GB2068831A - Fixing into sandwich panels - Google Patents
Fixing into sandwich panels Download PDFInfo
- Publication number
- GB2068831A GB2068831A GB8102652A GB8102652A GB2068831A GB 2068831 A GB2068831 A GB 2068831A GB 8102652 A GB8102652 A GB 8102652A GB 8102652 A GB8102652 A GB 8102652A GB 2068831 A GB2068831 A GB 2068831A
- Authority
- GB
- United Kingdom
- Prior art keywords
- fixing
- foam material
- skin
- foam
- density
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000006261 foam material Substances 0.000 claims abstract description 20
- 239000006260 foam Substances 0.000 claims abstract description 13
- 238000000034 method Methods 0.000 claims description 10
- 230000009471 action Effects 0.000 claims description 2
- 238000009826 distribution Methods 0.000 claims description 2
- 238000005538 encapsulation Methods 0.000 claims 1
- 239000000463 material Substances 0.000 abstract description 6
- 239000011162 core material Substances 0.000 description 13
- 238000004519 manufacturing process Methods 0.000 description 6
- 239000004619 high density foam Substances 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 238000005253 cladding Methods 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- 229920005830 Polyurethane Foam Polymers 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 239000004620 low density foam Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000011496 polyurethane foam Substances 0.000 description 1
- 238000009417 prefabrication Methods 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
- B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
- B29C44/0461—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities by having different chemical compositions in different places, e.g. having different concentrations of foaming agent, feeding one composition after the other
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0801—Separate fastening elements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0801—Separate fastening elements
- E04F13/0832—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements
- E04F13/0833—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements not adjustable
- E04F13/0835—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements not adjustable the fastening elements extending into the back side of the covering elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2607/00—Walls, panels
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Laminated Bodies (AREA)
Abstract
A foam-cored sandwich panel has a fixing point 4 encapsulated in a portion 3 of the foam material, which portion 3 has a density higher than that of the remaining foam material 2. The portion 3 of foam material of greater density acts both as an anchor and a spreader of the load and the fixing preferably includes spreader means for distributing the load through the portion 3. The fixing can be encapsulated in the portion 3 of foam material on one skin 1b of the sandwich panel any by holding a mould jig against a surface of the skin 1b, attaching the fixing 4 within the mould jig and introducing the foam of greater density into the mould jig to encapsulate the fixing 4 with the foam material 3. Thereafter, the jig is removed and the other skin 1a and material 2 of lesser density are secured in position.
Description
SPECIFICATION
Fixing into sandwich panels.
This invention relates to a method of making an attachment to a sandwich panel.
Foam-cored sandwich panels have high strength and stiffness combined with low weight and outstanding thermal insulation.
These advantages make them very attractive for a variety of applications, in particular as external cladding to buildings. However, despite their high overall strength and stiffness, sandwich panels are not capable of carrying high concentrated loads because of the relatively low strength of the core material. Where significant concentrated loads are applied to the panel, some form of local reinforcement is necessary, and this usually involves the insertion of a block of solid material (usually wood or metal) between the skins of the sandwich in place of the core material. Solid inserts have a number of disadvantages, some of which are:
1. They have to be prefabricated and are therefore expensive.
2. Matching insert thickness with core thickness is difficult.
3. They create local loss of thermal insulation (cold bridging).
4. Unless they are of the same material as the skins they can cause differential thermal expansion.
5. The sudden change in shear stiffness at the interface between insert and core can cause peeling of the skin away from the insert.
6. Bonding-in the insert can be difficult and time consuming.
According to this invention there is provided a design and a method of making an attachment point in a foam-cored sandwich panel, which is intended to avoid the disadvantages listed above.
This is achieved by having a fixing point encapsulated into a foam material of greater density than the foam of the core. The foam of greater density acts both as an anchor and as a spreader, but is not so different in its relevant physical properties from the remainder of the core that disadvantages such as those listed at 3 to 6 above recur. There is no separate prefabrication or problem of thickness matching because the fixing point can be encapsulated in situ on a first skin of the sandwich, probably using a separate mould jig to restrain the spread of high density material-the remainder of the core is added subsequently either before or after positioning of the second skin.
The fixing point may be of any sort, e.g. an internally threaded sleeve for reception of a bolt, but preferably will have spreader means to assure some degree of load distribution through the higher density foam material.
In the attached drawings, Figure 1 is a section through a finished panel, and Figures 2 to 6 show stages in its production.
The principal features of the attachment point are shown in Fig. 1 attached, in which:
In Fig. 1 two GRP skins of 1a, Ib of a sandwich panel are united by core material 2 (typically a thermosetting plastics foam). A moulded plug 3 of plastics foam of higher density than the core material encapsulates a fixing 4. The plug 3 is of tapered (frusto conical or frusto pyramidal) shape, with a wedge action in the direction of expected loads. The fixing 4 shown is a threaded metal tube welded to a metal plate 7. Other materials and types of fixing can be used equally well, as long as they incorporate some means such as a generous plate to spread the load into the foam plug 3. A steel angle 5 is the sort of member to which the panel might be fixed in practice, by means of a hexagon headed bolt and washer 6, screwed into the fixing 4.
It can be seen how the plug 3 spreads the loads received by the fixing and yet can be of a material physically compatible with the remainder of the core and with the functions of the panel.
Generally, the production technique used is as follows:
1. A layer of skin material is layed out on a flat surface, outside surface down.
2. A mould jig of suitable dimensions is pressed onto the skin at the point where the fixing point is to be made. The fixing is attached to the mould jig in the correct location.
3. A measured quantity of thermosetting foam of higher density than the sandwich core is mixed and poured into the mould jig.
4. The high density foam fills the mould jig and encapsulates the fixing.
5. The mould jig is removed, leaving the attachment point adhered to the skin material.
6. Manufacture of the sandwich panel is completed by adding the second skin and remainder of the core material, i.e. lower density foam, in whichever order is preferred.
It will be necessary to drill a hole in the skin la over the fixing. This can be done before or after the skin is attached.
The high density foam plug should be tapered so that tensile loads on the fixing are transferred from high density to low density foam by compression. This makes the process of load transfer more gradual and gives a higher load carrying capacity than a parallelsided plug. It also makes removal of the mould jig easier.
A particular application will now be described in detail, by way of example. This is the attachment point in a foam-cored GRP sandwich cladding panel, which is required to resist tensile loads up to 1 .7kN perpendicular to the panel.
The procedure is as follows; referring to
Figs. 2-7 attached:
1. The GRP skin 1 b is laid up in a female
mould or table 8 (Fig. 2).
2. While the skin 1 b is still wet a mould jig 9 is coated internally with release agent and pressed onto the skin. It is located and
held there by a clamp attached to the side of the mould 8.
A metal tube-and-plate fixing 4 is attached to the mould jig 9 (Fig. 3). It is temporarily plugged to avoid foam material entering it.
When the tube of the fixing 4 is screwthreaded, a threaded bolt 10 may be used both to attach the fixing to the mould jig 9 and to plug the tube.
3. High density foam 10 (approximately 200kg/m3 cured density) is mixed and poured into the mould jig 9, (Fig. 4).
4. The foam expands to fill the mould jig and encapsulates the fixing (Fig. 5).
5. When the foam plug 3 is hard the mould jig 9 is removed, leaving the fixing point adhered to the skin 1 b (Fig. 6).
6. Low density polyurethane foam (approximately 35 kg/m3 cured density) is sprayed onto the skin 1 b to the required thickness within the mould 8, allowed to set and then planed off flush with the high density foam plug 3. GRP skin 1a is then laid-up onto the core and cured. This method of sandwich manufacture is the subject of our co-pending patent application No. 80.21455 (publication
No. 2053785).
7. The skin 1 a is drilled to give access to the fixing point 4, and the finished panel is removed from the mould 8 to yield the panel seen in Fig. 1.
Claims (10)
1. A sandwich panel including a pair of skins, a core of foam material between the skins, at least a portion of which foam material has a density greater than that of the remainder, a fixing point encapsulated within the portion of foam material of greater density and an aperture in one of the skins to allow access to the fixing point.
2. A sandwich panel according to claim 1, wherein the fixing point includes spreader means to provide load distribution through the foam material of greater density.
3. A sandwich panel according to claim 1 or claim 2, wherein the fixing point is a sleeve which is internally threaded for reception of a bolt.
4. A sandwich panel according to any one of the preceding claims, wherein the portion of foam material of greater density is of tapered shape with a wedge action in the direction of expected load.
5. A sandwich panel according to any one of the preceding claims substantially as herein described and as illustrated with reference to the accompanying drawings.
6. A method of providing a fixing point in a foam cored sandwich panel, which method includes encapsulating a fixing in a portion of the foam material on one side of the panel, which portion is to be of a density greater than that of the remaining foam material and, in either order, providing the remainder of the foam material and securing the other skin in position, which other skin is provided with an aperture to allow access to the fixing.
7. A method according to claim 6, wherein the said step of encapsulating the fixing in the portion of foam material of greater density on the one skin of the panel is carried out by releasably holding a mould jig against a surface of the one skin, releasably touching the fixing within the mould jig, introducing the foam of greater density into the mould jig to encapsulate the fixing and releasing the fixing from the mould jig and leave the fixing encapsulated within the foam of greater density on the one skin.
8. A method according to claim 7, wherein the mould jig is of frusto-conical or frusto-pyrimidal shape to provide a wedge shaped said portion of foam material of greater density.
9. A method according to claim 6, claim 7 or claim 8, wherein the one skin is laid up in a female mould, and after said encapsulation of the fitting in the portion of foam material of greater density, the remaining foam material is introduced into the female mould and allowed to set.
10. A method according to any one of claims 6 to 9, substantially as herein described with reference to and as illustrated in the accompanying drawings.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB8102652A GB2068831B (en) | 1980-02-06 | 1981-01-29 | Fixing into sandwich panels |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB8004005 | 1980-02-06 | ||
| GB8102652A GB2068831B (en) | 1980-02-06 | 1981-01-29 | Fixing into sandwich panels |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB2068831A true GB2068831A (en) | 1981-08-19 |
| GB2068831B GB2068831B (en) | 1983-11-02 |
Family
ID=26274417
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB8102652A Expired GB2068831B (en) | 1980-02-06 | 1981-01-29 | Fixing into sandwich panels |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2068831B (en) |
Cited By (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE3403819A1 (en) * | 1984-02-03 | 1985-08-14 | Rheinhold & Mahla GmbH, 8000 München | Process for anchoring a force-introduction element in a sandwich board |
| FR2632242A1 (en) * | 1988-06-03 | 1989-12-08 | Arnaud Guy | Method of manufacturing a composite material based on expanded thermosetting resin and novel material obtained |
| EP0370354A1 (en) * | 1988-11-25 | 1990-05-30 | Constral Ag | Anchoring for wall panels, and method or its manufacture |
| EP0473372A2 (en) * | 1990-08-31 | 1992-03-04 | General Electric Company | Composite element |
| EP0648905A1 (en) * | 1993-10-14 | 1995-04-19 | Dagard S.A. | Partitioning panel having a built-in fastening device |
| EP0870885A1 (en) * | 1997-04-08 | 1998-10-14 | SOCIETE CIVILE NEURONE Société Civile dite : | Façade covering and process for its manufacture |
| FR2883221A1 (en) * | 2005-03-18 | 2006-09-22 | Faurecia Interieur Ind Snc | Manufacturing automobile vehicle part, comprises introducing fixing part of an insert in a hollow area, conforming a foam layer between armature and the insert, placing the armature, and bringing a foaming material in the foaming cavity |
| WO2006132641A2 (en) * | 2004-06-18 | 2006-12-14 | L & L Products, Inc. | Panel structure |
| EP1871662B2 (en) † | 2005-03-23 | 2013-09-04 | The Boeing Company | Integrated aircraft structural floor |
| AT514314A4 (en) * | 2013-07-24 | 2014-12-15 | Wolfgang Dipl Ing Winter | Fixing system for insulation elements |
| WO2022243593A1 (en) * | 2021-05-21 | 2022-11-24 | Cerámica Malpesa, S.A. | Method for producing a panel for the construction of cladding, and resulting panel |
-
1981
- 1981-01-29 GB GB8102652A patent/GB2068831B/en not_active Expired
Cited By (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE3403819A1 (en) * | 1984-02-03 | 1985-08-14 | Rheinhold & Mahla GmbH, 8000 München | Process for anchoring a force-introduction element in a sandwich board |
| FR2632242A1 (en) * | 1988-06-03 | 1989-12-08 | Arnaud Guy | Method of manufacturing a composite material based on expanded thermosetting resin and novel material obtained |
| EP0370354A1 (en) * | 1988-11-25 | 1990-05-30 | Constral Ag | Anchoring for wall panels, and method or its manufacture |
| EP0473372A2 (en) * | 1990-08-31 | 1992-03-04 | General Electric Company | Composite element |
| EP0473372A3 (en) * | 1990-08-31 | 1992-10-21 | General Electric Company | Composite element |
| FR2711211A1 (en) * | 1993-10-14 | 1995-04-21 | Dagard | Partition panel with integrated fixing device. |
| EP0648905A1 (en) * | 1993-10-14 | 1995-04-19 | Dagard S.A. | Partitioning panel having a built-in fastening device |
| EP0870885A1 (en) * | 1997-04-08 | 1998-10-14 | SOCIETE CIVILE NEURONE Société Civile dite : | Façade covering and process for its manufacture |
| WO2006132641A2 (en) * | 2004-06-18 | 2006-12-14 | L & L Products, Inc. | Panel structure |
| WO2006132641A3 (en) * | 2004-06-18 | 2007-06-07 | L & L Products Inc | Panel structure |
| FR2883221A1 (en) * | 2005-03-18 | 2006-09-22 | Faurecia Interieur Ind Snc | Manufacturing automobile vehicle part, comprises introducing fixing part of an insert in a hollow area, conforming a foam layer between armature and the insert, placing the armature, and bringing a foaming material in the foaming cavity |
| EP1871662B2 (en) † | 2005-03-23 | 2013-09-04 | The Boeing Company | Integrated aircraft structural floor |
| AT514314A4 (en) * | 2013-07-24 | 2014-12-15 | Wolfgang Dipl Ing Winter | Fixing system for insulation elements |
| AT514314B1 (en) * | 2013-07-24 | 2014-12-15 | Wolfgang Dipl Ing Winter | Fixing system for insulation elements |
| WO2022243593A1 (en) * | 2021-05-21 | 2022-11-24 | Cerámica Malpesa, S.A. | Method for producing a panel for the construction of cladding, and resulting panel |
Also Published As
| Publication number | Publication date |
|---|---|
| GB2068831B (en) | 1983-11-02 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PCNP | Patent ceased through non-payment of renewal fee |