Composite panel

Abstract

A composite cladding panel 1 comprises a backing tray 2 and an external skin 3 with a layer of foam insulation material 4 such as a phenolic or polyurethane based foam material therebetween. One of the skins, in this case the external skin 3 has a plurality of tongue and mortise blocks 5 fastened to the panel 1 by fasteners 12. Each fastener 12 comprises a peel rivet having a mandrel, a stress plate, and a main body. Pilot holes 13 are first drilled through the blocks 5 and the rivet 12 is inserted. On operation of a rivet gun the main body curls up 22 and is clamped against the inside surface of the external skin 3. The blocks 5 are thereby efficiently and effectively clamped to the external skin 3. A composite insulating panel with an integrated high performance brick cladding is provided.

1 - 15 . (canceled) 
   
   
       16 . A composite cladding panel comprising an internal skin and an external skin with insulation material therebetween, one of the skins having a plurality of tongue and mortise blocks mounted directly to the panel by a mounting means to form a cladding. 
   
   
       17 . The panel as claimed in  claim 16  wherein the blocks have mounting holes and the mounting means comprises a fastener for insertion through the hole to fasten the block to the panel. 
   
   
       18 . The panel as claimed in  claim 17  wherein the fastener comprises a clamping fastener. 
   
   
       19 . The panel as claimed in  claim 18  wherein the clamping fastener comprises a peel rivet that clamps to the inside of the external skin. 
   
   
       20 . The panel as claimed in  claim 16  wherein the external skin of the panel has an adhesive on the inner face thereof. 
   
   
       21 . The panel as claimed in  claim 20  wherein the adhesive is applied to the inner face of the external skin prior to lay-down of liquid insulating foam reactants. 
   
   
       22 . method for manufacturing a composite cladding panel comprising the steps of:
 manufacturing a composite insulating panel comprising an internal skin, an external skin with insulation material therebetween;   providing a plurality of tongue and mortise blocks with mounting holes through the blocks;   providing a plurality of fasteners;   placing the blocks along at least portion of the external face of a skin; and   fastening the blocks to the skin by inserting the fasteners through the holes in the blocks.   
   
   
       23 . The method as claimed in  claim 22  wherein the fastener comprises a clamping fastener for clamping to the inside of the external skin. 
   
   
       24 . The method as claimed in  claim 23  wherein the clamping fastener comprises a peel rivet. 
   
   
       25 . The method as claimed in  claim 24  comprising the step of fixing the blocks to the panel using the rivets. 
   
   
       26 . The method as claimed in  claim 22  comprising the steps of laying the external skin down with the outer side lowermost, applying an adhesive to the inner face of the external skin, applying liquid foam reactants over the adhesive, applying an internal skin over the liquid form reactants and heating the sandwich thus formed in an oven to form the composite insulating panel. 
   
   
       27 . The method as claimed in  claim 22  comprising boring holes through the blocks to provide the mounting holes.