Liner panels

Abstract

A building panel ( 1 ) is made from a laminate of polystyrene (EPS) (A) as a core material to provide rigidity and flexible sheet materials (B) preferably including kraft paper. Multiple layers of the core material (A) and kraft paper (B) can be used to provide a panel which is lightweight, waterproof, has good impact resistance and insulation properties and is easily worked with conventional tools. The panels are formed using a sheet laminating process and fire retardant adhesives improve the fire rating.

1 . A liner panel comprising a laminate of flexible material including a paper and a semi-rigid foam material cliaracterised in that the flexible material is interposed between two layers of the rigid material.  
   
   
       2 . A panel as claimed in  claim 1  wherein the rigid material is polystyrene.  
   
   
       3 . A panel as claimed in  claim 1  comprising a first layer of kraft paper, a second layer of polystyrene foam, a third layer of kraft paper and a fourth layer of polystyrene foam.  
   
   
       4 . A panel as claimed in  claim 3  including a fifth layer of krafl paper laminated to said fourth layer of polystyrene foam.  
   
   
       5 . A panel as claimed in any one of  claims 1  to  4  wherein the laminate is approximately 20 mm thick.  
   
   
       6 . A panel as claimed in any one  claims 1  to  5  wherein the sheets of the laminate are attached using a fire retardant bonding agent or adhesive.  
   
   
       7 . A panel as claimed in any one of  claims 1  to  6  wherein the sheets of polystyrene are of substantially equal thickness.  
   
   
       8 . A panel as claimed in any one of  claims 1  to  7  wherein the sheets of kraft paper are of equal or variable thicknesses.  
   
   
       9 . A method of forming a panel as claimed in any one of  claims 1  to  8  wherein the laminate is formed in a single stage process.  
   
   
       10 . A method as claimed in  claim 9  wherein the laminate is formed in a two-stage process.  
   
   
       11 . A method as claimed in  claim 9  wherein the laminate is crushed to improve rigidity, to reduce thickness and to improve impact resistance.  
   
   
       12 . A panel substantially as herein described with reference to the accompanying drawings.  
   
   
       13 . A method of forming a panel as herein described with reference to the accompanying drawings.