GB2325639A

GB2325639A - Manufacturing insulating panels

Info

Publication number: GB2325639A
Application number: GB9711263A
Authority: GB
Inventors: Eoin T Mccarthy; Patrick Mcdonald; Thomas Mcguinness; Paul Martin
Original assignee: Kingspan Research and Developments Ltd
Current assignee: Kingspan Research and Developments Ltd
Priority date: 1997-05-30
Filing date: 1997-05-30
Publication date: 1998-12-02
Also published as: GB9711263D0

Abstract

A panel 1 comprises a profiled external skin 2, an internal backing tray 3 and an insulating core 4 which fills the space between the skin 2 and tray 3. A strip of reflective tape is applied to the external skin 2. External skins 2 are overlapped and joined by tape, liquid foam reactants applied and a backing tray 3 is applied over the skins 2. The liquid foam reactants expand, on heating in an oven 50, 51 to form a foam insulating core. The backing tray 3 and foam core 4 are cut in a single cutting stage. A protective material in the form of blobs of hot melt adhesive is applied to the exposed face of the backing tray 3 to form panel spacers 86. The panels 1 are separated (see Figures 15 to 17) at the joint and then stacked for packing.

Description

"Method and Apparatus for Manufacturing Insulating Panels" Introduction The invention relates to a method and apparatus for manufacturing insulating panels of the type comprising a profiled external skin and an internal backing tray having an insulating core therebetween.

UK-A-2227712 AND UK-A-2257086 describe methods and apparatus for manufacturing insulating panels. These methods are very efficient in use, however, there is an increasing need to improve the manufacturing efficiency to cut costs and maximise the production of such insulating panels.

This invention is therefore directed towards providing an improved method and apparatus for efficient manufacturing of insulating panels.

Statements of Invention According to the invention, there is provided a method for manufacturing an insulating panel of the type comprising a profiled external skin and an internal backing tray having an insulating core therebetween, the method comprising the steps of: conveying a first skin along a flat bed with the outer surface of the skin lowermost; applying liquid insulating foam reactants onto the skin; leading a second skin over the first skin to form an assembly; heating the assembly in an oven to allow the liquid foam reactants to expand to form an insulating core between the skins; cutting at least one of the skins and foam core to form an insulating panel; and automatically applying a protective material to preset locations on the panel.

In a preferred embodiment of the invention, the first skin is an external skin and the second skin is a backing tray.

Preferably, the protective material is automatically applied at spaced locations across and along the exposed face of the internal backing tray of the panel. Ideally, the protective material is automatically applied adjacent end edges of the backing tray of the insulating panel.

Preferably, the protective material is of a flowable material which is applied to the exposed face of the internal backing tray. Most preferably, the flowable protective material is deposited at preset locations on the exposed face of the internal backing tray in the form of a blob of material.

In a preferred arrangement, the protection material is applied through a number of applicator heads spaced-apart above the exposed face of the tray, the applicator heads being activated to deliver protective material onto the exposed face of the tray as the preset locations pass under the applicator heads.

Preferably, the protective material is a hot melt adhesive which, an application to the panel cures to form a spacer means between adjacent panels, on stacking. Typically, the method includes the step of stacking panels one on top of the other so that the protective material lies between adjacent panels in the stack.

In another embodiment of the invention, the method includes the steps of: applying a reflective tape to a preset location of a first skin; conveying the first skin along a flat bed; applying liquid insulating foam reactants onto the first skin; leading a second skin continuously over the first skin to form an assembly; heating the assembly in an oven to allow the liquid foam reactants to expand to form an insulating core between the skins; detecting the location of the reflective tape; and, in accordance with the location of the tape, cutting at least one skin and foam core through to the other skin.

Preferably, the method in this case includes the steps of: leading a first skin sheet from a supply reel; applying the reflective tape to a preset location of the skin; profiling the skin; and conveying the profiled skin along a flat bed.

Ideally, the first skin is cut to a desired length prior to application of the reflective tape.

Preferably, the method includes the steps of: cutting a leading first skin to a desired length; laying a following first skin adjacent to the leading skin to form a joint; after cutting of the second skin and foam core through to the first skin, detecting the location of the reflective tape; and in accordance with the location of the tape, applying a separating force to separate the panels at the joint.

Preferably, the method includes the steps of: cutting a leading first skin to a desired length; laying a following first skin adjacent to the leading first skin; detecting the location of the reflective tape; and in accordance with the location of the tape, applying a jointing tape to the joint between the first skins.

Typically, the method includes the steps, after the formation of the panel of: detecting the location of the reflective tape; and, in accordance with the location of the tape, applying a protective material to the panel.

In this case, preferably the protective material is applied to the panel after cutting of the backing tray and foam core through to the external skin.

Ideally, the reflective tape is applied by: drawing reflective tape from a supply reel; positioning the tape at a desired location of the skin; cutting the reflective tape to a desired length; and pressing the cut length of tape against the skin to apply the tape to the skin.

Preferably, a desired length of reflective tape is drawn from the supply reel by operation of an indexing means.

Preferably, the indexing means is an indexing ram which is operated to turn a pinion through a preset rotation corresponding to a desired length. In this case, preferably the reflective tape is drawn over an applicator head from the supply reel and the applicator head presses the tape against the external skin to apply the tape.

Ideally, the reflective tape is retained in position on the applicator head prior to application by drawing the tape to the head. Typically, the tape is drawn to the head by applying suction. In one arrangement, the applicator head is driven from an initial rest position to receive reflective tape from the supply reel, through an intermediate position against a blade means to cut the tape to length, to a tape applying position in which the cut tape is applied to the external skin. Preferably, the applicator head is driven by a cutting and applicator ram means, a first stroke of the ram cutting the tape to length against the blade means, and a second stroke applying the tape to the external skin.

In one arrangement of the invention, the method includes the steps of: conveying a first skin along a flat bed with an outer surface of the skin lowermost; cutting a leading first skin to a desired length; laying a following first skin adjacent to the leading first skin; drawing a jointing tape across the joint between the leading and following first skins; conforming the tape to the profile of the first skins; automatically applying the tape to the joint between the skins; applying liquid insulating foam reactants onto the skins; leading a second skin over the first skins and joint; heating the assembly in an oven to allow the liquid foam reactants to expand to form an insulating core between the internal backing tray and external skin; cutting the second skin and foam core through to the first skin at the joint; and separating the panels thus formed.

In this case, preferably above the first skin, jointing tape is drawn off a reel, cut to length, applied over a tape applying head, and the tape applying head is moved downwardly to apply the jointing tape over the joint.

Preferably, the tape is applied over the tape applying head by drawing the tape under suction to the tape applying head. Ideally, the method includes the step of forming part of the jointing tape into at least one loop for applying to a corrugation profile of the external skin. Preferably, the jointing tape applying head comprises a number of sections, and portion of the tape is formed into a loop by moving adjacent sections laterally apart prior to moving the tape applying head downwardly to apply the tape.

In one embodiment of the invention, the method includes the steps of: conveying a first skin with the outer surface of the skin lowermost; applying liquid insulating foam reactants onto the first skin; delivering a second skin over the first skin; inserting a spacer means between the first and second skins, the spacer means comprising a plurality of spacers extending between the skins, each spacer being mounted on an individual spacer arm, a first spacer means comprising a plurality of first spacers, each mounted on an associated spacer arm; heating the assembly thus formed in an oven to allow the liquid foam reactants to expand to form an insulating core between the skins; and as required to produce panels with a different thickness of insulating core, changing the spacing means by: mounting second spacers on the spacer arms; and moving the spacer arms from a first position in which the first spacers are in portion in the oven and the second spacers are removed to a second position in which the first spacers are removed and the second spacers are in position.

Preferably, after mounting the second spacers on the spacer arms, the upper bed of the oven is lifted to facilitate moving the spacer arms so that the first spacers are removed and the second spacers are in position, and subsequently moving the upper bed of the oven downwardly to the lower bed with the second spacers between the upper and lower beds of the oven. Ideally, the spacer arms are mounted for swinging from a first position with the first spacers in position in the oven to a second position with the first spacers removed and the second spacers in position.

Preferably, the spacer arms are rotatably mounted for rotation between the first and second positions. Most preferably, all of the spacer arms are operated substantially simultaneously from the first to the second positions. Typically, the spacer arms are operated by ram means which rotates the arms through a rack and pinion means.

In one embodiment of the invention, the method includes the steps of: conveying a first skin along a flat bed with the outer surface of the skin lowermost; applying liquid insulating foam reactants onto the first skin; leading a second skin over the first skin to form an assembly; heating the assembly in an oven to allow the liquid foam reactants to expand to form an insulating core between the first and second skins; and in a single cutting step, automatically cutting the second skin and foam core through to the first skin at a preset location of the panel.

Preferably, the second skin and foam core are cut through to the first skin by automatically driving a cutting means across the assembly as the assembly is travelling along a cutting bed. Ideally, the cutting means comprising a leading saw and a trailing blade, the leading saw cutting through the second skin and at least part of the foam core to define a first cut and the trailing blade travelling in the first cut for close cutting of the foam core through to the first skin. Typically, the leading saw is a crossout circular saw for cutting through the second skin and at least part of the foam core to define the first cut.

Preferably, the trailing blade is a guillotine blade which extends into the first cut to cut the remaining foam core through to the internal face of the first skin of the assembly. Ideally, the method includes the steps of automatically driving the trailing blade towards the internal face of the first skin in accordance with the profile of the first skin to cut the foam through to the internal face of the first skin. Most preferably, the method includes the step of vibrating the trailing blade as it is driven through the first cut defined by the leading saw.

In one embodiment of the invention, the method includes the steps of: conveying a first skin along a flat bed with the outer surface of the skin lowermost, cutting a leading first skin to a desired length; laying a following first skin adjacent to the leading first skin; applying a jointing means across the joint between the leading and following first skins; applying liquid insulating foam reactants onto the first skins; leading a second skin over the first skins and joint; heating the assembly in an oven to allow the liquid foam reactants to expand and form an insulating core between the skins; cutting the second skin and foam core through to the first skin; using a first clamping means, clamping a leading panel adjacent to the joint; using a second clamping means clamping a trailing panel adjacent to the joint; and after clamping, applying a separating force between the first and second clamping means to separate the panels at the joint.

Ideally, at least one of the first and second clamping means includes upper and lower clamping heads which clamp the panel therebetween. Preferably, both the first and second clamping means include upper and lower clamping heads. Typically, the or each of the upper clamping heads are positioned a preset distance above the upper face of the backing tray of the panels. Preferably, the clamping means are mounted on a carriage which travels with the panels and the panels are separated without stopping the run of the panels.

The invention also provides apparatus for manufacturing an insulating panel comprising: means for conveying a first skin with an outer surface of the skin lowermost; foam applicator means for applying liquid foam reactants to the first skin; means for leading a second skin continuously over the first skin to form an assembly; an oven for heating the assembly to allow the liquid foam reactants to expand to form an insulating core between the skins; cutting means for cutting at least the second skin and foam core to form an insulating panel; and applicator means for automatically applying a protective material to present locations on the panel.

Preferably, the apparatus includes detecting means for detecting desired locations on the panel, and actuation means for actuating the applicator means to apply the protective material to the panel. Ideally, the applicator means comprises a number of applicator heads spaced-apart above the exposed face of the panel. In one embodiment of the invention, the apparatus includes a storage vessel for the protective material and pump means for delivering the protective material for the storage vessel to the applicator means, on demand. Preferably, the protective material is a hot melt adhesive and the apparatus includes heating means for heating the adhesive to a flowable form for delivery to the applicator means. In a preferred embodiment of the invention, the apparatus comprises: means for applying a reflective tape to a preset location of a first skin; conveying means for conveying the first skin along a flat bed with the outer surface of the skin lowermost; foam applicator means for applying liquid insulating foam reactants onto the first skin; means for leading a second skin continuously over the first skin to form an assembly; an oven for heating the assembly to allow the liquid foam reactants to expand to form an insulating core between the skins; detecting means for detecting the location of the reflective tape; and cutting means for cutting the second skin and foam core through to the first skin in accordance with the location of the tape.

Preferably, the apparatus includes: means for leading first skin sheet from a supply reel; means for applying reflective tape to a preset location of the first skin; profiling means for profiling the first skin; and conveying means for conveying the profiled first skin with the outermost surface of the skin lowermost along a flat bed.

In a preferred arrangement, the apparatus includes: cutting means for cutting a leading first skin to a desired length; means for laying a following first skin adjacent to the leading first skin to form a joint; means for detecting the location of the reflective tape after cutting of the second skin foam core through to the profiled first skin; and in accordance with the location of the tape, means for applying a separating force to separate the panels at the joint.

Ideally, the apparatus includes: cutting means for cutting a leading first skin to a desired length; means for laying a following first skin adjacent to the leading first skin; detection means for detecting the location of the reflective tape; and means for applying a jointing tape to the joint between the first skins in accordance with the location of the tape.

Preferably, the apparatus includes detection means for detecting the location of the reflective tape after formation of the panel; and in accordance with the location of the tape means for applying a protective material to the panel.

In one arrangement, the apparatus includes: means for drawing reflective tape from a supply reel; means for positioning the tape at a desired location of the first skin; cutting means for cutting the reflective tape to a desired length; and pressing means for pressing the cut length of tape against the first skin to apply the tape to the first skin.

Ideally, the indexing means is an indexing ram which is operated to turn a pinion through a preset rotation corresponding to a desired length. Typically, the reflective tape is drawn over an applicator head from the supply reel and the applicator head presses the tape against the external skin to apply the tape. Preferably, the tape is retained in position on the applicator head prior to application, by drawing the tape to the head.

Ideally, the tape is drawn to the head by applying suction. In one embodiment of the invention, the applicator head is driven from an initial rest position to receive reflective tape for the supply reel, through an intermediate position against a blade means to cut the tape to length, to tape applying position in which the cut tape is applied to the skin. Preferably, the applicator head is driven by a cutting and applicator ram means, a first stroke of the ram cutting the tape to length against the blade means, and a second stroke applying the tape to the skin.

In another embodiment of the invention, the apparatus comprises: means for conveying a profiled first skin with an outer surface of the skin lowermost; cutting means for cutting a leading first skin to a desired length; means for laying a following first skin adjacent to the leading first skin; gripper means for drawing a jointing tape across the joint between the leading and following first skins; conforming means for conforming the tape to the profile of the first skins; an applicator head for applying the tape to the joint between the first skins; foam applicator means for applying liquid insulating foam reactants onto the first skins; means for leading a second skin continuously over the first skin to form an assembly; an oven for heating the assembly to allow the liquid foam reactants to expand and form an insulating core between the skins; cutting means for cutting the second skin and foam core through to the first skin at the joint; and separating means for separating the panels thus formed.

Preferably, the gripper means for drawing a jointing tape across the joint comprises gripper jaw means and translation means attached to the gripper means for extending the gripper means across a bed to a supply reel and for drawing the tape from the reel across the bed.

Ideally, the applicator head comprises a number of sections which are laterally spaced across the bed and at least some of the sections have suction means for releasably holding the tape to the head sections.

Typically, at least some of the applicator head sections are laterally movable relative to one another to form a loop of tape for application to a corrugation profile of the first skins at the joint. Preferably, the apparatus includes positioning means for positioning the drawn tape under the applicator head. Ideally, the tape is cut to length from the supply reel by the cutting means as the tape is positioned under the applicator head.

In a preferred embodiment of the invention, the apparatus comprises an oven having a top bed and a bottom bed and spacer means for inserting between the top and bottom beds to set the depth of an insulating core, the spacer means comprising a plurality of spacers, each spacer being mounted on an individual spacer arm, a first spacer means comprising a plurality of first spacers, each mounted on an associated arm, a second spacer means comprising a plurality of second spacers, each mounted on an associated spacer arm, and means for moving the spacer arms to move the first spacers from the oven and to move the second spacers into the oven. Preferably, first and second spacers are mounted on a common spacer arm. Ideally, the apparatus includes lifting means for lifting the upper bed of the oven to facilitate movement of the spacer arms.

Preferably, the spacer arms are rotatably mounted for movement of the spacers into and out of the oven.

In one embodiment of the invention, the apparatus includes operating means for moving the spacer arms substantially simultaneously. Preferably, the operating means comprises an operating ram which moves the spacer arms through a rack and pinion means. Ideally, the lifting means comprising a lifting ram.

In another embodiment of the invention, the apparatus comprises : - conveying means for conveying a first skin with the outer surface of the skin lowermost; means for applying liquid insulating foam reactants onto the first skin; means for leading a second skin over the first skin; and an oven having a top bed and a bottom bed and spacer means for inserting between the top and bottom beds to set the depth of an insulating core, the spacer means comprising a plurality of spacers, each spacer being mounted on an individual spacer arm, a first spacer means comprising a plurality of first spacers, each mounted on an associated arm, a second spacer means comprising a plurality of second spacers, each mounted on an associated spacer arm, and means for moving the spacer arms to move the first spacers from the oven and to move the second spacers into the oven.

Preferably, the apparatus comprises: means for conveying a first skin with an outer surface of the skin lowermost; foam applicator means for applying liquid foam reactants to the first skin; means for leading a second skin over the first skin to form an assembly; an oven for heating the assembly to allow the liquid foam reactants to expand to form an insulating core between the skins; cutting means for cutting at least the second skin and foam core to form an insulating panel; and cutting means for automatically cutting the second skin and foam core through to the first skin at a preset location of the panel.

Ideally, the apparatus includes a cutting bed along which the assembly is led and mounting means for mounting the cutting means to travel with the assembly along the cutting bed as the cutting means cuts the second skin and foam core through to the first skin. In one arrangement, the cutting means comprises a leading saw and a trailing blade mounted to and travelling across the assembly with the leading saw. Preferably, the leading saw is a cross cut saw. Most preferably, the trailing blade is a guillotine blade. Ideally, the apparatus includes vibrating means for vibrating the trailing blade as it travels through the cut made by the leading saw.

Preferably, the apparatus includes biassing means for biassing the trailing blade into a raised position.

Typically, the apparatus includes ram means for driving the trailing blade against the biassing of the biassing means to cut the foam through to the internal face of the first skin. Ideally, the apparatus includes means for detecting the profile of the first skin, and means for operating the ram means to drive the blade downwardly to follow the profile of the first skin.

In a preferred embodiment of the invention, the apparatus comprises : - means for conveying a first skin with an outer surface of the skin lowermost; means for laying a following first skin adjacent to the leading skin; means for applying a jointing means across the joint between the leading and following first skins; foam applicator means for applying liquid insulating foam reactants onto the first skins; means for leading a second tray over the first skins and joint; cutting means for cutting the second skin and foam core through to the first skin; first clamping means for clamping the leading panel adjacent to the joint; second clamping means for clamping the trailing panel adjacent to the joint; and means for applying a longitudinal separating force between the first and second clamping means to separate the panels at the joint.

Preferably, the first and\or second clamping means comprises an upper clamping head and a lower clamping head which clamp the panel therebetween. Ideally, both of the first and second clamping means comprises an upper clamping head and a lower clamping head which clamp the panel therebetween. Preferably, the apparatus includes positioning means for positioning the upper clamping heads a preset distance above the upper face of the backing tray of the panel. Typically, the clamp head positioning means comprises a roller mounted on an arm, ram means interconnecting the clamp head and the arm, the ram operating to position the clamp head a preset distance above the upper face of the second skin of the panel. In one arrangement, the apparatus includes a ram means for moving the upper clamp head and lower clamp head between released and engaged clamping positions. Preferably, the first clamp means is mounted on a first carriage, the second clamp means is mounted on a second carriage and the carriages are moved apart to separate the panel, on clamping. Typically, both carriages travel with the panels to separate the panels without interrupting the forward movement of the panels.

The invention also provides insulated panels whenever manufactured by a method of the invention and/or using an apparatus of the invention.

Brief Description of the Drawings Fig. 1 is a flow chart of the method of the invention; Fig. 2 is a perspective view of a reflective tape applicator used in the method; Fig. 3 is a side view of the reflective tape applicator; Fig. 4 is a perspective view of a jointing tape applicator used in the method of the invention; Figs. 5(a) to 5(c) are end elevational views of the jointing tape applicator of Fig. 4, in use; Fig. 6 is a perspective view of an oven with a spacer changeover apparatus used in the method of the invention; Fig. 7 is an end cross sectional view of part of the spacer changeover apparatus; Fig. 8 is a perspective view of a part of a cutting means used in the method of the invention; Fig. 9 is another perspective view of the cutting means part of Fig. 8; Fig. 10 is a perspective view of the cutting means in use; Fig. 11 is a side elevational view illustrating the operation of the cutting means; Fig. 12 is a perspective view of a protective material applicator used in the method of the invention; Fig. 13 is a side view of the protective material applicator of Fig. 12; Fig. 14 is a side view of a stack of panels with a protective material therebetween; Fig. 15 is a side, partially cross sectional view of a panel breaker apparatus used in the method of the invention in a first position of use; Fig. 16 is a side view of the breaker apparatus of Fig. 15 in a second position of use; Fig. 17 is a side view of the breaker apparatus of Fig. 15 in a final position of use; Figs. 18(a) and 18(b) are side, partially cross sectional views of panels separated using the apparatus of Figs. 15 to 17; and Fig. 19 is a cross sectional view of a typical panel formed using the method and apparatus of the invention.

Detailed Description of the Invention Referring to the drawings, the method and apparatus of the invention is for forming an insulated panel of the type which is illustrated in Fig. 19 and indicated generally by the reference numeral 1. The panel 1 comprises a profiled external skin 2 of steel or aluminium material, an internal backing tray 3 also of steel or aluminium material and an insulating core 4 of polyurethane or polyisocyanurate foam material which fills the space between the external skin 2 and backing tray 3. The insulated panel 1 is typically used for roofing and/or cladding systems, adjacent panels being overlapped both longitudinally and transversely to clad and/or roof a particular area.

Referring particularly to Fig. 1, the method according to the invention for forming the panel 1 in a substantially continuous manner comprises the step A of leading a sheet of external skin material from a reel onto a flat bed with the outermost face of the external skin 2 lowermost.

Reflective tape is applied in step B to the external skin 2 at a desired location as will be described in more detail below. The desired longitudinal overlap between adjacent panels are automatically marked using an ink jet apparatus. The external skin 2 is then profiled at C and cut to length in step D. The trailing edge of the external skin 2 of a first leading panel in the line is lifted up and placed down on the leading edge portion of in which the reactants are heated and allowed to expand to the desired thickness of foam insulating core 4.

The output from the oven is a continuous longitudinal sheet of insulating panels 1 interconnected by the jointing tape. As will be described in more detail below, at the joint between adjacent external skins, the backing tray 3 and foam core 4 are cut in a single cutting stage through to the internal (or upper) face of the external skin 2 in step Q. A protective material is applied to the exposed face of the backing tray 3 in step R and adjacent panels 1 are separated at the joint in step S in preparation for stacking and packaging.

Referring particularly to Figs. 2 and 3, there is illustrated a reflective tape applicator 10 used in the method of the invention for applying a length of reflective tape 11 to a desired location, typically adjacent a side edge, of the external skin 2. The reflective tape 16 is led from a supply reel 12 over guide wheels 13 to a grooved index wheel 14 and on to an applicator head 15. A desired length of tape 16 is drawn from the supply reel by an indexing ram 20 carrying a rack 21 which engages with a pinion 21 of the index wheel 14 to deliver the tape to the applicator head 15. The tape 16 may be applied in different lengths to initiate particular processing parameters. Typically, the indexing ram 20 is operated once to deliver a length of tape 16 for a right hand panel and may be operated twice to deliver a double length of tape 16 to indicate a left hand panel.

The tape 16 is held in place on the applicator head 15 by suction. The applicator head 15 is driven by a cutting and applicator ram 25 from an initial rest position (Fig.

3) to receive reflective tape, through an intermediate position against a blade 26 to cut the tape to length, to a final tape applying position (Fig. 2) in which the cut tape is applied to the external skin 2. When the length of tape 11 is applied, the ram 25 is released and the process is repeated to apply a length of tape 11 at desired locations of the external skin 2.

The length of reflective tape 11 applied to the upper face of the external skin 2 is used to automatically actuate various further steps in the method of the invention. It may be used, for example, to automatically activate the cutting means for cutting the backing tray and foam core through to the external skin. It may also be used to automatically activate the breaking means to separate the cut panels at the joint. In addition, the reflective tape 11 may trigger the operation of the jointing tape applying apparatus described below and/or the protective material applicator which is also described below.

Referring particularly to Figs. 4 and 5, there is illustrated an automatic jointing tape applicator 30 used in the method of the invention to apply a jointing tape at the joint between adjacent external skins 2. Jointing tape 32 is led from a supply reel 31 to a guide 33.

Gripper jaws 34 are then used to grip the free end of the tape 32 and to draw it across the bed on which the profiled external skin is travelling. The length of the jointing tape 32 drawn across the bed is longer than the width of the skin 2 to take account of the profile of the skin 2.

The length of tape 32 is then drawn under an applicator head 35 which has a number of sections 36 corresponding to the flat portions of the profile of the external skin 2 and a number of sections 37 corresponding to the corrugations of the external skin 2. The applicator head 35 is moved up and down by a ram 39 and the outer two of the head sections 36 may be moved in and out by a second ram (not shown).

As the tape 32 is drawn under the applicator head 35, it is cut to length by engaging against a blade 40. The outer two applicator head sections 36 are then moved from the outer position illustrated in Fig. S(a) to the inner position illustrated in Fig. 5(b) to form the tape 32 into loops in the region of the corrugations. The ram 39 is then operated to drive the applicator head 35 downwardly to apply the jointing tape 32 across the profile of the external skins 2 at the overlapped joint between adjacent skins 2 as illustrated in Fig. 5(c).

The tape 32 is maintained in position on the applicator head sections 36 by suction.

The line of external skins 2 is not stopped while the jointing operation takes place as the applicator 30 is mounted on a carriage 40 which travels with the line to optimise production efficiency.

The jointing tape applicator 30 may be automatically operated when the reflective tape described above is detected by a suitable detector.

Referring particularly to Figs. 6 and 7, in the method of the invention the assembly of the external skin 2, backing tray 3 and liquid foam reactants are heated in a long oven having a top bed 50 and a bottom bed 51. During the heating process the spacing between the backing tray 3 and external skin 2 is maintained by a continuous course of spacer blocks (not shown) on both sides. The top bed 50 is maintained at the desired spaced position from the bottom bed 51 by a plurality of first spacers 52 which are each interposed on rods 53 interconnecting the top and bottom oven beds 50, 51. The top bed 51 is lifted up from the bottom bed 50 by lifting rams 54.

A quick safe changeover from one thickness of panel to another is effected by lifting up the top bed 51 on operation of the rams 54 and changing over to second spacers 55 which in this case are thicker than the first spacers 52.

The spacers 52 are each mounted on a spacer arm 56. The top bed 51 is lifted up from the bottom bed 50 by operating the rams 54. The spacer arms 56 are then pushed out by pusher rams. Each spacer arm 56 is pivotally mounted at 57 for rotation from a first position in which the first spacer 52 is between the beds 50, 51 through 1800 to a second position in which the first spacer 52 is removed and the second spacer 55 is in position between the beds 50, 51.

All of the spacer arms 56 may be rotated substantially at the same time by operating a single or a number of spacer arm rotating rams 59. A ram 59 rotates the arm 56 through a rack 60 and pinion 61 arrangement.

The pusher rams are then reversed to push the second spacers 55 into position before closing down the top bed 51 of the oven on operation of retraction of the main rams 54.

Referring particularly to Figs. 8 to 11, cutting means 70 for cutting the backing tray 3 and foam core 4 through to the inner face of the external skin 2 at the joint between overlapping skins 2 in a single step comprises a cross cut saw 71 and a guillotine blade 72. The guillotine blade 72 is operated by a ram 73 against the biassing of a spring 74. The blade 72 is mounted on a bracket 75 which is in turn bolted to the housing 76 of the cross cut saw 71 so that the blade 72 travels across following the cross cut saw 71. The blade 72 is angled forwardly in the rest position and is held in that position by the spring 74.

As the blade 72 is moved across, it is angled back and joggled up and down to provide a clean cutting action.

The cross cut saw 71 is set so that the cutting edge is spaced slightly above the upper face of the flat surface of the external skin 2. The guillotine blade 72 is set so that as it moves across its cutting edge just engages the upper face of the flat surface of the skin 2. It is held in this position by the spring 74. A detector (not shown) is used to detect the position of the corrugations of the external skin as the blade 72 travels across. When a corrugation is detected, the ram 73 is operated to drive the blade down to engage the corrugation and to cut the foam core 4 in the corrugation through to the upper face of the external skin. The guillotine blade 72 may also be vibrated by a vibrating means (not shown) to provide a clean cut.

As will be particularly apparent from Fig. 11, when the joint between external skins is detected, particularly using the reflective tape as described above, the cutting means 70 is automatically operated to cut the backing tray 3 and foam core 4. The cross cut saw 71 makes a first cut in which the guillotine blade travels to cut through the remaining core to the external skin 2 providing, in a very efficient way, a clean cut.

For maximum processing efficiency, the cutting means 70 is mounted on a carriage (not shown) which travels with the panel as it progresses along the line.

Referring particularly to Figs. 12 and 13, there is illustrated a protective material applicator means 80 used in the method of the invention. The applicator means 80 in this case comprises three nozzles 81 which are mounted on and spaced-apart across a carriage 82 above the upper face of the backing tray 3 of the panels 1. Each of the nozzles 81 is supplied with a flowable protective material through individual supply pipes 83. On detection of the reflective tape applied as described above, the protective material is automatically applied in a number of blobs 85 at spaced locations along and across the panels 1. The blobs 85 of protective material harden to provide spacers 86 between adjacent panels 1 when they are stacked as illustrated in Fig. 10 for storage and transportation. In this way, damage to the surface of the panels is substantially prevented.

In this case, the protective material is a hot melt adhesive which is prepared from granules stored in a storage vessel and delivered on demand to a heater which melts the material into a flowable form which is then delivered along the pipes 83 to the nozzles 81. The hot melt adhesive cures rapidly in ambient conditions to form the panel spacers 86.

Referring to Figs. 15 to 17, there is illustrated a panel breaking apparatus 90 used in the method of the invention for separating a leading panel 91 from a trailing panel 92 at the cut joint 93. A first clamp comprising a first upper clamping head 94 and a first lower clamping head 95 grips the leading panel 91. A second clamp comprising a second upper clamping head 96 and a second lower clamping head 97 grips the trailing panel 91. The first and second clamps are mounted on separate carriages 98, 99 which are moved apart from the position illustrated in Figs. 15 and 16 to the separated position illustrated in Fig. 17 to separate the adjacent panels 91, 92 at the joint from the joined position illustrated in Fig. 18(a) to the separated position illustrated in Fig. 18(b).

The carriages 98, 99 each comprise a post 101, 102 which is fixed relative to the respective panel 91, 92 and a movable post 103, 104. The posts 101, 103 and 102, 104 are interconnected by pivot arms 105, 106 and the posts 101, 102, 103, 104 are also interconnected by respective rams 107, 108. To engage the upper clamp heads 94, 96 with the adjacent panels 91, 92, the rams 107, 108 are operated from the raised release position illustrated in Fig. 15 to move the posts 103, 104 on the pivot arms 105, 106 to the extended engaged position illustrated in Figs.

16 and 17. The lower clamps 95, 97 are also operated by lower rams, not shown.

At least the leading clamp may be provided with a roller 110 on a guide arm 111 pivotally connected to the movable post 104 and movable by a guide ram 112. The roller 110 rides on the surface of the backing tray 3 of the panel 91 to position the upper clamps 94, 96 as short a distance as possible above the backing tray. In this way, the distance through which the upper clamp heads 94, 96 travel is minimised. Consequently, the speed of the panel separation process is optimised.

It will be noted that the lower clamp heads 95 and 97 are spaced in the release position illustrated in Fig. 15 below the lower surface of the panels 91, 92. This ensures that grit and dirt are not trapped which could lead to damage to the exposed surface of the panel.

The carriages 98, 99 on which the clamps are mounted travel with the panels as they progress along the production line. This is important in ensuring that processing time is optimised as the panels are not stopped during the separation process.

The separating apparatus may be automatically actuated by a suitable detector picking up the reflective tape applied as described above.

The invention provides a highly optimised and efficient method and apparatus for manufacturing insulating panels.

The invention is not limited to the embodiments hereinbefore described which may be varied in detail.

Claims

1. A method for manufacturing an insulating panel of the type comprising a first skin and a second skin having an insulating core therebetween, the method comprising the steps of: conveying a first skin along a flat bed with the outer surface of the skin lowermost; applying liquid insulating foam reactants onto the first skin; leading a second skin over the first skin to form an assembly; heating the assembly in an oven to allow the liquid foam reactants to expand to form an insulating core between the skins; cutting at least the second skin and foam core to form an insulating panel; and automatically applying a protective material to preset locations on the panel.

2. A method as claimed in claim 1 wherein the protective material is automatically applied at spaced locations across and along the exposed face of the second skin of the panel.

3. A method as claimed in claim 2 wherein the protective material is automatically applied adjacent end edges of the second skin of the insulating panel.

4. A method as claimed in claim 2 or 3 wherein the protective material is of a flowable material which is applied to the exposed face of the second skin.

5. A method as claimed in claim 4 wherein the flowable protective material is deposited at preset locations on the exposed face of the second skin in the form of a blob of material.

6. A method as claimed in any preceding claim wherein the protective material is applied through a number of applicator heads spaced-apart above the exposed face of the second skin, the applicator heads being activated to deliver protective material onto the exposed face of the second skin as the preset locations pass under the applicator heads.

7. A method as claimed in any preceding claim wherein the protective material is a hot melt adhesive which, an application to the panel cures to form a spacer means between adjacent panels, on stacking.

8. A method as claimed in any preceding claim including the step of stacking panels one on top of the other so that the protective material lies between adjacent panels in the stack.

9. A method as claimed in any preceding claim wherein the first skin is a profiled external skin and the second skin is a backing tray.

10. A method for manufacturing an insulating panel substantially as hereinbefore described with reference to the accompanying drawings.

11. Apparatus for manufacturing an insulating panel comprising: means for conveying a first skin with an outer surface of the skin lowermost; foam applicator means for applying liquid foam reactants to the first skin; means for leading a second skin continuously over the first skin to form an assembly; an oven for heating the assembly to allow the liquid foam reactants to expand to form an insulating core between the skins; cutting means for cutting at least the second skin and foam core to form an insulating panel; and applicator means for automatically applying a protective material to present locations on the panel.

12. Apparatus as claimed in claim 11 including detecting means for detecting desired locations on the panel, and actuation means for actuating the applicator means to apply the protective material to the panel.

13. Apparatus as claimed in claim 11 or 12 wherein the applicator means comprises a number of applicator heads spaced-apart above the exposed face of the second skin.

14. Apparatus as claimed in any of claims 11 to 13 including a storage vessel for the protective material and pump means for delivering the protective material for the storage vessel to the applicator means, on demand.

15. Apparatus as claimed in claim 14 wherein the protective material is a hot melt adhesive and the apparatus includes heating means for heating the adhesive to a flowable form for delivery to the applicator means.

16. Apparatus as claimed in any of claims 11 to 15 wherein the first skin is a profiled external skin and the second skin is an internal backing tray.

17. Apparatus for manufacturing an insulating panel substantially as hereinbefore described with reference to the accompanying drawings.

18. An insulating panel whenever produced by a method as claimed in any of claims 1 to 10 and/or using an apparatus as claimed in any of claims 11 to 17.

19. A method for manufacturing an insulating panel of the type comprising a first skin and a second skin having an insulating core therebetween, the method comprising the steps of: applying a reflective tape to a preset location of a first skin; conveying the first skin along a flat bed with the outer surface of the skin lowermost; applying liquid insulating foam reactants onto the first skin; leading a second skin continuously over the first skin to form an assembly; heating the assembly in an oven to allow the liquid foam reactants to expand to form an insulating core between the skins; detecting the location of the reflective tape; and, in accordance with the location of the tape, cutting the second skin and foam core through to the first skin.

20. A method as claimed in claim 19 wherein the first skin is an external skin and the second skin is an internal backing tray.

21. A method as claimed in claim 20 including the steps of: leading the external skin sheet from a supply reel; applying the reflective tape to a preset location on the external skin; profiling the external skin; and conveying the profiled external skin with the outermost surface of the skin lowermost along a flat bed.

22. A method as claimed in claim 21 wherein the external skin is cut to a desired length prior to application of the reflective tape.

23. A method as claimed in any of claims 19 to 22 including the steps of: cutting a leading first skin to a desired length; laying a following first skin adjacent to the leading first skin to form a joint; after cutting of the second skin and foam core through to the first skin, detecting the location of the reflective tape; and in accordance with the location of the tape, applying a separating force to separate the panels at the joint.

24. A method as claimed in any of claims 19 to 23 including the steps of: cutting a leading first skin to a desired length; laying a following first skin adjacent to the leading first skin; detecting the location of the reflective tape; and in accordance with the location of the tape, applying a jointing tape to the joint between the first skins.

25. A method as claimed in any of claims 19 to 24 including the steps, after the formation of the panel of: detecting the location of the reflective tape; and in accordance with the location of the tape applying a protective material to the panel.

26. A method as claimed in claim 25 wherein the protective material is applied to the panel after cutting of the second skin and foam core through to the external skin.

27. A method as claimed in any of claims 19 to 26 wherein the reflective tape is applied by: drawing reflective tape from a supply reel; positioning the tape at a desired location of the first skin; cutting the reflective tape to a desired length; and pressing the cut length of tape against the first skin to apply the tape to the external skin.

28. A method as claimed in claim 27 wherein a desired length of reflective tape is drawn from the supply reel by operation of an indexing means.

29. A method as claimed in claim 28 wherein the indexing means is an indexing ram which is operated to turn a pinion through a preset rotation corresponding to a desired length.

30. A method as claimed in any of claims 27 to 29 wherein the reflective tape is drawn over an applicator head from the supply reel and the applicator head presses the tape against the first skin to apply the tape.

31. A method as claimed in claim 30 wherein the reflective tape is retained in position on the applicator head prior to application by drawing the tape to the head.

32. A method as claimed in claim 31 wherein the tape is drawn to the head by applying suction.

33. A method as claimed in any of claims 30 to 32 wherein the applicator head is driven from an initial rest position to receive reflective tape from the supply reel, through an intermediate position against a blade means to cut the tape to length, to a tape applying position in which the cut tape is applied to the first skin.

34. A method as claimed in claim 33 wherein the applicator head is driven by a cutting and applicator ram means, a first stroke of the ram cutting the tape to length against the blade means, and a second stroke applying the tape to the first skin.

35. A method as claimed in any of claims 21 to 34 wherein the first skin is an external skin and the second skin is an internal backing tray.

36. A method for manufacturing an insulating panel as claimed in any of claims 19 to 35 substantially as hereinbefore described with reference to the accompanying drawings.

37. Apparatus for manufacturing an insulating panel comprising: means for applying a reflective tape to a preset location of a first skin; conveying means for conveying the first skin along a flat bed with the outer surface of the skin lowermost; foam applicator means for applying liquid insulating foam reactants onto the first skin; means for leading a second skin continuously over the first skin to form an assembly; an oven for heating the assembly to allow the liquid foam reactants to expand to form an insulating core between the skins; detecting means for detecting the location of the reflective tape; and cutting means for cutting the second skin and foam core through to the first skin in accordance with the location of the tape.

38. Apparatus as claimed in claim 37 including: means for leading a first skin sheet from a supply reel; means for applying reflective tape to a preset location of the first skin; profiling means for profiling the first skin; and conveying means for conveying the profiled first skin with the outermost surface of the skin lowermost along a flat bed.

39. Apparatus as claimed in claim 38 wherein the first skin is cut to a desired length prior to application of the reflective tape.

40. Apparatus as claimed in claim 38 or 39 including: means for cutting a leading first skin to a desired length; means for laying a following first skin adjacent to the leading first skin to form a joint; means for detecting the location of the reflective tape after cutting of the second skin and foam core through to the first skin; and in accordance with the location of the tape, means for applying a separating force to separate the panels at the joint.

41. Apparatus as claimed in any of claims 38 to 40 including: cutting means for cutting a leading first skin to a desired length; means for laying a following first skin adjacent to the leading first skin; detection means for detecting the location of the reflective tape; and means for applying a jointing tape to the joint between the first skins in accordance with the location of the tape.

42. Apparatus as claimed in any of claims 38 to 41 including detection means for detecting the location of the reflective tape after formation of the panel; and means for applying a protective material to the panel in accordance with the location of the tape.

43. Apparatus as claimed in any of claims 38 to 42 including: means for drawing reflective tape from a supply reel; means for positioning the tape at a desired location of the first skin; cutting means for cutting the reflective tape to a desired length; and pressing means for pressing the cut length of tape against the first skin to apply the tape to the first skin.

44. Apparatus as claimed in claim 43 wherein a desired length of reflective tape is drawn from the supply reel by operation of an indexing means.

45. Apparatus as claimed in claim 44 wherein the indexing means is an indexing ram which is operated to turn a pinion through a preset rotation corresponding to a desired length.

46. Apparatus as claimed in any of claims 43 to 45 wherein the reflective tape is drawn over an applicator head from the supply reel and the applicator head presses the tape against the first skin to apply the tape.

47. Apparatus as claimed in claim 46 wherein the reflective tape is retained in position on the applicator head prior to application by drawing the tape to the head.

48. Apparatus as claimed in claim 47 wherein the tape is drawn to the head by applying suction.

49. Apparatus as claimed in any of claims 46 to 48 wherein the applicator head is driven from an initial rest position to receive reflective tape from the supply reel, through an intermediate position against a blade means to cut the tape to length, to a tape applying position in which the cut tape is applied to the external skin.

50. Apparatus as claimed in claim 49 wherein the applicator head is driven by a cutting and applicator ram means, a first stroke of the ram cutting the tape to length against the blade means, and a second stroke applying the tape to the external skin.

51. Apparatus for manufacturing an insulating panel as claimed in any of claims 37 to 50 substantially as hereinbefore described with reference to the accompanying drawings.

52. An insulating panel whenever produced by a method as claimed in any of claims 19 to 36 and\or using an apparatus as claimed in any of claims 37 to 51.

53. A method for manufacturing an insulating panel of the type comprising a first skin and a second skin having an insulating core therebetween, the method comprising the steps of: conveying a first skin along a flat bed with an outer surface of the skin lowermost; cutting a leading first skin to a desired length; laying a following first skin adjacent to the leading first skin; drawing a jointing tape across the joint between the leading and following first skins; conforming the tape to the profile of the first skins; automatically applying the tape to the joint between the first skins; applying liquid insulating foam reactants onto the first skins; leading a second skin over the first skin and joint; heating the assembly in an oven to allow the liquid foam reactants to expand to form an insulating core between the skins; cutting the second skin and foam core through to the first skin at the joint; and separating the panels thus formed.

54. A method as claimed in claim 53 wherein, above the first skins, jointing tape is drawn off a reel, cut to length, applied over a tape applying head, and the tape applying head is moved downwardly to apply the jointing tape over the joint.

55. A method as claimed in claim 54 wherein the tape is applied over the tape applying head by drawing the tape under suction to the tape applying head.

56. A method is claimed in either of claims 54 or 55 including the step of forming part of the jointing tape into at least one loop for applying to a corrugation profile of the first skin.

57. A method as claimed in claim 56 wherein the jointing tape applying head comprises a number of sections, and portion of the tape is formed into a loop by moving adjacent sections laterally apart prior to moving the tape applying head downwardly to apply the tape.

58. A method as claimed in any of claims 53 to 57 wherein the first skin is a profiled external skin and the second skin is an internal backing tray.

59. A method for manufacturing an insulating panel as claimed in any of claims 53 to 58 substantially as hereinbefore described with reference to the accompanying drawings.

60. Apparatus for manufacturing an insulating panel comprising: means for conveying a first skin with an outer surface of the skin lowermost; cutting means for cutting a leading first skin to a desired length; means for laying a following first skin adjacent to the leading first skin; gripper means for drawing a jointing tape across the joint between the leading and following first skins; conforming means for conforming the tape to the profile of the first skins; an applicator head for applying the tape to the joint between the first skins; foam applicator means for applying liquid insulating foam reactants onto the first skins; an oven for heating the assembly to allow the liquid foam reactants to expand and form an insulating core between the skins; cutting means for cutting the second skin and foam core through to the first skin at the joint; and separating means for separating the panels thus formed.

61. Apparatus as claimed in claim 60 wherein the gripper means for drawing a jointing tape across the joint comprises gripper jaw means and translation means attached to the gripper means for extending the gripper means across a bed to a supply reel and for drawing the tape from the reel across the bed.

62. Apparatus as claimed in claim 60 or 61 wherein the applicator head comprises a number of sections which are laterally spaced across the bed and at least some of the sections have suction means for releasably holding the tape to the head sections.

63. Apparatus as claimed in claim 62 wherein at least some of the applicator head sections are laterally movable relative to one another to form a loop of tape for application to a corrugation profile of the first skins at the joint.

64. Apparatus as claimed in any of claims 60 to 63 including positioning means for positioning the drawn tape under the applicator head.

65. Apparatus as claimed in claim 64 wherein the tape is cut to length from the supply reel by the cutting means as the tape is positioned under the applicator head.

66. Apparatus as claimed in any of claims 60 to 65 wherein the first skin is a profiled external skin and the second skin is an internal backing tray.

67. Apparatus for manufacturing an insulating panel as claimed in any of claims 60 to 66 substantially as hereinbefore described with reference to the accompanying drawings.

68. An insulated panel whenever manufactured by a method as claimed in any of claims 53 to 59 and\or using an apparatus as claimed in any of claims 60 to 67.

69. A method for manufacturing insulating panels of the type comprising a first skin and a second skin having an insulating core therebetween, the method comprising the steps of: conveying a first skin with the outer surface of the skin lowermost; applying liquid insulating foam reactants onto the first skin; delivering a second skin over the first skin; inserting a spacer means between the first skin and second skin, the spacer means comprising a plurality of spacers extending between the first skin and second skin, each spacer being mounted on an individual spacer arm, a first spacer means comprising a plurality of first spacers, each mounted on an associated spacer arm; heating the assembly thus formed in an oven to allow the liquid foam reactants to expand to form an insulating core between the first skin and second skin; and, as required to produce panels with a different thickness of insulating core, changing the spacing means by: mounting second spacers on the spacer arms; and moving the spacer arms from a first position in which the first spacers are in position in the oven and the second spacers are removed to a second position in which the first spacers are removed and the second spacers are in position.

70. A method as claimed in claim 69 wherein, after mounting the second spacers on the spacer arms, the upper bed of the oven is lifted to facilitate moving the spacer arms so that the first spacers are removed and the second spacers are in position, and subsequently moving the upper bed of the oven downwardly to the lower bed with the second spacers between the upper and lower beds of the oven.

71. A method as claimed in claim 69 or 70 wherein the spacer arms are mounted for swinging from a first position with the first spacers in position in the oven to a second position with the first spacers removed and the second spacers in position.

72. A method as claimed in claim 71 wherein the spacer arms are rotatably mounted for rotation between the first and second positions.

73. A method as claimed in any of claims 69 to 72 wherein all of the spacer arms are operated substantially simultaneously from the first to the second positions.

74. A method as claimed in claim 73 wherein the spacer arms are operated by ram means which rotate the arms through a rack and pinion means.

75. A method as claimed in any of claims 69 to 74 wherein the first skin is a profiled external skin and the second skin is an internal backing tray.

76. A method for manufacturing insulating panels as claimed in any of claims 69 to 75 substantially as hereinbefore described with reference to the accompanying drawings.

77. Apparatus for manufacturing insulating panels comprising an oven having a top bed and a bottom bed and spacer means for inserting between the top and bottom beds to set the depth of an insulating core, the spacer means comprising a plurality of spacers, each spacer being mounted on an individual spacer arm, a first spacer means comprising a plurality of first spacers, each mounted on an associated arm, a second spacer means comprising a plurality of second spacers, each mounted on an associated spacer arm, and means for moving the spacer arms to move the first spacers from the oven and to move the second spacers into the oven.

78. Apparatus as claimed in claim 77 wherein first and second spacers are mounted on a common spacer arm.

79. Apparatus as claimed in claim 77 or 78 including lifting means for lifting the upper bed of the oven to facilitate movement of the spacer arms.

80. Apparatus as claimed in any of claims 77 to 79 wherein the spacer arms are rotatably mounted for movement of the spacers into and out of the oven.

81. Apparatus as claimed in any of claims 77 to 80 including operating means for moving the spacer arms substantially simultaneously.

82. Apparatus as claimed in claim 81 wherein the operating means comprises an operating ram which moves the spacer arms through a rack and pinion means.

83. Apparatus as claimed in any of claims 79 to 82 wherein the lifting means comprising a lifting ram.

84. Apparatus for manufacturing insulating panels comprising: conveying means for conveying a first skin with the outer surface of the skin lowermost; means for applying liquid insulating foam reactants onto the first skin; means for leading a second skin over the first skin; and an oven having a top bed and a bottom bed and spacer means for inserting between the top and bottom beds to set the depth of an insulating core, the spacer means comprising a plurality of spacers, each spacer being mounted on an individual spacer arm, a first spacer means comprising a plurality of first spacers, each mounted on an associated arm, a second spacer means comprising a plurality of second spacers, each mounted on an associated spacer arm, and means for moving the spacer arms to move the first spacers from the oven and to move the second spacers into the oven.

85. Apparatus for manufacturing insulating panels as claimed in any of claims 77 to 84 substantially as hereinbefore described with reference to the accompanying drawings.

86. Insulating panels wherever manufactured by a method as claimed in any of claims 69 to 76 and\or using an apparatus as claimed in any of claims 77 to 85.

87. A method for manufacturing an insulating panel of the type comprising a first skin and a second skin having an insulating core therebetween, the method comprising the steps of: conveying a first skin along a flat bed with the outer surface of the skin lowermost; applying liquid insulating foam reactants onto the first skin; leading a second skin over the external skin to form an assembly; heating the assembly in an oven to allow the liquid foam reactants to expand to form an insulating core between the skins; and in a single cutting step, automatically cutting the second skin and foam core through to the first skin at a preset location of the panel.

88. A method as claimed in claim 87 wherein the second skin and foam core are cut through to the first skin by automatically driving a cutting means across the assembly as the assembly is travelling along a cutting bed.

89. A method as claimed in claim 87 or 88 wherein the cutting means comprising a leading saw and a trailing blade, the leading saw cutting through the second skin and at least part of the foam core to define a first cut and the trailing blade travelling in the first cut for close cutting of the foam core through to the first skin.

90. A method as claimed in claim 89 wherein the leading saw is a cross-out circular saw for cutting through the second skin and at least part of the foam core to define the first cut.

91. A method as claimed in claim 89 or 90 wherein the trailing blade is a guillotine blade which extends into the first cut to cut the remaining foam core through to the internal face of the first skin of the assembly.

92. A method as claimed in any claims 89 to 91 including the steps of automatically driving the trailing blade towards the internal face of the first skin in accordance with the profile of the first skin to cut the foam through to the internal face of the first skin.

93. A method as claimed in claim 92 including the steps of biassing the trailing blade into a normally raised position and driving the trailing blade downwardly against the biassing in accordance with the profile of the first skin.

94. A method as claimed in any of claims 89 to 93 wherein the method includes the step of vibrating the trailing blade as it is driven through the first cut defined by the leading saw.

95. A method as claimed in any of claims 89 to 94 wherein the first skin is a profiled external skin and the second skin is an internal backing tray.

96. A method for manufacturing an insulating panel as claimed in any of claims 87 to 95 substantially as hereinbefore described with reference to the accompanying drawings.

97. Apparatus for manufacturing an insulating panel comprising: means for conveying a first skin with an outer surface of the skin lowermost; foam applicator means for applying liquid foam reactants to the first skin; means for leading a second skin over the first skin to form an assembly; an oven for heating the assembly to allow the liquid foam reactants to expand to form an insulating core between the skins; cutting means for cutting at least the second skin and foam core to form an insulating panel; and cutting means for automatically cutting the second skin and foam core through to the profiled first skin at a preset location of the panel.

98. Apparatus as claimed in claim 9711 including a cutting bed along which the assembly is led and mounting means for mounting the cutting means to travel with the assembly along the cutting bed as the cutting means cuts the second skin and foam core through to the first skin.

99. Apparatus as claimed in claim 97 or 98 wherein the cutting means comprises a leading saw and a trailing blade mounted to and travelling across the assembly with the leading saw.

100. Apparatus as claimed in claim 99 wherein the leading saw is a cross cut saw.

101. Apparatus as claimed in claim 99 or 100 wherein the trailing blade is a guillotine blade.

102. Apparatus as claimed in any of claims 99 to 101 including vibrating means for vibrating the trailing blade as it travels through the cut made by the leading saw.

103. Apparatus as claimed in any of claims 99 to 102 wherein the apparatus includes biassing means for biassing the trailing blade into a raised position.

104. Apparatus as claimed in claim 103 wherein the apparatus includes ram means for driving the trailing blade against the biassing of the biassing means to cut the foam through to the internal face of the first skin.

105. Apparatus as claimed in claim 103 or 104 including means for detecting the profile of the first skin, and means for operating the ram means to drive the blade downwardly to follow the profile of the first skin.

106. Apparatus as claimed in any of claims 97 to 105 wherein the first skin is a profiled external skin and the second skin is an internal backing tray.

107. Apparatus for manufacturing an insulating panel as claimed in any of claims 97 to 106 substantially as hereinbefore described with reference to the accompanying drawings.

108. An insulating panel wherever manufactured by a method as claimed in any of claims 87 to 96 and/or using an apparatus as claimed in any of claims 97 to 107.

109. A method for manufacturing an insulating panel of the type comprising a first skin and a second skin having an insulating core therebetween, the method comprising the steps of: conveying a first skin along a flat bed with the outer surface of the skin lowermost, cutting a leading first skin to a desired length; laying a following first skin adjacent to the leading first skin; applying a jointing means across the joint between the leading and following first skins; applying liquid insulating foam reactants onto the first skins; leading a second skin over the first skins and joint; heating the assembly in an oven to allow the liquid foam reactants to expand and form an insulating core between the skins; cutting the second skin and foam core through to the first skin; using a first clamping means, clamping the leading panel adjacent to the joint; using a second clamping means, clamping the trailing panel adjacent to the joint; and after clamping, applying a separating force between the first and second clamping means to separate the panels at the joint.

110. A method as claimed in claim 109 wherein at least one of the first and second clamping means includes upper and lower clamping heads which clamp the panel therebetween.

111. A method as claimed in claim 110 wherein both the first and second clamping means include upper and lower clamping heads.

112. A method as claimed in claim 110 or 111 wherein the or each of the upper clamping heads are positioned a preset distance above the upper face of the second skin of the panels.

113. A method as claimed in any of claims 109 to 112 wherein the clamping means are mounted on a carriage which travels with the panels and the panels are separated without stopping the run of the panels.

114. A method as claimed in any of claims 109 to 113 wherein the first skin is a profiled external skin and the second skin is an internal backing tray.

115. A method for manufacturing an insulating panel as claimed in any of claims 109 to 114 substantially as hereinbefore described with reference to the accompanying drawings.

116. Apparatus for manufacturing an insulating panel comprising: means for conveying a first skin with an outer surface of the skin lowermost; foam applicator means for applying liquid foam reactants to the first skin; means for leading a second skin continuously over the first skin to form an assembly; an oven for heating the assembly to allow the liquid foam reactants to expand to form an insulating core between the skins; tray cutting means for cutting the second skin and foam core through to the first skin; first clamping means for clamping the leading panel adjacent to the joint; second clamping means for clamping the trailing panel adjacent to the joint; and means for applying a longitudinal separating force between the first and second clamping means to separate the panels at the joint.

117. Apparatus as claimed in claim 116 wherein the first and\or second clamping means comprises an upper clamping head and a lower clamping head which clamp the panel therebetween.

118. Apparatus as claimed in claim 117 wherein both of the first and second clamping means comprises an upper clamping head and a lower clamping head which clamp the panel therebetween.

119. Apparatus as claimed in claim 117 or 118 including positioning means for positioning the upper clamping heads a preset distance above the upper face of the second skin of the panel.

120. Apparatus as claimed in claim 119 wherein the clamp head positioning means comprises a roller mounted on an arm, ram means interconnecting the clamp head and the arm, the ram operating to position the clamp head a preset distance above the upper face of the second skin of the panel.

121. Apparatus as claimed in any of claims 117 to 120 including a ram means for moving the upper clamp head and lower clamp head between released and engaged clamping positions.

122. Apparatus as claimed in any of claims 116 to 121 wherein the first clamp means is mounted on a first carriage, the second clamp means is mounted on a second carriage and the carriages are moved apart to separate the panel, on clamping.

123. Apparatus as claimed in claim 122 wherein both carriages travel with the panels to separate the panels without interrupting the forward movement of the panels.

124. Apparatus as claimed in any of claims 116 to 123 wherein the first skin is a profiled external skin and the second skin is an internal backing tray.

125. Apparatus for manufacturing an insulating panel as claimed in any of claims 116 to 124 substantially as hereinbefore described with reference to the accompanying drawings.

126. Insulated panels whenever manufactured by a method as claimed in any of claims 109 to 115 and/or using an apparatus as claimed in any of claims 116 to 125.