WO1989000265A1

WO1989000265A1 - Angled laminate panel, apparatus and method of manufacture

Info

Publication number: WO1989000265A1
Application number: PCT/AU1988/000222
Authority: WO
Inventors: Norman Lindsay Wood
Original assignee: Norman Lindsay Wood
Priority date: 1987-06-29
Filing date: 1988-06-29
Publication date: 1989-01-12

Abstract

A laminate panel (6) comprises a first outer skin (8) and a second outer skin (11), the first and second outer skins (8, 11) each being bent to form a predetermined angle, and having insulation material (9) sandwiched between the first and second skins (8, 11). A cutter means is also disclosed having a first frame positioned above the panel for cutting a top surface (8), the first frame shaped substantially in accordance with the lateral cross-section of the panel (6), and a second frame pivotable about a point adjacent an apex of the panel and adapted to cut a bottom surface (11) of the panel, the cutter means further comprising clamping means to hold the cutter relative to the moveable panel to effect a cutting operation of the panel in a lateral direction. There is further disclosed apparatus for forming the panel and a method of manufacture thereof. The forming apparatus disclosed includes means for trimming and bending aluminium strip sheet, gluing and laminating, auxiliary forming and cutting, all in a continuous process.

Description

ANGLED LAMINATE PANEL, APPARATUS AND METHOD OF MANUFACTURE FIELD OF INVENTION

The present invention relates to laminate panels, particularly insulating panels and their manufacture. More 5 particularly, the present invention relates to laminate panels of any predetermined length, the panels being bent and formed to a prescribed angle. BACKGROUND ART

In recent times, the erection of buildings or ,_Q structures such as, cold storage facilities, site accommodation buildings, farm sheds, factories and indoor sporting complexes, has seen the use of pre-fabricated panels for the walls of the building. One such panel used for these structures is the stressed skin panel manufactured ₅ by Olympic General Products Pty. Ltd. comprising a slab of polystyrene sandwiched between two metal sheets of colorbond aluminium.

These panels are manufactured in a continuous fashion and are then cut into lengths of any size. Lengths ₀ of 10 metres or 30 feet or more are not uncommon for these buildings.

The construction of wall corners has been achieved to date by providing a mitred joining of two panels, requiring the angled cutting along the major edge of two _c panels and joining together the two panels with the aid of mastic, thereafter riveting an angled metal strip thereover to further seal the join. This procedure is undesirable. It is product, time consuming, expensive and requires at least two people to enable assembly of the corner. _Q Furthermore, the resultant join is weak and prone to leakages from the thermal air mass contained in the building, which leakage can render the insulating panel useless after a period of time. OBJECTS OF INVENTION An object of the present invention is to provide a corner panel that is an integral piece that can be manufactured quickly and used with the minimum of labour. - 2 -

A further object of the present invention is to provide a laminate panel which can be formed bent to a predetermined angle.

A further object of the present invention is to

_ provide a method and apparatus for manufacturing the panel b of the present invention. SUMMARY OF INVENTION

The present invention provides a laminate panel having a jointless corner.

The present invention provides a laminate panel

10 having a first and second outer skin, each skin being bent to a predetermined angle, and having an insulating material sandwiched therebetween. The panel may be formed in a continuous manner and later cut to any desired length.

The present invention also provides apparatus for 5 forming a bent laminate panel, the panel having first and second outer skins with an insulating material sandwiched therebetween, said first and second skins each being bent to form two sections arranged at a predetermined angle to each other, said apparatus comprising a housing or frame and sets 0 of rollers therein defining at least a pair of first passageways spaced from one another having at least one roller in each of said first passageways adapted to bend a respective outer skin received therein to said predetermined angle, there being further provided a space between the 5 skins to receive insulating material and comprising further rollers defining a second passageway that sandwich the insulating material between the first and second outer skins.

The present invention also provides an apparatus

30 for forming a bent laminate panel, the panel having first and second sheets bent to a predetermined angle and having insulation material laminated therebetween, the apparatus comprising a pair of sheet forming means each defining a

35 passageway for material in the form of a web or individual sheets whereby the sheet material is bent to form arms arranged at said predetermined angle relative to one another - upon movement of the sheet material through said passageway, and a space being provided between each said sheet forming means allowing insulation material to be introduced between the sheet material bent by said sheet forming means, and laminating means comprising a further passageway defined by rollers opposingly spaced apart to receive the sheet material having insulation material therebetween, the rollers being adapted to press the sheet material against the insulation material located therebetween to form said bent laminate panel.

Preferably, the apparatus further provides adhesion means enabling the elements to bond together when laminated or sandwiched. The adhesion means can take the form of wipers, brushes or spray nozzles applying adhesive to the insulating material or inside surfaces of the outer skins prior to the sandwiching of the elements. In circumstances where the adhesive requires the application of heat for setting or curing, heating means can be further provided as part of the adhesion means, whereby heat can be applied prior to and/or during sandwiching of the elements.

Preferably, the space between the pair of first passageways and also the space between the rollers of the second passageway are alterable in size, the space being altered according to thickness of insulating panel.

Preferably, the apparatus is also provided with cutting means to cut the insulated panel at any desired length. One example of cutting means may be rotating blades placed beneath and/or above the surfaces of the panel at a point after the insulating panel has been sandwiched together. The cutting means can be fixed to and moveable with the panel during the cutting operation, thereby allowing cutting of a continuously manufactured panel.

A further preferred feature of the apparatus is a set of rollers at the entry point of the first and second outer skins which rollers apply patterned ridges to one or each skin. The patterning can provide extra wall rigidity and strength. - 4 -

The present invention also provides cutter means comprising a first frame slidably mounted on an apparatus for sliding movement in a longitudinal direction, the apparatus providing a panel continuously moveable in the longitudinal direction, the first frame being positioned above the panel for cutting of a top surface, the first frame shaped substantially in accordance with the lateral cross-section of the panel, and a second frame pivotable about a point adjacent an apex of said panel and adapted to cut a bottom surface of the panel, the cutter means further comprising clamping means to hold the cutter relative to the moveable panel to effect a cutting operation of the panel in a lateral direction.

The present invention also provides cutter means comprising a first frame slidably mounted for sliding movement in a longitudinal direction on an apparatus, the apparatus providing a panel continuously moveable in the longitudinal direction, the first frame being positioned above the panel for cutting a top surface of the panel, the first frame shaped substantially in accordance with the lateral cross-section of the panel, and a second frame pivotable about a point adjacent an apex of said panel and adapted to cut a bottom surface of the panel, the cutter means further comprising at least two pads fixed to the first frame, one pad located to act on the top surface, the other pad located to act on the bottom surface, each pad having stops which are forced against each respective surface to hold the cutter means in relative position to the panel thereby holding the cutter in relative juxtaposition to the panel to effect a cutting operation of the panel in a lateral direction.

The present invention still further provides a method of forming a bent laminate panel comprising the steps of bending a first sheet to a predetermined angle, bending a second sheet to the predetermined angle, - - inserting insulation material between the bent first and second sheets, and laminating the insulation material between the first and second sheets.

_ According to a further aspect of the invention there is provided a method of manufacturing an insulated corner panel utilising the said apparatus, the method comprising the steps of bending outer skins to the required angle, inserting an insulating material therebetween and bonding the outer skins to form an insulating panel in a sandwiched or laminate fashion.

Due to geometrical considerations, the preferred configuration of a right angled corner insulating panel has one outer skin wider than the other by an amount that is twice the thickness of the panel to be made. The insulation 1b material inserted can be rectangular, preferably styrene slabs (with squared edges) that therefore abut each other.

One of the insulation slabs will also need to be wider by the same distance as the thickness of the panel so that the

_ major edges of the finished insulating panel will be flush and at right angles to the surfaces of the panel.

Alternatively, the insulating material may be of any width, whereby the insulating material is trimmed to the required width.

It can be seen from the above that the corner panel

•&_ 3 can be produced in a fraction of the time it presently takes to make a corner, with the added advantage of being a single component and therefore a stronger building element. The costs of making the corner panel are less than those _n associated with the manufacture of corners at present in that there is substantially no waste in the manufacture of the corner with no offcuts due to mitring and no requirement for metal stripping and silicon sealant.

The construction of the building using a corner _ panel according to the invention is simplified in that it does not require extra labourers to secure the corner in position compared to the number of labourers that would be normally used to join commonly available flat panels together. - 6 -

A preferred embodiment of the present invention will now be described with reference to the accompanying drawings, wherein:

Figure 1 shows the prior art corner panel.

Figure 2 shows one form of angled laminate panel according to the present invention.

Figure 3 shows, in block diagram form, one form of apparatus used to manufacture the laminate panel in a continuous process.

Figure 4 shows sheet metal rolls from which outer panel skins are obtained.

Figure 5 shows one form of sheet metal trimmer.

Figure 6 shows first bend means.

Figure 7 shows further bend means.

Figure 8 shows the gluing mechanism.

Figure 9 and 10 show insertion of insulation material and lamination means.

Figure 11 shows patterning means.

Figures 12 to 15 show a cutter means of the present invention.

Like numerals throughout the Figures denote like elements or components.

The following description will be made with reference to a panel useful in coolrooms. The panel elements commonly comprise, for this use, sheet metal (e.g. aluminium or steel) and polystyrene insulating material. The panel can be also used in building construction, for example offices, houses and warehouses. There are also other suitable purposes where a lightweight, cheap, insulating panel is of advantageous use. Obviously, sheet metals other than colorbond aluminium are useful, as would be known by those skilled in the art. Furthermore, other insulating materials are also useful, as also known by a skilled addressee.

Figure 1 shows a typical prior art coolroo corner comprising two mitred panels 3,4. Aluminium angle pieces 1,2 are used to seal the mitre join together with silicone sealant 5. Rivets (not shown) are used to hold the angle 1,2 to the panels 3,4. This arrangement often tends to leak, allowing moisture into the panel and thereby nullifying the panel's insulating properties.

The laminate panel 6 of the present invention 5 comprises an insulating panel angled or bent to a predetermined angle. The panel 6 may be formed at any given angle by simply altering or adjusting the bending means (100,120 in Figure 3) of the apparatus of the present invention. For the purpose of simplifying further 0 description, the following disclosure relates to a 90° corner laminate panel, an example of which is shown in Figure 2.

The panel comprises a first outer skin 8, a second outer skin 11, and sandwiched therebetween is insulating 5 material 9. Grooves 10 are preferably provided at each end of the panel to facilitate joining of the corner to another insulating panel in the conventional manner known to those skilled in the art.

As can be seen, the panel of the present invention 0 does not require a sealing arrangement at the corner. Furthermore, the panel 6 may be manufactured to any prescribed length, width and/or height in order to facilitate ease of installation.

Figure 3 shows, in block diagram form, an apparatus in accordance with the present invention for manufacturing the laminate panel hereinbefore described.

As shown in Figure 4, roll 20 and roll 40 are respective sources of sheet material 11 and 8, hereinafter referred to as first skin 11 and second skin 8. The sheet _Q material from roll 40 can be trimmed to a required width. In the case of a 90° corner panel, the second skin must have twice the width of the laminate panel trimmed since the inner surface of the panel is smaller than the outer surface. The amount of trim is proportional to the amount of bend or angle of the panel. A or both sheet(s) may be trimmed in order to obtain a laminate panel of desired width. - 8 - Figure 5 shows one form of trimmer 60, comprising adjustable bar 61 for positioning the cutter 63 in relation to the sheet material 8 so as to trim a^' equired amount from the sheet of roll 40. Bar 62 holds the cutter 63 in cutting _ς relationship with the sheet material. The cutter 63 can be a sharp edged disc, pivotable about an axle or pin located on bar 62. Cutting is effected by tension of the sheet in a longitudinal direction from being pulled through the apparatus and/or a co-operating plate or support under the

₁₀ sheet, holding the sheet in place coacting with the cutter 63. Roller 65 adds to also stabilise the sheet during cutting.

Figure 6 shows a pattern mechanism 80 for embossing the sheet material 8 and/or 11 by means of mechanical

₁₅ deformation. The figure shows a series of discs 81 which deform the sheet material 8. The discs are moveable about or with a bar 82 supported on another bar 83. This pattern mechanism 80 is cosmetic and is not essential to the present invention. The pattern 80 may be incorporated or be ₀ integral with the first bend means 100, or may be separated, if at all used. If incorporated with the bend means, bars 82 should form the angle of the first bend. In fact, it is possible for the patterning and bending to be accomplished by the same mechanism. 5 Figure 6 also shows first bend means 100, which is used to bend the sheet material 8 or 11 about an imaginary line 104. Further bending of the sheet may take place about line 104, until the sheet is bent to the predetermined angle. The bend means 100 comprises a longitudinal plate ₀ 101 positioned on the line 104, about which the sheet is bent, and non-horizontally extending arms or rollers 102, one located above and one below the sheet, which cause the sheet to be bent about plate 101 as the sheet passes through the arms 102. Preferably, the sheet is bent about its 5 centre lines so that a corner with equal length sides is produced. It is also possible to "off-centre" the bend line 104 by means of displacing the sheet laterally by way of alignment means 140 preferably comprising plates 141 and - - 142. The plates 141,142 serve to align the sheet material prior to bending at bend means 100. Further bending occurs about line 104.

Figure 7 shows further bend means 115 and final bend means 120, both having bending arms 117 and 122, respectively, above and below the sheet material. The bend at line 104 serves to align the sheet for further bending, the bend at line 104 being centred about the apex of arms 122. Further guide or alignment means 143 can also be used 0 to retain alignment of the bent sheet. As shown, the longitudinal lines denote a pattern on sheet 8 and there is provided a first bend 100 of approximately 10°; a further bend 115 of approximately 45° and a final bend 120 of 90°to form sheets 8 and 11 for a right angled corner laminate ,5 panel. It is to be understood that the sheet material can be formed to any angle, using at least two bend means, a first and a final bend means. Further bend means 115 are preferable only.

As can be seen in Figure 1 , both sheets 8 and 11 0 are bent in the same manner, and preferably at the same time. The bend means can be formed with three vertically spaced adjacent arms, thereby allowing each sheet to pass through each aperture formed between the arms. As the sheet is drawn through the aperture, the sheet is bent correspondingly to the angle formed by the arms of the bend means.

Figure 8 shows the next step, glue application. The glue applying mechanism 160 comprises a glue reservoir 161, a pump 162 and glue spreader 163. The apparatus has at 0 least two mechanisms 163, each side of the bend having a mechanism 164. A suitable glue can be fed to spreader 163 via a pump 162 or by a gravity feed system wherein the reservoir 161 is located higher than the spreader 163. Preferably the glue is drip fed onto the inside of sheets 8 5 and 11 and then distributed with the spreader 163. The spreader preferably takes the form of flat spreader blades (not shown) attached to the radially extending arms 164 in a propellor blade arrangement, the spreader extending from the - 10 - bend 104 to the outerside of the metal sheet. A blade arrangement is located on the inner side of sheet 11 and another blade arrangement is located on^' the inner side of sheet 8 so that glue application is distributed relatively c evenly to enhance lamination. Arm 165 may be used to keep sheets 8 and 11 apart to allow for glue application.

The glue may, alternatively, be applied by way of a spray gun (not shown). The spray gun can apply the glue in the space provided between sheets 8 and 11. The type of 0 glue application does depend on the type of glue used in the process, as would be known by those skilled in the art.

A heater 200 (not shown) may be located adjacent the glue mechanism 160 when a heat curing glue is used. The heater can begin "setting-off" the glue in preparation for

,g lamination of the panel.

Figures 9 and 10 show further step(s) in the manufacture of the bent laminated panel. Figure 9 shows sheets 8 and 11 with glue applied thereto, at point A. Insulation material 181 or other material which is to be

20 laminated between sheets 8 and 11 is inserted prior to lamination by laminating means 260. The insulation material, preferably styrene and most preferably polystyrene, is inserted in blocks having been cut or made to a desired thickness. The length of the styrene blocks is

2 not important, however large blocks are easier to insert between the sheets 8 and 11, if the insulation is inserted manually. The insulation material can be inserted between the sheets from both sides of the bend.

Guide means 240 is used to push and hold the

30 styrene towards the centre of the panel (i.e. towards the bend). In this way, gaps between styrene blocks is minimised.

Laminating means 260 comprises an elevator 265 which is adjustable vertically such that laminate panels of

35 various thicknesses can be accommodated. In practice, panels of thickness from about 25 mm to 200 mm can be accommodated. Other size thickness panels are not normally commercially desirable, although the apparatus of the present invention could be configured for thicker or thinner panels.

The elevator 265 comprises a rectangular type frame mounted about a main frame 268. Main rollers 261,262,263 and 264 (not shown) and further rollers 266 are used to compressively laminate sheets 8 and 11 and insulation 181 and are a means of moving the panel (drawing sheets 8 and 11 from the rolls and pushing the laminated panel to further processing in the machine). The rollers are configured as lower rollers

263,264,266 and upper rollers 261,262,269. The lower rollers are fixed at the desired angle at which the panel is to be bent to the frame 268. The upper rollers are fixed at the desired angle adjacent (vertically) the lower rollers to the elevator 265. As the elevator is raised or lowered to accommodate a particular thickness laminate panel, the upper rolls also moved vertically the same amount. Elevator movement can be accomplished by a series of chain driven screws or hydraulics such that the frame 268 and elevator 265 remain substantially parallel in a horizontal plane, thereby ensuring uniform panel lamination.

The upper rollers act on the upper sheet 8, and the lower rollers act on the lower sheet 11 to compress the sheets and insulation together as the glue sets. Further rollers 266 and 269 can be spaced at set intervals along the path of movement of the sheet, the intervals being such that delamination does not occur.

Further heater means 270 (not shown) may be interposed the rollers to assist in speeding up the curing of the glue.

The sheet material 8 and 11 used is preferably aluminium. This material is thin and the edges are usually sharp. To alleviate injury to persons working with the laminate panel, a sharp edge remover (not shown) which comprises a grooved disc or wheel located such that the sheet edge is deformed inwardly to the insulation material by the grooved wheel as the laminate panel is pushed out of the apparatus. - 12 -

The apparatus preferably also includes an insulation material patterning means as shown in Figure 11.

The pattern means 300 comprises a wheel having three discs thereon. The wheel is motor driven and causes grooves 302 in the insulation material 181. These grooves are used in the joining of insulation panels as known by those skilled in the art.

The laminate panel of the present invention is made in a continuous form. The rollers of the laminating means o 260 draw the sheet from the rolls of sheet 20,40 and push the manufactured bent laminated panel out of the machine. Therefore, it is necessary to cut the formed laminate panel. It is also desirable to cut the formed panel to any desired length. Figures 12, 13, 14 and 15 show cutter means 320 of 5 the present invention. The cutter is formed of two separately operating cutters, one cutter acts on the top (inner) surface of the panel as shown in Figure 12, the other acts on the bottom (outer) surface of the panel as shown in Figures 13 and 14. 0 Figure 15 shows a pneumatically operated pad 328 which is fixed to the frame of the cutter means. Pads are located at several positions on the frame, at least one pad operative to act on the lower surface of the panel and at least one other pad operative to act on the upper surface of the panel. The pads are preferably located adjacent each other on opposite sides of the panel. When the pads are activated, stops 329 are pushed against the surface of the panel and are held against the panel surface, effectively temporarily fixing the cutter frame to the panel. As aforementioned, manufacture of the laminate panel of the present invention is a continuous process, therefore the cutter, once fixed to the panel, must be moveable relative to the panel forming apparatus. The cutter is therefore slidingly mounted on the panel apparatus frame 326 by way of roller bearings slidable in a "C" channel frame 326. Furthermore, the cutter can be moved along the frame 326 relative to the laminate panel to effect cutting of the panel to any desired length. Figure 12 shows the top (inner) surface portion of cutter 320. The top portion comprises a pneumatic cylinder and arm 321, pivotally coupled to an arm 322 which is pivotably attached to saw 325. Another arm 328 has one side also pivotably coupled to the saw 325, the other side of which is slidingly received and pivotable in a pivot mechanism 323. The saw has a blade 324. Arm 328 acts to stabilise movement of the saw in a lateral direction. The top portion of cutter 320 operates to effect cut 340. The top portion also comprises first and second switches each located at opposite ends of the saw's 325 travel. The switches operate the power for the saw and trigger valve 341 which regulates the direction of travel of arm 321, by way of pneumatic cylinder 329. In its initial position (as shown in Figure 12), the arm 321 is fully extended. When activated, the first switch (not shown) turns "on" the saw 325 and triggers valve 341 to cause arm 321 to be drawn (inwards) towards its cylinder. As arm 321 is drawn inwards, the saw 325 is pushed and pivoted relative to the pivot mechanism 323 across one side of the surface of the laminate panel, thereby causing cut 340. The saw 325, preferably has rollers (not shown) located thereon to facilitate movement of the saw 325 across surface 8. The weight of saw 325 has been found satisfactory in maintaining saw 325 against surface 8 to cause effective cutting of surface 8.

At the apex of the bent panel, the rollers on the saw facilitate movement of the saw 325 up the other side of the surface 8. The arm 321 is now pulled further inwards to effect movement of the saw up the other side. Once the saw has travelled across surface 8, the second switch is activated, causing arm 321 to now move outwards causing the saw to return to its initial position. The saw can still be operative when returning to ensure a clean cut.

The cutting depth of the saw is set to puncture the metal surface 8 and to cut to a depth less than half the insulation material. The saw on the bottom side cuts surface 11 and also less than half the insulation material. The cut panel can then just be picked up, thereby fracturing the remaining insulation material along cut 340. As the saws for top and bottom operate independently, each saw cutting less than half the depth of insulation panel will avoid collision between the blades of the saw as they move along surfaces 8 and 11, respectively.

Figures 13 and 14 show the bottom (outer) surface portion of cutter 320. As shown, a power saw 345 with cutting blade 346 is slidingly mounted on a pivotable frame 344. The frame 344 pivots about a point 343 adjacent the apex of the bent laminate panel when arm 342 is pushed or pulled by pneumatic cylinder 341. Two switches (not shown) are located at the end points of the saw's travel. Another pivot switch is located adjacent point 343. Figure 13 shows saw 345 almost at its initial position. When activated, cylinder 341 draws arm 342 inwards, thereby pivoting frame 344 towards surface 11 of the laminate panel. When activated, saw 345 powers blade 346 for cutting and motor 347 is powered to drive the saw along the frame 344 and the panel by means of a continuous chain drive 348. This causes a cut in one (outer) side of the laminate panel. At point, 343, the pivot switch is activated causing activation of cylinder 341 which pushes arm 342 outwards. This causes frame 344 to pivot from the position shown in Figure 14 up into contact with surface 11. The saw then travels further along frame 344 thereby causing cut 350. At the end of the cut, a second switch is activated, causing motor 347 to reversably drive the saw back down that side of the panel, once again activating the pivot switch and causing the frame 344 to pivot into contact with the initial side of the laminate panel.

The top and bottom cutters are preferably set to opposingly cut the bent laminate panel. However, it may also be advantageous to have the top and bottom cutters adjustable in a longitudinal direction with the laminate panel, to effect longitudinally offset cutting of the panel.

One end of the laminate panel, which is to be used or coupled to a roof portion of a coolroom can have the sheet 8 (inner side) cut the thickness of the panel less than the length of sheet 11 (outside). This would allow for nestling of the roof panel in the removed portion of the bent laminate panel.

Modifications and variations to the above are herein contemplated as would be clear to those skilled in the art.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. A laminate panel comprising a first outer skin and a second outer skin, said first and second outer skins each being bent to form a predetermined angle, and insulation material sandwiched between said first and second skins.

2. A panel as claimed in Claim 1 or 2, wherein the predetermined angle is substantially 90°.

3. A panel as claimed in Claim 1 or Claim 2 , wherein the first and second skins are aluminium sheet.

4. A panel as claimed in any one of Claims 1 to 3, wherein the insulation material is polystyrene.

5. A panel as claimed in any one of Claims 1 to 4, wherein at least one groove is provided longitudinally extending along one edge of said insulation material, the or each groove being adapted to facilitate joining of the panel.

6. An apparatus for forming a bent laminate panel, the panel having first and second sheets bent to a predetermined angle and having insulation material laminated therebetween, the apparatus comprising a pair of sheet forming means each defining a passageway for sheet material in the form of a web or individual sheets whereby the sheet material is bent to form arms arranged at said predetermined angle relative to one another upon movement of the sheet material through said passageway, and a space being provided between each said sheet forming means allowing insulation material to be introduced between the sheet material bent by said sheet forming means, and - - laminating means comprising a further passageway defined by rollers opposingly spaced apart to receive the sheet material having insulation material therebetween, the rollers being adapted to press the sheet material against the insulation material located therebetween to form said bent laminate panel.

7. An apparatus as claimed in Claim 6, wherein adhesive applying means applies adhesive between the sheet material and the insulation material.

8. An apparatus as claimed in Claim 6 or Claim 7, wherein the insulation material is inserted after the sheet material is bent and before lamination.

9. An apparatus as claimed in any one of Claims 6 to

8, wherein guide means are provided prior to the laminating means, the guide means acting on the insulation material and directing the insulation material toward the bend in the sheet material.

10. An apparatus as claimed in any one of Claims 7 to

9, wherein the adhesve applying means comprises a glue spreader, the glue spreader being fed glue from a glue reservoir and having flat arms arranged in a propeller fashion, the spreader being rotatably driven to distribute the glue.

11. An apparatus as claimed in any one of Claims 6 to

10, further comprising trimmer means to trim excess material from said sheet material.

12. An apparatus as claimed in Claim 11, wherein the trimmer means is located prior to the sheet forming means.

13. An apparatus as claimed in any one of Claims 6 to 12, wherein pattern forming means are further provided to emboss at least one sheet or web of said sheet material.

14. An apparatus as claimed in any one of Claims 6 to

13, wherein the housing has arms defining a second pair of first passageways, the second pair of first passageways having their arms located to bend the sheets received therein to an initial angle.

15. An apparatus as claimed in any one of Claims 6 to

14, wherein edge forming means is provided to alleviate sharp edges from the sheet material, the edge forming means serving to bend the edge of the sheets inwardly toward the insulation material.

16. An apparatus as claimed in Claim 15, wherein the edge forming means is provided after the laminating means.

17. An apparatus as claimed in any one of Claims 6 to

16, wherein each of said passageways are adjustable to provide lamination of panels of varying thickness.

18. An apparatus as claimed in any one of Claims 6 to

17, wherein cutter means is provided to cut the bent laminated panel to a desired length.

19. Cutter means comprising a first frame slidably mounted on an apparatus for sliding movement in a longitudinal direction, the apparatus providing a panel continuously moveable in the longitudinal direction, the first frame being positioned above the panel for cutting of a top surface, the first frame shaped substantially in accordance with the lateral cross-section of the panel, and a second frame pivotable about a point adjacent an apex of said panel and adapted to cut a bottom surface of the panel, the cutter means further comprising clamping means to hold the cutter relative to the moveable panel to effect a cutting operation of the panel in a lateral direction.

20. A cutter as claimed in Claim 19, wherein the first frame is substantially V-shaped.

21. A cutter as claimed in Claim 19 or 20, wherein the cutter means further comprises a first saw means coupled to the first frame, the first saw means comprising a first powered blade for cutting the panel coupled to an arm slidingly pivotable about a point adjacent the apex of the panel, the arm being moveable in response to pneumatic pressure to force the saw means to cut the top surface of the panel.

22. A cutter as claimed in Claims 19, 20 or 21, wherein the cutter means further comprises a second saw means coupled to the second frame, the second saw means comprising a second powered blade for cutting the bottom surface of the panel, the second blade being motoringly driven along the bottom surface and further wherein pivot means is provided to pivot the second blade around the apex of the panel into contact with the remainder of the bottom side.

23. A method of forming a bent laminate panel comprising the steps of bending a first sheet to a predetermined angle, bending a second sheet to the predetermined angle, inserting insulation material between the bent first and second sheets, and laminating the insulating material between the first and second sheets.

SKP:RCTS:JC (7.20)