IE20040357A1

IE20040357A1 - Manufacture of insulating panels

Info

Publication number: IE20040357A1
Application number: IE20040357A
Authority: IE
Inventors: Patrick Mcdonald
Original assignee: Kingspan Res & Dev Ltd
Priority date: 2003-05-30
Filing date: 2004-05-21
Publication date: 2004-12-01
Also published as: GB2402101B; IES20040365A2; GB2402101A; GB0411455D0

Abstract

A method for manufacturing a insulating panel of the type comprising a first skin and a second skin having an insulating core therebetween, comprises conveying a first skin (2) along a flat bed with the outer surface of the skin lowermost, cutting a leading first skin (2) to a desired length, laying a following first skin (2) adjacent to the leading first skin forming a joint between the first skins, applying liquid insulating foam reactants onto the first skins and leading a second skin (3) over the first skins (2) and joint. The assembly is heated in an oven to allow the liquid foam reactants to expand and form an insulating core (4) between the skins (2,3) of adjacent panels (21, 22). The second skin (3) and potion of the foam core (4) is cut forming a cut (23) and leaving a residue of uncut foam core. Using a first clamping means (24,25) a leading panel section (21) is clamped adjacent to the joint and using a second clamping means (26,27), a trailing panel section (22) is clamped adjacent to the joint. During or after clamping, the residue foam core is cut with a ram operated profile blade (52) and subsequently a separating force is applied between the clamping means (24,25 & 26,27) to separate the panel sections (21,22) at the joint. <Figure 2>

Description

"Manufacture of insulating panels" ΙΕ η 4 Ο 3 5 7 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 first skin and a second skin having an insulating core therebetween, the method comprising the steps of: 25 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 liquid insulating foam reactants onto the first skins; mmmi wra___i fc>3g-fei jiff IE 0 4 0 3 5 7 -2leading a second skin over the first skins; 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 portion of the foam core forming a cut and leaving a residue of uncut foam core; using a first clamping means, clamping a leading panel section adjacent to the joint; using a second clamping means, clamping a trailing panel section adjacent to the joint; and during or after clamping, cutting the residue foam core and subsequently applying a separating force between the clamping means to separate the panel sections at the joint.

In one embodiment the residue foam core is cut by inserting a blade means into the cut formed on cutting the second skin and portion of the foam core.

The blade means is preferably movable from a raised disengaged position to a lowered cutting position. The blade means may be movable by a ram means. Preferably the blade means is substantially vertically movable.

In one embodiment the method includes the step, after insertion into the cut, of vibrating the blade means.

In one embodiment the first skin is profiled and the blade means is profiled to correspond with the profile of the skin.

IE 0 4 0 3 5 7 -3The blade means may comprise an arm interconnecting a number of separate profiled blade sections, the blade section being movable on movement of the arm.

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 The invention will be more clearly understood from the following description thereof given by way of example only with reference to the accompanying drawings, in which: Fig. 1 is a flow chart of the method of the invention; Fig. 2 is a side, partially cross sectional view of a panel breaker and cutting apparatus used in the method of the invention in a first position of use; Fig. 3 is a side view of the breaker apparatus of Fig. 2 in a second position of use; Fig. 4 is a side view of the breaker apparatus of Fig. 2 in a final position of use; Figs. 5(a) to 5(c) are side, partially cross sectional views of panels being separated and cut using the apparatus of Figs. 2 to 4; Fig. 6 is a perspective view of the cutting means used in the method of the invention, in use; and -4Fig. 7 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 used for forming an insulated panel of the type which is illustrated in Fig. 7 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, polyisocyanurate or phenolic 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. The desired longitudinal overlap between adjacent panels are automatically marked using an ink jet apparatus. The external skin 2 is then profiled at B and cut to length in step C. 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 the following external skin 2 in step D. A joint between the external skins 2 is made by automatically applying a jointing tape at E. The external skins 2 are then preheated at F prior to application of liquid foam reactants at G.

A sheet of backing tray material is led from a reel in step H, profiled in step I, and preheated in step J. The profiled backing tray 3 is then continuously applied over the overlapped external skins 2 and liquid foam reactants in step K. As the backing tray 3 is applied, a longitudinally extending side sealing tape 5 is also applied at L between IE 0 4 0 3 5 7 -5 the backing tray 3 and the external skin 2 to confine the foam core 4 in the desired space.

The liquid foam reactants are then allowed to expand to fill the space between the external skin 2 and backing tray 3 by passing the assembly through the oven in step M 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. At the joint between adjacent external skins, the backing tray 3 and foam core 4 are cut in a cutting stage towards the internal (or upper) face of the external skin 2 in step N. At the separating station residue foam remaining at the joint is cut in step O leaving clean faces at the joint. A protective material is applied to the exposed face of the backing tray 3 in step P and adjacent panels 1 are separated at the joint in step Q in preparation for stacking and packaging.

Referring to Figs. 2 to 6, there is illustrated a panel breaking apparatus 10 and final cutting apparatus 5 used in the method of the invention for separating a leading panel 21 from a trailing panel 22 at the cut joint 23. A first clamp comprising a first upper clamping head 24 and a first lower clamping head 25 grips the leading panel 21. A second clamp comprising a second upper clamping head 26 and a second lower clamping head 27 grips the trailing panel 21. The first and second clamps are mounted on separate carriages 28, 29 which are moved apart from the position illustrated in Figs. 2 and 3 to the separated position illustrated in Fig. 4 to separate the adjacent panels 21, 22 at the joint from the joined position illustrated in Fig. 5(a) to the separated position illustrated in Fig. 5(c).

The carriages 28, 29 each comprise a post 31, 32 which is fixed relative to the respective panel 21, 22 and a movable post 33, 34. The posts 31, 33 and 32, 34 are interconnected by pivot arms 35, 36 and the posts 31, 32, 33, 34 are also interconnected by respective rams 37, 38. To engage the upper clamp head 24, 26 IE 04 035 7 - 6 with the adjacent panels 21, 22, the rams 37, 38 are operated from the raised release position illustrated in Fig. 2 to move the posts 31, 34 on the pivot arms 35, 36 to the extended engaged position illustrated in Figs. 3 and 4. The lower clamps 25, 27 are also operated by lower rams, not shown.

At least the leading clamp may be provided with a roller 40 on a guide arm 41 pivotally connected to the movable post 44 and movable by a guide ram 42. The roller 40 rides on the surface of the backing tray 3 of the panel 21 to position the upper clamps 24, 26 as short a distance as possible above the backing tray. In this way, the distance through which the upper clamp heads 24, 26 travel is minimised. Consequently, the speed of the panel separation process is optimised.

It will be noted that the lower clamp heads 25 and 27 are spaced in the release position illustrated in Fig. 2 below the lower surface of the panels 21, 22. This ensures that grit and dirt are not trapped which could lead to damage to the exposed surface of the panel.

The carriages 28, 29 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 backing tray 3 and portion of the foam core 4 are cut prior to delivery of the panel assembly to the breaker apparatus 10. A final cutting apparatus 50 is incorporated into the breaker apparatus 10 to remove residual foam remaining uncut at the joint. This is especially a problem in the case of panels with profiled external sheets 2 as illustrated in Fig. 7. It is extremely difficult to remove all of the foam from the cut especially at the deepest portions of the trapezoidal profiles.

The invention solves this problem by providing a final blade means 50 comprising an arm 51 interconnecting a number of spaced-apart guillotine blade sections 52. Each IE Ο 4 Ο 3 5 7 -7guillotine blade section 52 is sized and shaped to substantially conform to the shape of a trapezoidal groove of the external sheet 2.

The blade means 50 is operated by a ram having a cylinder 60 connected to a post 33 5 of the clamping means and a rod 61 connected to the blade means 50. The ram is used to move the blade 50 substantially vertically from a raised inactive retracted position illustrated in Fig. 2 and 5(a) to a lowered cutting position as illustrated in Fig. 3 and (b), the residue foam being cleanly severed as the blades 52 are forced through the residue foam by the ram guillotine action. The blade 50 is operated as illustrated, prior to application of the separating force.

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, cutting a leading first skin to a desired length; laying a following first skin adjacent to the leading first skin; applying liquid insulating foam reactants onto the first skins; leading a second skin over the first skins; 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 portion of the foam core forming a cut and leaving a residue of uncut foam core; using a first clamping means, clamping a leading panel section adjacent to the joint; using a second clamping means, clamping a trailing panel section adjacent to the joint; and IE 04 035 7 -9during or after clamping, cutting the residue foam core and subsequently applying a separating force between the clamping means to separate the panel sections at the joint. 5

2. A method as claimed in claim 1 wherein the residue foam core is cut by inserting a blade means into the cut formed on cutting the second skin and portion of the foam core.

3. A method as claimed in claim 2 wherein the blade means is movable from a 10 raised disengaged position to a lowered cutting position.

4. A method as claimed in claim 3 wherein the blade means is movable by a ram means. 15

5. A method as claimed in claim 3 or 4 wherein the blade means is substantially vertically movable. A method as claimed in any of claims 2 to 5 including the step, after insertion into the cut, of vibrating the blade means. A method as claimed in any of claims 2 to 6 wherein the first skin is profiled and the blade means is profiled to correspond with the profile of the skin. A method as claimed in claim 7 wherein the blade means comprises an arm interconnecting a number of separate profiled blade sections, the blade section being movable on movement of the arm. A method for manufacturing an insulating panel substantially as hereinbefore described with reference to the accompanying drawings. IE 0 4 0 3 5 7 -1010. Insulating panels when manufactured by a method as claimed in any preceding claim.