METHOD OF MANUFACTURING A COMPOSITE BUILDING ELEMENT AND SYSTEM THEREFOR

Abstract

The invention relates to a method of manufacturing a composite building element that includes a casing material, a bulk material, and a locking element, the method including the steps of: (a) continuously feeding a first sheet of casing material into a filling station; (b) securing the bulk material to the first sheet of casing material; (c) continuously feeding the bulk material and the first sheet of casing material out of the filling station; the method characterised by the step of: (d) securing the locking element to the first sheet of casing material prior to securing the bulk material to the first sheet of casing material.

Claims

1.-27. (canceled)

28. A method of manufacturing a composite building element, wherein the method uses a filling station configured to secure a bulk material to a first sheet of casing material, a feed station configured to feed the first sheet of casing material into the filling station, an insert station that is configured to secure a locking element to the first sheet of casing material before the bulk material is secured to the first sheet of casing material, wherein the system is configured to feed the first sheet of casing material from the insert station into the filling station, the method comprising the steps of: (a) using the feed station to continuously feed the first sheet of casing material into the filling station; (b) using the filling station to secure the bulk material to the first sheet of casing material; (c) using the insert station to secure the locking element to the first sheet of casing material prior to the filling station securing the bulk material to the first sheet of casing material.

29. The method of claim 28, including a step of feeding a second sheet of the casing material into the filling station so that there is a gap between the first and second sheets of the casing material.

30. The method of claim 29, wherein the step of securing the bulk material to the sheet material involves injecting an insulation material into the gap.

31. The method of claim 30, including a step of curing the insulation material.

32. The method of claim 28, including a step of deforming a sheet of casing material so as to create a connection cavity.

33. The method of claim 32, wherein the step of deforming a sheet of casing material involves bending a side edge of the casing material.

34. The method of claim 32, wherein the step of securing the locking element to the first sheet of casing material involves inserting a foot of the locking element into the connection cavity.

35. The method of claim 28, wherein the step of securing the locking element to the first sheet of casing material involves clamping.

36. The method of claim 28, including cutting the first sheet of casing material and the bulk material after step (b) to form a composite building element of a desired length.

37. A composite building element manufactured using a system for manufacturing composite building elements, the system comprising: a filling station configured to secure a bulk material to a first sheet of casing material, a feed station configured to feed the first sheet of casing material into the filling station, an insert station that is configured to secure a locking element to the first sheet of casing material before the bulk material is secured to the sheet of casing material, wherein the system is configured to feed the first sheet of casing material from the insert station into the filling station.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0130] Further aspects of the present invention will become apparent from the ensuing description which is given by way of example only and with reference to the accompanying drawings in which:

[0131] FIG. 1 is a schematic of a system according to the present invention;

[0132] FIG. 2 is an exploded view of a composite sandwich panel;

[0133] FIG. 3A is an end on view showing side edges of two sheets of casing materials forming a female edge of composite building element;

[0134] FIG. 3B is an end on view showing side edges of two sheets of casing materials forming a male edge of a composite building element;

[0135] FIG. 3C is an end on view showing interaction of male and female side edges of adjacent composite building elements according to the present invention;

[0136] FIG. 3D is an end on view of two adjacent panels secured together;

[0137] FIG. 4A is an end on view of a male locking element;

[0138] FIG. 4B is a front on view of FIG. 4A;

[0139] FIG. 5A is an end on view of a female locking element;

[0140] FIG. 5B is a front view of FIG. 5A;

[0141] FIG. 6 is an exploded view of male and female locking elements;

[0142] FIG. 7 is functional architecture showing connectivity of components of a system according to the present invention;

[0143] FIG. 8 is a close up side view of a feed station according to the present invention;

[0144] FIGS. 9A & 9B are close up views of a case forming station;

[0145] FIGS. 10A & 10B are side views showing transition between a case forming station and a shaping station;

[0146] FIG. 11 is a side view of an insert station and a shaping station;

[0147] FIG. 12 is a side view of a cutting station.

BEST MODES FOR CARRYING OUT THE INVENTION

[0148] There is provided a system for manufacturing composite sandwich panels (1), a method of using the system (1) and composite sandwich panels (3) manufactured using the system (1) and method.

[0149] Referring first to FIGS. 2A and 2B, composite sandwich panel (3) has a first layer of casing material (4) and a second layer of casing material (5). Side edges (6, 7) of the layers of casing material (4, 5) are deformed so as to define a female side edge, generally indicated as (8).

[0150] Side edges (9, 10) of layers of casing materials (4, 5) are deformed to define a male side edge, generally indicated as (11).

[0151] A male locking element (12) and a female locking element (13) are secured to the layer of casing material (4) so that in-use locking elements (12, 13) can engage with a complementary locking element on an adjacent panel.

[0152] The locking elements (12, 13) and securing these to the sandwich panels (3) are discussed in more detail below.

[0153] The male and female edges (11, 8) are complementary. Therefore, the male side edge (11) can extend into the female edge (8). This is as generally as shown in FIGS. 3 and 3DB.

[0154] The gap between layers of casing material (4, 5), generally indicated as (14) is filled with a bulk material in the form of a polyurethane foam. For simplicities sake the polyurethane foam is not shown in the Figures.

[0155] Manufacture and other aspects of the sandwich panel (3) should become clearer from the following description.

[0156] Referring now to FIGS. 1 and 7.

[0157] The system (1) generally includes: [0158] a feed station (15); [0159] a case forming station (16); [0160] a heating station (17); [0161] an insert station (18); [0162] a shaping station (19); [0163] a cutting station (20); [0164] a filling station (21).

[0165] The method of using the (1) is continuous meaning that sandwich panels (3) are produced from the shaping station (19) in indefinite lengths.

[0166] The components of the system (1) are linked to and in communication with a computer processing apparatus (22).

[0167] The computer processing apparatus is configured to control operation of each of the components of the system (1). This may include the speed at which the system (1) produces sandwich panels (3), or other parameters of the system's operation.

[0168] Further aspects of the system will now be discussed with reference to each of the stations.

[0169] Stations

[0170] The feed station (15) includes a first decoiler (23) holding a first roll (24) and a second decoiler (25) holding a second roll (26) of casing material in the form of steel. The casing material on roll (24) will be casing material (4) while the material of roll (26) will be casing material (5) in sandwich panel (3). Therefore the casing material provided by rolls (24, 26) being fed through the system (1) will be referred to as (4, 5).

[0171] Each of the rolls (24, 26) is coated with a food grade quality coating, in the form of paint (not shown).

[0172] The first and second decoilers (23, 25) include drive means (27, 28) configured to rotate the first and second rolls (24, 26). This facilitates feeding of lengths of casing material into the case forming station.

[0173] The feed station (15) also includes secondary decoilers (29, 30) as are shown in FIG. 8. In use the secondary decoilers (29, 30) facilitate continuous manufacturing of composite sandwich panels (3). The secondary decoilers (29, 30) are configured to feed casing material that can be joined to an end of casing material on the first and second rolls (24, 26). This is as should be understood by one skilled in the art.

[0174] Reference will be made herein to the direction of travel of the casing material (4, 5). This should be understood as movement of the casing material (4, 5) from one component to another, eventually passing from feed station (15) to cutting station (20). The direction of travel is generally indicated by arrows in FIG. 1.

[0175] Accumulators, indicated as (31) hold additional length of the casing material (4, 5). This facilitates securing ends of casing materials on rolls on decoilers (23, 25, 29, 30) together and thereby provision of a continuous method. This is as should be understood by one skilled in the art.

[0176] Case forming station (16) includes a first roll press (32) and second roll press (33).

[0177] The first and second roll presses (32, 33) are each configured to deform a side edge (6, 7, 9, or 10) of the sheets of casing material (4, 5) as these pass therethrough. Reformation of the side edges (6, 7, 9 or 10) creates connection cavities (100). The connection cavities (100) are best seen in FIGS. 3C and 3D.

[0178] The deformation of the sheets of casing material (4, 5) will be discussed in more detail below.

[0179] Insert station (18) includes first insert robot (34) and second insert robot (35) mounted on a carriage (36).

[0180] The carriage (36) is configured to move along the direction of movement of the casing materials (4, 5) as these move from first and second roll presses (32, 33) towards filling station (21).

[0181] The first and second insert robots (34, 35) and carriage (36) are substantially below casing material (4) and above casing material (5) e.g. the carriage (36) is in between the sheets of casing material (4, 5).

[0182] A store (not shown) of male locking elements (12) is positioned adjacent to first insert robot (34). A store (not shown) of female locking elements (13) is positioned adjacent to second robot insert (35). Each of the first and second insert robots (34, 35) is configured to pick up a locking element (12 or 13) from a store and insert that into a connection cavity in the sheets of casing material (4, 5).

[0183] A heating station (17) in the form of infrared heaters is configured to heat the casing material (4, 5) as this passes from the case forming station (16) to the filling station (21).

[0184] Filling station (21) includes an injection mechanism, indicated generally as (37). The injection mechanism (37) is configured to deliver a polyurethane foam under pressure, which facilitates mixing of components in the foam.

[0185] The injection mechanism (37) is as should be known to those skilled in the art.

[0186] The shaping station (19) includes a dual belt press including a top press element (38) and a bottom press element (39). The spacing of the top and bottom press elements can be altered.

[0187] The top and bottom press elements (38, 39) are commercially available moulds currently used in the known systems for continuous manufacture of composite sandwich panel building elements. Accordingly, the top and bottom press elements (38, 39) are as should be known to one skilled in the art.

[0188] The shaping station (16) also includes taping devices (not visible). The taping devices are configured to apply a tape material to a polyurethane foam, in the gaps between side edges (6-10) of casing materials (4, 5).

[0189] Supplementary belt presses (not shown) are position to be on distal side of casing materials (4, 5) to each other, and extend along the direction of travel of casing materials (4, 5).

[0190] The supplementary presses (not shown) are configured to apply pressure to the sheets of casing material (4, 5) as they pass therethrough. This, in combination with the controlling of the spacing of the top and bottom press elements (38, 39), assists in controlling the volume to which the polyurethane foam can expand.

[0191] The secondary press (42) prevents polyurethane foam expanding beyond the side edges of casing materials (4, 5).

[0192] The system (1) also includes supplementary rollers (41) and conveyors (42). The rollers (41) and conveyors (42) assist in moving the casing materials (4, 5) through components according to the present invention.

[0193] Cutting station (20) includes a carriage (43) and cutting element (44) in the form of a rotary saw. The carriage (43) is configured to move the rotary saw along the direction of movement of the casing material (4, 5). Accordingly, the carriage facilitates the cutting element (44) cutting the casing material (4, 5) as this exits from the shaping station (19) without the need to stop the feed of casing materials (4, 5). Accordingly, it is possible to produce sandwich panels (3) according to the present invention continuously in the form of a marking.

[0194] A marking device (45) is configured to apply a visual indication onto a sheet of casing material (4).

[0195] The marking is identified by sensor (46) in cutting station (20). The computer processing apparatus (22) receives a signal indicative of marking and sends instructions to cutting element (44) to cut sandwich panel (3) at a desired length.

[0196] Locking Elements

[0197] Referring now to FIGS. 4A-6 showing male and female locking elements (12, 13) according to the present invention.

[0198] The male locking element (12) is formed from a first part (47) and a second part (48).

[0199] First part has a body (49) and a foot portion (50). In use, foot (50) abuts an inner surface of a casing material (4).

[0200] The second part (48) includes a housing (51). The housing has a locking member (52) rotatably mounted therein. An opening (53) in top surface (54) of housing (51) enables a key (not shown) to be used to engage and rotate the locking member (52).

[0201] A side (55) of the housing (51) has an aperture (56). The aperture (56) enables the member (52) to protrude from housing (51) and to engage with a female locking element (13) in an adjacent composite sandwich panel (3) when the locking elements (12, 13) are in use.

[0202] The legs (60) extend away from the body (49). Each leg (60) has an upturned lip (61).

[0203] Top surface (57) of first part (49) has a plurality of apertures (58). The apertures (58) are configured to receive detents (58B) on housing (51).

[0204] The apertures (58) and detents (58B) engage in a press fit manner so as to secure first part (47) and second part (48) together.

[0205] Foot (50) has a plurality of apertures 50B. The apertures provided a lattice work web. A polyurethane foam can expand through the lattice work web to facilitate securing the locking element (12) with respect to casing materials (4, 5) and thereby forming of a sandwich panel (3).

[0206] Female locking element (13) is formed from a first part (62) and a second part (63).

[0207] The first part (62) has a body (62B) and a foot (64). The foot (64) extends away from body (62B). The foot (64) has a step, indicated as (65).

[0208] The second part (63) has a housing (66). A female locking member (not shown) is secured in housing (66). Side (68) of housing (66) has an aperture (68B). This enables rotation of male locking member to extend through aperture (69) into the housing (66) and engage the female locking element (not shown) so as to secure the locking elements (12, 13) together.

[0209] First part (62) top surface (69), has a plurality of apertures (70). The apertures (70) are configured to receive detents (71) on housing (66). The apertures (70) and detents (71) engage in a press fit manner so as to secure first and second parts together (62, 63).

[0210] The first parts (62, 47) can be selected to have a height corresponding to the size of panel (3) being manufactured. This is important to ensure that second parts (48, 63) are positioned substantially within the centre of a panel.

[0211] The locking elements (12, 13) are made from a reinforced plastics material. This is beneficial in reducing transfer of heat through composite sandwich panels according to the present inventions.

[0212] Method

[0213] Referring now primarily to FIG. 1.

[0214] The desired parameters for panels (3) to be produced by the system (1) are input to computer processing apparatus (22). This may include selection of:

[0215] 1. fire safety rating for panels;

[0216] 2. panel length;

[0217] 3. total number of locking elements required per panel;

[0218] 4. separation of (centre spacing of) of locking elements;

[0219] 5. insulative (heat transfer) properties for the panel;

[0220] 6. panel thickness.

[0221] These properties are as should be understood by one skilled in the art.

[0222] The computer processing apparatus calculates parameters for operation of the system (1), including: [0223] feed rate for casing materials (4, 5); [0224] rise time required for polyurethane foam; [0225] separation for top and bottom press elements.

[0226] Reference will be made herein to the term “feed rate”. This should be understood as referring to the rate (meters per minute) of casing material entering into shaping station. It should be understood that reference to the term “feed rate” also describes the rate of movement of the casing material along its direction of travel at other stages of the system (1).

[0227] The computer processing apparatus sends instructions to the components of the system (1).

[0228] Decoilers (23, 25) are engaged to rotate so as to feed casing materials (4, 5) into roll formers.

[0229] Roll presses (32, 33) deform side edges (7-10) of casing materials (4, 5). The shape of the side edges of the casing materials (4, 5) as these exit from roll presses (25, 35) is best seen in FIGS. 3A-3C.

[0230] Rotation of roll presses (32, 33) feeds casing material (4, 5) towards and through insert station (18).

[0231] First insert robot (34) engages and lifts a male locking element (12) and second insert robot (35) engages and lifts a female locking element (13).

[0232] The robots position locking elements (12, 13) with respect to side edges of casing material (4). Carriage (36) moves arms along direction of travel at the feed rate. The insert robots push locking members (12, 13) so that the lip (61) and step (65) are each inserted into one of the connection cavities(100).

[0233] Presses (not shown) applies pressure to casing material (4). This clamps and deforms casing material (4) around lip (61) and step (65).

[0234] Insert robots disengage locking elements (12, 13).

[0235] Carriage (36) returns robots (34, 35) to the start point so that they can secure subsequent locking elements (12, 13) to casing material (4).

[0236] Marker device (45) applies markings to a top surface of casing material (4). The markings indicate the division between two panels being manufactures by system (1), and corresponds to the location at which cutting element (44) must cut the panel exiting from the shaping station.

[0237] The above process is repeated to enable robots to secure sufficient locking elements to casing material (4) according to instructions programmed into computer programming apparatus (22).

[0238] Heating station (17) applies infrared radiation to casing elements (4, 5) so as to heat these to a temperature between 40-50° C.

[0239] Filing station (21) delivers a polyurethane foam into casing material (5) according to instructions sent by the computer programming apparatus.

[0240] The polyurethane foam may vary in blowing agent delivered, foam ingredients so as to alter properties such as fire resistance and/or insulative values, or volume of polyurethane foam delivered.

[0241] In effect, casing material (5) which has been deformed by roll press (33) forms a tray to receive the polyurethane foam.

[0242] The foam starts to expand as casing materials (4, 5) moves from filing station (22) towards shaping station (19).

[0243] The rate of travel of casing material (5) from filling station to shaping station (19) allows the polyurethane foam to cure. The curing time is determined according to parameters as should be known by one skilled in the art. The cure time will depend on the parameters for the composite sandwich panel (3) being produced. It may also vary according to the distance between filling station (22) and shaping station (19).

[0244] Casing materials (4, 5) converge to have a separation substantially equal to the desired thickness of panel (3). As the materials converge, and the polyurethane foam expands, the locking elements (12, 13) are substantially submerged within polyurethane foam. The foam's expansion causes the foam to fill in the apertures in first parts of locking elements.

[0245] Taping devices (not shown) apply tape to polyurethane foam in the gap between side edges (7-10) of casing materials (4, 5).

[0246] Shaping station (19) applies pressure to the top and bottom surfaces of casing materials (4, 5) and to polyurethane via taped material. The shaping station (19) limits expansion of the polyurethane foam. Therefore, the shaping station defines the dimensions of the panel.

[0247] The time taken for casing materials (4, 5) to move between filling station (21) and shaping station (19) is determined according to the rise time required to achieve a panel (3) having desired dimensions. This is as should be understood by one skilled in the art.

[0248] The sheets of casing material (4, 5) with the polyurethane foam exit the shaping station (19) and are continuously fed into the cutting station (20).

[0249] The marking device (45) applies a visual indication onto a sheet of casing material (4).

[0250] The carriage (43) moves the rotary saw along the direction of movement of the casing materials (4, 5) at the identical rate of movement. The cutting element cuts the casing materials (4, 5) and the bulk material so as to provide a composite sandwich panel (3) having a desired length.

[0251] The casing materials (4, 5) and bulk material continue to be fed out of shaping station. The carriage (43) returns the cutting element towards the shaping station (19). This enables the cutting element to cut the casing materials (4, 5) and bulk material to provide another composite sandwich panel (3) having a desired length. The above steps are repeated as necessary.

[0252] Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof as defined in the appended claims.