HK1062423B - Method for manufacturing a sandwich building element - Google Patents

Description

Method for manufacturing sandwich building component

Technical Field

The invention relates to a method of manufacturing a sandwich building element comprising a core consisting of a mineral wool sheet (lamellae) extending longitudinally with respect to the building element and having fibres substantially perpendicular to the surface layer, and a surface layer on opposite main surfaces of the core, which method comprises bonding the surface layer to the core by fixing the surface layer to the opposite main surfaces of the core with an adhesive.

Disclosure of Invention

It is an object of the present invention to provide an improved manufacturing method for the manufacture of sandwich building elements, which method makes it possible to carry out a continuous-action manufacture of the building elements, while also making it possible to produce smaller batches, even single-piece building elements. To achieve this object, the method of the invention is characterized in that the method comprises supplying the first and second surface layers with sections of a desired length, said sections being arranged sequentially so that the downstream end of a preceding section abuts against or leaves a gap between the upstream end of a following section, said sections then being temporarily joined together for forming a continuous string of surface layer material, which string is then joined to the opposite major surfaces of the core to produce a continuous string of sandwich building elements having the junctions of the first and second strings of surface layer material arranged substantially in line with each other, and then cutting the continuous string of elements at the junctions of the surface layer material.

In the method of the invention, successive sections of surface layer material are preferably joined together in a welt-like manner in such a way that the ends of successive sections opposite each other are at a distance from each other, so that the cutting action is applied substantially only to the core.

The method of the invention makes it possible to produce sheet products and components with end profiles in a continuous action. It is noted that the sheet products include, for example, particle board, fiber board components, and gypsum board.

Brief description of the drawings

The invention will be described in detail below with reference to the attached drawing figures, wherein:

FIGS. 1a-1c schematically show several steps to be carried out in a method of the invention;

figures 2a-2b schematically show a building element obtainable by the method of the invention;

FIG. 3 shows an implementation step in a method of the invention;

fig. 4a-4d schematically show several alternative embodiments of a building element, which may be implemented by means of a method according to the invention.

Detailed Description

Fig. 1a schematically shows the sequential arrangement of sections 10, 11 of surface layer material on a production line and at a welt/taping (taping) to provide a joint 5 between sequential components. The bond is preferably formed by welting so that the mutually opposite ends of the successive elements are maintained at a distance which preferably corresponds to the thickness of the cutting tool, e.g. the blade of a dicing saw, used in the subsequent cutting step of the divided building elements. In the embodiment described, the lengths of the sections 10 and 11 of the surface layer material are not equal. The segments may also differ from each other in material, color, width, thickness, and other properties. Of course, the sequential segments may also be identical to each other. The segments of surface layer material joined together form a string 12 of surface layer material. Temporary bonding by various film (film) connectors, mechanical fasteners or plastic welding is also contemplated.

The strings of surface layer material applied to the opposite main surfaces of the building elements are manufactured separately from each other and the surface layer material for the opposite main surfaces of each building element may be the same or different from each other.

Fig. 1b shows a mineral wool core 2 and its construction. The core 2 consists of mineral wool lamella sections 7-9, the fibre faces of which are located in the finished building element perpendicular to the surface layer material (perpendicular to the paper face in fig. 1 b). The lamella sections are preferably made of a common mineral wool board, wherein the fibres lie in a plane substantially parallel (co-directional) to the main surface of the board. The board is then cut into strips having a width corresponding to the thickness of the core of the building element to be manufactured. In a next step the strips are turned 90 ° and connected to each other transversely to form a mineral wool mat of sheet structure, which is connected behind the preceding mat, so that the sheets of each mat are displaced in their longitudinal direction with respect to the adjacent sheets to form a continuous configuration of the core 2, as shown in fig. 1b, in which adjacent sheet sections 7-9 have abutting joints 7a, 8a, 9a of sheet sections which are staggered with respect to each other. For example, publication US5313758 discloses a method of manufacturing such a core.

Fig. 1c shows by way of example a method of laminating a core 2 and a strand 12 of surface layer material to produce a continuous strand 13 of building elements. A glue application device 6 is used to apply an adhesive or some other bonding agent to the inner surface of the surface layer material 12 adjacent to the core 2, whereafter the string of surface layer material 12 is applied by roller conveyors 18a and 18c against the main surface of the core 2 conveyed by the roller conveyor 18b and conveyed to a laminating mechanism (not shown) and subjected to a suitable pressure load P between pressure members 19 comprised in the laminating mechanism. After the adhesive layer has cured, the building element string 13 is cut by a blade 17 of a cutting device 16 to separate the building elements 1 at the joints 5 of the surface layer material, which joints 5 preferably have a spacing between the ends of the successive surface layer sections (the lower part of fig. 1c is shown in a slightly enlarged scale relative to the upper part to make the joint spacing clearer), so that the cutting operation essentially only acts on the core 2 and the application tape connecting the successive surface layer sections to each other. This greatly extends the useful life of the blade and reduces the power requirements required for the cutting operation.

Another idea of carrying out the invention is that the surface layer material applied to one of the main surfaces comprises a continuous material consisting of a uniform, integral material, for example a sheet of plastic-encapsulated steel, stretched from a roll, and that only the surface layer material applied to the opposite main surface consists of the above-mentioned surface layer material sections 10, 11, which may be identical to or different from each other and which are temporarily connected to each other to form a continuous string. Thus, the cutting of the building element, for example by sawing, is carried out at the joints 5 of the temporarily connected sections 10, 11 on one main surface, so that the surface layer material consisting of one piece of material and located on the opposite main surface will be cut at a corresponding location. This solution is suitable, for example, when it is desired to use various facade materials, while the inner surface remains unchanged.

Fig. 2a and 2b schematically depict in somewhat more detail a building element 1 having a core 2 with a surface layer 3 and 4, respectively, on each of its opposite main surfaces, which in this embodiment has a tongue and groove structure at its longitudinal edges.

Fig. 3 schematically shows an embodiment in which the surface layer material comprises a sheet of plastic-encapsulated steel with a profiled surface. The smooth sheet material is unwound from a roll 20 and transferred to a cutting device 21 for cutting a surface layer material section 23 of a desired length, which is fed to a profile forming means 22 for forming the longitudinal edges thereof into a desired profile, for example a tongue and groove. The profile forming means may also be used to form various patterns of grooves on the surface of the sheet material, for example for decorative and/or reinforcing purposes. Furthermore, it is also conceivable to profile the short sides (end regions) of the sheet material as desired, or alternatively to provide the end regions with separate end members to produce the cassette members.

The profile forming means 22 is followed by transporting the profiled section 23a to an assembly line to temporarily connect it with the preceding section, preferably by welting, as shown in fig. 1 a. Tight facing across the width of the surface layer material is the most preferred joining technique because then the adhesive or other bonding agent applied to the core 2 during lamination does not seep out of the joint to soil the structure and/or the building element to be produced and possibly cause mechanical failure.

Fig. 4a-4d show several embodiments of building elements manufactured by a method according to the invention, wherein the core 2 comprises at least two different sheets.

In fig. 4a, one edge sheet 20 is made of a mineral wool material which is stronger and/or better in its refractory properties than the other sheets of the core. The lamella elements 20 also have channels 28, for example for cables. In fig. 4b, in addition to an edge lamella 21, a centrally located lamella 22 is also formed from a mineral wool which is stronger than the lamella 25, and the edge lamella 21 is provided integrally with the ventilation tube 30 and the lamella elements 22 are provided integrally with the ventilation tube 29 and the cable duct 28. In fig. 4c the edge webs 23 are integrally provided with a formation 31 for receiving e.g. a building frame element concealed within a wall structure. The edge sheet 23 is made of a stronger material than the sheet 25. Figure 4d illustrates an embodiment in which an outermost sheet 24 is formed with a configuration 32 for accommodating the cable channel 28, and the core further has a centrally located sheet element 22, which sheet element 22 has the ventilation tube 29 and the cable channel 28. Furthermore, in the embodiment of fig. 4d, the surface layer material consists of a thicker building board than in the embodiment of fig. 4a-c, which preferably comprises a sheet of plastic-encapsulated steel. The surface layer materials 26 and 27 may comprise, for example, a board comprising stone, fiber board or gypsum board.

The sheet may also have fasteners or bracket elements integrally formed therewith to bear against the surface plate for various engagement requirements. The fixing or bracket elements adhere reliably to the inner face of the surface plate during the bonding of the sheet to the surface plate.

Claims (9)

1. A method of manufacturing a sandwich building element (1), said building element comprising a core (2) and surface layers (3, 4) on its two opposite main surfaces, said core (2) consisting of a mineral wool sheet (7, 8, 9) extending in longitudinal direction with respect to the building element and in which the fibre faces are perpendicular to the surface layers, said method comprising bonding the surface layers to the core by fixing the surface layers to the opposite main surfaces of the core with an adhesive, characterized in that the method comprises supplying material to the first and second surface layers in segments (10, 11) of a desired length, which segments are arranged sequentially so that the downstream end of a preceding segment abuts against or has a gap with the upstream end of a succeeding segment, after which the segments are temporarily joined (A) together to form a continuous string (12) of surface layer material, the string is then bonded to the opposite major surfaces of the core (2) to produce a continuous string (13) of sandwich building elements having the junctions (5) of the first and second strings of surface layer material aligned with each other, and the continuous string (13) of elements is then cut (B) at the junctions (5) of surface layer material.

2. A method according to claim 1, characterised in that the sections of surface layer material are temporarily joined to each other by welting, by means of a thin layer of material or by means of mechanical fasteners.

3. A method according to claim 1, characterized in that the method comprises using sections of surface layer material which differ in their material and/or colour and/or size and which are temporarily joined together for forming a continuous string (12) of surface layer material.

4. A method according to claim 1, characterised in that at least some of the sections of surface layer material are manufactured from sheet metal with a profile, which sheet metal is first cut (21) to a desired length (23), fed to a profile forming means (22) for the forming process and, after the forming process, is transferred to a production line for joining the sheet to other sections of surface layer material.

5. A method according to claim 1, wherein the longitudinal ends of a section of skin material are provided with profiled end sections before the section is temporarily joined to other sections.

6. A method according to claim 1, characterized in that the opposite surface layers (3, 4) of the building element (1) consist of materials different from each other.

7. A method according to claim 1, characterized in that the core (2) is made by using at least two sheets (20-25) which differ from each other in their melt resistance, strength or other properties.

8. A method according to claim 1, characterized in that at least one of the sheets is provided integrally with a channel member (28, 29).

9. A method of manufacturing a sandwich building element (1), which building element comprises a core (2), and surface layers (3, 4) on opposite main surfaces of the core, which core (2) consists of mineral wool sheets (7, 8, 9) extending in the longitudinal direction of the building element, in which sheets the fibre faces are perpendicular to the surface layers, which method comprises bonding the surface layers to the core by fixing the surface layers to the opposite main surfaces of the core with an adhesive, characterized in that the method comprises supplying material to at least one surface layer in segments (10, 11) of a desired length, which segments are arranged sequentially so that the downstream end of a preceding segment abuts against the upstream end of a succeeding segment or with a gap therebetween, after which the segments are temporarily joined (A) together to form a continuous string (12) of surface layer material, this string is then bonded to one main surface of the core (2), the opposite main surface of the core (2) being bonded with a corresponding string of surface layer material consisting of a desired length of a section of surface layer material or with a continuous surface layer material made of the same material, to produce a continuous string (13) of sandwich building elements, the string (13) of building elements being cut (B) at the junction (5) of the strings of surface layer material present on at least one main surface.