U.S. patent application number 11/792820 was filed with the patent office on 2008-06-05 for composite cladding.
Invention is credited to James Carolan.
Application Number | 20080127586 11/792820 |
Document ID | / |
Family ID | 35736097 |
Filed Date | 2008-06-05 |
United States Patent
Application |
20080127586 |
Kind Code |
A1 |
Carolan; James |
June 5, 2008 |
Composite Cladding
Abstract
The panel 1 comprises a steel skin or backing tray (2) and an
external steel skin (3) with a layer of foam insulation material
(4) such as a phenolic or polyurethane based foam material
therebetween. One of the skins, in this case the external skin 3
has a plurality of mountings for fixing cladding elements such as
tiles (5) to the panel to form a cladding. The mountings comprise
rails (10) and fasteners (12) for fastening the rails (10) to the
external skin (3). Each fastener (12) comprises an internal
clamping sleeve (15) and a bolt (16). A hole is first drilled
through the skin (3) and the sleeve (15) is inserted. On tightening
of the bolt (16), the sleeve (15) splays and is clamped against the
inside surface of the external skin (3), and the rails (10) are
fixed to the panels. To enhance the peel strength of the composite
panel a layer (30) of an adhesive is applied to the internal face
of the external skin (3). The adhesive layer (30) is a pre-lay-down
adhesive which is compatible with the material of the insulting
core (4). The use of such an adhesive greatly enhances the peel
strength of the panel and enables the panel to carry the additional
load of the cladding tiles.
Inventors: |
Carolan; James; (Kingscourt,
IE) |
Correspondence
Address: |
JACOBSON HOLMAN PLLC
400 SEVENTH STREET N.W., SUITE 600
WASHINGTON
DC
20004
US
|
Family ID: |
35736097 |
Appl. No.: |
11/792820 |
Filed: |
December 14, 2005 |
PCT Filed: |
December 14, 2005 |
PCT NO: |
PCT/IE05/00140 |
371 Date: |
June 12, 2007 |
Current U.S.
Class: |
52/309.9 ;
52/584.1; 52/745.19 |
Current CPC
Class: |
E04F 13/0875 20130101;
F16B 11/006 20130101; F16B 13/0833 20130101; F16B 5/12 20130101;
E04F 13/0803 20130101; E04C 2/292 20130101 |
Class at
Publication: |
52/309.9 ;
52/584.1; 52/745.19 |
International
Class: |
E04C 2/296 20060101
E04C002/296; E04C 2/26 20060101 E04C002/26; E04B 2/04 20060101
E04B002/04 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 14, 2004 |
IE |
2004/0836 |
Claims
1-16. (canceled)
17. A composite cladding panel comprising an internal skin and an
external skin with insulation material therebetween, one of the
skins having a plurality of mountings for fixing tiles or the like
to the panel to form a cladding.
18. The panel as claimed in claim 17 wherein the mountings comprise
a rail and a plurality of fasteners for fastening the rail to the
panel.
19. The panel as claimed in claim 18 wherein the fastener comprises
a clamping fastener.
20. The panel as claimed in claim 19 wherein the clamping fastener
comprises an internal sleeve and a bolt, the sleeve clamping to the
inside of the external skin on tightening of the bolt.
21. The panel as claimed in claim 18 wherein the rails comprise
receivers for receiving cladding elements such as bricks.
22. The panel as claimed in claim 17 wherein the external skin of
the panel has an adhesive on the inner face thereof.
23. The panel as claimed in claim 22 wherein the adhesive is
applied to the inner face of the external skin prior to lay-down of
liquid insulating foam reactants.
24. A method for manufacturing a composite cladding panel
comprising the steps of: manufacturing a composite insulating panel
comprising an internal skin, an external skin with insulation
material therebetween; aligning mounting rails along at least
portion of the external face of a skin; and fastening the rails to
the skin.
25. The method as claimed in claim 24 comprising the steps of
drilling holes in the skin, inserting internal sleeves into the
holes, and tightening bolts in the sleeves to clamp to the inside
of the skin.
26. The method as claimed in claim 25 comprising the step of fixing
the rail to the panel using the bolts.
27. The method as claimed in claim 24 comprising the steps of
laying the external skin down with the outer side lowermost,
applying an adhesive to the inner face of the external skin,
applying liquid foam reactants over the adhesive, applying an
internal skin over the liquid form reactants and heating the
sandwich thus formed in an oven to form the composite insulating
panel.
28. The panel when manufactured by a method as claimed in claim
24.
29. The composite cladding panels when manufactured by a method as
claimed in claim 24.
Description
INTRODUCTION
[0001] The invention relates to a composite cladding panel of the
type comprising an inner skin and an external skin with insulation
foam material therebetween.
[0002] Buildings comprising a steel frame on which pre-formed
panels are mounted may be erected quickly and more cheaply than
buildings with brick or block facades.
[0003] One of the problems with buildings constructed from
pre-formed panels is that such panels can often be uninteresting
aesthetically. It is known to form such panels with various
profiles and in various colours, however, there is still a need to
provide an aesthetically different facade in some cases.
[0004] This invention is directed towards providing a panel system
which will address this need.
STATEMENTS OF INVENTION
[0005] According to the invention there is provided a composite
cladding panel comprising an internal skin and an external skin
with insulation material therebetween, one of the skins having a
plurality of mountings for fixing tiles or the like to the panel to
form a cladding.
[0006] In one embodiment the mountings comprise a rail and a
plurality of fasteners for fastening the rail to the panel. The
fastener may comprise a clamping fastener.
[0007] In one case the clamping fastener comprises an internal
sleeve and a bolt, the sleeve clamping to the inside of the
external skin an tightening of the bolt.
[0008] In one embodiment the rail comprises receivers for receiving
cladding elements such as bricks.
[0009] In one embodiment the external skin has an adhesive on the
inner face thereof. The adhesive may be applied to the inner face
of the external skin prior to lay-down of liquid insulating foam
reactants.
[0010] The invention also provides a method for manufacturing a
composite cladding panel comprising the steps of: [0011]
manufacturing a composite insulating panel comprising an internal
skin, an external skin with insulation material therebetween;
[0012] aligning mounting rails along at least portion of the
external face of a skin; and [0013] fastening the rails to the
skin.
[0014] In one embodiment the method comprises the steps of drilling
holes in the skin, inserting internal sleeves into the holes, and
tightening bolts in the sleeves to clamp to the inside of the skin.
The rail may be fixed to the panel using the bolts.
[0015] In one case the method comprises the steps of laying the
external skin down with the outer side lowermost, applying an
adhesive to the inner face of the external skin, applying liquid
foam reactants over the adhesive, applying an internal skin over
the liquid form reactants and heating the sandwich thus formed in
an oven to form the composite insulating panel.
[0016] The invention further provides composite cladding panels
when manufactured by a method of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention will be more clearly understood from the
following description thereof given by way of example only, in
which:
[0018] FIG. 1 is a cross-sectional view of a composite insulating
cladding panel according to the invention;
[0019] FIG. 2 is cross-sectional view of the composite panel of
FIG. 1 with no tiles in place;
[0020] FIGS. 3 and 4 are cross-sectional views illustrating a
fastener used with the panel;
[0021] FIG. 5 is a perspective view of the fastener, in use;
[0022] FIG. 6 is an elevational view illustrating the panel with
rails in place; and
[0023] FIG. 7 is an elevational view of the panel with some
cladding tiles such as bricks in place.
DETAILED DESCRITION
[0024] Referring to the drawings there is illustrated a composite
cladding panel 1 according to the invention. The panel 1 comprises
a steel skin or backing tray 2 and an external steel skin 3 with a
layer of foam insulation material 4 such as a phenolic or
polyurethane based foam material therebetween. The panel may be of
any suitable type such as that described in our UK2325678A, the
entire contents of which are hereby incorporated by reference.
[0025] One of the skins, in this case the external skin 3 has a
plurality of mountings for fixing facade or cladding elements such
as tiles 5 to the panel. The tiles may be brick, ceramic or the
like to form a cladding for the panel. The mountings comprise rails
10 and fasteners 12 for fastening the rails 10 to the external skin
3.
[0026] Each fastener 12 comprises an internal clamping sleeve 15
and a bolt 16. One such fastening systems is that referred to in a
Fablok (Trade Mark). A hole is first drilled through the skin 3 and
the sleeve 15 is inserted as illustrated in FIG. 3. On tightening
of the bolt 16, the sleeve 15 splays and is clamped against the
inside surface of the external skin 3 as will be particularly
apparent for FIGS. 4 and 5. The rail 10 has pre-drilled holes
through which the shanks of the bolts 16 are inserted. On
tightening of the bolts 16, the rails 10 are fixed to the panels.
In this way the rails 10 are efficiently and effectively clamped to
the external skin 3. The rails 10 are omitted from FIGS. 2 to 5 for
clarity.
[0027] The rails 10 and associated tiles 5 may be of the type
available from Agrob Buchtal of Germany. The rails 10 have
formations 20 which inter-engage with corresponding formations 21
on the tiles 5 for ease of assembly of the tiles 5 to the rails 10
without a requirement for fixing screws and the like.
[0028] To enhance the peel strength of the composite panel a layer
30 of an adhesive is applied to the internal face of the external
skin 3. The adhesive layer 30 is a pre-lay-down adhesive which is
compatible with the material of the insulting core 4. We have found
that the use of such an adhesive greatly enhances the peel strength
of the panel and enables the panel to carry the additional load of
the cladding tiles.
[0029] In manufacture, an external skin 3 is drawn from a reel and
laid down in a lay-down bed with the internal face uppermost. The
adhesive 30 is then uniformly applied over the internal face of the
slin 3 prior to lay-down of liquid foam reactants. The inner skin 2
is then led from a reel and located above the liquid foam
reactants.
[0030] The assembly is the passed through an oven in which the
liquid foam reactants expand to form the insulating core 4. A
desired length of panel is then cut. The rails 10 are laid out
across the external face of the skin 3 and the locations for
fastening the receiving holes to be drilled in the panel are
marked. The rails may be removed, the holes drilled and the
clamping sleeves 15 inserted. The holes in the rails 10 are aligned
with the clamping sleeves 15 and the bolts are inserted and
tightened, clamping the rails 10 to the skin 3 as described above.
The tiles 5 are then fixed to the rails 10 using the clipping
system provided by the spaced-apart formations 20 on the rails and
the corresponding formations 21 of the tiles 5. The tiles are
clicked into place and held on the brackets/rails 10. No fixing
screws or the like are required to mount the tiles 5 on the rails
10.
[0031] The invention provides a composite panel of relatively
simple but highly robust construction which facilitates easy on
site cladding with finishing tiles such as brick tiles.
[0032] The invention is not limited to the embodiments hereinbefore
described which may be varied in detail.
* * * * *