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(11) | EP 2 548 673 B1 |
| (12) | EUROPEAN PATENT SPECIFICATION |
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Process and plant for production of prefabricated insulating panels for roofing of buildings Verfahren und Anlage zur Herstellung von vorgefertigten Dämmplatten zum Überdachen von Gebäuden Procédé et installation pour la production de panneaux isolants préfabriqués pour toitures de bâtiments |
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| Note: Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. Notice of opposition shall be filed in a written reasoned statement. It shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention). |
Field of the invention
[0001] The present invention relates to prefabricated insulating panels for roofing of buildings and has been developed with particular reference to panels of a sandwich type, i.e., comprising a lower sheet made of rigid or semirigid material, an upper sheet made of rigid material, and a layer made of insulating material between the upper and lower sheets.
Prior art
[0002] The structure of the panels referred to, made up of the aforesaid layer of insulating material firmly set between the two rigid or semirigid sheets, is substantially monolithic, and this guarantees good characteristics of tightness to infiltrations, thermal insulation, and strength. For this reason, the panels of the type referred to are widely used for producing roofings of buildings.
[0003] In the majority of cases, the panels have an overall plane configuration - albeit with surface ribs - and are used for forming individual pitches of a roof. To produce two-pitch roofs, hence, each pitch is formed by a respective plurality of juxtaposed panels. The waterproof joint between the two opposite inclined pitches, each formed by a respective plurality of panels, is obtained by installing an additional ridge element, which defines the ridge line of the roof. Plane panels of this type require relatively complex or extensive substructures, which are designed to sustain the panels that form each pitch in an inclined position.
[0004] Processes and plants having the features of the preambles of claims 1 and 10 are generally known in the field of production of prefabricated insulating panels. A process and a plant basically of this kind is also diclosed in US 3738895 A, in which, however, none of the sheets to form the panel is shaped so as to define a respective longitudinal rib at at least one of its two opposite side edges.
[0005] Also known are prefabricated insulating panels that have an overall curved shape. Also the monolithic structure of these panels comprises an upper sheet and a lower sheet, curved according to one and the same radius and arranged parallel to one another, set between which is the layer of insulating material. Also these curved panels are modular, with the possibility of the front and back of different panels being coupled together in the direction of length of the span.
[0006] On account of production constraints, dimensional constraints, or installation constraints - including the need to guarantee an adequate load-bearing capacity - the curved panels for the applications referred to are in general produced with relatively small radii of curvature. Consequently, the top surface of these panels has a steep slope, even higher than 50%, and practically does not provide a surface on which it is possible to walk, other than with a high risk of slipping. This circumstance complicates possible interventions that must be performed on the roof (for example, cleaning or maintenance), as well as the installation of additional elements (for example, planar photovoltaic modules). The curved panels can also be formed with wide radii of curvature, but the consequence of this is that the maximum load admissible for the panels themselves is considerably reduced.
[0007] The production of curved panels is then relatively slow, complicated, and/or implies considerable investments. In the majority of cases, curved panels of the type referred to are obtained using purposely provided presses designed to make one panel at a time (see, for example, WO 02/34493). Said presses are generally complex, and in any case production is relatively slow. Specific plants have also been proposed for the continuous production of curved panels (see, for example, WO 2004/071691), but also these are extremely complicated, cumbersome, and difficult to handle.
Aim of the invention
[0008] In view of what has been set forth above, the aim of the present invention is basically to provide new methodologies and systems for the production of monolithic sandwich panels, which enable the problems referred to previously to be overcome. Said general aim is achieved, according to the present invention, by a process and by a plant which have the characteristics specified in the annexed claims. The claims form an integral part of the technical teaching provided herein in relation to the invention.
Brief description of the drawings
[0009] The characteristics and advantages of the invention will emerge clearly from the ensuing description, with reference to the annexed drawings, which are provided purely by way of non-limiting example and in which:
- Figure 1 is a perspective view of an insulating panel obtained according to the invention;
- Figure 2 is a partial and schematic cross section of a plurality of panels obtained according to the invention, either coupled or juxtaposed;
- Figure 3 is a partial perspective view of two panels obtained according to the invention, in a step of coupling or juxtaposition;
- Figure 4 is a perspective schematic view of a plurality of panels obtained according to the invention, coupled or juxtaposed;
- Figures 5 and 6 are partial and schematic cross sections according to the lines V-V and VI-VI of Figure 4, respectively;
- Figure 7 is a schematic representation of the layout of a first plant for the production of insulating panels according to the invention;
- Figures 8-11 are partial and schematic cross sections of a bending device of the plant of Figure 7, in different operating positions;
- Figure 12 is a partial and schematic cross section of a foaming device of the plant of Figure 7;
- Figures 13 and 14 are partial and schematic cross sections, according to two mutually orthogonal planes, of a continuous press of the plant of Figure 7;
- Figures 15-17 are schematic representations aimed at exemplifying operation of a system for lateral containment of the continuous press of Figures 13 and 14;
- Figure 18 is a vertical cross-sectional view of a lateral-containment member of the system of Figures 15-17, in a first condition, with the corresponding actuation and guide means, in a first operative condition;
- Figure 19 is a rear view in elevation of the containment member of Figure 18;
- Figure 20 is a view similar to that of Figure 18, in a second operative condition;
- Figure 21 is a schematic top plan view of a plurality of containment members of Figures 18-20;
- Figure 22 is a schematic representation of the layout of a second plant for the production of insulating panels according to the invention;
- Figures 23, 24 and 25 are a side view, a view from beneath, and a front view, respectively, of a shuttle used in the plant of Figure 22;
- Figures 26 and 27 are a side view and a top plan view, respectively, of first and second means for mutual coupling of two shuttles of the type represented in Figures 23-25;
- Figure 28 is a view similar to that of Figure 27, with the aforesaid coupling means in the respective operative or engaged condition;
- Figure 29 is a view similar to that of Figure 13, regarding a continuous press of the plant of Figure 22;
- Figures 30-33 are schematic sections that illustrate possible variant embodiments of insulating panels obtained according to the invention; and
- Figure 34 is a view similar to that of Figure 13, regarding a variant of continuous press for the plant of Figure 7.
Description of preferred embodiments of the invention
[0010] The reference to "an embodiment" or "one embodiment" in the context of the present description is intended to indicate that a particular configuration, structure, or characteristic described in relation to the embodiment is comprised in at least one embodiment. Hence, phrases such as "in an embodiment" or "in one embodiment" and the like, which may be present in various points of the present description, do not necessarily all refer to one and the same embodiment. Moreover, the particular configurations, structures, or characteristics can be combined in any adequate way in one or more embodiments. The references used in what follows are only provided for convenience and do not define the sphere of protection or the scope of the embodiments.
[0011] Represented in Figure 1 is a prefabricated insulating panel, obtained according to a possible preferred embodiment of the invention, for example, for the roofing of individual spans of buildings. The panel, designated as whole by 1, has a monolithic structure that comprises a lower length of sheet or plate 2, preferably but not necessarily made of metal material, and an upper length of sheet or plate 3 made of metal material. Set between the plates 2 and 3 is a layer or mass of insulating material 4. The layer 4 is preferably obtained starting from a chemical product - of a type in itself known in the sector - designed to expand to form a solid foam, such as, for example, a self-extinguishing polyurethane resin or a polyisocyanide foam or a foam containing flame retardant additives. The gluing capacity of the aforesaid expanded material can be advantageously exploited for fixing together the aforementioned components 2-4 of the panel 1 in order to obtain the aforesaid monolithic structure and thus prevent the need for welded or mechanical connections.
[0012] Identifiable in the panel 1 are two longitudinal ends, designated by S, and two side edges, designated by F and R, hereinafter defined as front and back, respectively, merely by way of reference according to the modalities of coupling between a number of panels. The panel 1 has a length L, understood as distance between the ends S, and a width W, understood as distance between the front F and the back R. At least the upper plate 3, and preferably also the lower plate 2, are corrugated; i.e., they have parallel ribs, which extend substantially throughout the length of the plates themselves, between the ends S. In this perspective, the plates 2 and 3 can be obtained via rolling from sheet metal, for example, of stainless or galvanized steel, or of aluminium or copper, possibly painted or subjected to other surface treatment. In the course of the profiling step, in the lower plate 2 parallel ribs can be defined, which are the same as one another, some of which are designated by 5 in Figure 3. Likewise, in the course of profiling of the upper plate 3, defined in the latter are longitudinal ribs projecting upwards, in such a way that the top surface of the panel 1 presents a recurrent pattern.
[0013] In the case exemplified (see Figure 2), the upper plate 3 envisages a plurality of deep ribs, some of which are designated by 6a, 6b, 6c, and a plurality of shallow ribs, some of which are designated by 7. Between two deep ribs there preferably extends a plurality of shallow ribs, in the same longitudinal direction. The presence of these deep and shallow ribs enables strengthening of the structure of the upper plate 3, and hence of the entire panel 1. Once again in order to strengthen the monolithic structure of the panel 1, as has been said, also the lower plate 2 can present a plurality of ribs 5 substantially parallel to one another and with respect to the front F and back R of the panel.
[0014] The front F and back R are shaped so as to enable waterproof juxtaposition between a number of similar panels 1. In particular, in the embodiment exemplified herein, the front F (or the back R) of one panel 1 can be coupled via overlapping on the back R (or on the front F) of another panel 1. In the embodiment exemplified, at the front F of the panel 1, the upper plate 3 is shaped to form part of a deep rib 6a, which is external to the space for containing the insulating mass 4. On the other side, at the back R of the panel 1, the upper plate 3 is shaped to define a deep rib 6b, designed for shape coupling with the rib 6a of another panel 1.
[0015] The concept is, for example, visible also in Figure 3, which is a schematic illustration of the step of superposition of the rib 6a of one panel 1 on the rib 6b of a different panel 1. Likewise, Figures 2 and 4 show, via a schematic cross-sectional view and a perspective view respectively, a number of panels 1 coupled in the way described. The final fixing between the panels 1 juxtaposed in the aforesaid way can be obtained with modalities and means in themselves known in the sector, for example, screws and U-bolts.
[0016] As represented only in Figure 2, the shape coupling between the front F and the back R of two different panels 1 can also include a longitudinal appendage (comprising, for example, a shaped portion of the rear edge of the lower plate 2) of one panel 1, which is to be coupled in a longitudinal recess defined in the face of the insulating mass 4 that is located at the front of another panel 1.
[0017] The panel 1 has at least one ridge region that extends between the front F and the back R. In the panels 1, the upper plate 3 defines, in parts opposite to the aforesaid ridge region, two opposite pitches, which are preferably straight or planar. In particular, as may be seen in the case exemplified in Figure 1, the plate 3 is shaped to define two inclined planes, designated by 10, which form the two aforesaid pitches, with the ridge region of the panel 1, designated by 11, that is defined in the intermediate area or area of transition between the two inclined surfaces 10.
[0018] In this way, the panel 1 has a generally substantially double plane-pitch configuration, and said shape, in addition to guaranteeing the necessary off-flow of water, enables the typical problems of curved panels of the type described previously to be overcome, in particular in order to render the surface treadable and/or guarantee robustness thereof and resistance to loads and/or facilitate installation thereon of additional units, such as photovoltaic modules. Obviously, the fact that the two pitches constituted by the surfaces 10 are obtained via deformation of one and the same sheet of material avoids the need to provide an additional ridge element.
[0019] The slope of at least one of the inclined surfaces 10, preferably of each inclined surface 10, is less than 25%. In the embodiment currently deemed preferential, said slope is comprised between approximately 3% and approximately 8%, preferably approximately 5-6%. The two inclined surfaces or pitches 10 can have one and the same slope and length, with respect to the ridge of the panel 1, as in the case of Figure 1: in other embodiments, on the other hand, it is possible to envisage slopes and/or lengths different from one another for the two pitches 10.
[0020] According to a preferred characteristic of the panels obtained in accordance with the invention, and unlike curved panels of a known type, the general development of the plate 2 in the longitudinal direction (i.e., between the two ends S) is different from the general development of the plate 3 in the longitudinal direction.
[0021] In the case of the embodiment of Figures 1 and 4, the lower plate 2 has a substantially straight general longitudinal development; i.e., it lies substantially in a plane. The upper plate 3 has, instead, a general longitudinal development that defines the two surfaces 10 that have opposite inclinations. In this embodiment, then, the panel 1 has, in cross section, an at least approximately triangular shape.
[0022] With this configuration, the thickness of the layer of insulating material 4 is variable starting from each end S up to the area corresponding to the ridge region 11; in particular, in the case exemplified, the thickness increases by a minimum, at the end S, to a maximum, in the ridge region 11. With this type of embodiment, the overall structure of the panel 1 is very sturdy and distinguished by an increased capacity to withstand loads. As compared to curved panels with parallel sheets, the panel 1 thus has also an insulating mass of increased thickness. The configuration of the bottom formed by the plate 2 presents the further advantage - in the installed condition of the panels - of reducing the internal space of the building that is to be heated in the cold seasons, as compared to a roofing obtained via the curved panels described previously. It will be appreciated that the same advantages highlighted above can be obtained also with a not exactly plane plate 2. In said perspective, the plate 2 could also be corrugated (albeit set according to a respective general substantially rectilinear plane), or again could be a slightly arched plate 2, with concavity facing upwards or downwards.
[0023] In the embodiment exemplified, the two inclined surfaces 10 defined by the upper plate 3 intersect at the ridge region 11, to define a ridge line 11a of the panel 1 (Figure 1). In other embodiments (not represented), the ridge region defined by the upper plate 3 cannot be cusp-shaped: in other words, the plate 3 can be bent in the production stage to define, for example, between the two inclined surfaces 10 an intermediate or transition area that is horizontal or an area with some other profile (see, by way of example, Figure 31).
[0024] As may be appreciated also from Figures 5 and 6, to the height D (distance out of fret between the lower plate 2 and the ridge 11a of the upper plate 3) and to the height E (distance out of fret between the upper plate 3 and the lower plate 2 in the end regions of the panel 1) there correspond different thicknesses of the insulating mass 4 that fills the gap between the two plates 2 and 3.
[0025] It should once again be noted how, in the preferred embodiment of the panels 1, the upper plate 3 is shaped so as to present, in the regions of the ends S, stretches S' that are angled with respect to the corresponding surfaces 10, which are preferably generally rectilinear and are substantially parallel to the lower sheet 2. In the example represented in the figures, the stretches S' project substantially in cantilever fashion outwards beyond the insulating mass 4 and the lower plate 2. The stretches S' can indicatively have a length of approximately 10 cm. The provision of these stretches S' in the two longitudinal end areas S is particularly advantageous in the course of production of the panel, in so far as it facilitates the operations of cutting of the plate 3 and enables drip mouldings for the panels 1 to be obtained.
[0026] The prefabricated insulating panels 1 obtained according to the invention are advantageously usable also for the top roofing of individual spans, i.e., of the space comprised between two parallel rests or load-bearing elements of a building, with each panel 1 set perpendicular to the aforesaid rests, i.e., with the end regions of the panels 1 that are supported by them.
[0027] The process of production of the panels according to the invention will now be described with reference to Figures 7-29. Figures 7-21 refer to a plant for implementing a first possible process of production of the panels 1, whilst Figures 22-29 refer to a plant for implementing a second possible process of production of the panels 1. As will emerge clearly hereinafter, the aforesaid first plant enables continuous production of panels 1, whilst the aforesaid second plant enables substantially continuous or semi-continuous production of panels 1.
[0028] With particular reference to Figure 7, designated by 100 and 101 are first feed means and second feed means, for continuously feeding the plant with a first continuous band and a second continuous band, preferably of metal material. The means 100 and 101 can be constituted by reels of a type commonly used in the sector. The aforesaid bands constitute a first sheet 102 and a second sheet 103 necessary for production of the panels 1: from the sheets 102 and 103 there are in fact obtained the plates 2 and 3 of each panel 1, as will emerge hereinafter.
[0029] Designated by 104 is a first roll forming machine, which is also of a conception known in the sector, provided for forming in the sheet 102 the ribs 5 (see Figure 2). Designated by 105 is a second roll forming machine, which is also of a conception known in the sector, provided for forming in the sheet 103 the ribs 6a, 6b, 6c and the ribs 7 (see again Figure 2). In the specific case, the roll forming machines 104 and 105 also constitute the means that enable longitudinal displacement of the two sheets 102 and 103 in the direction of advancement of the plant, designated by X in Figure 7. Also further roller-type or endless-loop members provided downstream of the roll forming machines 104 and 105 can contribute to the advance along the plant. As may be seen, the arrangement is such that the two sheets 102 and 103 travel in the direction of advancement X generally set on top of, and at a distance from, one another.
[0030] Designated by 110 is a bending station, where at least the sheet 103 is bent. Between the feed means 102, 103 and the bending station 110 there can, if necessary, be provided radiusing roller tracks, of a type in itself known, one of which is designated by 106 in Figure 7.
[0031] Provided in the station 110 are the bending means configured for bending the sheet 103 according to a bending line that extends between the two side edges of the sheet itself, and hence transverse to the direction of advancement X. This bending line, designated by 11' in some of the subsequent figures, is to form a ridge line of a panel 1.
[0032] In this embodiment, the bending means of the station 110 are configured for bending the sheet 103 while this is advancing in the direction of advancement X. For this purpose, a bending device is provided that is movable to and fro - i.e., in opposite senses - in the direction X, in particular from a first position to a second position in a first sense, and from the second position to the first position, in a second sense opposite to the first sense.
[0033] The concept is exemplified in Figures 8-11, where designated as whole by 111 is the bending device, basically comprising a top die 112 and a bottom counter-die 113, both mounted on a structure 114 - represented dashed - that is movable parallel to the direction of advancement X. Of course, the die and the counter-die have facing surfaces which have a ribbed profile congruent with that of the sheet 103 (which, as has been said, is provided with the ribs 6a-6c and 7).
[0034] Figure 8 illustrates the aforesaid first position, where the die 112 and the counter-die 113 are set at a distance, with the sheet 103 that advances between them in the direction X: in said condition, the structure 114 is stationary. When the control system of the bending station 110 governs approach between the die 112 and the counter-die 113, the structure 114 starts to translate in the direction X, in the same sense of advance as that of the sheet 103. Of course, the control parameters of the device 111, such as the speed of translation of the structure 114 and the speed of closing of the die and counter-die, are controlled according to the speed of advance of the sheet 103 and taking into account the yield envisaged for the sheet itself due to its bending.
[0035] The translation of the structure 114 proceeds slightly also after closing of the die and the counter-die (Figure 9), when the latter start to move away from one another, and until the sheet 103 provided with the bending line 11' is released, as may be seen in Figure 10. The structure 114 is located now in a second stationary position, advanced with respect to that of Figure 8, and from said second position it can be made to return towards the first position, as exemplified in Figure 11, ready for a new bending operation on the sheet 103.
[0036] The actuation means used to obtain translation of the structure 114 are not represented in Figures 8-11 in so far as they can be implemented according to modalities that appear obvious to the person skilled in the branch. For example, said actuation means can be of a type similar to that of actuation means already commonly used in plants for the production of traditional insulating panels, for translating in the direction of advancement - in opposite senses - a saw that makes the transverse cut in the bands and in the layer of insulating material.
[0037] To return to Figure 7, downstream of the bending station 110, the sheets 102 and 13 are guided - once again in a condition where they are generally superimposed and with modalities in themselves known - through a foaming station, designated as whole by 120, provided for applying on the surface of one of the sheets 102 and 103 a chemical product in substantially liquid form, designed to expand, once again while the sheets are advancing in the direction X. The aforesaid chemical product, once expanded, forms the insulating layer 4 of a panel 1 obtained according to the invention (see, for example, Figure 1). As mentioned previously, the material in question may, for example, be a polyurethane resin.
[0038] As exemplified in Figure 12, the station 120 comprises dispensing or spraying means 121, operative in the gap G defined between the two sheets; in the example represented, the aforesaid means 121 are designed to spray the chemical product 122 on the face of the sheet 103 that faces the sheet 102. Possibly, upstream of the station 120 a station can be provided for pre-heating the sheet 103 or both of the sheets 102 and 103.
[0039] The general configuration of the spraying means 121 can be of any type known in the sector. For example, said means 121 can comprise at least one substantially tubular dispenser, which extends in length in the direction of advancement X, as in the case exemplified, provided with nozzles for spreading the chemical product 122 on the aforesaid face of the sheet 103, and where said dispenser is movable in a reciprocating way between the two opposite side edges of the sheet itself. In another embodiment, the dispenser can instead extend in length in a direction transverse to the sheet 103 and be provided with nozzles for spreading the chemical product on the aforesaid face of the sheet between its two opposite side edges; in such an embodiment, the dispenser may possibly be translatable in opposite senses in the direction of advancement X.
[0040] It should be recalled that panels of a known type have a substantially constant thickness, and for this reason, in the production stage, the amounts of chemical product deposited is substantially constant or homogeneous, in the longitudinal direction of the corresponding sheet. As has been seen previously (see, for example, Figures 5 and 6), in a panel 1 obtained according to the invention the layer of insulating material has a variable thickness, starting from a minimum in a first longitudinal end area of the panel (Figure 6), up to a maximum in the intermediate region of the panel that includes the ridge region 11 (Figure 5), and then returns to a minimum in the second longitudinal end area of the panel 1.
[0041] According to a preferred characteristic, then, and irrespective of their specific embodiment, the spraying means 121 are provided for cyclically applying amounts of chemical product 122 that are variable in the longitudinal direction of the sheet 103 while this is advancing, between a minimum amount and a maximum amount. Preferably, the amounts of chemical product 122 dispensed during each cycle of application range from a first minimum amount, to a second maximum amount, to a third minimum amount, where namely:
- the first amount is applied substantially downstream of the bending line 11', or in an area of the sheet 103 corresponding to the first longitudinal end region of a panel 1 to be obtained;
- the second amount is applied substantially at the bending line 11', or in an area of the sheet corresponding to an intermediate area of the panel 1 to be obtained, which includes a respective ridge region; and
- the third amount is applied substantially upstream of the bending line 11', or in an area of the sheet corresponding to the second longitudinal end region of the panel 1 to be obtained.
[0042] Adjustment of the aforesaid amounts can be obtained in different ways, taking of course into account parameters such as the width of the sheet 103, its speed of advance, the type of spraying nozzles, and their distance from the sheet 102, the type of chemical product 122, etc.. For example, adjustment of the amounts can be varied by varying the flowrate or pressure of the chemical product 122 dispensed according to the area of application, or else - keeping the flowrate or pressure constant - by varying the speed of translation of the dispenser 121 between a minimum and a maximum according to the area of application (with a translation that is faster and slower in the areas that need a smaller and greater amount of chemical material, respectively).
[0043] To return to Figure 7, downstream of the foaming station 120, the sheets 102 and 13 are made to travel in a continuous press 130, at a substantially predefined distance from one another. Obtained within the continuous press 130 is expansion of the chemical material 122 applied on the sheet 103 so as to form the insulating layer 4 of the panels and obtain its adhesion to the sheets 102 and 103. The continuous press 130 is preferably contained in an environment kept at a substantially controlled temperature, according to a technique in itself known.
[0044] The press 130 is devised to contain expansion in height of the chemical material 122, i.e., to keep the sheets 102 and 103 at the substantially predetermined distance while the material itself expands in solid foam: these "vertical" containment means are represented schematically in Figure 13. The press 130 is moreover devised to contain expansion of the material 122 laterally in order to prevent it from coming out of the two sides of the gap G defined between the sheets 102 and 103: these "lateral" containment means are instead represented schematically in Figure 14.
[0045] As may be seen in Figure 13, the means designed to keep the two sheets 102 and 103 at the predefined distance basically comprise an upper contrast device 131 for the sheet 102, constituted, for example, by a motor-driven endless belt, of a conception generally known, and a lower contrast device 132 for the sheet 103.
[0046] Also the contrast device 132 has a structure substantially resembling that of a motor-driven endless belt: however, given the configuration of the sheet 103, which here presents a succession of V bends, said belt bears rests or contrast elements 133 shaped for forming between them, in the forward branch of the endless belt, a shape that is the negative of - i.e., is substantially complementary to - the portion of sheet 103 that includes the bending line 11' and the two respective opposite inclined stretches, upstream and downstream of said bending line, as may be clearly seen in Figure 13. Of course, the schematic representation of Figure 13 is merely provided by way of example of the conformation of the rests or contrast elements 133. Of course, moreover, the lower contrast device 132 is controlled in a co-ordinated way with respect to the stations that precede it, so that the aforesaid substantially complementary shape defined by the contrast elements 133 is found each time to be in the correct position for coupling with the variable profile of the sheet 103.
[0047] Figure 14 is a schematic representation according to a view orthogonal to the schematic cross-sectional view of Figure 13, and visible therein are the means designed to contain lateral expansion of the chemical material. Said means comprise two lateral contrast devices 135 and 136, which are also of a substantially endless-loop type and each of which bears a respective plurality of containment members 140 and 150. The lateral contrast devices 135 and 136 are arranged in such a way that, in the forward branch of the corresponding endless-loop path, the corresponding containment members 140 and 150 will be movable in the direction of advancement X, at the side edges of the two sheets 102 and 103. In this way, the containment members 140 and 150 occlude the gap between the two sheets laterally so as to stop lateral expansion of the chemical product that is expanding. It should be noted that, for the sake of clarity, represented in Figure 14 is just the sheet 103, the opposite side edges of which are designated by 103a and 103b; moreover represented in the figure are the ribs 6a, 6b and 6c of the sheet 103.
[0048] As has been seen previously, in the preferred embodiment of the panels obtained according to the invention, the upper plate 3 of a panel 1 (and hence the sheet 103) has, at a first longitudinal edge thereof, the rib 6a jutting out with respect to the mass of insulating material (see, for example, Figures 1-4): for this reason, according to one aspect of the invention, it is advantageous to envisage that, at the corresponding edge 103a of the sheet 103, the containment members 140 are translatable also in a substantially vertical direction, in opposite senses.
[0049] More in particular, the containment members 140 are mounted for so as to be able to move from a raised position towards a lowered position so as to be able to adapt to the variable profile of the edge 103a, and then return towards the raised position.
[0050] The concept is exemplified in Figure 15, where it may be seen how the containment members 140 are able to displace in the vertical direction Y in order to adapt their position in height to the V-shaped profile of the edge of the sheet 103, between a minimum and a maximum. It should be noted that for greater clarity, in said schematic figures (as in Figures 16 and 17), there are not been represented either the rib 6a or the transmission member that defines the endless-loop path of the containment members 140, and that the latter are represented slightly set at a distance from one another only in order to render representation thereof clearer: in actual fact, and as will be seen hereinafter, the members 140 are set up against one another in order to close the gap G between the sheets 102 and 103 laterally.
[0051] From Figures 15 and 16 it may be noted also how, in a preferred embodiment, there is provided a guide 151 for the members 140, which follows the return branch of the endless-loop path and has two end terminal portions 151a and 151b substantially at the start and at the end of the forward branch of said path, respectively. As will emerge clearly hereinafter, the guide 151, and in particular its end terminal portions 151a and 151b are shaped to define a cam surface aimed at facilitating entry of the members 140 within the rib 6a of the sheet 103 (portion 151a of the guide 151) and then their exit from said rib (portion 151b of the guide 151). Figure 16 is a schematic illustration of the side of the containment device 135 opposite to what is represented in Figure 15: as may be noted, the cam surface defined by the member 151 can extend substantially in one and the same plane, except for the two inclined portions designated by 151a and 151b in Figure 15.
[0052] Illustrated in Figures 18-21 is a possible embodiment of the containment members 140, with the corresponding transmission, support, and guide means.
[0053] In Figure 18, designated as whole by 160 is a stationary structure of the movable press 130, defined within which is a seat 161 for movement for an endless-loop transmission member 162, substantially in the form of a chain, driven by motor means. The chain 162 includes pins 162a, from which there branches off radially a corresponding arm 163, fixed at the ends of which is a bracket 164 for supporting a corresponding containment member 140. As may be seen also in Figure 19 (where just the member 140 with the corresponding bracket is illustrated), mounted idle on the bracket 164 is a bottom wheel 165, which can turn according to a substantially horizontal axis. The wheel 165 co-operates with a bottom rolling surface of a guide 166, fixed with respect to the structure 160, so as to guide the bracket 164 together with the transmission member 161 in a precise way.
[0054] The bracket 164 has, in its portions 164a and 164b generally parallel to the axis of rotation of the wheel 165, a through hole (not shown), slidably inserted in which is a corresponding vertical stem or rod 167, fixed with respect to the body 141 of the containment member 140 and mounted in a cavity 142 of the latter (see also Figure 18). The body 141 is preferably made of plastic or synthetic material.
[0055] The stem 167, which extends axially, is constrained, at the bottom end, to the body 141 and, at the top end, to a plate 143, fixed with respect to said body. The plate 143 supports laterally an upper wheel 170, which can turn along a respective substantially horizontal axis parallel to the axis of rotation of the lower wheel 165, as may be clearly seen also in Figure 19. From Figure 18 it may be seen how the upper wheel 170 co-operates with a top rolling surface of the guide member designated previously by 151, which, as has been said, substantially provides a cam surface.
[0056] Preferably, the containment member 140 is normally forced towards a respective lowered position, via a means for storing mechanical energy. In the example represented, a helical spring 171 fitted on the stem 167 is provided for this purpose. The ends of the spring 171 are set substantially bearing upon the bottom of the cavity 142 that houses the stem 167 and, on the other side, upon the portion 164a of the bracket 164 that has the hole for guiding the stem itself. As may be appreciated, then, the spring 171 is normally operative for forcing the member 140, and hence its body 141, towards the aforesaid lowered position.
[0057] In normal operation of the containment device 135 (Figure 14), the transmission member 161 moves along the corresponding endless-loop path, carrying with it the brackets 164 and hence the containment members 140. As has been seen, the movement is further guided by the lower wheels 165 and, in the upper part, by means of the wheels 170 that roll on the surface defined by the guide 151 (see also Figures 15 and 16). As has been said, this guide 151 is not completely an endless-loop guide, but has two end portions 151a and 151b, substantially corresponding to the initial and final parts of the forward branch of the endless-loop path, the descending one (151a) and the ascending one (151b) - see Figure 15.
[0058] In the course of advance of the sheets 102 and 103, as well as of the movement of the containment device 135, in the return stretch of the endless-loop path (Figure 16) the wheels 170 rest upon the plane or horizontal part of the guide 151, with the containment members 140 that are thus kept in the corresponding raised condition, countering the action of the corresponding springs 171. At a certain point, soon after start of the forward stretch of the looped path, the wheel 170 of a member 140 - which basically functions as cam-follower - engages the descending stretch 151a of the guide 151 (right-hand part of Figure 15), with the members 140 that can then start to drop progressively, forced in this by the action of the corresponding springs 171, towards the sheet 103, and more in particular towards its rib 6a - see also Figure 18. The dropping movement stops when the bottom end of the body 141 of the containment member 140 engages the rib 6a of the sheet 102, as is clearly exemplified in Figure 20. The member 140 then comes to bear upon the surface of the rib 6a and moves along with it in the direction X. The bottom end of the body 141 is preferably shaped for coupling with the required precision in the rib 6a; in the case exemplified, and as may be clearly seen in Figures 18 and 20, the fit is substantially a shape fit. Of course, the shape of the body 141 may also be different from the one exemplified.
[0059] As may be seen, thanks to this configuration, the containment members 140 can adapt their position in height to the variable profile of the edge 103a of the sheet 103, which here includes the rib 6a and, in the specific case, has a general V-shaped configuration. Consequently, once again with reference to the specific case represented, the containment members 140 enable compensation also of the different distance between the sheets 102 and 103. Obviously, in any case, the height of the members 140 - at least in their front containment face - will be at least equal to the maximum distance between the two sheets 102 and 103.
[0060] Practically, at the end of the forward branch of the endless-loop path, the wheels 170 engage the ascending stretch 151b of the guide member 151 (left-hand part of Figure 15), thus starting the corresponding raising, from beneath upwards. Once the ascending stretch 105b is completed, the wheels 170 return onto the plane part of the guide member 151, and hence into the initial raised position, and then traverse the return branch of the endless-loop path (Figure 16).
[0061] Figure 15 evidently illustrates an example of one of the possible conditions of relative positioning between the members 140 and the sheet 103, where the bending line 11' is located substantially in a central area of the forward branch of the looped path of the lateral containment device 135. It is on the other hand evident that, given the movement in the direction of advancement of the members 140 and their possibility of vertical translation, they can adapt continuously to the profile of the edge 103a of the sheet 103, i.e., of the rib 6a: Figure 17 illustrates, once again by way of example, a different condition that can be assumed by a lateral containment device 135 (here represented slightly more extended in the longitudinal direction) in the course of advance of the sheet 103.
[0062] As mentioned previously, the containment members 140 are preferably set up against one another, as may be seen in Figure 21, in order to provide for closing of the gap existing between the sheets 102 and 103 within the part of the press 130 involved. In a possible embodiment, the body 141 of each member 140 is shaped for lateral coupling, preferably substantially by a shape coupling, with the body 141 of the elements adjacent thereto.
[0063] To return to Figure 7, after passage through the continuous press 130, the two sheets 102 and 103, with the material 122 which is by now expanded and substantially solidified between them (so as to provide the insulating mass 4), pass into a cutting station, designated as whole by 180. Said station is of a conception in itself known in the sector and devised for executing the cutting operation while the sheets 102 and 103 continue to advance. As already mentioned previously, for said purpose, the cutting device that carries out the operation (for example, including a disk saw) can be mounted on a corresponding movable structure of a conception similar to the one designated previously by 114 in relation to the bending device of Figures 8-11, i.e., translatable to and fro in the direction of advancement X.
[0064] As has been seen, in the preferred embodiment, the longitudinal end regions S of the panels 1 comprise a stretch S' of plate 3 that is angled with respect to the two opposite pitches 10 and is substantially parallel to the lower plate 2 and set in cantilever fashion with respect to the insulating mass (see Figures 1, 3 and 4). For this purpose, the bending station 110 will evidently be provided so as to enable definition of the aforesaid stretches S'. In the course of the operation executed in the station 180 there will then be carried out two distinct cutting operations, namely a first transverse cut that will regard only the sheet 102 and the prevalent part of the thickness of the insulating mass 4, and a second transverse cut - parallel to the first - that will regard the two sheets 102 and 103, as well as the insulating mass 4: thanks to the second cut there may be removed the lengths in excess of the sheet 102 and of the insulating mass 4 in order to obtain the stretches that jut out S' of the upper plate 3 of each panel. The cutting device can possibly also comprise one or more blades, movable in a direction perpendicular to the direction of advancement for cutting the part of insulating mass 4 present in the ribs 6b-6c substantially along the second cut.
[0065] Downstream of the cutting station 180, the panels, which have by now been formed, finally reach an unloading station, designated by 190 in Figure 7, of a conception in itself known.
[0066] The plant and the methodology described above with reference to Figures 7-21 enable continuous production of the panels 1, in an extremely fast and efficient way. The general structure of the plant is to a large extent of a classic type widely known in the sector, such as to require only modifications - and hence investments - on a traditional plant that are relatively contained, basically limited to the provision of the bending station, the modalities of control of the foaming station, and the adaptation of the continuous press.
[0067] Figures 22-28 regard a second possible embodiment of a plant for the substantially continuous or semi-continuous production of panels 1. As will emerge clearly hereinafter, in fact, in said plant the sheet 102 is fed continuously, whilst the other sheet is fed in the form of a succession of lengths, substantially corresponding to the upper plates 3 of the individual panels to be obtained.
[0068] In this embodiment, the lengths of sheet corresponding to the plates 3 are provided and bent upstream of the plant represented in Figure 22, via a roll forming machine and a bending machine of a known conception, and hence not represented. The feed means 102 of the plant of Figure 7 are consequently not necessary and are instead replaced by a station for feeding the lengths, designated as whole by 202.
[0069] In said station 202 the individual lengths 3 of ribbed and bent sheet are loaded on corresponding shuttles, one of which is represented in different views in Figures 23-25, where it is designated as whole by 210.
[0070] Basically, each shuttle 210 comprises a supporting structure or frame 211, preferably made of metal material, which in the example has a generally rectangular shape. The frame supports a shaping body 212, for example, made of plastic material, such as polystyrene, the top face of which is shaped in a way substantially complementary to the profile of the lengths of sheet 3, and hence includes at least two inclined surfaces that meet in a bottom point, corresponding to the ridge line 11 of a plate 3, as may be clearly seen in Figure 23. Of course, the shaping body 212 also has longitudinal grooves 212a, which have a position and dimensions congruent with the ribs 6a-6c and 7 of the plate 3, as may be clearly seen in Figure 25.
[0071] The shuttles are devised for being engaged to one another in succession and, for said purpose, are provided at the opposite longitudinal ends with mutual-coupling means. In particular, in the example represented, provided at a first end of the frame 211 are first coupling means 220, which are able to be engaged in a releasable way to second coupling means 230 provided at the opposite longitudinal end. In effect, hence, a plurality of shuttles 210 can be engaged in succession, in order to reproduce a continuous feed of the plant of Figure 22.
[0072] A possible embodiment of the aforesaid coupling means between two shuttles 210 is exemplified in Figures 26-28.
[0073] In the example, the first coupling means basically consist of a fixed pair of teeth 220 projecting at the front from the frame 211, each tooth defining a respective inclined plane 220a. The second coupling means 230 basically consist of a pair of fixed brackets 231, projecting at the rear from the frame 211, in positions substantially homologous to those of the teeth 220.
[0074] Each bracket 231 of a shuttle 210 supports in a rotatable way, via a vertical pin 232, a lever 233, which is here substantially L-shaped. Provided at the distal ends of the arm 233a of the lever 233 is a vertical pin 234, which can engage the inclined surface 220a of a respective tooth 220 of another shuttle 210, for the purposes of mutual coupling, as described hereinafter. Engaged to the second arm 233b of the lever 233 is the first end of a spring 235, the second end of which is connected to the frame 211. The spring 235 is operative for keeping the lever 233 bearing upon a contrast element 236 carried by the bracket 231, in a normally closed condition, i.e., with the arm 233a substantially parallel to the tooth 220. As may be noted in Figures 27 and 28, preferably the distal end of the arm 233b projects laterally with respect to the frame 211.
[0075] For the purposes of coupling it is sufficient to push one shuttle 210 towards a previous shuttle 210, with the coupling means 220 facing the coupling means 230. In this way, each inclined surface 220a of a tooth 220 is in contact with the respective pin 234, first determining angular movement of the lever 233, countering the action of the spring 235. Once the inclined surface 220a has passed beyond the pin 234, the lever 233 can return to the initial position, by virtue of the action of the spring 235, with the pin itself that is engaged by the tooth 220. In this way, the two shuttles are engaged to one another.
[0076] The shuttles engaged in succession in the aforesaid way are then made to advance from the station 202 of the plant of Figure 22, in the direction of advancement X. The advance is motor-driven in an appropriate way, for example, by providing a roller track or a motor-driven conveyor suitable for pushing the shuttles 210 in the plant, at a substantially constant rate.
[0077] The sheet 102 and the plates 3 carried by the shuttles 210 thus advance, on a suitable roller track or conveyor, through the foaming station 120, where the chemical product, which is designed to expand according to modalities similar to the ones already described previously, is applied on the plate 3.
[0078] Next, the sheet 102 and the succession of plates 3 carried by the shuttles 210 pass into the continuous press 130, to bring about expansion and consolidation of the chemical material. As compared to the previous embodiment, the lower contrast device 132 of Figure 13 can be replaced by a simple conveyor or roller track, designed to sustain the shuttles 210, whilst the latter travel, with the plates 3 at the predefined distance from the sheet 102, whilst the upper contrast device may be similar to the one designated by 131 in Figure 13. Such an embodiment is exemplified in Figure 29. It will be appreciated that the lateral-containment means will be similar to the ones already described previously with reference to Figures 14-17.
[0079] As has been seen, in this embodiment the plates 3 are separated from one another so that, in view of the operation of foaming and subsequent passage through the press 130, it is preferable to occlude the gap G on the side of the plates themselves. For this purpose, in the example shown in Figure 29, between the facing edges of two plates 3 carried by two successive shuttles (i.e., substantially in the facing stretches S' of the two plates - see Figure 1) an adhesive tape is applied in a transverse direction, in the area designated by 3a. This operation can be performed, for example, in the loading station 202. Alternatively, the shuttles 210 can be configured in such a way that, following upon the corresponding coupling, the facing stretches S' of two successive plates 3 partially overlap.
[0080] At exit from the continuous press 130, the upper sheet will be rendered fixed, via the insulating mass formed by the expanded material, with respect to the plates 3 carried by the shuttles 210, and then reaches the cutting station 180. In said station, given that the plates 3 are already separated from one another, just cutting of the sheet 102 and of a corresponding part of insulating material 4 will be performed, as has already been mentioned previously in relation to the first embodiment, in order to obtain the portions that jut out in cantilever fashion S' of the plate 3, for the longitudinal ends of the panels 1. Also in this case, the cutting device can comprise one or more blades for cutting the part of insulating mass 4 present in the ribs 6b-6c substantially along the aforesaid cut.
[0081] Next, the panels 1 which are by now formed reach the unloading station 190, where they will then be picked up from the corresponding shuttles 210. The latter will then be sent back to the loading station 202 of the plant. It will be appreciated that loading of the lengths 3 on the shuttles 210 and corresponding entry into the plant can be carried out in an automated way, for example, using carousel systems. Likewise, also return of the shuttles 210 to the input station 202 after unloading of the panels 1, as represented schematically by the arrow Z of Figure 22, can be conveniently automated.
[0082] Preferably, the shuttle-conveying system 210 is prearranged so as to include means for obtaining automatic uncoupling between one shuttle and another, in particular in the unloading station 190. Advantageously, in one embodiment, said uncoupling means comprise the levers 233.
[0083] As has been seen previously (Figures 27-28), the distal ends of the arms 233b of the levers 233 project at least slightly on the two sides of the frame 211 of the shuttles 210: in this way, practically at the end of advance of a shuttle at the unloading station 190, said projecting ends will come into contact with a respective fixed contrast surface. In this way, an angular movement - in a counterclockwise direction, in the case exemplified with a thin line in Figure 27 - of opening of each lever 233 is obtained, such as to release the pin 234 from the tooth 220. The shuttle 210 downstream will be consequently uncoupled from the shuttle upstream and may be brought back into the loading station 202, for example, in an automated way along the line Z.
[0084] It may be appreciated how the plant and the methodology described above with reference to Figures 22-28 will enable substantially continuous production - or semi-continuous production - of the panels 1 according to the invention, in an extremely fast and efficient way. Also in this case, the general structure of the plant can be of a classic type, obviously except for the limited adaptations necessary, basically consisting of the provision of the loading station for the shuttles 210, of the system that determines advance thereof along the plant and the possible automated return, of the adaptation of the control of the foaming station, and of the adaptation of the continuous press. The means for rib and bending the lengths 3 are, as has been said, of any type in itself known normally present in any plant for the production of fretted panels and metal sheets.
[0085] From the foregoing description, the characteristics and advantages of the present invention consequently emerge clearly. It is clear that numerous variations may be made the person skilled in the art to the processes, plants, and panels described herein merely by way of example, without thereby departing from the scope of the invention as defined by the annexed claims.
[0086] The invention has been described previously with particular reference to panels which have an approximately triangular section, i.e., where the upper plate 3 defines a single ridge line and two substantially plane inclined surfaces (apart from ribs), whilst the lower plate is substantially plane and horizontal. It will be appreciated, however, that, thanks to the teachings of the present invention, the processes and plants can be conveniently adapted for obtaining panels of shapes and sizes different from the one represented. Some of the innumerable embodiments that can be obtained are illustrated by way of example in Figures 30-33.
[0087] Figure 30 illustrates the case of a panel 1 where two opposite pitches 10 of the upper plate 3 have different lengths and slopes, as already mentioned previously. Once again as has already been mentioned, Figure 31 illustrates the case of a panel in which there is provided a ridge region 11 or region of transition between two pitches 10 which does not present a cusp, but is generally flattened and hence defined via two parallel bending or ridge lines; obviously the region 22 could also have other shapes, for example, arched.
[0088] Figure 32 illustrates the case of a panel 1, the upper plate 3 of which is generally curved or arched. Of course, in this case there is not envisaged a single bending line, but the plate 3 is in any case bent to define a ridge line or region 11 and two opposite pitches 10. Said shape of the plate 3 can, for example, be obtained via calendering, according to known modalities.
[0089] Figure 33 illustrates the case of a panel 1, the top sheet 3 of which is shaped so as to present two ridge lines 11, each defining two respective inclined opposite pitches 10, here substantially planar.
[0090] It will be appreciated that the invention, and in particular the lateral-containment system proposed, enables the embodiments exemplified above, as well as others still, to be obtained in a convenient way by virtue of the possibility of adaptation of the system itself to the variable lateral profiles of the plates of the panel.
[0091] In the embodiment exemplified, the sheet 103 is made to advance underneath the sheet 102, but it will be appreciated that the arrangement could be reversed, with kinematic adaptations and reversal of the components described previously, which are evident for a person skilled in the art.
[0092] In the embodiment exemplified in Figures 18-20, regarding the lateral-containment means, the containment members 140 are carried and guided individually - i.e., one by one - by the transmission member 162-163 and by the cam surface defined by the guide 151. It will be appreciated, however, that in possible variants one and the same bracket 164 can be configured for supporting in a vertically translatable way a plurality of members 140, for example, two or three; in such a perspective, for example, one such bracket could comprise a plurality of pairs of portions 164a-164b, each pair being configured for coupling with the stem 167 of a respective member 140.
[0093] Finally, it will be appreciated that the system of shuttles described previously with reference to the embodiment of Figures 22-29 may be advantageously used also in the case of the continuous plant illustrated in Figures 7-21, and in particular in relation to the continuous press 130. Such an embodiment is exemplified in Figure 34.
[0094] Basically, in accordance with this embodiment, before the continuous sheet 103, already provided with the bending lines 11', enters the continuous press 130, at the bottom thereof the shuttles 210 are guided in a co-ordinated way according to the profile of the sheet itself. In this way, the bent sheet 103 is supported and kept at the correct distance from the sheet 102.
[0095] As may be appreciated, said technical solution is conceptually similar to that of Figure 29: the lower contrast device 132 of Figure 13 can then be replaced by a simple conveyor or roller track, designed to sustain the shuttles 210 whilst these travel, with the sheet 103 at the predefined distance from the sheet 102; the upper contrast device may be similar to the one already designated by 131 in Figure 13. Also in this case, the lateral-containment means will be similar to the ones already described previously with reference to Figures 14-17.
a) longitudinally advancing two sheets (102, 103; 102, 3) in a direction of advancement (X), generally superimposed to each other so as to define a gap (G) therebetween, wherein at least one first sheet (103; 3) is shaped so as to define one respective longitudinal rib (6A, 6B) at at least one of its two opposite side edges (103a, 103b),
b) applying on the surface of a sheet (103; 3) that faces the other sheet (102) a chemical product (122) capable of expanding, while the sheets (102, 103; 102, 3) are advancing in the direction of advancement (X),
c) causing expansion of the chemical product (122) while the sheets (102, 103; 102,
3) are advancing in the direction of advancement (X), such that the expanded chemical
product (4) fills the gap (G) between the two sheets (102, 103; 102, 3),
wherein step c) comprises the operation of occluding the gap (G) at the side edges
(103a, 103b) of the two sheets (102, 103; 102, 3) for laterally containing expansion
of the chemical product (122), while the sheets are advancing in the direction of
advancement (X), the operation of occluding the gap (G) being carried out at at least
one first side edge (103a) of the sheets (102, 103; 102, 3) by means of a succession
of containment members (140) which are movable in the direction of advancement (X),
the process being characterized in that, prior to step c), at least the first sheet (103; 3) is bent to define at least one
ridge line (11, 11') that extends substantially orthogonal between the two respective
side edges (103a, 103b), the profile of the side edges (103a, 103b) of the first sheet
(103; 3) thus being variable, and in that the operation of occluding the gap (G) is carried out by means of containment members
(140) that are displaceable also in a generally vertical direction (Y), in opposite
senses, the containment members (140) being movable from above down and from below
up, or vice-versa, for adapting the position thereof to the profile of the first side
edge (103a) of the first sheet (103; 3).
- the first amount being applied substantially downstream of the ridge line (11, 11') or in an area of the sheet (103; 3) corresponding to a first longitudinal end region of a panel (1) to be obtained,
- the second amount being applied substantially at the ridge line (11, 11') or in an area of the sheet (103; 3) corresponding to an intermediate region of the panel (1) to be obtained,
- the third amount being applied substantially upnstream of the ridge line (11, 11') or in an area of the sheet (103; 3) corresponding to a second longitudinal end region of the panel (1) to be obtained.
- the two sheets (102, 103) consist of continuous bands,
- the band (103) constituting the first sheet is bent to define the ridge line (11') prior to step c) while the same band is advancing in the direction of advancement (X) and, after step c),
- the two bands (102, 103) and the expanded chemical product (4) are cut in a direction transverse to the direction of advancement (X).
- the second sheet consists of a continuous band (102),
- the first sheet (3) consists of a plurality of lengths of band which are fed in succession in the direction of advancement (X) and, after step c),
- the continuous band (102) and the expanded chemical product (4) are cut in a direction transverse relative to the direction of advancement (X).
- each length of band (3) is bent according to the ridge line (11') prior to step a),
- each bent lengths of band (3) is loaded onto a respective movable supporting member (210), a number of movable supporting members (210) being coupled in succession for being fed in the direction of advancement (X).
a) means of advancement (104-16, 131-132, 135-136; 104, 202, 106, 130, 210), for longitudinally advancing two sheets (102, 103; 102, 3) in a direction of advancement (X), with the two sheets (102, 103; 102, 3) which are generally superimposed so as to define a gap (G) therebetween, wherein at least one first sheet (103; 3) is shaped so as to define a longitudinal rib (6a, 6b) at at least one of its two opposite side edges (103a, 103b),
b) dispensing means (120) for applying on a surface of a sheet (103; 3) that faces the other sheet (102) a chemical product (122) designed to expand, while the sheets (102, 103; 102, 3) are advancing in the direction of advancement (X),
c) a continuous press (130), to cause expansion of the chemical product (122) while
the sheets (102, 103; 102, 3) are advancing in the direction of advancement (X), such
that the expanded chemical product (4) fills the gap (G) between the two sheets (102,
103; 102, 3),
wherein the continuous press (130) comprises a first lateral containment device (135)
and a second lateral containment device (136) which are movable in the direction of
advancement (X) at the side edges (103a, 13b) of the two sheets (102, 103; 102, 3),
and are designe dto occlude the gap (G) for laterally containing the expansion of
the chemical product (122) while the sheets are advancing in the direction of advancement
(X), at least one first lateral containment device (135) being of the closed-loop
type and carrying a respective plurality of containment members (140),
the plant being characterized by comprising bending means (111) upstream of the continuous press (130), for bending
at least the first sheet (103; 3) in order to define therein at least one ridge line
(11, 11') that extends substantially orthogonal between the respective two side edges
(103a, 103b), the profile of the side edges (103a, 103b) thus being variable, and in that the containment members (140) carried by the first lateral containment device (135)
are mounted displaceable in a substantially vertical direction (Y), in opposite senses,
the containment members (140) being movable from above down and from below up, or
vice-versa, for adapting the position thereof to the profile of the first side edge
(103a) of the first sheet (103; 3).
- feed means (100, 101), for feeding substantially countinuously two continuous bands (102, 103), which constitute the first and the second sheet, and cutting means (180), downstream of the continuous press (130), for cutting the two bands (102, 103) and the expanded chemical product (4) in a direction transverse to the direction of advancement (X), the bending means comprising in particular a bending device (111) which is movable to-and-fro in the direction of advancement (X), and
- first feed means (100), for feeding substantially continuously a continuous band (120), which constitutes the second sheet, second feed means (202, 2010), for feeding in succession a plurality of lengths of bands (3) that constitute the first sheet, and cutting means (180), downstream of the continuous press (130), for cutting the continuous band (120) and the expanded chemical product (4) in a direction transverse to the direction of advancement (X).
a) Fortbewegen in Längsrichtung in einer Bewegungsrichtung (X) zweier Bleche (102, 103; 102, 3), die im wesentlichen einander derart überlagern, dass sie einen Zwischenraum (G) zwischen sich bilden, wobei wenigstens ein erstes Blech (103; 3) derart geformt wird, dass es eine entsprechende Längsrippe (6A, 6B) an wenigstens einem seiner beiden gegenüberliegenden Seitenränder (103a, 103b) bildet,
b) Aufbringen auf die Oberfläche eines Bleches (103; 3), das dem anderen Blech (102) gegenüberliegt, eines chemischen Produktes (122), das in der Lage ist, sich auszudehnen, während sich die Bleche (102, 103; 102, 3) in der Bewegungsrichtung (X) fortbewegen,
c) Bewirken einer Ausdehnung des chemischen Produktes (122), während sich die Bleche
(102, 103; 102, 3) in der Bewegungsrichtung (X) fortbewegen, so dass das ausgedehnte
chemische Produkt (4) den Zwischenraum (G) zwischen den beiden Blechen (102, 103;
102, 3) füllt,
wobei der Schritt c) den Vorgang des Verschließens des Zwischenraumes (G) an den Seitenrändern
(103a, 103b) der beiden Bleche (102, 103; 102, 3) für das seitliche Fassen der Ausdehnung
des chemischen Produktes (122) umfasst, während sich die Bleche in der Bewegungsrichtung
(X) fortbewegen, und der Vorgang des Verschließens des Zwischenraumes (G) an wenigstens
einem ersten Seitenrand (1 03a) der Bleche (102, 103; 102, 3) mit Hilfe einer Abfolge
von Einfassungselementen (140) ausgeführt wird, die in der Bewegungsrichtung (X) beweglich
sind, und
der Vorgang dadurch gekennzeichnet ist, dass vor Schritt c) wenigstens das erste Blech (103; 3) derart gebogen wird, dass es wenigstens
eine Firstlinie (11, 11') bildet, die sich im wesentlichen orthogonal zwischen den
beiden entsprechenden Seitenrändern (103a, 103b) erstreckt, wodurch das Profil der
Seitenränder (103a, 103b) des ersten Bleches (103; 3) variabel ist, und dass der Vorgang
des Verschließens des Zwischenraumes (G) mit Hilfe von Einfassungselementen (140)
ausgeführt wird, die ebenfalls in einer im wesentlichen vertikalen Richtung (Y) in
entgegengesetzten Richtungen verschiebbar sind und die Einfassungselemente (140) von
oben nach unten und von unten nach oben oder umgekehrt beweglich sind, um die Position
derselben an das Profil des ersten Seitenrandes (103a) des ersten Bleches (103; 3)
anzupassen.
- die erste Menge im wesentlichen stromabwärts von der Firstlinie (11, 11') oder in einem Bereich des Bleches (103; 3) aufgebracht wird, der einem ersten Längsendbereich eines Paneels (1) entspricht, das zu erzeugen ist,
- die zweite Menge im wesentlichen an der Firstlinie (11, 11') oder in einem Bereich des Bleches (103; 3) aufgebracht wird, der einem Zwischenbereich des Paneels (1) entspricht, das zu erzeugen ist, und
- die dritte Menge im wesentlichen stromaufwärts von der Firstlinie (11, 11') oder in einem Bereich des Bleches (103; 3) aufgebracht wird, der einem zweiten Längsendbereich des Paneels (1) entspricht, das zu erzeugen ist.
- die beiden Bleche (102, 103) aus kontinuierlichen Bahnen bestehen,
- die Bahn (103), die das erste Blech bildet, gebogen wird, um die Firstlinie (11') vor Schritt c) zu bilden, wobei sich diese Bahn in der Bewegungsrichtung (X) fortbewegt, und nach Schritt c)
- die beiden Bahnen (102, 103) und das ausgedehnte chemische Produkt (4) in einer Richtung quer zu der Bewegungsrichtung (X) geschnitten werden.
- das zweite Blech aus einer kontinuierlichen Bahn (102) besteht,
- das erste Blech (3) aus einer Vielzahl von Längen der Bahn besteht, die nacheinander in der Bewegungsrichtung (X) zugeführt werden, und nach Schritt c)
- die kontinuierliche Bahn (102) und das ausgedehnte chemische Produkt (4) in einer Richtung quer relativ zu der Bewegungsrichtung (X) geschnitten werden.
- jede Länge der Bahn (3) in Übereinstimmung mit der Firstlinie (11') vor Schritt a) gebogen wird und
- jede der gebogenen Längen der Bahn (3) auf ein entsprechendes bewegliches Trägerelement (210) geladen wird, wobei eine Anzahl beweglicher Trägerelemente (210) aufeinanderfolgend verbunden wird, um in der Bewegungsrichtung (X) zugeführt zu werden.
a) eine Fortbewegungseinrichtung (104-16, 131-132, 135-136; 104, 202, 106, 130, 210) für die Fortbewegung zweier Bleche (102, 103; 102, 3) in Längsrichtung in einer Bewegungsrichtung (X), wobei die beiden Bleche (102, 103; 102, 3) einander im wesentlichen überlagern, um zwischen sich einen Zwischenraum (G) zu bilden, und wenigstens ein erstes Blech (103; 3) derart geformt wird, dass es eine Längsrippe (6a, 6b) an wenigstens einem seiner beiden gegenüberliegenden Seitenränder (103a, 103b) bildet,
b) eine Ausgabeeinrichtung (120) zum Aufbringen auf eine Oberfläche eines Bleches (103; 3), das dem anderen Blech (102) zugewandt ist, eines chemischen Produktes (122), das dazu eingerichtet ist, sich auszudehnen, während sich die Bleche (102, 103; 102, 3) in der Bewegungsrichtung (X) fortbewegen,
c) eine kontinuierliche Presse (130), um eine Ausdehnung des chemischen Produktes
(122) zu bewirken, während sich die Bleche (102, 103; 102, 3) in der Bewegungsrichtung
(X) fortbewegen, so dass das ausgedehnte chemische Produkt (4) den Zwischenraum (G)
zwischen den beiden Blechen (102, 103; 102, 3) füllt,
wobei die kontinuierliche Presse (130) eine erste seitliche Einfassungsvorrichtung
(135) und eine zweite seitliche Einfassungsvorrichtung (136) umfasst, die in der Bewegungsrichtung
(X) an den Seitenrändern (103a, 13b) der beiden Bleche (102, 103; 102, 3) beweglich
und dazu eingerichtet sind, den Zwischenraum (G) zu verschließen, um die Ausdehnung
des chemischen Produktes (122) seitlich einzufassen, während sich die Bleche in der
Bewegungsrichtung (X) fortbewegen, wobei wenigstens eine erste seitliche Einfassungsvorrichtung
(135) von dem Typ eines geschlossenen Kreises ist und eine entsprechende Vielzahl
von Einfassungselementen (140) befördert,
wobei die Anlage dadurch gekennzeichnet ist, dass sie Biegeeinrichtungen (111) stromaufwärts der kontinuierlichen Presse (130) zum
Biegen wenigstens des ersten Bleches (103; 3) umfasst, um in diesem wenigstens eine
Firstlinie (11, 11') zu bilden, die sich im wesentlichen orthogonal zwischen den entsprechenden
beiden Seitenrändern (103a, 103b) erstreckt, wodurch das Profil der Seitenränder (103a,
103b) variabel ist, und dass die Einfassungselemente (140), die von der ersten seitlichen
Einfassungsvorrichtung (135) befördert werden, verschiebbar in einer im wesentlichen
vertikalen Richtung (Y) in entgegengesetzten Richtungen angebracht sind und die Einfassungselemente
(140) von oben nach unten und von unten nach oben oder umgekehrt beweglich sind, um
deren Positionen an das Profil des ersten Seitenrandes (130a) des ersten Bleches (103;
3) anzupassen.
- eine Zuführeinrichtung (100, 101) zum im wesentlichen kontinuierlichen Zuführen zweier kontinuierlicher Bahnen (102, 103), die das erste und das zweite Blech bilden, und Schneideinrichtungen (180) stromabwärts der kontinuierlichen Presse (130) zum Schneiden der beiden Bahnen (102, 103) und des ausgedehnten chemischen Produktes (4) in einer Richtung quer zu der Bewegungsrichtung (X), wobei die Biegeeinrichtungen insbesondere eine Biegevorrichtung (111) umfassen, die in der Bewegungsrichtung (X) hin- und herbewegt werden kann, und
- erste Zuführeinrichtungen (100) zum im wesentlichen kontinuierlichen Zuführen einer kontinuierlichen Bahn (120), die das zweite Blech bildet, zweite Zuführeinrichtungen (202, 2010) zum aufeinanderfolgenden Zuführen einer Vielzahl von Längen von Bahnen (3), die das erste Blech bilden, und Schneideinrichtungen (180) stromabwärts der kontinuierlichen Presse (130) zum Schneiden der kontinuierlichen Bahn (120) und des ausgedehnten chemischen Produktes (4) in einer Richtung quer zu der Bewegungsrichtung (X).
a) faire avancer longitudinalement deux feuilles (102, 103 ; 102, 3) dans une direction d'avancement (X), généralement superposée entre elles afin de définir un espace (G) entre elles, dans lequel au moins une première feuille (103 ; 3) est formée afin de définir une nervure longitudinale (6A, 6B) respective au niveau d'au moins l'un de ses deux bords latéraux opposés (103a, 103b),
b) appliquer, sur la surface d'une feuille (103 ; 3) qui fait face à l'autre feuille (102), un produit chimique (122) capable de subir une expansion, alors que les feuilles (102, 103 ; 102, 3) avancent dans la direction d'avancement (X),
c) provoquer l'expansion du produit chimique (122) alors que les feuilles (102, 103
; 102, 3) avancent dans la direction d'avancement (X), de sorte que le produit chimique
expansé (4) remplit l'espace (G) entre les deux feuilles (102, 103 ; 102, 3),
dans lequel l'étape c) comprend l'étape consistant à boucher l'espace (G) au niveau
des bords latéraux (103a, 103b) des deux feuilles (102, 103 ; 102, 3) pour contenir
latéralement l'expansion du produit chimique (122), alors que les feuilles avancent
dans la direction d'avancement (X), l'étape consistant à boucher l'espace (G) étant
réalisée au niveau d'au moins un premier bord latéral (103a) des feuilles (102, 103
; 102, 3) au moyen d'une succession d'éléments de confinement (140) qui sont mobiles
dans la direction d'avancement (X),
le procédé étant caractérisé en ce que, avant l'étape c), au moins la première feuille (103 ; 3) est pliée afin de définir
au moins une ligne de faîte (11, 11') qui s'étend sensiblement de manière orthogonale
entre les deux bords latéraux (103a, 103b) respectifs, le profil des bords latéraux
(103a, 103b) de la première feuille (103 ; 3) étant ainsi variable, et en ce que l'étape consistant à boucher l'espace (G) est réalisée au moyen d'éléments de confinement
(140) qui sont déplaçables également dans une direction généralement verticale (Y),
dans des sens opposés, les éléments de confinement (140) étant mobiles de haut en
bas et de bas en haut ou vice-versa, pour adapter leur position au profil du premier
bord latéral (103a) de la première feuille (103 ; 3).
- la première quantité qui est appliquée sensiblement en aval de la ligne de faîte (11, 11') ou dans une zone de la feuille (103 ; 3) correspondant à une première région d'extrémité longitudinale d'un panneau (1) à obtenir,
- la deuxième quantité qui est appliquée sensiblement au niveau de la ligne de faîte (11, 11') ou dans une zone de la feuille (103 ; 3) correspondant à une région intermédiaire du panneau (1) à obtenir,
- la troisième quantité qui est appliquée sensiblement en amont de la ligne de faîte (11, 11') ou dans une zone de la feuille (103 ; 3) correspondant à une seconde région d'extrémité longitudinale du panneau (1) à obtenir.
- les deux feuilles (102, 103) se composent de bandes continues,
- la bande (103) constituant la première feuille est pliée pour définir la ligne de faîte (11') avant l'étape c) alors que la même bande avance dans la direction d'avancement (X) et après l'étape c),
- les deux bandes (102, 103) et le produit chimique (4) expansé sont coupés dans une direction transversale par rapport à la direction d'avancement (X).
- la seconde feuille se compose d'une bande continue (102),
- la première feuille (3) se compose d'une pluralité de longueurs de bande qui sont amenées en succession dans la direction d'avancement (X) et après l'étape c),
- la bande continue (102) et le produit chimique expansé (4) sont coupés dans une direction transversale par rapport à la direction d'avancement (X).
- chaque longueur de bande (3) est pliée selon la ligne de faîte (11') avant l'étape a),
- chaque longueur pliée de bande (3) est chargée sur un élément de support mobile (210) respectif, un certain nombre d'éléments de support mobiles (210) qui sont couplés en succession pour être amenés dans la direction d'avancement (X).
a) des moyens d'avancement (104-16, 131-132, 135-136 ; 104, 202, 106, 130, 210) pour faire avancer longitudinalement deux feuilles (102, 103 ; 102, 3) dans une direction d'avancement (X), avec les deux feuilles (102, 103 ; 102, 3) qui sont généralement superposées afin de définir un espace (G) entre elles, dans laquelle au moins une première feuille (103 ; 3) est formée afin de définir une nervure longitudinale (6a, 6b) au niveau d'au moins l'un de ses deux bords latéraux opposés (103a, 103b),
b) des moyens de distribution (120) pour appliquer, sur une surface d'une feuille (103 ; 3) qui fait face à l'autre feuille (102), un produit chimique (122) conçu pour subir une expansion, alors que les feuilles (102, 103 ; 102, 3) avancent dans la direction d'avancement (X),
c) une presse continue (130) pour provoquer l'expansion du produit chimique (122)
alors que les feuilles (102, 103 ; 102, 3) avancent dans la direction d'avancement
(X), de sorte que le produit chimique expansé (4) remplit l'espace (G) entre les deux
feuilles (102, 103 ; 102, 3),
dans laquelle la presse continue (130) comprend un premier dispositif de confinement
latéral (135) et un second dispositif de confinement latéral (136) qui sont mobiles
dans la direction d'avancement (X) au niveau des bords latéraux (103a, 13b) des deux
feuilles (102, 103 ; 102, 3) et sont conçus pour boucher l'espace (G) afin de contenir
latéralement l'expansion du produit chimique (122) alors que les feuilles avancent
dans la direction d'avancement (X), au moins un premier dispositif de confinement
latéral (135) étant du type à boucle fermée et portant une pluralité respective d'éléments
de confinement (140),
l'installation étant caractérisée en ce qu'elle comprend des moyens de pliage (111) en amont de la presse continue (130), pour
plier au moins la première feuille (103 ; 3) afin de définir à l'intérieur de cette
dernière, au moins une ligne de faîte (11, 11') qui s'étend de manière sensiblement
orthogonale entre les deux bords latéraux (103a, 103b) respectifs, le profil des bords
latéraux (103a, 103b) étant donc variable, et en ce que les éléments de confinement (140) portés par le premier dispositif de confinement
latéral (135) sont montés de manière déplaçable dans une direction sensiblement verticale
(Y), dans des sens opposés, les éléments de confinement (140) étant mobiles de haut
en bas et de bas en haut ou vice-versa, pour adapter leur position au profil du premier
bord latéral (103a) de la première feuille (103 ; 3).
- des moyens d'alimentation (100, 101) pour amener, de manière sensiblement continue, deux bandes continues (102, 103) qui constituent la première et la seconde feuille, et des moyens de coupe (180), en aval de la presse continue (130), pour découper les deux bandes (102, 103) et le produit chimique expansé (4) dans une direction transversale par rapport à la direction d'avancement (X), les moyens de pliage comprenant, en particulier, un dispositif de pliage (111) qui est mobile d'avant en arrière dans la direction d'avancement (X), et
- des premiers moyens d'alimentation (100) pour amener sensiblement de manière continue, une bande continue (120) qui constitue la seconde feuille, des seconds moyens d'alimentation (202, 2010), pour amener en succession une pluralité de longueurs de bandes (3) qui constituent la première feuille et des moyens de coupe (180), en aval de la presse continue (130), pour couper la bande continue (120) et le produit chimique expansé (4) dans une direction transversale par rapport à la direction d'avancement (X).
REFERENCES CITED IN THE DESCRIPTION
This list of references cited by the applicant is for the reader's convenience only. It does not form part of the European patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be excluded and the EPO disclaims all liability in this regard.
Patent documents cited in the description