in Figs. (a) and 5(b). It will also be noted that the backing sheet 6 of the panel sections 2, 3 have a projecting part 23 on one side and a recess or dimple 24 on the opposite side which on jointing, define a recess which is filled with adhesive 15b. Similarly, on jointing, adhesive 15a is squeezed between the male overlap part 1] and the female overlap part 10 of adjacent panel sections. We have found that these metal to metal adhesive bonds are particularly effective in providing a bonded weather proof joint. Because there is metal to metal bonding on both the backing sheet or tray and the external sheet the bonded panel has good strength during transportation and handling on site.
Advantages of the wide panel of the invention include speed of construction with less panel handling and consequential reduction in damage, less crane costs and the like. Further, the adhesive bonding of one panel to another before the panels are delivered to a construction site ensures that correct sealing and bonding between the joined panels can be assured. Thus quality assurance is improved. In addition, generally trailers are about 2 metres wide and can therefore more readily and efficiently accommodate the larger panel of the invention.
Referring to Figs. 4(a) through 4(k) the various steps in the manufacture of the panel I of the invention are illustrated. Firstly [Figs 4(a) to 4(c)] a plurality of panels 2, 3 are manufactured, for example as described in detail in our GB-A-2325640A the entire contents of which are herein incorporated by reference. Panels 2, 3 are drawn from a stack of the panels [Fig. 4(d)] and a pair of panels 2, 3 are placed side-by-side with their corresponding side overlap portions adjacent [F ig. 4(e)]. If the panels in the stack are nested, every second one is turned over. Adhesive 15 is applied [Fig. 4(f)] and then one of the panels 3 is lifted up, moved across, and dropped onto the overlap portion of the panel 2 [Fig. 4(g)]. Pressure may be applied at the joint [Fig. 4(h)] to ensure bonding. After curing, panels I may be stacked, for example by turning alternate panels I [FigS- 4(i), 40)]- The invention is not limited to the embodiments hereinbefore described which may be varied in detail within the scope of the claims.

Claims (20)

1. A manufactured insulating panel comprising:- 5 a first panel portion; and a second panel portion similar to the first panel portion the first and second panel portions each being of the type comprising a profiled external 10 metal sheet and an internal metal backing tray having a foam insulating core therebetween, the panel portions each having an overlap part for receiving part of an adjacent like panel, on assembly, the first and second panel portions being bonded together at the overlap parts 15 therebetween, wherein the overlap parts are side overlap parts, wherein the external sheet of the panel portions have a longitudinally extending recessed region along both side edges, the recess region along one side being filled with foam and defining a male side overlap part and the recessed region along the opposite side being open to define a female overlap part for reception of the male 20 overlap part of an adjacent panel portion; and wherein the recessed regions of the external sheets are bonded together at the side overlap. wherein the backing tray of the panel portions comprise a projecting part extending along one side edge and a recessed part extending along the opposite 25 side edge, the projecting and recessed parts of the backing sheets of the panel sections being overlapped, and wherein the backing tray projecting part and recessed part of the panel portions are bonded together at the side overlap. 30
2. An insulating panel as claimed in claim 1 wherein the recess regions are of generally trapezoidal form.
3. An insulating panel as claimed in claim 1 or 2 wherein the panel portions are adhesiveiy bonded.
4. An insulated panel as claimed in any of claims 1 to 3 wherein at least one further similar panel portion is bonded to the first or the second panel portion.
5. An insulated panel as claimed in any of claims 1 to 4 having a width of from about 2 to 3 metres.
6. An insulated panel as claimed in any of claims 1 to 5 having a width of about 2 metres.
7. An insulated panel as claimed in claim 5 or 6 wherein there are two panel portions and the width of each panel portion is half the width of the insulated panel.
8. An insulating panel substantially as hereinbefore described with reference to the accompanying drawings.
9. A stack comprising a plurality of insulated panels as claimed in any of claims I to 8.
10. A stack as claimed in claim 9 wherein the panels in the stack are nested.
11. A stack as claimed in claim 10 wherein alternate panels in the stack are in different orientations.
12. A method for manufacturing an insulating panel comprising the steps 0f:- providing a first insulating panel portion; providing a second insulating panel portion; the first and second panel portions each being of the type comprising a profiled external metal sheet and an internal metal backing tray having an insulating core therebetween, the panel portions each having an overlap part for receiving part of an adjacent like panel portion, on assembly, wherein the external sheet of the panel portions have a longitudinally extending recessed region along both side edges, the recess region along one side being filled with foam and defining a male side overlap part and the recessed region along the opposite side being open to define a female overlap part for reception of the male overlap part of an adjacent panel portion wherein the backing tray of the panel portions comprise a projecting part extending along one side edge and a recessed part extending along the opposite side edge, the projecting and recessed parts of the backing sheets of the panel sections being overlapped, placing the first and second panel portions such that corresponding overlap parts of the panel portions are engaged, and before, during or after the engagement of the overlap parts, bonding the panel portions at the joint therebetween to provide a manufactured insulating panel.
13. A method as claimed in claim 12 comprising the step, prior to engagement, of applying an adhesive to the overlap parts of the panel portions.
14. A method as claimed in claim 13 wherein prior to application of the adhesive at least one of the side overlap parts are pre-treated.
15. A method as claimed in claim 14 wherein the pre-treatment comprises heating.
16. A method as claimed in any of claims 12 to 15 comprising post-treating after joining of the panel portions.
17. A method as claimed in claim 16 wherein the post-treating comprises pressing the panel portions together at the joint therebetween.
18. A method as claimed in any of claims 12 to 17 comprising the step of stacking the panels.
19. A method as claimed in claim 18 comprising the step of inverting alternate panels during stacking.
20. A method for manufacturing an insulated panel substantially as hereinbefore described with reference to the accompanying drawings.
IE2007/0411A 2007-06-11 A composite insulating panel IE85804B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
IE2007/0411A IE85804B1 (en) 2007-06-11 A composite insulating panel

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
IEIRELAND13/06/20062006/0444
IE20060444 2006-06-13
IE20070004 2007-01-04
IE2007/0411A IE85804B1 (en) 2007-06-11 A composite insulating panel

Publications (2)

Publication Number Publication Date
IE20070411A1 IE20070411A1 (en) 2008-02-06
IE85804B1 true IE85804B1 (en) 2011-07-06

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