WO2020056450A1 - Composite panels - Google Patents

Composite panels Download PDF

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Publication number
WO2020056450A1
WO2020056450A1 PCT/AU2019/000145 AU2019000145W WO2020056450A1 WO 2020056450 A1 WO2020056450 A1 WO 2020056450A1 AU 2019000145 W AU2019000145 W AU 2019000145W WO 2020056450 A1 WO2020056450 A1 WO 2020056450A1
Authority
WO
WIPO (PCT)
Prior art keywords
frame
layers
layer
panel assembly
sheet
Prior art date
Application number
PCT/AU2019/000145
Other languages
French (fr)
Inventor
Daniel Charles Underwood
Original Assignee
Underwood Companies Holdings Pty 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
Publication date
Priority claimed from AU2018903563A external-priority patent/AU2018903563A0/en
Application filed by Underwood Companies Holdings Pty Ltd filed Critical Underwood Companies Holdings Pty Ltd
Publication of WO2020056450A1 publication Critical patent/WO2020056450A1/en

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8605—Walls made by casting, pouring, or tamping in situ made in permanent forms without spacers
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G9/00—Forming or shuttering elements for general use
    • E04G9/02—Forming boards or similar elements
    • E04G9/05—Forming boards or similar elements the form surface being of plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/688—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks the inserts being meshes or lattices
    • 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
    • B32B15/02—Layer formed of wires, e.g. mesh
    • 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
    • B32B15/08—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 synthetic resin
    • B32B15/085—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 synthetic resin comprising polyolefins
    • 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
    • B32B15/18—Layered products comprising a layer of metal comprising iron or steel
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • 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 form; Layered products having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
    • 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 form; Layered products 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 form; Layered products 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
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products 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 an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B32B37/065—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method resulting in the laminate being partially bonded
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/144—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/18—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
    • B32B37/182—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only one or more of the layers being plastic
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/66—Sealings
    • E04B1/665—Sheets or foils impervious to water and water vapor
    • 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
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
    • E04C2/205—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced
    • 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
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
    • E04C2/22—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics reinforced
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G9/00—Forming or shuttering elements for general use
    • E04G9/08—Forming boards or similar elements, which are collapsible, foldable, or able to be rolled up
    • E04G9/083—Forming boards or similar elements, which are collapsible, foldable, or able to be rolled up which are foldable
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G9/00—Forming or shuttering elements for general use
    • E04G9/10—Forming or shuttering elements for general use with additional peculiarities such as surface shaping, insulating or heating, permeability to water or air
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/38—Meshes, lattices or nets
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B32B2307/7242—Non-permeable
    • B32B2307/7246—Water vapor barrier
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B32B2307/734—Dimensional stability
    • B32B2307/736—Shrinkable
    • 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
    • B32B2311/00—Metals, their alloys or their compounds
    • B32B2311/30—Iron, e.g. steel
    • 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
    • B32B2323/00—Polyalkenes
    • B32B2323/04—Polyethylene
    • 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
    • B32B2323/00—Polyalkenes
    • B32B2323/04—Polyethylene
    • B32B2323/046—LDPE, i.e. low density polyethylene
    • 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
    • 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
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/42—Gratings; Grid-like panels
    • E04C2/421—Gratings; Grid-like panels made of bar-like elements, e.g. bars discontinuous in one direction
    • E04C2/422—Gratings; Grid-like panels made of bar-like elements, e.g. bars discontinuous in one direction with continuous bars connecting at crossing points of the grid pattern

Definitions

  • THIS INVENTION relates to composite panels and in particular but not limited to composite panels forming lost formwork for inhibiting moisture passage across the formwork.
  • EP2857605A1 is considered relevant but according to the report lacks perforated heat securement layer but according to the report that feature may be provided by US4150186.
  • the perforations in US4150186 are used to draw hot melt adhesive by suction as part of the particular and quite different process described in that patent.
  • a composite panel assembly having a structural grid frame supporting at least two layers of thin plastics film, the first layer being a securement layer and the second layer being a moisture impermeable layer, the layers being secured to the frame.
  • the layers are secured together and thereby being secured to the frame.
  • the layers may be a tight fit and secured about a peripheral edge of the frame as an envelope or across mating surfaces or through the frame or be independently secured to the frame.
  • the composite panel assembly comprises a sandwich structure where the frame is between the securement layer and the moisture impermeable layer.
  • the layers are secured to each other through spaces in the frame.
  • the securement layer may be used to secure the assembly by being heated to shrink about the frame and/or heated to weld itself to the other layer without affecting the moisture impermeability characteristic of that layer.
  • a margin of at least a portion of the securement layer be wrapped around and over the frame and a corresponding margin of the other layer so that upon a heating and rolling stage the wrapped over portion adheres to the other sheet and by reason of its shrinkage pulls both sheets drum tight over the frame
  • the heating and rolling stage preferably includes the use of one or more blowers to aid adhesion of the overlapping marginal edge portions of the layers.
  • the frame may be of a metal grid frame and may be a rigid frame or may be bendable or otherwise deformable so that it may be fashioned into different formwork shapes as in for example a trench like shape for footings and so on.
  • the plastics layers may be applied so that in a finished flat assembly the whole assembly may be deformed as may be required.
  • marginal end portions of adjacent assemblies may overlap or a tape may be employed with the tape overlapping abutting edges.
  • the frames have a grid of wires, typically welded together at the junctures of the wires in one embodiment at least the first wire running along the line of the intended overlap is located on the opposite side of the frame so that the wires extending across the overlap of the overlapping panels are in contact across the full width of the overlap by reason of the wire being on the opposite side.
  • the marginal edge regions of the moisture impermeable layer may extend out and around onto the opposite side of the frame.
  • the present invention resides in a method of producing a composite panel assembly as described above, the method including the following steps:-
  • step (2) includes the further step of applying the moisture impermeable layer to the frame with an edge region or otherwise accumulated marginal edge region and step (3) includes the further step of applying the securement layer over the marginal edge region and then securing them together.
  • the panel assemblies may be joined together along edges, at least to juxtaposed panel assemblies, the use of a tape, a first panel assembly having a vertical edge, the tape secured to the first panel assembly along a margin and having a fold which extends along the edge, the tape having a releasable layer adapted to be peeled away to expose about half of an adhesive layer and in use being peeled away the full vertical length of the first panel assembly, at the same time or subsequently upon a second panel assembly having a matching vertical edge being brought into abutment or overlaying the edge of the first panel assembly, a further release sheet being progressively peeled away to expose more of the adhesive layer and as it is peeled away the tape may be manually applied to the second panel assembly, thus the two panel assemblies
  • Figure 1 is an underside view of a composite panel assembly according to a preferred embodiment of the present invention.
  • Figures 2 and 3 are a details 2 and 3 from Figure 1 ;
  • Figure 4 is a schematic section through a panel just prior to entering an oven, the section being across the direction of travel;
  • Figures 5A and 5B are drawings showing the passage of a panel assembly through a heating process
  • FIG. 6 is detail of the process by which the sheets are heated and welded together in accordance with Figures 5A and 5B;
  • Figures 7 through 9 are drawings showing how two adjacent panel assemblies may be joined or connected along adjacent vertical edges.
  • FIG. 1 Referring to the drawings and initially to Figures 1 through 3 there is illustrated a composite panel assembly 10 comprising a sandwich structure using a structural grid frame 11 between an underside of heat shrink plastic sheet 12 and an upper side moisture impervious sheet 13
  • the view in Figures 1 and 3 is from an underside and along the edges of the sheet 12 at 14 there is shown a congealed mass where respective edges of the sheets 12 and 13 have been welded together during a heating process and also along each 15 and 16 noting that the sheet has been fed into a heater in the direction of arrow 17.
  • the relative shrinkage is such that the edge of sheet 12 has started on the upper side and has pulled the sheet 13 around the frame to the opposite side so that margin of the sheet 12 is on the underside.
  • the sheet 12 is perforated to allow air to be expelled as the composite panel is being formed in an oven while passing through upper and lower rollers as depicted more clearly in Figure 6. This process results in the spaces between the grid like frame being occupied by the plastics sheets and the plastic sheets therein being welded together across the surface at 18.
  • FIG. 4 there is illustrated the arrangement of the sheets 12 and 13 as they reach the rollers.
  • This is a schematic only it being appreciated that in a dynamic process blowers are used to lift the margin 19 and as the assembly moves through an oven at an appropriate temperature and speed, the sheets soften, the margins 19 will sag onto the sheet 13 and the welding process and shrinking process will begin, the press rollers will then push the sheets together along the edges and inside the frame. Air will also be expelled by the rollers through the perforated heat shrinkable sheet 12.
  • the marginal edge section 19 is wrapped around and overlapping the vapour impermeable sheet 13 at its marginal edge 20 on each side so that as the panel passes through the rollers 21 and 22 and pressure is duly applied as illustrated in Figure 6 the marginal edge section 19 adheres to the marginal edge section 20.
  • the heat shrinkable sheet pulls the other sheet around the edge 23 of the grid frame to the position illustrated in Figure 1 thus both sheets of plastic have become taught while at the same time being welded together along the side edges and in the spaces 18.
  • a roller conveyor not shown carries the frame 11 which draws the plastic sheets off rollers 24 and 25, the roller 25 being marginally wider as shown in Figure 4, a heated cutter 26 at the entrance to oven cuts and welds what becomes the trailing edge of one panel 27 from the leading edge of the next panel 28. Leading edge 28 is shown just about to enter the rollers 21 and 22.
  • the present invention results in a composite panel that has plastics sheet drawn tight around a frame.
  • a tape In order to use the panels in an assembly of the panels applicant has devised the use of a tape.
  • a first panel 30 has a vertical edge 31
  • a tape 32 is secured to the panel along a margin 33 and has a fold 34 which extends parallel with edge 31. This can be made up at the factory or it can be added on-site.
  • a release sheet 35 may be peeled away as shown in Figure 8 to expose about half of an adhesive layer 36, this is peeled away the full vertical length of the panel 30.
  • a release sheet 39 may be progressively peeled away to expose more of the adhesive layer 36 and as it is peeled away the tape may be manually applied to panel 37. This the two panels a sealed together. This may be repeated with more panels to make a line of panels.
  • the panel assembly shown in solid on the right would have its first wire deprivedd on the opposite side to that shown so that the next panel may slide into overlap without the wire interfering. This means the edge of the panel shown in phantom would slide up and abut with the next wire. If the overlap is more than than more wires would be welded onto the opposite side. It follows that frames could be made with one wire on each edge welded onto the opposite side and it is just a matter of flipping alternative panels.

Abstract

A composite panel assembly (10) comprising a sandwich structure using a structural grid frame (11) between an underside of heat shrink plastic sheet (12) and an upper side moisture impervious sheet (13). The edges of the sheet (12) at (14) form a congealed mass where respective edges of the sheets (12) and (13) have been welded together during a heating process and also along each (15) and (16) noting that the sheet has been fed into a heater and that the relative shrinkage is such that the edge of sheet (12) has started on the upper side and has pulled the sheet (13) around the frame to the opposite side so that margin of the sheet (12) is on the underside.

Description

COMPOSITE PANELS
TECHNICAL FIELD
[0001] THIS INVENTION relates to composite panels and in particular but not limited to composite panels forming lost formwork for inhibiting moisture passage across the formwork.
BACKGROUND
[0002] Concrete construction often employs formwork that is stripped after concrete has sufficiently cured. In other cases lost formwork is left in-situ. Moisture at any time can be detrimental to the finished concrete. It is an object of the present invention to provide a panel which may be used in concrete formwork, especially lost formwork, to inhibit the passage of moisture across the formwork.
[0003] The International Search Report conducted by the Patent Office in respect of Provisional Application 2018903563 revealed the following patent documents EP2857605A1 ;
EP1837164A2; US4150186; US5023143; US5676894. In that report EP2857605A1 is considered relevant but according to the report lacks perforated heat securement layer but according to the report that feature may be provided by US4150186. However, upon close examination the perforations in US4150186 are used to draw hot melt adhesive by suction as part of the particular and quite different process described in that patent.
OUTLINE
[0004] In one broad aspect there is provided a composite panel assembly having a structural grid frame supporting at least two layers of thin plastics film, the first layer being a securement layer and the second layer being a moisture impermeable layer, the layers being secured to the frame. Preferably, the layers are secured together and thereby being secured to the frame. The layers may be a tight fit and secured about a peripheral edge of the frame as an envelope or across mating surfaces or through the frame or be independently secured to the frame.
[0005] In a preferred embodiment the composite panel assembly comprises a sandwich structure where the frame is between the securement layer and the moisture impermeable layer. Typically, in this embodiment the layers are secured to each other through spaces in the frame.
[0006] The securement layer may be used to secure the assembly by being heated to shrink about the frame and/or heated to weld itself to the other layer without affecting the moisture impermeability characteristic of that layer. In this regard there is preferably a temperature differential between the melting points of the plastics employed so that during a process heating phase, heat is applied to effect the securement layer to a greater degree that the moisture impermeable layer. As part of this process it is preferable that a margin of at least a portion of the securement layer be wrapped around and over the frame and a corresponding margin of the other layer so that upon a heating and rolling stage the wrapped over portion adheres to the other sheet and by reason of its shrinkage pulls both sheets drum tight over the frame The heating and rolling stage preferably includes the use of one or more blowers to aid adhesion of the overlapping marginal edge portions of the layers.
[0007] The frame may be of a metal grid frame and may be a rigid frame or may be bendable or otherwise deformable so that it may be fashioned into different formwork shapes as in for example a trench like shape for footings and so on. The plastics layers may be applied so that in a finished flat assembly the whole assembly may be deformed as may be required.
[0008] Preferably, in use marginal end portions of adjacent assemblies may overlap or a tape may be employed with the tape overlapping abutting edges. Where the frames have a grid of wires, typically welded together at the junctures of the wires in one embodiment at least the first wire running along the line of the intended overlap is located on the opposite side of the frame so that the wires extending across the overlap of the overlapping panels are in contact across the full width of the overlap by reason of the wire being on the opposite side. [0009] The marginal edge regions of the moisture impermeable layer may extend out and around onto the opposite side of the frame.
[0010] In another aspect the present invention resides in a method of producing a composite panel assembly as described above, the method including the following steps:-
(1) providing a supporting frame;
(2) applying the said two layers to the frame;
(3) subsequently heating the frame and the layers applied thereto to complete securement of the layers to the frame.
[0011 ] Preferably step (2) includes the further step of applying the moisture impermeable layer to the frame with an edge region or otherwise accumulated marginal edge region and step (3) includes the further step of applying the securement layer over the marginal edge region and then securing them together. In use, the panel assemblies may be joined together along edges, at least to juxtaposed panel assemblies, the use of a tape, a first panel assembly having a vertical edge, the tape secured to the first panel assembly along a margin and having a fold which extends along the edge, the tape having a releasable layer adapted to be peeled away to expose about half of an adhesive layer and in use being peeled away the full vertical length of the first panel assembly, at the same time or subsequently upon a second panel assembly having a matching vertical edge being brought into abutment or overlaying the edge of the first panel assembly, a further release sheet being progressively peeled away to expose more of the adhesive layer and as it is peeled away the tape may be manually applied to the second panel assembly, thus the two panel assemblies a sealed together.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In order that the present improvements may be more readily understood and put into practical effect reference will now be made to the accompanying drawings and wherein:-
Figure 1 is an underside view of a composite panel assembly according to a preferred embodiment of the present invention;
Figures 2 and 3 are a details 2 and 3 from Figure 1 ;
Figure 4 is a schematic section through a panel just prior to entering an oven, the section being across the direction of travel;
Figures 5A and 5B are drawings showing the passage of a panel assembly through a heating process;
Figure 6 is detail of the process by which the sheets are heated and welded together in accordance with Figures 5A and 5B; and
Figures 7 through 9 are drawings showing how two adjacent panel assemblies may be joined or connected along adjacent vertical edges.
METHOD OF PERFORMANCE
[0013] Referring to the drawings and initially to Figures 1 through 3 there is illustrated a composite panel assembly 10 comprising a sandwich structure using a structural grid frame 11 between an underside of heat shrink plastic sheet 12 and an upper side moisture impervious sheet 13 The view in Figures 1 and 3 is from an underside and along the edges of the sheet 12 at 14 there is shown a congealed mass where respective edges of the sheets 12 and 13 have been welded together during a heating process and also along each 15 and 16 noting that the sheet has been fed into a heater in the direction of arrow 17. It will be appreciated that the relative shrinkage is such that the edge of sheet 12 has started on the upper side and has pulled the sheet 13 around the frame to the opposite side so that margin of the sheet 12 is on the underside.
[0014] The sheet 12 is perforated to allow air to be expelled as the composite panel is being formed in an oven while passing through upper and lower rollers as depicted more clearly in Figure 6. This process results in the spaces between the grid like frame being occupied by the plastics sheets and the plastic sheets therein being welded together across the surface at 18.
[0015] Referring now to Figure 4 there is illustrated the arrangement of the sheets 12 and 13 as they reach the rollers. This is a schematic only it being appreciated that in a dynamic process blowers are used to lift the margin 19 and as the assembly moves through an oven at an appropriate temperature and speed, the sheets soften, the margins 19 will sag onto the sheet 13 and the welding process and shrinking process will begin, the press rollers will then push the sheets together along the edges and inside the frame. Air will also be expelled by the rollers through the perforated heat shrinkable sheet 12. The marginal edge section 19 is wrapped around and overlapping the vapour impermeable sheet 13 at its marginal edge 20 on each side so that as the panel passes through the rollers 21 and 22 and pressure is duly applied as illustrated in Figure 6 the marginal edge section 19 adheres to the marginal edge section 20. The heat shrinkable sheet pulls the other sheet around the edge 23 of the grid frame to the position illustrated in Figure 1 thus both sheets of plastic have become taught while at the same time being welded together along the side edges and in the spaces 18.
[0016] Referring now to Figures 5A and 5B a roller conveyor not shown carries the frame 11 which draws the plastic sheets off rollers 24 and 25, the roller 25 being marginally wider as shown in Figure 4, a heated cutter 26 at the entrance to oven cuts and welds what becomes the trailing edge of one panel 27 from the leading edge of the next panel 28. Leading edge 28 is shown just about to enter the rollers 21 and 22.
[0017] Before entering the oven the bottom sheet 12 lays flat along its side edges. In the oven blowers are used to lift the side edges and as it softens it will approximate the arrangement of Figure 4 so that as it passes through the rollers 21 and 22 and combined with the relative shrinkage properties as the whole assembly cools it is transformed to the arrangement of Figures 1-3.
EXAMPLES
[0018] Set out in the table below are examples of two applications of the above invention where a first perforated sheet is used with a similar characteristic sheet and in the second column a relatively thin high shrink film or films are used with a thicker non-permeable sheet.
TECHNICAL SPECIFICATION
Figure imgf000007_0001
Figure imgf000008_0001
Figure imgf000009_0001
[0019] The present invention results in a composite panel that has plastics sheet drawn tight around a frame. In order to use the panels in an assembly of the panels applicant has devised the use of a tape. One example is shown in Figures 7 through 9. A first panel 30 has a vertical edge 31 , a tape 32 is secured to the panel along a margin 33 and has a fold 34 which extends parallel with edge 31. This can be made up at the factory or it can be added on-site. A release sheet 35 may be peeled away as shown in Figure 8 to expose about half of an adhesive layer 36, this is peeled away the full vertical length of the panel 30. At the same time or subsequently upon a second panel 39 (in phantom in Figure 9) with its vertical edge 38 brought into abutment with edge 31 a release sheet 39 may be progressively peeled away to expose more of the adhesive layer 36 and as it is peeled away the tape may be manually applied to panel 37. This the two panels a sealed together. This may be repeated with more panels to make a line of panels. In the case where panels are to overlap then as shown in Figure 9 the panel assembly shown in solid on the right would have its first wire wended on the opposite side to that shown so that the next panel may slide into overlap without the wire interfering. This means the edge of the panel shown in phantom would slide up and abut with the next wire. If the overlap is more than than more wires would be welded onto the opposite side. It follows that frames could be made with one wire on each edge welded onto the opposite side and it is just a matter of flipping alternative panels.
[0020] Whilst the above has been given by way of illustrative example many variations and modifications will be apparent to those skilled in the art without departing from the broad ambit and scope of the invention as set out in the appended claims.

Claims

Claims
1 A composite panel assembly having a structural grid frame supporting at least two layers of thin plastics film, the first layer being on one side of the frame and the second layer being a moisture impermeable layer on the other side of the frame, the layers being secured to the frame, a margin of at least a portion of one layer be wrapped around and over a periphery of the frame so the layers are secured together just inside the periphery of the frame.
2. A composite panel assembly having a structural grid frame supporting at least two layers of thin plastics film, the first layer being a securement layer and the second layer being a moisture impermeable layer, the layers being secured to the frame.
3. A composite panel assembly having a structural grid frame supporting at least two layers of thin plastics film on opposite sides of the frame, the grid frame having spaces where the layers touch, the first layer being a perforated heat shrink securement layer and the second layer being a moisture impermeable layer, the layers being secured to each other along overlapping edges and thereby to the frame by a heating process whereby the layers weld together along the overlapping edges and in the spaces between the frames.
4. The invention according to any one of the preceding claims wherein the layers are secured together and thereby being secured to the frame.
5. The invention according to any one of the preceding claims wherein a heating process has been used to apply the layers tightly to the frame there being a temperature differential between the melting points of the plastics employed so that during a process heating phase, heat is applied to effect the securement layer to a greater degree that the moisture impermeable layer.
6. The invention according to any one of the preceding claims wherein a heating process has been used to apply the layers tightly to the frame and as part of this process a margin of at least a portion of the securement layer be wrapped around and over the frame and over a corresponding margin of the other layer so that upon a heating and rolling stage the wrapped over portion adheres to the other sheet and by reason of its shrinkage pulls both sheets drum tight over the frame.
7. The invention according to any one of the preceding claims wherein a heating process has been used to apply the layers tightly to the frame, followed by a rolling stage, the heating stage being accompanied by the use of one or more blowers to aid adhesion of overlapping marginal edges portions of the layers.
8. The invention according to any one of the preceding claims wherein marginal edge regions of the moisture impermeable layer extend around onto the opposite side of the frame.
9. A method of producing a composite panel assembly as described above, the method including the following steps:-
(1) providing a supporting frame;
(2) applying the said two layers to the frame;
(3) subsequently heating the frame and the layers applied thereto to complete securement of the layers to the frame
10. The method according to claim 9 wherein step (2) includes the further step of applying the moisture impermeable layer to the frame with an edge region or otherwise accumulated marginal edge region and step (3) includes the further step of applying the securement layer over the marginal edge region and then securing them together.
11. The method according to claim 9 or claim 10 wherein there is employed a heating stage and a rolling stage, the wrapped over portions of the layers adheres to each other and by reason of differential shrinkage under heat one sheet pulls both sheets drum tight over the frame.
12. The method according to claim 9 or claim 10 or claim 11 wherein one or more blowers are employed to aid adhesion of overlapping marginal side edges of the layers.
13. The invention according to many one of the preceding claims where, the layers and method employed are substantially in accordance with the following technical specification:
TECHNICAL SPECIFICATION
Figure imgf000012_0001
Figure imgf000013_0001
14. In use, the panel assemblies according to any one of claims 1 -8 or by the method of any one of claims 9-11 or as specified in claim 13, at least ot juxtaposed panel assemblies, the use of a tape, a first panel assembly having a vertical edge, the tape secured to the first panel assembly along a margin and having a fold which extends along the edge, the tape having a releasable layer adapted to be peeled away to expose about half of an adhesive layer and in use being peeled away the full vertical length of the first panel assembly, at the same time or subsequently upon a second panel assembly having a matching vertical edge being brought into abutment or overlaying the edge of the first panel assembly, a further release sheet being progressively peeled away to expose more of the adhesive layer and as it is peeled away the tape may be manually applied to the second panel assembly, thus the two panel assemblies a sealed together.
15. The invention according to any one of the preceding claims wherein in use marginal end portions of adjacent assemblies may overlap and where the frames have a grid of wires, at least the first wire running along the line of the intended overlap is located on the opposite side of the frame so that the wires extending across the overlap of the overlapping panels are in contact across the full width of the overlap by reason of the wire being on the opposite side.
16. The invention according to any one of the preceding claims wherein edges of the layers are joined to form a congealed mass where respective edges of the sheets have been welded together during a heating and rolling process.
PCT/AU2019/000145 2018-09-21 2019-11-20 Composite panels WO2020056450A1 (en)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4150186A (en) * 1976-07-21 1979-04-17 Nissan Motor Company, Limited Composite board structure and a method of and an apparatus for producing the board structure
US5023143A (en) * 1989-03-14 1991-06-11 W. R. Grace & Co.-Conn. Low shrink force shrink film
US5676894A (en) * 1994-06-02 1997-10-14 The Tensar Corporation Panel framing system with panel tensioning by heat shrinking
EP1837164A2 (en) * 2006-03-23 2007-09-26 Lammi-Perustus Oy Method and apparatus for applying plastic sheets to the walls of a foundation mould element
EP2857605A1 (en) * 2013-10-07 2015-04-08 Peca Verbundtechnik GmbH Formwork element

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4150186A (en) * 1976-07-21 1979-04-17 Nissan Motor Company, Limited Composite board structure and a method of and an apparatus for producing the board structure
US5023143A (en) * 1989-03-14 1991-06-11 W. R. Grace & Co.-Conn. Low shrink force shrink film
US5676894A (en) * 1994-06-02 1997-10-14 The Tensar Corporation Panel framing system with panel tensioning by heat shrinking
EP1837164A2 (en) * 2006-03-23 2007-09-26 Lammi-Perustus Oy Method and apparatus for applying plastic sheets to the walls of a foundation mould element
EP2857605A1 (en) * 2013-10-07 2015-04-08 Peca Verbundtechnik GmbH Formwork element

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