US20100031592A1 - Composite panel - Google Patents

Composite panel Download PDF

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Publication number
US20100031592A1
US20100031592A1 US12449469 US44946908A US2010031592A1 US 20100031592 A1 US20100031592 A1 US 20100031592A1 US 12449469 US12449469 US 12449469 US 44946908 A US44946908 A US 44946908A US 2010031592 A1 US2010031592 A1 US 2010031592A1
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US
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Patent type
Prior art keywords
panel
blocks
skin
external skin
external
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US12449469
Inventor
James Carolan
David Cookson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
KIINGSPAN RESEARCH AND DEVELOPMENTS Ltd
Original Assignee
KIINGSPAN RESEARCH AND DEVELOPMENTS Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26Building 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
    • E04C2/284Building 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
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26Building 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
    • E04C2/284Building 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
    • E04C2/292Building 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
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings 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
    • E04F13/0801Separate fastening elements
    • E04F13/0832Separate fastening elements without load-supporting elongated furring elements between wall and covering elements
    • E04F13/0833Separate fastening elements without load-supporting elongated furring elements between wall and covering elements not adjustable
    • E04F13/0835Separate fastening elements without load-supporting elongated furring elements between wall and covering elements not adjustable the fastening elements extending into the back side of the covering elements
    • E04F13/0837Separate fastening elements without load-supporting elongated furring elements between wall and covering elements not adjustable the fastening elements extending into the back side of the covering elements extending completely through the covering elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings 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
    • E04F13/0862Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of a number of elements which are identical or not, e.g. carried by a common web, support plate or grid
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49616Structural member making
    • Y10T29/49623Static structure, e.g., a building component
    • Y10T29/49629Panel

Abstract

A composite cladding panel 1 comprises a backing tray 2 and an external skin 3 with a layer of foam insulation material 4 such as a phenolic or polyurethane based foam material therebetween. One of the skins, in this case the external skin 3 has a plurality of tongue and mortise blocks 5 fastened to the panel 1 by fasteners 12. Each fastener 12 comprises a peel rivet having a mandrel, a stress plate, and a main body. Pilot holes 13 are first drilled through the blocks 5 and the rivet 12 is inserted. On operation of a rivet gun the main body curls up 22 and is clamped against the inside surface of the external skin 3. The blocks 5 are thereby efficiently and effectively clamped to the external skin 3. A composite insulating panel with an integrated high performance brick cladding is provided.

Description

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

Claims (13)

  1. 1-15. (canceled)
  2. 16. A composite cladding panel comprising an internal skin and an external skin with insulation material therebetween, one of the skins having a plurality of tongue and mortise blocks mounted directly to the panel by a mounting means to form a cladding.
  3. 17. The panel as claimed in claim 16 wherein the blocks have mounting holes and the mounting means comprises a fastener for insertion through the hole to fasten the block to the panel.
  4. 18. The panel as claimed in claim 17 wherein the fastener comprises a clamping fastener.
  5. 19. The panel as claimed in claim 18 wherein the clamping fastener comprises a peel rivet that clamps to the inside of the external skin.
  6. 20. The panel as claimed in claim 16 wherein the external skin of the panel has an adhesive on the inner face thereof.
  7. 21. The panel as claimed in claim 20 wherein the adhesive is applied to the inner face of the external skin prior to lay-down of liquid insulating foam reactants.
  8. 22. method for manufacturing a composite cladding panel comprising the steps of:
    manufacturing a composite insulating panel comprising an internal skin, an external skin with insulation material therebetween;
    providing a plurality of tongue and mortise blocks with mounting holes through the blocks;
    providing a plurality of fasteners;
    placing the blocks along at least portion of the external face of a skin; and
    fastening the blocks to the skin by inserting the fasteners through the holes in the blocks.
  9. 23. The method as claimed in claim 22 wherein the fastener comprises a clamping fastener for clamping to the inside of the external skin.
  10. 24. The method as claimed in claim 23 wherein the clamping fastener comprises a peel rivet.
  11. 25. The method as claimed in claim 24 comprising the step of fixing the blocks to the panel using the rivets.
  12. 26. The method as claimed in claim 22 comprising the steps of laying the external skin down with the outer side lowermost, applying an adhesive to the inner face of the external skin, applying liquid foam reactants over the adhesive, applying an internal skin over the liquid form reactants and heating the sandwich thus formed in an oven to form the composite insulating panel.
  13. 27. The method as claimed in claim 22 comprising boring holes through the blocks to provide the mounting holes.
US12449469 2007-02-12 2008-02-12 Composite panel Abandoned US20100031592A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
IE20070086 2007-02-12
IE2007/0086 2007-02-12
PCT/IE2008/000011 WO2008099372A1 (en) 2007-02-12 2008-02-12 A composite panel

Publications (1)

Publication Number Publication Date
US20100031592A1 true true US20100031592A1 (en) 2010-02-11

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ID=39247507

Family Applications (1)

Application Number Title Priority Date Filing Date
US12449469 Abandoned US20100031592A1 (en) 2007-02-12 2008-02-12 Composite panel

Country Status (5)

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

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100095952A1 (en) * 2008-10-16 2010-04-22 Fmi Products, Llc Masonry structure

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011150035A3 (en) 2010-05-28 2012-10-26 The Diller Corporation Cladding system for building laminates
WO2011154929A3 (en) * 2010-06-08 2013-01-03 Kingspan Holdings (Irl) Limited A structural infill wall panel module
DE102013221277A1 (en) * 2013-10-21 2015-04-23 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. A facade element and method of assembly

Citations (12)

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US3803791A (en) * 1972-12-18 1974-04-16 W Turnbull Device for and method of mounting wall facings
US4104840A (en) * 1977-01-10 1978-08-08 Inryco, Inc. Metal building panel
US4109436A (en) * 1974-11-27 1978-08-29 Adrien Berloty Reinforced foam building panel element
US4711606A (en) * 1985-02-18 1987-12-08 Sf-Vollverbundstein-Kooperation Gmbh Shaped (concrete) block for retaining walls and also a retaining wall
US4736560A (en) * 1986-12-01 1988-04-12 Engineered Construction Components (America) Peel rivet
US5031378A (en) * 1986-12-01 1991-07-16 Engineered Construction Components (America) Inc. Method of inserting a rivet into a roof structure
US5678369A (en) * 1992-12-28 1997-10-21 Ig-Technical Research Inc. Refractory/heat insulating panels
US6029416A (en) * 1995-01-30 2000-02-29 Golvabia Ab Jointing system
US6096416A (en) * 1997-06-26 2000-08-01 Altenberg; Milton J. Metal sandwich panels
US6108995A (en) * 1995-06-02 2000-08-29 Produits Alba, Inc. Block for the mortarless construction of a wall
US6332733B1 (en) * 1999-12-23 2001-12-25 Hamberger Industriewerke Gmbh Joint
US7621589B1 (en) * 2006-05-22 2009-11-24 Perry Gerome Panels for a walled enclosure

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DE3837217A1 (en) * 1987-12-09 1989-06-22 Asta Ullrich Gmbh Annweiler Am Multilayered, prefabricated structural panel
GB2214204B (en) * 1988-01-11 1992-06-10 Hunter Douglas Ind Bv A sandwich wall system panel
GB9127334D0 (en) * 1991-12-24 1992-02-19 Hunter Douglas Ind Bv Curtain wall cladding system
DE4320190C2 (en) 1993-06-18 1996-07-11 Heinemann Herbert Cladding for building walls
DE69819319D1 (en) 1997-05-21 2003-12-04 Kingspan Res & Dev Ltd Thermally insulated paneel
DE19804890A1 (en) * 1998-02-07 1999-09-02 Sonnleitner Holzwerk Gmbh Building wall for wooden houses
GB0006335D0 (en) 2000-03-17 2000-05-03 Thermaliner Insulation Sys Ltd Panel
WO2006064489A1 (en) 2004-12-14 2006-06-22 Kingspan Research And Developments Limited A composite cladding
EP1838938B1 (en) 2005-01-05 2017-08-09 Novabrik International Inc. A starter element for stackable inter-engaging bricks.

Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3803791A (en) * 1972-12-18 1974-04-16 W Turnbull Device for and method of mounting wall facings
US4109436A (en) * 1974-11-27 1978-08-29 Adrien Berloty Reinforced foam building panel element
US4104840A (en) * 1977-01-10 1978-08-08 Inryco, Inc. Metal building panel
US4711606A (en) * 1985-02-18 1987-12-08 Sf-Vollverbundstein-Kooperation Gmbh Shaped (concrete) block for retaining walls and also a retaining wall
US4736560A (en) * 1986-12-01 1988-04-12 Engineered Construction Components (America) Peel rivet
US5031378A (en) * 1986-12-01 1991-07-16 Engineered Construction Components (America) Inc. Method of inserting a rivet into a roof structure
US5678369A (en) * 1992-12-28 1997-10-21 Ig-Technical Research Inc. Refractory/heat insulating panels
US6029416A (en) * 1995-01-30 2000-02-29 Golvabia Ab Jointing system
US6108995A (en) * 1995-06-02 2000-08-29 Produits Alba, Inc. Block for the mortarless construction of a wall
US6096416A (en) * 1997-06-26 2000-08-01 Altenberg; Milton J. Metal sandwich panels
US6332733B1 (en) * 1999-12-23 2001-12-25 Hamberger Industriewerke Gmbh Joint
US7621589B1 (en) * 2006-05-22 2009-11-24 Perry Gerome Panels for a walled enclosure

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100095952A1 (en) * 2008-10-16 2010-04-22 Fmi Products, Llc Masonry structure

Also Published As

Publication number Publication date Type
WO2008099372A1 (en) 2008-08-21 application
EP2126245A1 (en) 2009-12-02 application
CA2679630A1 (en) 2008-08-21 application
GB0802567D0 (en) 2008-03-19 grant
GB2446521A (en) 2008-08-13 application
GB2446521B (en) 2011-11-16 grant

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Legal Events

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AS Assignment

Owner name: KIINGSPAN RESEARCH AND DEVELOPMENTS LIMITED,IRELAN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:CAROLAN, JAMES;COOKSON, DAVID;REEL/FRAME:023374/0389

Effective date: 20090811