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WO2009036509A1 - Apparatus for manufacturing laminated panels - Google Patents

Apparatus for manufacturing laminated panels Download PDF

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Publication number
WO2009036509A1
WO2009036509A1 PCT/AU2008/001389 AU2008001389W WO2009036509A1 WO 2009036509 A1 WO2009036509 A1 WO 2009036509A1 AU 2008001389 W AU2008001389 W AU 2008001389W WO 2009036509 A1 WO2009036509 A1 WO 2009036509A1
Authority
WO
WIPO (PCT)
Prior art keywords
glue
sheet
panel
applicator
component
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/AU2008/001389
Other languages
French (fr)
Inventor
James Lewis Edwards
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2007905187A external-priority patent/AU2007905187A0/en
Application filed by Individual filed Critical Individual
Publication of WO2009036509A1 publication Critical patent/WO2009036509A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1284—Application of adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28D—WORKING STONE OR STONE-LIKE MATERIALS
    • B28D1/00—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor
    • B28D1/02—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing
    • B28D1/04—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing with circular or cylindrical saw-blades or saw-discs
    • B28D1/048—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing with circular or cylindrical saw-blades or saw-discs with a plurality of saw blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/52—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/74—Joining plastics material to non-plastics material
    • B29C66/748—Joining plastics material to non-plastics material to natural products or their composites, not provided for in groups B29C66/742 - B29C66/746
    • B29C66/7486—Paper, e.g. cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411—Roller, cylinder or drum types
    • B29C66/83413—Roller, cylinder or drum types cooperating rollers, cylinders or drums
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
    • B29C65/4815—Hot melt adhesives, e.g. thermoplastic adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B29C65/485—Multi-component adhesives, i.e. chemically curing as a result of the mixing of said multi-components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/52—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
    • B29C65/522—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive by spraying, e.g. by flame spraying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/52—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
    • B29C65/524—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive by applying the adhesive from an outlet device in contact with, or almost in contact with, the surface of the part to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/52—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
    • B29C65/526—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive by printing or by transfer from the surfaces of elements carrying the adhesive, e.g. using brushes, pads, rollers, stencils or silk screens
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8124—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the structure of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/81241—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the structure of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps being porous or sintered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2311/00—Use of natural products or their composites, not provided for in groups B29K2201/00 - B29K2309/00, as reinforcement
    • B29K2311/12—Paper, e.g. cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B2037/1269—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives multi-component adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/12—Paper, e.g. cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2325/00—Polymers of vinyl-aromatic compounds, e.g. polystyrene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details

Definitions

  • the present invention relates to an apparatus for producing a laminated panel.
  • Laminated panels are widely used in the building and construction industry.
  • wall panels are typically made from a core of hardened gypsum having sheets of paper attached to either side thereof.
  • These gypsum panels are usually made by pouring a gypsum slurry on to a lower sheet of paper, applying an upper sheet of paper to the gypsum slurry and drying the slurry by passing the panel through a drying oven.
  • Panels are also used in forming the ceilings, such as forming false ceilings in office buildings.
  • a ceiling support structure is suspended from the full immediately above and infill panels are placed on the ceiling support structure.
  • the infill panels typically comprise a gypsum panel or a foamed cementitious panel. These panels are relatively heavy, discolour with age and have little strength or resistance to water.
  • the present invention provides an apparatus for producing a laminated panel in which a panel of material has a sheet of material laminated on either side thereof, the apparatus comprising:
  • ⁇ feeding means for feeding the panel of material
  • a first roll holder for holding a first roll of sheet material
  • ⁇ first sheet feeding means for passing sheet material from the first roll into contact with one side of the panel of material
  • ⁇ second sheet feeding means for passing sheet material from the second roll into contact with another side of the panel of material
  • a first glue applicator for applying glue between the first sheet of material and the one side of the panel
  • ⁇ pressure applying means to apply pressure to the panel downstream from the glue applicators; and ⁇ cutting means for cutting laminated panels to a desired length.
  • the feeding means comprises a conveyor for feeding the panel of material. In another embodiment, the feeding means comprises a series of rollers for feeding the panel of material. In a further embodiment, the feeding means may comprise a chute or an inclined ramp. In some embodiments, the first sheet feeding means may comprise a drive means for rotatably turning the first roll of sheet material.
  • the second sheet feeding means may comprise a drive means for rotatably turning the second roll of sheet material.
  • the drive means may comprise a motor, such as an electric motor. Other motors may also be used.
  • the first sheet feeding means may further include guide means for guiding the sheet of material as it is fed off the first roll.
  • the second sheet feeding means may further include guide means for guiding the sheet of material as it is fed off the second roll.
  • the guide means may include one or more rollers or one or more guides, such as one or more guide plates.
  • the first glue applicator may apply glue to the first sheet of material prior to the sheet of material coming into contact with the panel.
  • the first glue applicator may apply the glue to the first sheet of material just prior to the sheet material coming into contact with the panel.
  • the first glue applicator may comprise a hollow bar or tube extending substantially across the width of the first sheet of material, with the glue being supplied to a passage formed within the hollow or tube.
  • bar or tube may include a plurality of holes through which the glue can pass and thereafter drop on to the first sheet of material.
  • the plurality of holes may have tubes extending therefrom so that the glue runs down the tubes and onto the sheet of material.
  • the second glue applicator may apply glue to the second sheet of material prior to the sheet of material coming into contact with the panel.
  • the second glue applicator may apply the glue to the second sheet of material just prior to the sheet material coming into contact with the panel.
  • the second glue applicator may comprise a hollow bar or tube extending substantially across the width of the first sheet of material, with the glue being supplied to a passage formed within the hollow or tube.
  • the hollow bar or tube may include a plurality of holes through which the glue can pass and thereafter drop on to the second sheet of material. .
  • the plurality of holes may have tubes extending therefrom so that the glue runs down the tubes and onto the sheet of material.
  • the glue that is applied comprises a mixture of a first glue component and a second glue component.
  • the first container may contain the first glue component and the apparatus may further comprise a second container for holding the second glue component.
  • the apparatus may further comprise a glue mixer for mixing the first glue component and the second glue component together.
  • the first glue component and the second glue component are suitably mixed together just prior to feeding the glue to the first glue applicator and the second glue applicator.
  • the apparatus is provided with a single glue mixer which feeds mixed glue to the first glue applicator and the second glue applicator.
  • the apparatus comprises a first glue mixer which feeds mixed glue to the first glue applicator and a second glue mixer which feeds mixed glue to the second glue update.
  • the first glue component is applied to the sheet of material and the second glue component is applied to the sheet of material, with the first and second glue component being mixed together on the sheet of material.
  • the first glue applicator may comprise a first component applicator for applying the first glue component to the sheet of material and a second component applicator for applying the second glue component to the sheet of material.
  • glue applicator may also comprise a similar arrangement. This is a desirable embodiment as the glue components mix externally of the glue applicators, thereby minimising or avoiding the risk of premature setting of the mixed glue in the glue applicators.
  • first glue component in the second glue component are mixed together in the first glue applicator and the second glue applicator.
  • the first glue component and the second glue component are suitably selected such that, when mixed, the mixed glue rapidly sets to ensure that the mixed glue sets shortly after it has been applied to the first sheet of material and the second sheet of material.
  • the mixed glue comprises a two component glue, with each separate component having a long shelf life but the mixed glue setting quite quickly once the two components have been mixed.
  • the skilled person would understand that there are a number of two component glues that can be selected for use in producing the panels, with the main requirements being that the two component glue sets quickly once mixed and that the two component glue is compatible for adhering the sheets of material to the panel of material.
  • the glue may be a filler glue in that it may fill any imperfections in the materials to which it is applied.
  • the glue may comprise a single component glue, such as a hot melt glue that is applied to the sheet of material.
  • a single glue container may be required.
  • the glue container may comprise a heated container to maintain a hot melt glue in a molten state (in embodiments where a hot melt glue is used).
  • the glue container may comprise a main glue container and one or more smaller glue containers that receive molten glue from the main glue container.
  • the first glue applicator or the second glue applicator may comprise at least one roller at least partly immersed in liquid or molten glue, the at least one roller being in contact with a sheet of material travelling past the at least one roller, the at least one roller applying glue to the sheet of material.
  • the sheet of material may contact the at least one roller and cause the at least one roller to rotate as the sheet of material travels past the at least one roller.
  • the at least one roller is at least partly immersed in molten or liquid glue, as the at least one roller rotates, it picks up glue on its 5
  • the molten or liquid glue may be supplied to the inside of a porous roller such that the glue moves through the roller and onto the sheet of material travelling past the roller.
  • a hot melt glue may also be applied to the sheet of material using an applicator tube or applicator bar, as described above.
  • the apparatus also comprises pressure applying means for applying pressure to the sheet of material once the group has been applied thereto.
  • the pressure applying means maintains good contact between the sheets of material and a panel of material whilst the glue sets. This assists in ensuring that solid adhesion between the sheets of material and the panel of material is obtained.
  • the pressure applying means may comprise one set of rollers or a plurality of rollers or one or more pressure plates. Once the laminated material passes through the pressure applying means, the laminated material is cut to a desired length. Any suitable apparatus known to be capable of cutting a moving web of material may be used in the present invention.
  • the cutting means comprises a rotatable cutter wheel which may move transversely to the laminated material.
  • the rotatable cutter wheel may be driven transversely by a drive means, such as a motor (for example, an electric motor), or a ram (such as a pneumatic ram or an hydraulic ram).
  • a drive means such as a motor (for example, an electric motor), or a ram (such as a pneumatic ram or an hydraulic ram).
  • the cutter is usually mounted to move with the panel in the direction of travel of the panel through the apparatus as the cutter traverses and cuts the panel.
  • the cutter may be mounted on biasing means, such as a spring, such that when the cutter contacts the panel the movement of the panel causes the cutter to move along with the panel. When the cutter is disengaged from the panel, the biasing means moves the cutter back to a cutter starting position.
  • the cutter may be mounted to a drive means (such as a motor or a random) that moves the cutter along with the panel during cutting.
  • the drive means is 6
  • the drive means may also return the cutter to a cutter starting position once the cutter has been disengaged from the panel.
  • the rotatable cutter wheel may comprise a saw blade.
  • the saw blade may be mounted for rotation about an axle.
  • the cutter may be movable in a vertical direction to allow engagement and disengagement with the laminated material.
  • the cutter can travel past the transverse edge of the laminated material to thereby disengage the cutter from the laminated material.
  • the laminated panels are stacked and packaged for transport.
  • the laminated panels may also be cut to a desired width., for example, by use of an inline hogger.
  • the apparatus may be provided with an accumulation table and side transfer conveyors.
  • the panel of material may comprise a polystyrene panel.
  • the polystyrene panel may be provided in the form of long sheets of polystyrene.
  • the sheets of material suitably comprise sheets of paper.
  • the first sheet of paper and the second sheet of paper are ideally of the same weight and the same thickness.
  • the present invention also extends to methods for forming laminated panels using the apparatus of the present invention.
  • the present invention allows for the production of laminated panels comprising a first sheet of material, a first panel of material, a second sheet of material, a second panel of material and a third sheet of material or laminated together.
  • the apparatus may produce a laminated panel that, in one embodiment, comprises a first paper sheet, a first polystyrene layer, a second paper sheet, a second polystyrene panel and a third paper sheet.
  • the apparatus further comprises a second panel feeding means for feeding a second panel of material, a third roll holder for holding a third roll of a sheet of material, a third glue applicator for applying glue between the second sheet of material and the second panel of material and 7
  • a fourth glue applicator for applying glue between the second panel of material and the third sheet of material, and pressure applying means for applying pressure to the second panel and downstream from the third and fourth glue applicators.
  • the particular components of this embodiment may be similar to the particular components described with reference to the embodiments of the present invention described herein above.
  • a single laminated panel may be produced and subsequently be again passed through the apparatus to adhere a further panel of material to one side thereof and adhere a further sheet of material to an exposed surface of the further panel of material.
  • a further glue applicator may be provided to apply glue between the second panel and an exposed surface of a sheet adhered to the first panel. This further glue applicator may be able to be moved away from the panel, typically in a lateral direction, to facilitate production of the first laminated panel ad moved towards the panel, typically in a lateral direction, to facilitate adding the second panel.
  • the present invention also extends to methods of manufacturing laminated panels as described herein.
  • Figure 1 shows a side schematic in view of an apparatus in accordance with the present invention
  • Figure 2 shows a plan schematic view of the apparatus shown in Figure 1;
  • Figure 3 shows a schematic view of one embodiment of a glue applicator for use in the present invention;
  • Figure 4 shows a schematic view of an alternative glue applicator for use in the present invention
  • Figure 5 shows a side schematic view showing application of glue in an embodiment of the present invention
  • FIG. 6 shows a schematic view of another alternative glue applicator for use in the present invention.
  • Figure 7 shows a perspective view of an embodiment of a cutter in accordance with the present invention.
  • Figure 8 shows a perspective view of the cutter shown in Figure 7 but with some parts removed to show further detail
  • Figure 9 shows a schematic side view of the cutting arrangement shown in figure five at the start of a cutting operation
  • Figure 10 shows a side review of the cutting arrangement shown in figure 5 at the end of a cutting operation
  • Figure 11 shows a schematic side view of another embodiment for applying glue to the sheets of material
  • Figure 12 shows an arrangement of glue containers that may be used in an embodiment where the glue comprises a hot melt glue
  • Figure 12 shows a schematic cross section of a laminated panel having two polystyrene panels and three sheets of paper. DETAILED DESCRIPTION OF THE DRAWINGS
  • FIG. 1 and 2 shows schematic views of an apparatus in accordance with an embodiment of the present invention.
  • the apparatus 10 comprises a loading section 12 for feeding panels of material.
  • the panels of material suitably comprise sheets or panels of polystyrene.
  • the sheets of polystyrene may be purchased from many different suppliers. They may be pre-cut to a desired thickness and to a desired width.
  • the loading section 12 may comprise any conventional panel handling equipment.
  • loading section 12 comprises a series of rollers 14, 16. In operation, a plurality of panels are positioned on rollers 14, 16. They are subsequently moved (via driven rollers) to the remainder of the apparatus. 9
  • the apparatus may include a second loading section 13 if dual core panels are to be made. Forklifts 7, 8 may be used to supply the panels to the loading sections 12, 13.
  • Edge rebating trimmers 17, 19 may be used to form a desired edge shape on the panels.
  • the panels of polystyrene have been positioned in the loading section 12, they are then moved to a lead-in section 18 and thereafter move into the glue application section 20.
  • the lead-in section 18 is used to correctly orient the polystyrene panels.
  • the glue application will be described in further detail with reference to figures 3, 4, 5 and 6.
  • the laminated panel passes through the main press section 22. This will also be described in further detail hereinafter.
  • the sheets of paper are unrolled from paper rolls 34, 38.
  • the glue applied to the panels dries very quickly and, in practice, it dries in a matter of seconds. Therefore, by the time the laminated panels have left the main press section 22, the glue has dried. In order to complete the panels, they pass through an edge trimming section 21, where the panels are trimmed to the required width (the edge trimmers may be of conventional technology) and a cutting section 24, where the laminated panels are cut to the desired length. The cut panels then become stacked on accumulation table 26. The stacks of panels are then passed to side transfer conveyors 28 (see figure 2), where the stacks of panels are prepared for transport. In this regard, the stacks of panels may be bound with tape or other bindings, or wrapped in a shrinkwrap plastic.
  • FIGS. 1 and 2 Also shown in figures 1 and 2 are dust collectors 23, 25, which collect dust from the various cutting and trimming operations.
  • a final dust collector 27 collects dust from the vicinity of the stacked final product.
  • Figures 3, 4, 5 and 6 show various views of the glue application section 20. Referring initially to figure 5, it can be seen that a polystyrene panel 30 is passing through the glue application section 20.
  • a first holder 32 which may be in the form of a roll holder, holds a first roll 34 of paper.
  • the paper is, of course, in the form of the sheet 10
  • a second holder 36 in the form of a second roll holder holds a second roll 38 of paper.
  • a first glue applicator 40 applies glue to the sheet 35 of paper leaving the first roll of paper 34.
  • the first glue applicator 40 will be described in further detail hereunder.
  • a second glue applicator 42 applies glue to a second sheet of paper 37 that is unrolled from the roll 38.
  • the second glue applicator 42 will also be described in further detail hereunder.
  • drive motors may be used to drive the roll holders 32 and 36.
  • the sheets of paper may be fed from the rolls 34, 38 and subsequently pulled off the rolls by virtue of the action of further rollers located in the apparatus 10.
  • the roll holders 32, 36 may allow for free rotation of the rolls 34 and 38.
  • the first glue applicator 40 is positioned so that it drops glue onto an upper surface of the sheet 35 of paper leaving the first roll 34.
  • the sheet of paper that is unrolled from roll 34 passes over guide rollers 31, 33 and 33A and then passes underneath glue applicator 40.
  • the paper with glue applied then passes over guide roller 44 and then comes into contact with the lower side of the polystyrene sheet 30.
  • a series of press rollers 46, 48, 50 which are arranged in pairs on either side of the polystyrene panel 30, subsequently presses sheet 35 into close contact with the polystyrene panel 30.
  • the second glue applicator 42 applies glue to the upper side of the sheet of paper 37.
  • the paper that is unrolled from roll 38 passes under guide roller 39 and thereafter passes under glue applicator 42.
  • glue applicator 42 It will be understood that the glue must be positioned between the upper surface of the polystyrene panel 30 and the sheet of paper 37. Therefore, the sheet of paper 37 passes over guide roller 52 after the glue has been applied. This effectively inverts the orientation of the sheet of paper so that the glue side faces the upper surface of polystyrene panel.
  • the sheet of paper 37 thereafter passes under press rollers 46, 48, 50.
  • the spacing between the respective pairs of press rollers 46, 48, 50 may be set such that there is a slight crushing of the polystyrene panel 30 as it passes through the 11
  • press rollers 46, 48, 50 It is believed that this slight crushing may assist in enhancing the strength of the final laminated panels.
  • the glue that is used in the apparatus of the present invention is a two component glue that sets very quickly after the two separate components have been mixed together.
  • Figures 3 and 4 show two possible embodiments for providing the glue.
  • a first container 60 holds a first glue component and a second container 62 holds a second glue component.
  • the first glue component 60 and the second glue component 62 have a long shelf life when that they are stored separately.
  • the first glue component from the first container 60 travels via line 61 into a mixing container 64.
  • the second component travels from second container 62 via line 63 into the mixing container 64.
  • the mixing container 64 is fitted with a stirrer or mixer 65 that is used to mix the first component and the second component together to form the glue.
  • the residence time of the glue in the mixing container 64 is desirably very short.
  • the mixed glue leaves the mixing container 64 via outlet line 65 and is immediately fed to a glue bar 66.
  • a glue bar similar to glue bar 66 forms part of the first glue applicator 40 and the second glue applicator 42. It will be appreciated that first glue applicator 40 and the second " glue applicator 42 are each provided with separate glue bars.
  • Glue bar 66 is in the form of a hollow tube or pipe having a plurality of openings 68 formed therein.
  • One end 70 of the glue bar 66 may be closed.
  • the other end receives line 65 in sealing relationship and therefore mixed glue is fed into the hollow passageway formed within glue bar 66.
  • the mixed glue moves out through openings 68 and thereafter drops onto the sheet of paper travelling underneath the glue bar 66.
  • the openings 68 are positioned on an upper part of the glue bar 66. However, it will be appreciated that the openings may also be positioned along a lower surface of the glue bar 66.
  • the mixed glue is suitably supplied to the glue bar 66 at a rate such that a steady stream of glue drops from the openings onto the sheet of paper passing underneath.
  • spreader plates 72, 74 may be provided just downstream from the glue applicators 40, 42 (see figure 4). 12
  • Figure 4 shows an alternative arrangement for providing glue to the glue bar 6&.
  • the first container 60 has an outlet line 61' through which the first glue component leaves the first container.
  • the second container 62' has an outlet line 63' through which the second component leaves the second container.
  • a mixing container 64 is not provided. Rather, the first line 61' and the second line 63' have a mixing junction 67 located close to the positioned at which the glue enters the glue bar 66'. Due to the flow characteristics of the first component and the second component, the two components are intimately mixed together at and downstream of the mixing junction 67 to thereby deliver the mixed glue to the glue bar 66'.
  • Figure 6 shows an alternative arrangement for providing glue.
  • the glue component containers 60" and 62" have outlet lines 61" and 63".
  • Outlet line 61" splits into two lines 61A and 61B.
  • outlet line 63" also splits into two lines 63A and 63B.
  • Outlet line 61A is connected to pump 71A and outlet line 61B is connected to pump 7 IB.
  • outlet line 63" is connected to pump 73 A and outlet line 63B is connected to pump 73B.
  • Pump 71B provides the first glue component via line 72 to a glue applicator tube 74.
  • Pump 73B provides the second glue component via line 74 to a glue applicator tube 76.
  • glue applicator tube 74 is separate to glue applicator tube 76.
  • the glue applicator tubes 74 and 76 both include a plurality of smaller tubes 77.
  • the respective glue components pass into their respective glue applicator tubes 74 or 76 and thereafter escape through holes in the glue applicator tube 74, 76 to which the smaller tubes 77 attached and flow through or down the smaller tubes 77. Therefore, the glue components are applied to the paper 34A passing underneath. Accordingly, the glue components mix together only when they are both on the paper.
  • a spreader bar 78 78 contacts the upper surface of the paper sheet 34A.
  • the spreader bar 78 is connected via an eccentric coupling, such as a cam, to a motor 79 which causes the spreader bar to move back and forward, shown by the arrow 79A. This promotes mixing of the glue components on the paper. 13
  • a similar arrangement of glue applicator tubes is also connected to pump is 71 A and 73A in order to apply the glue components to the other sheet of paper.
  • a similar arrangement of the spreader bar mixer is also provided to mix the glue components that are applied to the other sheet of paper.
  • the polystyrene panel having the sheets of paper on its upper and lower surfaces then passes through the main press 22.
  • the main press 22 essentially comprises a continuation of the series of press rollers 46, 48, 50 as shown in figure 4. Other press arrangements may also be used, such as press plates and the like. Due to the quick setting nature of the mixed glue, once the laminated panel leaves the main press 22, the glue has essentially set and the laminated panel has essentially been formed. However, it is necessary to cut the laminated panel to the desired length and therefore the laminated panel passes through cutting section 24.
  • the cutting section 24 includes a rotating cutting wheel 80.
  • the rotating cutting wheel 80 is in the form of a saw blade, such as a saw blade for a circular saw.
  • the saw blade 80 is mounted for rotation about an axle 81 (see figure 8).
  • the cutting wheel 80 is arranged such that it can move transversely across the laminated panel, for example as shown by reference to the directions shown by arrow 82.
  • the saw blade 80 is mounted in a housing 84. Housing 84 is, in turn, attached to a vacuum extraction line 86 so that dust and particulate material formed during the cutting operation can be extracted from the vicinity of the cutting wheel 80. This minimises dusting in the environment of the apparatus.
  • the cutting wheel 80 is attached to a further housing 90 that is itself mounted to rod 92.
  • the second housing 90 can slide along rod 92 to thereby move the cutting wheel 80 transversely to the laminated panels passing through the apparatus 10.
  • a pneumatic ram or hydraulic ram is used to move the second housing 90 along the rod 92.
  • a further cutting wheel 80' is positioned below the cutting wheel 80.
  • the second cutting wheel 80' in use, is positioned below the laminated panel that is to be cut.
  • the second cutting wheel 80' is suitably mounted for transverse movement in a fashion similar to that described for cutting wheel 80. 14
  • Rod 92 is mounted to a cutter section frame 94.
  • Cutter section frame 94 is, in turn, mounted to rod 96 that is itself mounted to table 98.
  • a similar mounting for the cutter section frame 94 is provided on the other side of the cutter section frame 94. This enables the cutter section frame 94 to move back and forward along the longitudinal direction of the apparatus 10 so that the cutter section frame 94 can move with a laminated panel travelling through the cutter section 22 when that panel is being cut.
  • the cutter section also includes a plurality of rollers 100 that are mounted to a pivoted scissor link arrangement 102. This is best shown in figures 9 and 10.
  • the pivoted scissor link arrangement 102 is connected at 104 to the cutter section frame 94.
  • the cutter wheel 80 When the cutter wheel 80 is actuated to come into contact with a laminated panel that is passing through the cutter section 22, the cutter wheel 80 contacts the laminated panel. As the cutter wheel 80 is forced to move transversely to the laminated panel, the cutter wheel 80 cuts along the laminated panel. The laminated panel, in turn, pushes the cutter wheel along in the direction of travel and this causes the pivoted scissor link arrangement 102 to move from its extended position (as shown in figure 6) to a compressed position as shown in figure 7. Thus, the cutter wheel 80 moves along with the laminated panel as the laminated panel moves through the cutter section 22. This assist in obtaining a straight, clean cut.
  • the scissor link arrangement 102 moves back from the position shown in figure 10 to the extended position shown in figure 9. In this position, the next cutting operation can commence.
  • the cutter section may be provided with an appropriate spring or drive (such as a screw or worm drive, or a hydraulic ram or a pneumatic ram).
  • the operation of the cutter section involves having the cutter wheels 80, 80' rotating in a fashion similar to the operation of a pizza wheel used when cutting a pizza. It has been found that having the cutter wheels 80, 80' operate in this fashion provides for a clean cut in the laminated polystyrene panels. 15
  • the accumulating table 26 allows for a stack of panels to be formed.
  • the stack of panels is then transferred to side transfer conveyors 28, where the stacks are transferred laterally for storage or further transport.
  • the stacks may be bound or wrapped to facilitate handling thereof.
  • Figure 11 shows a schematic side view of an alternative embodiment for applying glue to the sheets of material.
  • the glue is a single component liquid glue or molten glue.
  • features that are common to the features shown in figure 5 are denoted by the same reference numerals as used in figure 5, but with the addition of a '.
  • the sheet of paper 35' that is unrolled from roll 34' passes underneath a tray 110.
  • Tray 110 is filled with a liquid glue or a molten glue 111.
  • the glue 111 may comprise a molten hot melt glue.
  • the tray 111 has a roller 112 mounted in an opening in the bottom thereof. Roll 112 is sealingly mounted in the opening in the bottom of tray 111. As can be seen from figure 11, roller 112 is immersed in the molten glue 111.
  • An opposed roller 114 is positioned below roller 112 and the sheet of paper 35 passes through the nip between rollers 112 and 114. As the sheet of paper passes between rollers 112 and 114, roller 112 is caused to rotate.
  • a similar arrangement is used to provide glue to the second sheet of paper 39' that is removed from roll 38'.
  • a second tray 116 that contains liquid glue or molten glue 117 is provided.
  • Second tray 117 has a roller 118 mounted thereto for rotation.
  • roller 117 is partly immersed in the liquid glue or molten glue such that when the roller 117 rotates, it carries a film of glue on its outer surface.
  • An opposed roller 120 is provided above roller 118 and the sheet of paper 39' passes between the nip of rollers 118 and 120. This causes roller 118 to apply a film of glue to the lower surface of the sheet of paper 39'.
  • roller 46' presses the sheet of paper and the glue into contact with the panel of polystyrene 30'.
  • the opposed rollers 46' are sufficient to act as the press section in this embodiment.
  • the glue has been found to have set or hardened once it has passed through the set of rollers 46'.
  • the set of rollers 46' may be spaced apart from each other at a distance such that a slight crushing of the panel of polystyrene 30' takes place as the panel of polystyrene and the paper passes through the rollers 46'.
  • FIG 12 shows one possible arrangement of glue containers suitable for use in figure 11.
  • glue trays 110 and 116 are shown.
  • Main glue container 130 includes a heating element 132 (in embodiments where the glue comprises a hot melt glue).
  • the hot melt glue in molten form, is passed via lines 134 and 136 to glue trays 110, 116, respectively.
  • the lines 134, 136 and/or the trays 110, 116 may themselves be heated in order to maintain the glue in molten form. It will be appreciated that if a liquid glue is used instead of a hot melt glue, heating may not be required. It will also be appreciated that if a liquid glue which requires a longer time to set is used, the press section 22 may be utilised with the glue application arrangement as shown in figure 11.
  • a laminated panel having a first layer of paper, a first layer of polystyrene, a second layer of paper, a second layer of polystyrene and a third layer of paper (as shown schematically in figure 13 which shows a first layer of paper 150, a first layer of polystyrene 152, a second layer of paper 154, a second layer of polystyrene 156 and a third layer of paper 158, which may be a panel as described in Australian patent number 2002311245, the entire contents of which are herein incorporated by cross- reference)
  • a laminated panel having a first layer of paper 150, a first layer of polystyrene 152 and a second layer of paper 154 may be manufactured using the apparatus as described in figures 1 to 12 using the method as described with reference to those figures. 17
  • Those laminated panels are then returned to panel feed stack 12 (as shown in figure 1) and are again fed through the apparatus.
  • a second stack 13 of polystyrene panels is also provided. Glue is applied between the upper surface of the laminated panel and the lower surface of the polystyrene panel taken from stack 13 using a glue feed applicator arrangement similar to those shown in figures 3, 4, 11 or 12. This glue is applied to the underside of the polystyrene panel taken from stack 13 or to the upper side of the laminated panel taken from the first stack 12 at a position as indicated by reference numeral 19A in figure 1.
  • Glue and paper is then applied to the upper surface of the polystyrene panel 156 taken from stack 13 in a fashion that is similar to the application of the top sheet of paper to be polystyrene panel 152. Cutting to length then completes the fabrication of the laminated panel as shown schematically in figure 13.

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Abstract

An apparatus for producing a laminated panel in which a panel of material has a sheet of material laminated on either side thereof comprise feeding means for feeding the panel of material, a first roll holder for holding a first roll of sheet material, first sheet feeding means for passing sheet material from the first roll into contact with one side of the panel of material a second roll holder for holding a second roll of sheet material, second sheet feeding means for passing sheet material from the second roll into contact with another side of the panel of material, a container for holding a glue component, a first glue applicator for applying glue between the first sheet of material and the one side of the panel, a second glue applicator for applying glue between the second sheet of material and the other side of the panel, pressure applying means to apply pressure to the panel downstream from the glue applicators, and cutting means for cutting laminated panels to a desired length.

Description

APPARATUS FOR MANUFACTURING LAMINATED PANELS FIELD OF THE INVENTION
The present invention relates to an apparatus for producing a laminated panel. BACKGROUND TO THE INVENTION Laminated panels are widely used in the building and construction industry. For example, wall panels are typically made from a core of hardened gypsum having sheets of paper attached to either side thereof. These gypsum panels are usually made by pouring a gypsum slurry on to a lower sheet of paper, applying an upper sheet of paper to the gypsum slurry and drying the slurry by passing the panel through a drying oven. Panels are also used in forming the ceilings, such as forming false ceilings in office buildings. In order to form the ceilings, a ceiling support structure is suspended from the full immediately above and infill panels are placed on the ceiling support structure. The infill panels typically comprise a gypsum panel or a foamed cementitious panel. These panels are relatively heavy, discolour with age and have little strength or resistance to water.
BRIEF DESCRIPTION OF THE INVENTION
It is an object of the present invention to provide an apparatus for producing a laminated panel in which a panel of material has a sheet of material laminated on either side thereof. In a first aspect, the present invention provides an apparatus for producing a laminated panel in which a panel of material has a sheet of material laminated on either side thereof, the apparatus comprising:
■ feeding means for feeding the panel of material;
■ a first roll holder for holding a first roll of sheet material; ■ first sheet feeding means for passing sheet material from the first roll into contact with one side of the panel of material;
■ a second roll holder for holding a second roll of sheet material; 2
■ second sheet feeding means for passing sheet material from the second roll into contact with another side of the panel of material
■ a first container for holding a glue component;
■ a first glue applicator for applying glue between the first sheet of material and the one side of the panel;
■ a second glue applicator for applying glue between the second sheet of material and the other side of the panel;
■ pressure applying means to apply pressure to the panel downstream from the glue applicators; and ■ cutting means for cutting laminated panels to a desired length.
In one embodiment, the feeding means comprises a conveyor for feeding the panel of material. In another embodiment, the feeding means comprises a series of rollers for feeding the panel of material. In a further embodiment, the feeding means may comprise a chute or an inclined ramp. In some embodiments, the first sheet feeding means may comprise a drive means for rotatably turning the first roll of sheet material. The second sheet feeding means may comprise a drive means for rotatably turning the second roll of sheet material. The drive means may comprise a motor, such as an electric motor. Other motors may also be used. The first sheet feeding means may further include guide means for guiding the sheet of material as it is fed off the first roll. The second sheet feeding means may further include guide means for guiding the sheet of material as it is fed off the second roll. The guide means may include one or more rollers or one or more guides, such as one or more guide plates.
In some embodiments, the first glue applicator may apply glue to the first sheet of material prior to the sheet of material coming into contact with the panel. Suitably, the first glue applicator may apply the glue to the first sheet of material just prior to the sheet material coming into contact with the panel. The first glue applicator may comprise a hollow bar or tube extending substantially across the width of the first sheet of material, with the glue being supplied to a passage formed within the hollow or tube. The hollow 3
bar or tube may include a plurality of holes through which the glue can pass and thereafter drop on to the first sheet of material. The plurality of holes may have tubes extending therefrom so that the glue runs down the tubes and onto the sheet of material.
Similarly, the second glue applicator may apply glue to the second sheet of material prior to the sheet of material coming into contact with the panel. Suitably, the second glue applicator may apply the glue to the second sheet of material just prior to the sheet material coming into contact with the panel. The second glue applicator may comprise a hollow bar or tube extending substantially across the width of the first sheet of material, with the glue being supplied to a passage formed within the hollow or tube. The hollow bar or tube may include a plurality of holes through which the glue can pass and thereafter drop on to the second sheet of material. . The plurality of holes may have tubes extending therefrom so that the glue runs down the tubes and onto the sheet of material.
In some embodiments, the glue that is applied comprises a mixture of a first glue component and a second glue component. In this embodiment, the first container may contain the first glue component and the apparatus may further comprise a second container for holding the second glue component.
The apparatus may further comprise a glue mixer for mixing the first glue component and the second glue component together. The first glue component and the second glue component are suitably mixed together just prior to feeding the glue to the first glue applicator and the second glue applicator. In one embodiment, the apparatus is provided with a single glue mixer which feeds mixed glue to the first glue applicator and the second glue applicator. In another embodiment, the apparatus comprises a first glue mixer which feeds mixed glue to the first glue applicator and a second glue mixer which feeds mixed glue to the second glue update. In another embodiment, the first glue component is applied to the sheet of material and the second glue component is applied to the sheet of material, with the first and second glue component being mixed together on the sheet of material. In this embodiment, the first glue applicator may comprise a first component applicator for applying the first glue component to the sheet of material and a second component applicator for applying the second glue component to the sheet of material. The second 4
glue applicator may also comprise a similar arrangement. This is a desirable embodiment as the glue components mix externally of the glue applicators, thereby minimising or avoiding the risk of premature setting of the mixed glue in the glue applicators.
In a further embodiment, the first glue component in the second glue component are mixed together in the first glue applicator and the second glue applicator.
The first glue component and the second glue component are suitably selected such that, when mixed, the mixed glue rapidly sets to ensure that the mixed glue sets shortly after it has been applied to the first sheet of material and the second sheet of material. Effectively, the mixed glue comprises a two component glue, with each separate component having a long shelf life but the mixed glue setting quite quickly once the two components have been mixed. Within these parameters, the skilled person would understand that there are a number of two component glues that can be selected for use in producing the panels, with the main requirements being that the two component glue sets quickly once mixed and that the two component glue is compatible for adhering the sheets of material to the panel of material.
The glue may be a filler glue in that it may fill any imperfections in the materials to which it is applied.
In another embodiment, the glue may comprise a single component glue, such as a hot melt glue that is applied to the sheet of material. In this embodiment, only a single glue container may be required. The glue container may comprise a heated container to maintain a hot melt glue in a molten state (in embodiments where a hot melt glue is used). The glue container may comprise a main glue container and one or more smaller glue containers that receive molten glue from the main glue container.
The first glue applicator or the second glue applicator (or both) may comprise at least one roller at least partly immersed in liquid or molten glue, the at least one roller being in contact with a sheet of material travelling past the at least one roller, the at least one roller applying glue to the sheet of material. In one embodiment, the sheet of material may contact the at least one roller and cause the at least one roller to rotate as the sheet of material travels past the at least one roller. As the at least one roller is at least partly immersed in molten or liquid glue, as the at least one roller rotates, it picks up glue on its 5
outer surface and transfers that glue to the sheet of material as the sheet of material moves past the roller.
In another embodiment, the molten or liquid glue may be supplied to the inside of a porous roller such that the glue moves through the roller and onto the sheet of material travelling past the roller.
Further, a hot melt glue may also be applied to the sheet of material using an applicator tube or applicator bar, as described above.
The apparatus also comprises pressure applying means for applying pressure to the sheet of material once the group has been applied thereto. In this manner, the pressure applying means maintains good contact between the sheets of material and a panel of material whilst the glue sets. This assists in ensuring that solid adhesion between the sheets of material and the panel of material is obtained.
The pressure applying means may comprise one set of rollers or a plurality of rollers or one or more pressure plates. Once the laminated material passes through the pressure applying means, the laminated material is cut to a desired length. Any suitable apparatus known to be capable of cutting a moving web of material may be used in the present invention.
In one embodiment, the cutting means comprises a rotatable cutter wheel which may move transversely to the laminated material. The rotatable cutter wheel may be driven transversely by a drive means, such as a motor (for example, an electric motor), or a ram (such as a pneumatic ram or an hydraulic ram).
The cutter is usually mounted to move with the panel in the direction of travel of the panel through the apparatus as the cutter traverses and cuts the panel. In one embodiment, the cutter may be mounted on biasing means, such as a spring, such that when the cutter contacts the panel the movement of the panel causes the cutter to move along with the panel. When the cutter is disengaged from the panel, the biasing means moves the cutter back to a cutter starting position.
Alternatively, the cutter may be mounted to a drive means (such as a motor or a random) that moves the cutter along with the panel during cutting. The drive means is 6
suitably arranged such that it moves the cutter along the direction of travel at the same speed as the speed of the panel travelling through the apparatus. The drive means may also return the cutter to a cutter starting position once the cutter has been disengaged from the panel. The rotatable cutter wheel may comprise a saw blade. The saw blade may be mounted for rotation about an axle.
In some embodiments, the cutter may be movable in a vertical direction to allow engagement and disengagement with the laminated material.
In other embodiments, the cutter can travel past the transverse edge of the laminated material to thereby disengage the cutter from the laminated material.
Once the laminated panels have been cut to length, they are stacked and packaged for transport. The laminated panels may also be cut to a desired width., for example, by use of an inline hogger. To achieve this, the apparatus may be provided with an accumulation table and side transfer conveyors. The panel of material may comprise a polystyrene panel. The polystyrene panel may be provided in the form of long sheets of polystyrene.
The sheets of material suitably comprise sheets of paper. The first sheet of paper and the second sheet of paper are ideally of the same weight and the same thickness.
The present invention also extends to methods for forming laminated panels using the apparatus of the present invention.
In other embodiments, the present invention allows for the production of laminated panels comprising a first sheet of material, a first panel of material, a second sheet of material, a second panel of material and a third sheet of material or laminated together. In this regard, the apparatus may produce a laminated panel that, in one embodiment, comprises a first paper sheet, a first polystyrene layer, a second paper sheet, a second polystyrene panel and a third paper sheet. In this embodiment, the apparatus further comprises a second panel feeding means for feeding a second panel of material, a third roll holder for holding a third roll of a sheet of material, a third glue applicator for applying glue between the second sheet of material and the second panel of material and 7
a fourth glue applicator for applying glue between the second panel of material and the third sheet of material, and pressure applying means for applying pressure to the second panel and downstream from the third and fourth glue applicators. The particular components of this embodiment may be similar to the particular components described with reference to the embodiments of the present invention described herein above.
Alternatively, a single laminated panel may be produced and subsequently be again passed through the apparatus to adhere a further panel of material to one side thereof and adhere a further sheet of material to an exposed surface of the further panel of material. In this embodiment, a further glue applicator may be provided to apply glue between the second panel and an exposed surface of a sheet adhered to the first panel. This further glue applicator may be able to be moved away from the panel, typically in a lateral direction, to facilitate production of the first laminated panel ad moved towards the panel, typically in a lateral direction, to facilitate adding the second panel.
The present invention also extends to methods of manufacturing laminated panels as described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 shows a side schematic in view of an apparatus in accordance with the present invention;
Figure 2 shows a plan schematic view of the apparatus shown in Figure 1; Figure 3 shows a schematic view of one embodiment of a glue applicator for use in the present invention;
Figure 4 shows a schematic view of an alternative glue applicator for use in the present invention;
Figure 5 shows a side schematic view showing application of glue in an embodiment of the present invention;
Figure 6 shows a schematic view of another alternative glue applicator for use in the present invention; 8
Figure 7 shows a perspective view of an embodiment of a cutter in accordance with the present invention;
Figure 8 shows a perspective view of the cutter shown in Figure 7 but with some parts removed to show further detail; Figure 9 shows a schematic side view of the cutting arrangement shown in figure five at the start of a cutting operation;
Figure 10 shows a side review of the cutting arrangement shown in figure 5 at the end of a cutting operation;
Figure 11 shows a schematic side view of another embodiment for applying glue to the sheets of material;
Figure 12 shows an arrangement of glue containers that may be used in an embodiment where the glue comprises a hot melt glue; and
Figure 12 shows a schematic cross section of a laminated panel having two polystyrene panels and three sheets of paper. DETAILED DESCRIPTION OF THE DRAWINGS
It will be understood that the drawings have been provided for the purpose of illustrating embodiments of the present invention. Therefore, it will be appreciated that the present invention should not be considered to be limited to the features as shown in the drawings. Figures 1 and 2 shows schematic views of an apparatus in accordance with an embodiment of the present invention. The apparatus 10 comprises a loading section 12 for feeding panels of material. The panels of material suitably comprise sheets or panels of polystyrene. The sheets of polystyrene may be purchased from many different suppliers. They may be pre-cut to a desired thickness and to a desired width. The loading section 12 may comprise any conventional panel handling equipment. In the embodiments shown in figure 1, loading section 12 comprises a series of rollers 14, 16. In operation, a plurality of panels are positioned on rollers 14, 16. They are subsequently moved (via driven rollers) to the remainder of the apparatus. 9
The apparatus may include a second loading section 13 if dual core panels are to be made. Forklifts 7, 8 may be used to supply the panels to the loading sections 12, 13.
The panels leaving the loading section 12, 13 mainly the treated by edge rebating trimmers 17, 19. Edge rebating trimmers 17, 19 may be used to form a desired edge shape on the panels.
Once the panels of polystyrene have been positioned in the loading section 12, they are then moved to a lead-in section 18 and thereafter move into the glue application section 20. The lead-in section 18 is used to correctly orient the polystyrene panels. The glue application will be described in further detail with reference to figures 3, 4, 5 and 6. Once the glue has been applied to the sheets of paper, the laminated panel passes through the main press section 22. This will also be described in further detail hereinafter. The sheets of paper are unrolled from paper rolls 34, 38.
The glue applied to the panels dries very quickly and, in practice, it dries in a matter of seconds. Therefore, by the time the laminated panels have left the main press section 22, the glue has dried. In order to complete the panels, they pass through an edge trimming section 21, where the panels are trimmed to the required width (the edge trimmers may be of conventional technology) and a cutting section 24, where the laminated panels are cut to the desired length. The cut panels then become stacked on accumulation table 26. The stacks of panels are then passed to side transfer conveyors 28 (see figure 2), where the stacks of panels are prepared for transport. In this regard, the stacks of panels may be bound with tape or other bindings, or wrapped in a shrinkwrap plastic.
Also shown in figures 1 and 2 are dust collectors 23, 25, which collect dust from the various cutting and trimming operations. A final dust collector 27 collects dust from the vicinity of the stacked final product.
Figures 3, 4, 5 and 6 show various views of the glue application section 20. Referring initially to figure 5, it can be seen that a polystyrene panel 30 is passing through the glue application section 20. A first holder 32, which may be in the form of a roll holder, holds a first roll 34 of paper. The paper is, of course, in the form of the sheet 10
of paper rolled into the roll 34. Similarly, a second holder 36 in the form of a second roll holder, holds a second roll 38 of paper.
A first glue applicator 40 applies glue to the sheet 35 of paper leaving the first roll of paper 34. The first glue applicator 40 will be described in further detail hereunder. Similarly, a second glue applicator 42 applies glue to a second sheet of paper 37 that is unrolled from the roll 38. The second glue applicator 42 will also be described in further detail hereunder.
In order to unroll the sheets of paper from the respective first roll 34 and second roll 38, drive motors may be used to drive the roll holders 32 and 36. Alternatively, the sheets of paper may be fed from the rolls 34, 38 and subsequently pulled off the rolls by virtue of the action of further rollers located in the apparatus 10. In this embodiments, the roll holders 32, 36 may allow for free rotation of the rolls 34 and 38.
The first glue applicator 40 is positioned so that it drops glue onto an upper surface of the sheet 35 of paper leaving the first roll 34. As can be seen from figure 5, the sheet of paper that is unrolled from roll 34 passes over guide rollers 31, 33 and 33A and then passes underneath glue applicator 40. The paper with glue applied then passes over guide roller 44 and then comes into contact with the lower side of the polystyrene sheet 30. A series of press rollers 46, 48, 50, which are arranged in pairs on either side of the polystyrene panel 30, subsequently presses sheet 35 into close contact with the polystyrene panel 30.
The second glue applicator 42 applies glue to the upper side of the sheet of paper 37. The paper that is unrolled from roll 38 passes under guide roller 39 and thereafter passes under glue applicator 42. It will be understood that the glue must be positioned between the upper surface of the polystyrene panel 30 and the sheet of paper 37. Therefore, the sheet of paper 37 passes over guide roller 52 after the glue has been applied. This effectively inverts the orientation of the sheet of paper so that the glue side faces the upper surface of polystyrene panel. The sheet of paper 37 thereafter passes under press rollers 46, 48, 50.
The spacing between the respective pairs of press rollers 46, 48, 50 may be set such that there is a slight crushing of the polystyrene panel 30 as it passes through the 11
press rollers 46, 48, 50. It is believed that this slight crushing may assist in enhancing the strength of the final laminated panels.
The glue that is used in the apparatus of the present invention is a two component glue that sets very quickly after the two separate components have been mixed together. Figures 3 and 4 show two possible embodiments for providing the glue. In figure 3, a first container 60 holds a first glue component and a second container 62 holds a second glue component. The first glue component 60 and the second glue component 62 have a long shelf life when that they are stored separately. The first glue component from the first container 60 travels via line 61 into a mixing container 64. Similarly, the second component travels from second container 62 via line 63 into the mixing container 64. The mixing container 64 is fitted with a stirrer or mixer 65 that is used to mix the first component and the second component together to form the glue. The residence time of the glue in the mixing container 64 is desirably very short. The mixed glue leaves the mixing container 64 via outlet line 65 and is immediately fed to a glue bar 66. A glue bar similar to glue bar 66 forms part of the first glue applicator 40 and the second glue applicator 42. It will be appreciated that first glue applicator 40 and the second "glue applicator 42 are each provided with separate glue bars.
Glue bar 66 is in the form of a hollow tube or pipe having a plurality of openings 68 formed therein. One end 70 of the glue bar 66 may be closed. The other end receives line 65 in sealing relationship and therefore mixed glue is fed into the hollow passageway formed within glue bar 66. The mixed glue moves out through openings 68 and thereafter drops onto the sheet of paper travelling underneath the glue bar 66. In the embodiments shown in figure 2, the openings 68 are positioned on an upper part of the glue bar 66. However, it will be appreciated that the openings may also be positioned along a lower surface of the glue bar 66.
The mixed glue is suitably supplied to the glue bar 66 at a rate such that a steady stream of glue drops from the openings onto the sheet of paper passing underneath.
In order to spread the glue evenly over the surface of the sheet of paper, spreader plates 72, 74 (or any other form of spreaders) may be provided just downstream from the glue applicators 40, 42 (see figure 4). 12
Figure 4 shows an alternative arrangement for providing glue to the glue bar 6&.
In figure 3, the first container 60 has an outlet line 61' through which the first glue component leaves the first container. Similarly, the second container 62' has an outlet line 63' through which the second component leaves the second container. However, unlike the embodiment of figure 2, a mixing container 64 is not provided. Rather, the first line 61' and the second line 63' have a mixing junction 67 located close to the positioned at which the glue enters the glue bar 66'. Due to the flow characteristics of the first component and the second component, the two components are intimately mixed together at and downstream of the mixing junction 67 to thereby deliver the mixed glue to the glue bar 66'.
Figure 6 shows an alternative arrangement for providing glue. As shown in figure 6, the glue component containers 60" and 62" have outlet lines 61" and 63". Outlet line 61" splits into two lines 61A and 61B. Similarly, outlet line 63" also splits into two lines 63A and 63B. Outlet line 61A is connected to pump 71A and outlet line 61B is connected to pump 7 IB. Similarly, outlet line 63" is connected to pump 73 A and outlet line 63B is connected to pump 73B. Pump 71B provides the first glue component via line 72 to a glue applicator tube 74. Pump 73B provides the second glue component via line 74 to a glue applicator tube 76. As can be seen, glue applicator tube 74 is separate to glue applicator tube 76. The glue applicator tubes 74 and 76 both include a plurality of smaller tubes 77. The respective glue components pass into their respective glue applicator tubes 74 or 76 and thereafter escape through holes in the glue applicator tube 74, 76 to which the smaller tubes 77 attached and flow through or down the smaller tubes 77. Therefore, the glue components are applied to the paper 34A passing underneath. Accordingly, the glue components mix together only when they are both on the paper. In order to promote mixing of the glue components, a spreader bar 78 78, contacts the upper surface of the paper sheet 34A. The spreader bar 78 is connected via an eccentric coupling, such as a cam, to a motor 79 which causes the spreader bar to move back and forward, shown by the arrow 79A. This promotes mixing of the glue components on the paper. 13
A similar arrangement of glue applicator tubes is also connected to pump is 71 A and 73A in order to apply the glue components to the other sheet of paper. A similar arrangement of the spreader bar mixer is also provided to mix the glue components that are applied to the other sheet of paper. The polystyrene panel having the sheets of paper on its upper and lower surfaces then passes through the main press 22. The main press 22 essentially comprises a continuation of the series of press rollers 46, 48, 50 as shown in figure 4. Other press arrangements may also be used, such as press plates and the like. Due to the quick setting nature of the mixed glue, once the laminated panel leaves the main press 22, the glue has essentially set and the laminated panel has essentially been formed. However, it is necessary to cut the laminated panel to the desired length and therefore the laminated panel passes through cutting section 24.
The cutting section 24 is described with reference to figures 7 to 10. Referring initially to figure 7, the cutting section 24 includes a rotating cutting wheel 80. Desirably, the rotating cutting wheel 80 is in the form of a saw blade, such as a saw blade for a circular saw. The saw blade 80 is mounted for rotation about an axle 81 (see figure 8). The cutting wheel 80 is arranged such that it can move transversely across the laminated panel, for example as shown by reference to the directions shown by arrow 82. The saw blade 80 is mounted in a housing 84. Housing 84 is, in turn, attached to a vacuum extraction line 86 so that dust and particulate material formed during the cutting operation can be extracted from the vicinity of the cutting wheel 80. This minimises dusting in the environment of the apparatus.
The cutting wheel 80 is attached to a further housing 90 that is itself mounted to rod 92. In this fashion, the second housing 90 can slide along rod 92 to thereby move the cutting wheel 80 transversely to the laminated panels passing through the apparatus 10. A pneumatic ram or hydraulic ram is used to move the second housing 90 along the rod 92. As best shown in figure 8, a further cutting wheel 80' is positioned below the cutting wheel 80. The second cutting wheel 80', in use, is positioned below the laminated panel that is to be cut. The second cutting wheel 80' is suitably mounted for transverse movement in a fashion similar to that described for cutting wheel 80. 14
Rod 92 is mounted to a cutter section frame 94. Cutter section frame 94 is, in turn, mounted to rod 96 that is itself mounted to table 98. A similar mounting for the cutter section frame 94 is provided on the other side of the cutter section frame 94. This enables the cutter section frame 94 to move back and forward along the longitudinal direction of the apparatus 10 so that the cutter section frame 94 can move with a laminated panel travelling through the cutter section 22 when that panel is being cut. To facilitate this, the cutter section also includes a plurality of rollers 100 that are mounted to a pivoted scissor link arrangement 102. This is best shown in figures 9 and 10. The pivoted scissor link arrangement 102 is connected at 104 to the cutter section frame 94. When the cutter wheel 80 is actuated to come into contact with a laminated panel that is passing through the cutter section 22, the cutter wheel 80 contacts the laminated panel. As the cutter wheel 80 is forced to move transversely to the laminated panel, the cutter wheel 80 cuts along the laminated panel. The laminated panel, in turn, pushes the cutter wheel along in the direction of travel and this causes the pivoted scissor link arrangement 102 to move from its extended position (as shown in figure 6) to a compressed position as shown in figure 7. Thus, the cutter wheel 80 moves along with the laminated panel as the laminated panel moves through the cutter section 22. This assist in obtaining a straight, clean cut.
Once the cutter wheel 80 has completed its cut and is no longer in engagement with the laminated panel, the scissor link arrangement 102 moves back from the position shown in figure 10 to the extended position shown in figure 9. In this position, the next cutting operation can commence. In order to achieve the movement of the scissor link arrangement 102 from the retracted position shown in figure 10 to the extended position shown in figure 9, the cutter section may be provided with an appropriate spring or drive (such as a screw or worm drive, or a hydraulic ram or a pneumatic ram).
The operation of the cutter section involves having the cutter wheels 80, 80' rotating in a fashion similar to the operation of a pizza wheel used when cutting a pizza. It has been found that having the cutter wheels 80, 80' operate in this fashion provides for a clean cut in the laminated polystyrene panels. 15
The cut panels that leave the cutter section 22 pass on to an accumulating table
26. The accumulating table 26 allows for a stack of panels to be formed. The stack of panels is then transferred to side transfer conveyors 28, where the stacks are transferred laterally for storage or further transport. The stacks may be bound or wrapped to facilitate handling thereof.
Figure 11 shows a schematic side view of an alternative embodiment for applying glue to the sheets of material. In particular, in the embodiment shown in figure 11, the glue is a single component liquid glue or molten glue. In figure 11, features that are common to the features shown in figure 5 are denoted by the same reference numerals as used in figure 5, but with the addition of a '.
As shown in figure 11, the sheet of paper 35' that is unrolled from roll 34' passes underneath a tray 110. Tray 110 is filled with a liquid glue or a molten glue 111. For instance, the glue 111 may comprise a molten hot melt glue. The tray 111 has a roller 112 mounted in an opening in the bottom thereof. Roll 112 is sealingly mounted in the opening in the bottom of tray 111. As can be seen from figure 11, roller 112 is immersed in the molten glue 111. An opposed roller 114 is positioned below roller 112 and the sheet of paper 35 passes through the nip between rollers 112 and 114. As the sheet of paper passes between rollers 112 and 114, roller 112 is caused to rotate. This results in a film of molten glue or liquid glue being applied to the upper surface of sheet 35 of paper. The sheet 35 having the glue applied thereto then passes over press roller 46', which forces the sheet of paper and the glue into contact with the panel of polystyrene 30'.
A similar arrangement is used to provide glue to the second sheet of paper 39' that is removed from roll 38'. In particular, a second tray 116 that contains liquid glue or molten glue 117 is provided. Second tray 117 has a roller 118 mounted thereto for rotation. As can be seen from figure 11, roller 117 is partly immersed in the liquid glue or molten glue such that when the roller 117 rotates, it carries a film of glue on its outer surface. An opposed roller 120 is provided above roller 118 and the sheet of paper 39' passes between the nip of rollers 118 and 120. This causes roller 118 to apply a film of glue to the lower surface of the sheet of paper 39'. The sheet of paper 39' having the glue 16
applied thereto then passes underneath roller 46', which presses the sheet of paper and the glue into contact with the panel of polystyrene 30'.
As the liquid glue or molten glue may set very quickly, it has been found that the opposed rollers 46' are sufficient to act as the press section in this embodiment. In particular, the glue has been found to have set or hardened once it has passed through the set of rollers 46'. It will be appreciated that the set of rollers 46' may be spaced apart from each other at a distance such that a slight crushing of the panel of polystyrene 30' takes place as the panel of polystyrene and the paper passes through the rollers 46'.
In the embodiment shown in figure 11, the press section 22 which is shown in figures 1 and 2 is effectively replaced by the rollers 46'. This shortens the overall length of the apparatus and also reduces of the capital cost of the apparatus.
Figure 12 shows one possible arrangement of glue containers suitable for use in figure 11. In particular, in figure 12, glue trays 110 and 116 are shown. Also shown is a main glue container 130. Main glue container 130 includes a heating element 132 (in embodiments where the glue comprises a hot melt glue). The hot melt glue, in molten form, is passed via lines 134 and 136 to glue trays 110, 116, respectively. The lines 134, 136 and/or the trays 110, 116 may themselves be heated in order to maintain the glue in molten form. It will be appreciated that if a liquid glue is used instead of a hot melt glue, heating may not be required. It will also be appreciated that if a liquid glue which requires a longer time to set is used, the press section 22 may be utilised with the glue application arrangement as shown in figure 11.
In order to make a laminated panel having a first layer of paper, a first layer of polystyrene, a second layer of paper, a second layer of polystyrene and a third layer of paper (as shown schematically in figure 13 which shows a first layer of paper 150, a first layer of polystyrene 152, a second layer of paper 154, a second layer of polystyrene 156 and a third layer of paper 158, which may be a panel as described in Australian patent number 2002311245, the entire contents of which are herein incorporated by cross- reference), a laminated panel having a first layer of paper 150, a first layer of polystyrene 152 and a second layer of paper 154 may be manufactured using the apparatus as described in figures 1 to 12 using the method as described with reference to those figures. 17
Those laminated panels are then returned to panel feed stack 12 (as shown in figure 1) and are again fed through the apparatus. A second stack 13 of polystyrene panels is also provided. Glue is applied between the upper surface of the laminated panel and the lower surface of the polystyrene panel taken from stack 13 using a glue feed applicator arrangement similar to those shown in figures 3, 4, 11 or 12. This glue is applied to the underside of the polystyrene panel taken from stack 13 or to the upper side of the laminated panel taken from the first stack 12 at a position as indicated by reference numeral 19A in figure 1. Glue and paper is then applied to the upper surface of the polystyrene panel 156 taken from stack 13 in a fashion that is similar to the application of the top sheet of paper to be polystyrene panel 152. Cutting to length then completes the fabrication of the laminated panel as shown schematically in figure 13.
Those skilled in the art will appreciate that the present invention may be susceptible to variations and modifications other than those specifically described. It will be understood that the present invention encompasses all such variations and modifications that fall within its spirit and scope.

Claims

18CLAIMS.
1. An apparatus for producing a laminated panel in which a panel of material has a sheet of material laminated on either side thereof, the apparatus comprising:
■ feeding means for feeding the panel of material; ■ a first roll holder for holding a first roll of sheet material;
■ first sheet feeding means for passing sheet material from the first roll into contact with one side of the panel of material;
■ a second roll holder for holding a second roll of sheet material;
■ second sheet feeding means for passing sheet material from the second roll into contact with another side of the panel of material
■ a container for holding a glue;
■ a first glue applicator for applying glue between the first sheet of material and the one side of the panel;
■ a second glue applicator for applying glue between the second sheet of material and the other side of the panel;
■ pressure applying means to apply pressure to the panel downstream from the glue applicators; and
■ cutting means for cutting laminated panels to a desired length.
2. An apparatus as claimed in claim 1 wherein the feeding means comprises a conveyor for feeding the panel of material or the feeding means comprises a series of rollers for feeding the panel of material or the feeding means may comprise a chute or an inclined ramp.
3. An apparatus as claimed in claim 1 or claim 2 wherein the first sheet feeding means comprises a drive means for rotatably turning the first roll of sheet material. 19
4. An apparatus as claimed in any one of claims 1 to 3 wherein the first sheet feeding means further includes guide means for guiding the sheet of material as it is fed off the first roll.
5. An apparatus as claimed in any one of the preceding claims wherein the second sheet feeding means comprises a drive means for rotatably turning the second roll of sheet material.
6. An apparatus as claimed in any one of the preceding claims wherein the second sheet feeding means further includes guide means for guiding the sheet of material as it is fed off the second roll.
7. An apparatus as claimed in claim 4 or claim 6 wherein the guide means include one or more rollers or one or more guides plates.
8. An apparatus as claimed in any one of the preceding claims wherein the first glue applicator applies glue to the first sheet of material prior to the sheet of material coming into contact with the panel.
9. An apparatus as claimed in any one of the preceding claims wherein the first glue applicator comprises a hollow bar or tube extending substantially across the width of the first sheet of material, with the glue being supplied to a passage formed within the hollow bar or tube.
10. An apparatus as claimed in claim 9 wherein the hollow bar or tube includes a plurality of holes through which the glue can pass and thereafter drop on to the first sheet of material.
11. An apparatus as claimed in claim 10 wherein the plurality of holes has tubes extending therefrom so that the glue runs down the tubes and onto the sheet of material.
12. An apparatus as claimed in any one of the preceding claims wherein the second glue applicator applies glue to the second sheet of material prior to the sheet of material coming into contact with the panel. 20
13. An apparatus as claimed in claim 12 wherein the second glue applicator comprises a hollow bar or tube extending substantially across the width of the first sheet of material, with the glue being supplied to a passage formed within the hollow or tube.
14. An apparatus as claimed in claim 13 wherein the hollow bar or tube includes a plurality of holes through which the glue can pass and thereafter drop on to the second sheet of material.
15. An apparatus as claimed in claim 14 wherein the plurality of holes has tubes extending therefrom so that the glue runs down the tubes and onto the sheet of material.
16. An apparatus as claimed in any one of claims 1 to 8 or 12 wherein the first glue applicator or the second glue applicator or both the first and second glue applicator comprise at least one roller at least partly immersed in liquid or molten glue, the at least one roller being in contact with a sheet of material travelling past the at least one roller, the at least one roller applying glue to the sheet of material.
17. An apparatus as claimed in claim 16 wherein the sheet of material contacts the at least one roller and causes the at least one roller to rotate as the sheet of material travels past the at least one roller whereby as the at least one roller rotates, it picks up glue on its outer surface and transfers that glue to the sheet of material as the sheet of material moves past the roller.
18. An apparatus as claimed in any one of claims 1 to 8 or 12 wherein the first glue applicator or the second glue applicator or both the first and second glue applicator comprise at least one porous roller having molten or liquid glue supplied to the inside of the at least one porous roller such that the glue moves through the roller and onto the sheet of material travelling past the roller.
19. An apparatus as claimed in any one of the preceding claims wherein the glue comprises a hot melt glue.
20. An apparatus as claimed in any one of claims 1 to 18 wherein the glue comprises a mixture of a first glue component and a second glue component and the 21
apparatus comprises a first container containing the first glue component and the apparatus further comprise a second container for holding the second glue component.
21. An apparatus as claimed in claim 20 further comprising a glue mixer for mixing the first glue component and the second glue component together.
22. An apparatus as claimed in claim 20 or claim 21 wherein the first glue component is applied to the sheet of material and the second glue component is applied to the sheet of material, with the first and second glue component being mixed together on the sheet of material.
23. An apparatus as claimed in claim 22 wherein the first glue applicator comprises a first component applicator for applying the first glue component to the sheet of material and a second component applicator for applying the second glue component to the sheet of material.
24. An apparatus as claimed in claim 22 or claim 23 wherein the second glue applicator comprises a first component applicator for applying the first glue component to the sheet of material and a second component applicator for applying the second glue component to the sheet of material.
25. An apparatus as claimed in any one of the preceding claims wherein the pressure applying means comprises a set of rollers or a plurality of rollers or one or more pressure plates.
26. An apparatus as claimed in any one of the preceding claims wherein the cutting means comprises a rotatable cutter wheel which moves transversely to the laminated material.
27. An apparatus as claimed in claim 26 wherein the rotatable cutter wheel is driven transversely by a drive means.
28. An apparatus as claimed in any one of the preceding claims wherein the cutting means is mounted to move with the panel in the direction of travel of the panel through the apparatus as the cutting means traverses and cuts the panel.
29. An apparatus as claimed in claim 28 wherein the cutting means is mounted on biasing means such that when the cutting means contacts the panel the movement of 22
the panel causes the cutting means to move along with the panel and when the cutting means is disengaged from the panel, the biasing means moves the cutting means back to a cutting means starting position.
30. An apparatus as claimed in claim 28 wherein the cutting means is mounted to a drive means that moves the cutting means along with the panel during cutting, the drive means being arranged such that it moves the cutting means along the direction of travel at the same speed as the speed of the panel travelling through the apparatus, the drive means returning the cutting means to a cutting means starting position once the cutting means has been disengaged from the panel.
31. An apparatus as claimed in any one of the preceding claims wherein the cutting means is movable in a vertical direction to allow engagement and disengagement with the laminated material.
32. An apparatus as claimed in any one of claims 1 to 31 wherein the cutting means travels past the transverse edge of the laminated material to thereby disengage the cutting means from the laminated material.
33. An apparatus as claimed in any one of the preceding claims further comprising an accumulation table and side transfer conveyors for stacking and packaging of the panels.
34. An apparatus as claimed in any one of the preceding claims further comprising a second panel feeding means for feeding a second panel of material, a third roll holder for holding a third roll of a sheet of material, a third glue applicator for applying glue between the second sheet of material in the second panel of material and a fourth glue applicator for applying glue between the second panel of material and the third sheet of material, and pressure applying means for applying pressure to the second panel and downstream from the third and fourth glue applicators.
35. An apparatus as claimed in any one of claims 1 to 33 further comprising a second feeding means for feeding a second panel of material and a further glue application means for applying glue between a panel from a first feeding means and the 23
panel from the second feeding means, the apparatus also adhering a sheet to the second panel.
PCT/AU2008/001389 2007-09-21 2008-09-19 Apparatus for manufacturing laminated panels Ceased WO2009036509A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2007905187A AU2007905187A0 (en) 2007-09-21 Apparatus for Manufacturing Laminated Panels
AU2007905187 2007-09-21

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Publication Number Publication Date
WO2009036509A1 true WO2009036509A1 (en) 2009-03-26

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106515032A (en) * 2016-12-27 2017-03-22 郑州搜趣信息技术有限公司 Fiber wallboard buckling side machining device for building decoration
CN112223764A (en) * 2020-10-10 2021-01-15 合肥研力电子科技有限公司 A glue sticking module for a glue sticking machine

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US3152011A (en) * 1960-02-08 1964-10-06 Gerard George System for application for glue and adhesives
GB1429329A (en) * 1973-03-30 1976-03-24 Halberg Gebr Device for attaching foils to panels
US5360507A (en) * 1989-10-10 1994-11-01 Alusuisse-Lonza Services Ltd. Flame resistant to nonflammable composite panel
FR2837743A1 (en) * 2002-04-02 2003-10-03 Paneles Embo Sl Manufacturing panels covered on both sides by aluminum, supplies metal sheet from rolls, and presses it against hot adhesive coating on foam panels
US6805317B1 (en) * 2000-11-28 2004-10-19 Valmet-Karlstad Ab Adhesive dispenser in a reel-up in a paper machine

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Publication number Priority date Publication date Assignee Title
US3152011A (en) * 1960-02-08 1964-10-06 Gerard George System for application for glue and adhesives
GB1429329A (en) * 1973-03-30 1976-03-24 Halberg Gebr Device for attaching foils to panels
US5360507A (en) * 1989-10-10 1994-11-01 Alusuisse-Lonza Services Ltd. Flame resistant to nonflammable composite panel
US6805317B1 (en) * 2000-11-28 2004-10-19 Valmet-Karlstad Ab Adhesive dispenser in a reel-up in a paper machine
FR2837743A1 (en) * 2002-04-02 2003-10-03 Paneles Embo Sl Manufacturing panels covered on both sides by aluminum, supplies metal sheet from rolls, and presses it against hot adhesive coating on foam panels

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106515032A (en) * 2016-12-27 2017-03-22 郑州搜趣信息技术有限公司 Fiber wallboard buckling side machining device for building decoration
CN112223764A (en) * 2020-10-10 2021-01-15 合肥研力电子科技有限公司 A glue sticking module for a glue sticking machine

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