IES80818B2 - Panels - Google Patents

Abstract

A continuous lenght of a composite panel is delivered to a cutting station (2). A leading cross cut saw (3) with a band saw blade (4) and a trailing cross cut saw (5) with a band saw cutting blade (6) are operated to cut the panel to a desired length. The longitudinal distance between the blades (4,6) is set, a first panel location (12) being aligned with the leading blade (4) and a second panel location (13) aligned with the trailing blade (4). The saws (3,5) are operated simultaneously. A support roller (15) mounted on a scissors linkage (17) supports the panel during cutting. As the saws (3,5) operated they move longitudinally in timed relation to the movement of the panel (1) so that the production of following panel lengths is not interrupted. .

Description

The invention relates to a method and apparatus for manufacturing and handling panels. In particular, the invention relates to insulating panels of the type comprising a profiled external skin and an internal backing tray having an insulating case there between.

UK-A-2227712 and UK-A-2257086 describe methods and apparatus for manufacturing insulating panels. However, there is an increasing need to improve manufacturing and handling efficiency, to cut costs and maximise the production rates for such panels.

This invention is therefore directed towards providing an improved method and apparatus for efficient manufacturing and handling of such panels.

Statements of Invention According to the invention there is provided a method for cutting a panel to a desired length comprising the steps of;setting a distance between a pair of saws at a cutting station corresponding to a desired length between a first panel location and a second panel location spaced-apart from the first location; delivering the panel so that the first panel location is aligned with the blade of a leading saw and the second panel location is aligned with the blade of a trailing saw; -2cutting the panel at the first and second locations by traversing the panel with the leading saw and the trailing saw; and leading the cut panel length from the cutting station.

In one particularly preferred embodiment of the invention the panel is traversed simultaneously with the leading saw and the trailing saw.

In one embodiment of the invention the method includes the step of supporting the panel intermediate the first and second locations, during cutting. Preferably the panel is supported by a support roller means extending across underside of the panel, the support roller being moveable from a retracted position to an extended supporting position, during cutting.

In a preferred aspect the method includes the step of moving the saws longitudinally, during cutting, as the panel is delivered through the cutting station.

In another aspect the invention provides apparatus for cutting a panel to a desired length between a first panel location and a spaced-apart second panel location, the apparatus comprising: a first in-line saw a second in-line saw; and adjustment means for adjusting the distance between the saws corresponding to a desired length.

Preferably the apparatus includes track means on which the saws are mounted for longitudinal movement along a track means relative to a panel conveyor. -3In a preferred arrangement the adjustment means is arranged to move the saws apart longitudinally on the track means.

Ideally the track means is common for both saws.

Preferably the apparatus includes support means between the two saws for supporting a panel length intermediate the saws during cutting. In a preferred arrangement the support means is mounted for movement between a retracted position and an extended supporting position. Preferably the support means is a support roller which is mounted on a support frame, the support frame having operating means for moving the support roller between the retracted and supporting positions. In one embodiment the operating means is a ram means.

Preferably the support frame is pivotally mounted for movement between the retracted and supporting positions.

Brief Description of Drawings The invention will be more clearly understood from the following description thereof given by way of example only in which :Fig. 1(a) to 1(e) are plan views illustrating the method for cutting a panel according to the invention; Fig. 2 is an side elevational, partially cross sectional view of a panel cutting apparatus in an initial position of use; Fig. 3 is a side elevational, partially cross sectional view of the panel cutting apparatus in an intermediate position of use; -4Fig. 4 is a side elevational, partially cross sectional view of the panel cutting apparatus in a final position of use; and Fig. 5 is a cross sectional view of a joint between adjacent wall panels.

Detailed Description Referring to the drawings there is illustrated part of a method and apparatus used for manufacturing an insulated panel length 1 of the type having a profiled external skin, an internal hacking tray and an insulating core between the external skin and backing tray.

A continuous length of panel 1 is formed and delivered to a cutting station 2 having a leading cross cut saw 3 with a band saw cutting blade 4 and a trailing cross cut saw 5 with a bond saw cutting blade 6. Each of the saws 3, 5 are mounted on respective carriages 8, 9 which are movable longitudinally along parallel tracks 10 On opposite sides.

The longitudinal distance between the blades 4, 6 is first set automatically by a control means which moves one or both saws 3, 5 relative to each other. The set distance corresponds to a desired length between a first panel location 12 and a second panel location 13 spaced-apart from the first location 12. The panel length 1 is then delivered to the cutting station 2 by the control means so that the first panel location 12 is aligned with the leading blade 4 and the second panel location 13 is aligned with the trailing blade 6.

To support the panel during cutting a support roller 15 mounted on a scissors linkage 17 is extended by a ram 16 from a retracted position illustrated in Fig. 2 to a panel supporting extended position illustrated in Fig. 3 in which the support roller engages the lower face of the panel. -5The panel is cut to the desired length by traversing the panel with both the leading blade 4 and trailing blade 6 simultaneously. As the saws 3, 5 operate they move longitudinally in timed relation to the movement of die panel 1 so that production of the following panel lengths does not have to be interrupted during cutting. In this way production efficiency is optimised.

When the panel is cut to the desired length 20, the saws 3, 5 travel back along the tracks 10 to the next position to receive a further panel length. The sequence of io operations will be readily apparent from the drawings.

It will be appreciated that the invention provides a highly efficient method and apparatus for cutting desired panel lengths without interrupting the production of the panel to be cut. The cutting operation may be carried out automatically and extremely quickly leading to improved rates of production. In addition, the provision of the dual saw arrangement provides the flexibility to produce smaller panel lengths in a highly optimised manner.

The panel cutting method and apparatus of the invention is used as part of a method for forming a panel such as a wall panel in a substantially continuous manner. In this method a sheet of external skin material 50 is led from a reel, profiled and laid onto a flat bed with the outermost face of the external skin lowermost. The external skin may be pre-heated prior to application of liquid foam reactants.

A sheet of backing tray 51 material is led from a supply reel, profiled and preheated. The profiled backing tray is then continuously applied over the external skin and liquid foam reactants. -6The backing tray is maintained in spaced-apart relationship from the external skin by appropriately sized spacer blocks. The liquid foam reactants are then allowed to expand to fill the space between the external skin and the backing tray by passing the assembly through an oven in which the reactants are heated and allowed to expand to the desired thickness of foam insulating core 52. The output from the oven is a continuous longitudinal sheet of insulating panel which is cut to a desired length. The cut lengths are then delivered to the infeed panel conveyor of the stacking apparatus.

In the case of a wall panel 55, a seal or seals may be inserted in a side marginal edge of the panel and the profile of a joint between adjacent panels as illustrated in Fig. 6.

The invention is not limited to the embodiments hereinbefore described which may be varied in construction and detail.

Claims (5)

1. A method for cutting a panel to a desired length comprising the steps offsetting a distance between a pair of saws at a cutting station corresponding to a desired length between a first panel location and a second panel location spaced-apart from the first location; delivering the panel so that the first panel location is aligned with the blade of a leading saw and the second panel location is aligned with the blade of a trailing saw; cutting the panel at the first and second locations by traversing the panel with the leading saw and the trailing saw; and leading the cut panel length from the cutting station.

2. A method as claimed in claim 1 wherein the panel is traversed simultaneously with the leading saw and the trailing saw, preferably the method includes the step of supporting the panel intermediate the first and second locations, during cutting, preferably the panel is supported by a support roller means extending across the underside of the panel, the support roller being moveable from a retracted position to an extended supporting position, during cutting, preferably the method includes the step of moving the saws longitudinally, during cutting, as the panel is delivered through the cutting station.

3. Apparatus for cutting a panel to a desired length between a first panel location and a spaced-apart second panel location, the apparatus comprising: -8a first in-line saw a second in-line saw; and 5 adjustment means for adjusting the distance between the saws corresponding to a desired length.

4. Apparatus as claimed in claim 3 including track means on which the saws are mounted for longitudinal movement along the track means relative to a 10 panel conveyor, preferably the adjustment means is arranged to move the saws apart longitudinally on the track means, preferably die track means is common for both saws, preferably the apparatus includes support means between the two saws for supporting a panel length intermediate the saws during cutting, preferably the support means is mounted for movement 15 between a retracted position and an extended supporting position, preferably the support means is a support roller which is mounted on a support frame, the support frame having operating means for moving the support roller between the retracted and supporting positions, preferably the operating means is a ram means, preferably the support frame is 20 pivotally mounted for movement between the retracted and supporting positions.

5. A panel length whenever cut by a method as claimed in claim 1 or 2 and/or using an apparatus as claimed in claim 3 or 4.