IE87277B1

IE87277B1 - Method of manufacturing structural member

Info

Publication number: IE87277B1
Application number: IE20160009A
Authority: IE
Inventors: Price Richard; Matthew Neil
Original assignee: Tata Steel Uk Ltd Trading As Catnic A Tata Steel Enterprise
Priority date: 2015-01-13
Filing date: 2016-01-12
Publication date: 2021-11-24
Also published as: GB2535601A; GB201522078D0; GB2535601B; GB201500507D0; IE20160009A1

Abstract

The present invention concerns a method of manufacturing a structural member. More particularly, but not exclusively, this invention concerns a method of manufacturing a thermally broken lintel. The invention also concerns a method of manufacturing a thermally broken lintel. The method comprises the steps of providing a first load-bearing element in a first orientation, providing an insulating core, and applying an adhesive to the first load-bearing element or insulating core. The method then comprises bringing the first load-bearing element and insulating core into contact, providing a second load-bearing element, and applying an adhesive to the second load-bearing element or insulating core. The method then comprises bringing the second load-bearing element and insulating core into contact, changing the orientation of the structural member, and applying heat and pressure to at least one of the first load-bearing element and second load-bearing element to cure the adhesive.

Description

Method of manufacturing structural member Field of the Invention The present invention concerns a method of manufacturing a structural member. More particularly, but not exclusively, this invention concerns a method of manufacturing a lintel. The invention also concerns a method of manufacturing a thermally broken lintel.

Background of the Invention Lintels are load bearing components used in the construction industry. They are often made of a metal 15 box structure 10 and an insulating core material 12 located within the box, as shown in figure 1. As modern buildings are required to become ever more thermally efficient, it has been recognised that the metal box structure of a traditional lintel may reduce thermal 20 efficiency by providing a thermally conductive path from inside a building to outside a building. In order to avoid this problem, thermally broken lintels may be provided, where instead of a continuous box structure 10, a first metal load bearing element 18 and a second metal 25 load bearing element 16 are joined to an insulating core material 12, but not directly connected to each other, as shown in figure 2. Therefore, the thermal path from one side of the lintel to the other side of the lintel is removed. However, existing designs for thermally broken 30 lintels are difficult to manufacture, leading to poor quality control and/or increased expense.

The present invention seeks to mitigate the abovementioned problems. Alternatively or additionally, the - 2 11/10/2021 present invention seeks to provide an improved method of manufacture .

Summary of the Invention 5 The present invention provides, according to a first aspect, a method of manufacturing a structural member, the structural member having a longitudinal axis, the method comprising the steps of: providing a first load-bearing element in a first orientation, providing an insulating core, applying an adhesive to a substantially horizontal surface of the first load-bearing element or insulating core, bringing the first load-bearing element and insulating core into contact, providing a second load-bearing element, applying an adhesive to a substantially horizontal surface of the second load-bearing element or insulating core, bringing the second load-bearing element and insulating core into contact, rotating the structural member approximately 90 degrees about the longitudinal axis, and applying heat and pressure to at least one of the first load-bearing element and second load-bearing element to cure the adhesive associated with the first load-bearing element and/or second load-bearing element respectively.

The step of applying heat and pressure to at least one of the first load-bearing element and second loadbearing element may comprise passing the structural member through a heat press, and applying pressure and - 3 11/10/2021 heat to at least one of the first load-bearing element and second load-bearing element to cure the adhesive.

The step of applying heat and pressure to at least one of the first load-bearing element and second load5 bearing element may comprise applying a clamp to one or both of the first load-bearing element and second loadbearing element. The heat may then be applied by heating the clamp or heating the area around the clamp.

The structural member may be a lintel. The structural member may be a thermally-broken lintel. The first load-bearing element and/or second load-bearing element may be metal. The metal may be steel, stainless steel, or aluminium. The first load-bearing element and second load-bearing element may be joined to the insulating core such that there is no direct contact between the first load-bearing element and second loadbearing element.

The step of applying adhesive to the first loadbearing element or insulating core may comprise applying adhesive to the first load-bearing element. The adhesive may be applied via an adhesive spray or a bead applicator. Applying the adhesive via an adhesive spray or bead applicator may ensure an even coverage of adhesive. The insulating core may then be placed in contact with the adhesive. The first load-bearing element may be oriented such that the insulating core is moved into contact with the first load-bearing element in an approximately downwards, for example approximately vertically downwards, direction.

The step of applying adhesive to the second load- bearing element or insulating core may comprise applying adhesive to the insulating core. The adhesive may be applied via an adhesive spray or bead applicator. The insulating core may be oriented such that the second - 4 11/10/2021 load-bearing element is moved into contact with the insulating core in an approximately vertical downwards direction .

Constructing the structural member in this way may 5 ensure the accuracy of the placement of the first loadbearing element, second load-bearing element, and insulating core. Preferably, the application of adhesive is to an approximately horizontal surface, which reduces or prevents adhesive run off. This may reduce the amount 10 of wasted adhesive and/or keep the production line cleaner and reduce maintenance required. Applying adhesive to a horizontal surface may also ensure an even coverage of adhesive, resulting in a secure bonding of the load-bearing elements and the insulating core. 15 The heat press or clamp may apply pressure to the first load-bearing element or second load-bearing element by applying pressure in an approximately horizontal direction. Due to the rotation of the structural member, 20 the heat press or clamp may apply pressure to a side of the structural member which was previously the top or bottom of the structural member before the change of orientation. Applying the heat press or clamp in this orientation may reduce the possibility of the curing 25 process causing the misalignment of the two load-bearing elements and the insulating core.

The heat applied, for example via one or more rollers within a heated enclosure, accelerates the adhesive curing process, and the pressure applied to the 30 load-bearing elements ensures a good bond with the insulating core.

The insulating core may comprise an angled surface, corresponding to the shape of the second load-bearing element. The method may comprise applying pressure in a - 5 11/10/2021 heat press to the corresponding angled surface of the second load-bearing element. The method may comprise the movement of the structural member along a processing line. The processing line may comprise a plurality of 5 alignment rollers to ensure the correct alignment of the first load-bearing member, the insulating core, and the second load-bearing member.

The orientation of the structural member when it is removed from the processing line may be such that the 10 structural member is correctly oriented for stacking and/or labelling.

It will of course be appreciated that features described in relation to one aspect of the present invention may be incorporated into other aspects of the 15 present invention. For example, the method of the invention may incorporate any of the features described with reference to the apparatus of the invention and vice versa .

Description of the Drawings Embodiments of the present invention will now be described by way of example only with reference to the accompanying schematic drawings of which: Figure 1 shows a cross sectional view of a lintel according to the prior art; Figure 2 shows a cross sectional view of a thermally broken lintel according to the prior art; Figure 3 shows a number of steps of a method according to a first embodiment of the invention; Figure 4 shows a number of steps following the steps shown in figure 3; - 6 11/10/2021 Figure Figure 5 6 shows a number of steps following the st eps shown in figure 4; shows a cross-section taken from figure 3, taken through the section marked A-A. 5 Figure 7 shows a cross-section taken from figure taken through the section marked B-B; 3, Figure 8 shows a cross-section taken from figure taken through the section marked C-C; 3, 10 Figure 9 shows a cross-section taken from figure taken through the section marked D-D; 4, Figure 10 shows a cross-section taken from figure taken through the section marked E-E; 5, Figure 11 shows a cross-section taken from figure taken through the section marked F-F; 5, and Figures 12 to 16 show a second embodiment of the invention .

Detailed Description Figure 3, moving from left to right, shows a number of steps in a method of manufacturing a thermally-broken lintel according to a first aspect of the invention. A first load-bearing element 30 is loaded onto a processing line 32 at a loading station 33, the processing line 32 including a plurality of alignment rollers 34. The processing line 32 includes a number of rollers on which the first load-bearing element 30 is placed which are rotated to move the first load-bearing element along the processing line. The first load-bearing element 30 comprises an elongate square C-shaped metal beam, with a cross section as shown in figure 6. In an alternative embodiment, the first load-bearing element may be an elongate L-shaped metal beam. The processing line 32 moves the first load-bearing element 30 in the direction - 7 11/10/2021 X (left to right in figure 3), passing through a first processing station 36. The processing station 36 comprises a traversing adhesive bead applicator and a water mist spray, operated such that as the first load5 bearing element 30 moves through the processing station 36, adhesive beads and a water mist are applied to the top surface of the first load-bearing element 30. In an alternative embodiment, the processing station 36 may comprise a traversing adhesive spray. In further alternative embodiments, it may not be necessary that the processing station 36 includes a water mist spray, depending on the particular adhesive being used, and the humidity in the processing area.

The first load-bearing element 30 is moved into an 15 insulation load station 38, where an insulating core 40 is placed on the adhesive covered top surface of the first load-bearing member 30. The insulating core 40 is made of an insulating foam and is approximately cuboid, though with an angled face at the top of the insulating 20 core, as can be seen in figure 7. The insulating foam may be replaced by any suitable insulating material. Preferably, the insulating material has a low thermal conductivity, typically less than 0.1 W/mK. The bottom of the insulating core 40 is the same length and width as 25 the first load-bearing member 30, as can be seen in figure 7. In alternative embodiments, the insulating core may be made up of a plurality of sections, the sections when combined having the same length and width as the first load-bearing member 30. The insulating 30 core 40 is aligned with the first load-bearing member 30 by the alignment rollers 34. As can be seen in figure 7, the top of the insulating core 40 includes an angled surface, which corresponds with the shape of a second load-bearing element. - 8 11/10/2021 The first load-bearing element 30 and insulating core 40 are moved through a second processing station 42, which again comprises a traversing adhesive bead applicator and a water mist spray operated such that as 5 the insulating core 40 moves through the processing station 42, adhesive beads and a water mist are applied to the top surface of the insulating core 42.

The first load-bearing element 30 and insulating core 40 is moved to a top load station, where a second 10 load-bearing element 44 is placed on the top surface of the insulating core 40. The second load-bearing element 44 is an elongate approximately L-shaped metal beam, with a cross section that corresponds to the shape of the top surface of the insulating core 40, as shown in figure 8. 15 Again, the alignment rollers 34 ensure the correct alignment of the first load-bearing element 30, the insulating core 40, and the second load-bearing element 44 .

The lintel 45 is then rotated 90 degrees about the 20 longitudinal axis of the lintel 45, as shown in figure 9. The lintel 45 is then moved to a curing line 46, as is shown in figure 5, where the adhesive applied to the first load-bearing element 30, the insulating core 40, and the second load-bearing element 44 is cured. In 25 particular, the lintel is moved through a heat press 48, where rollers in a heated environment press the first load-bearing element 30 and second load-bearing element 44 into the insulating core 40. As can be seen in figure 10 the positioning of the rollers ensures the alignment 30 of the lintel does not change as the lintel is pressed.

A second section of rollers may also be used to cure the adhesive applied to the angled section of the insulating core 40 and second load-bearing element 44, as can be seen in figure 11. Once the curing process is complete, - 9 11/10/2021 the manufacture of the lintel is substantially complete. Some post processing steps may occur, for example, cutting the lintel to various sizes as required by the end user.

Figures 12 to 16 show a second embodiment of the invention. Like elements, for example the lintel 45' have the same numbers as those given with reference to the first embodiment of the invention. The method step of applying a heat press to the lintel 45, as described 10 with reference to the first embodiment of the invention, is replaced by the step of applying a clamp 50 to the lintel 45', and heating the lintel 45' whilst the clamp 50 is applied. Figure 12 shows the lintel 45' prior to application of the clamp, when the load-bearing elements 15 have been adhesively fastened to the insulating core, and the resultant lintel rotated 90 degrees in orientation, as described for the initial stages of figure 9. The clamp 50 is brought close to the lintel 45' as shown in figure 13, and then lowered and engaged with the first load-bearing element and second load-bearing element as shown in figure 14. Once clamped, heat is applied to the lintel 45' either by direct heating of the clamp 50, or heating the local environment of the lintel 45'. Once the adhesive has been cured, the clamp 50 is removed as shown in figure 15, and then the lintel 45' may be labelled and stacked as required. The clamp 50 may be adjustable for engagement with different sized lintels. In some embodiments of the invention, the clamp 50 may automatically sense the size of the lintel and adjust for 30 engagement with the lintel accordingly.

Whilst the present invention has been described and illustrated with reference to particular embodiments, it will be appreciated by those of ordinary skill in the art that the invention lends itself to many different - 10 variations not specifically illustrated herein. By way of example only, certain possible variations will now be described. Whilst the heat press has been described as comprising a number of rollers and a heated enclosure, 5 and the structural member is passed through the rollers and heated enclosure, an alternative heat press may comprise heated plates that are pressed into the structural member, for example when the structural member is stationary.

Claims

1. A method of manufacturing a structural member, the structural member having a longitudinal axis, the method 5 comprising the steps of: providing a first load-bearing element in a first orientation, providing an insulating core, applying an adhesive to a substantially horizontal 10 surface of the first load-bearing element or insulating core, bringing the first load-bearing element and insulating core into contact, providing a second load-bearing element, 15 applying an adhesive to a substantially horizontal surface of the second load-bearing element or insulating core, bringing the second load-bearing element and insulating core into contact, 20 rotating the structural member approximately 90 degrees about the longitudinal axis, and applying heat and pressure to at least one of the first load-bearing element and second load-bearing element to cure the adhesive associated with the first 25 load-bearing element and/or second load-bearing element respectively.

2. A method as claimed in claim 1, wherein the structural member is a lintel.

3. A method as claimed in claim 1 or claim 2, wherein the structural member is a thermally-broken lintel. - 12 11/10/2021

4. A method as claimed in any preceding claim, wherein the first load-bearing element and/or second load-bearing element is metal. 5

5. A method as claimed claim 1, wherein the first load- bearing element and second load-bearing element are joined to the insulating core such that there is no direct contact between the first load-bearing element and second load-bearing element.

6. A method as claimed in any preceding claim, wherein the step of applying adhesive to the first load-bearing element or insulating core comprises applying adhesive to the first load-bearing element.

7. A method as claimed in claim 6, wherein the first load-bearing element is oriented such that the insulating core is moved into contact with the first load-bearing element in an approximately downwards direction.

8. A method as claimed in any preceding claim, wherein the step of applying adhesive to the second load-bearing element or insulating core comprises applying adhesive to the insulating core.

9. A method as claimed in any preceding claim, wherein the insulating core is oriented such that the second load-bearing element is moved into contact with the insulating core in an approximately vertical downwards 30 direction.

10. A method as claimed in any preceding claim, wherein the step of applying heat and pressure to at least one of the first load-bearing element and second load-bearing - 13 11/10/2021 element comprises applying a heat press to at least one of the first load-bearing element and second load-bearing element. 5

11. A method as claimed in claim 10, wherein the heat press applies pressure to the first load-bearing element or second load-bearing element in an approximately horizontal direction. 10

12. A method as claimed in claim 12 or claim 13, wherein the insulating core comprises an angled surface, corresponding to the shape of the second load-bearing element, and the method comprises the step of applying pressure with a heat press to the corresponding angled 15 surface of the second load-bearing element.

13. A method as claimed in any of claims 12 to 12, wherein the heat press comprises one or more rollers. 20

14. A method as claimed in any of claims 1 to 9, comprising the step of clamping at least one of the first load-bearing element and second load-bearing element prior to applying heat to at least one of the first loadbearing element and second load-bearing element.

15. A method as claimed in claim 14, wherein the step of applying heat to at least one of the first load-bearing element and second load-bearing element comprises applying heat via the clamp.

16. A method as claimed in claim 14, wherein the step of applying heat to at least one of the first load-bearing element and second load-bearing element comprises applying heat in the vicinity of the clamp.

17. A method as claimed in any preceding claim, comprising the movement of the structural member along a processing line.

18. A method as claimed in claim 17, wherein the processing line comprises a plurality of alignment rollers to ensure the correct alignment of the first load-bearing member, the insulating core, and the second 10 load-bearing member.