APPARATUS FOR MANUFACTURING PANELS

Abstract: An installation for manufacturing panels used in build­ ing construction which panels comprise a metal framework of two parallel meshes joined by connector wires which obliquely pass through a core of lighweight material be­ tween the two parallel meshes to which latter said connector wires are welded, the installation including a conveyor device for entry into the machine, a first section of an intermittent traction and advancing device within the machine, a dispensing device for feeding connector wires to a fastening device for inserting them in the lightweight core, a second section of the intermittent traction and advancing device, a column of electrodes for welding the connector wires, a third section of the intermittent traction and advancing device, a saw device for shaping the resulting panels and automated mechanisms and systems for controll­ ing all these elements.

Description: This invention provides an apparatus or installation for the manufacture of a compound panel comprising a metal framework with a lightweight core, suitable for use in building construction. The metal framework of the panel is a three-dimensional wire grill or grating, normally in the form of two parallel meshes joined together by a series of wires welded to them, hereinafter referred to as connectors. The lightweight core may be a layer of foam resin or dense box material, fibre or plastics, with reinforcing walls which will allow a segment of wire easily to pass through it. These panels can be building elements used in the construction as walls or flooring and then coated with resistant mortar on both sides; the panels can easily be joined to one another on the building site by conventional means. Known panels of this type are described in US-A-3555131 and are made with very fine wire (2 mm gauge, and mesh opening of 50 mm) and were manufactured according to the following process: 1) The vertical meshes of the panel were preconstructed in ladderlike form, that is, with two parallel wires between which short cross-members were welded. 2) These elements were inserted in welding machines in a vertical position, and crosswires were welded to them to form the complete spatial structure. 3) These structures were slightly sunk or embedded in a sand bed which was made to advance upon a conveyor belt, and a foam resin was sprayed on them to form the lightweight core. The panels were constructed in standard sizes (5 m × 1.20 m, for example, making it necessary later to cut them on the job, with the consequential losses and expense. Production according to the method described in the U.S. patent is known to have taken place in large sheds or buildings (of an area of more than 500 m²) which demanded costly investment and full-time personnel. In FR-A-2177030 (which corresponds to US-A-3838241 ) a fundamentally different approach to panel making is disclosed from that of the present invention. In the French patent a wire matrix is formed first and then the core is formed within the matrix, whereas in the present invention the core is provided first and the wire matrix is then formed around it. The apparatus of the French patent therefore suffers from an inherent inflexibility of operation which does not afflict the apparatus of the present invention. According to the invention there is provided an apparatus for the manufacture by a continuous process of compound panels for building construction, said panels being of variable cross-section and of any desired shape and comprising a metallic framework and a lightweight core, the metallic framework consisting of a three-dimensional wire grille or grating generally presented in the form of two parallel meshes joined by a series of connector-wires welded to them, said connector-wires being inclined with respect to the wires of the meshes, the lightweight core consisting of a layer of foam resin or dense box material, paperboard laminate, fiber or plastics material, provided with reinforcing walls and unresistant to a wire segment passing through it, characterized in that it comprises: (a) a machine including an intermittent traction and advancing device located within the interim of the machine, means for providing wire mesh, and separating means to introduce said wire mesh in parallel and separated a suitable distance wherein said intermittent traction and advancing machine and said separating means introduces parallel and separated a suitable distance, two sheets of mesh and one sheet of lightweight material into one end of (b) said machine including means for adjusting said machine to accommodate various thicknesses of said two sheets of mesh and said one sheet of lightweight material, (c) said intermittent traction and advancing device intermittently moves the two sheets of mesh and the sheet of lightweight material a apparatus for the manufacture by a continuous process of compound panels for building construction, said panels being of variable cross-section and of any desired shape and comprising a metallic framework and a lightweight core the metallic framework consisting of a three-dimensional wire grille or grating generally presented in the form of two parallel meshes joined by a series of connector-wires welded to them, said connector-wires being inclined with respect to the wires of the meshes, the lightweight core consisting of a layer of foam resin or dense box material, paperboard laminate, fiber or plastics material, unresistant to a wire segment passing through it, comprising a machine including an intermittent traction and advancing device located within the interim of the machine, means for providing wire mesh, and separating means to introduce said wire mesh in parallel and separated a suitable distance wherein said intermittent traction and advancing machine and said separating means introduces parallel and separated a suitable distance, two sheets of mesh and one sheet of lightweight material into one end of said machine, said machine including means for adjusting said machine to accommodate various thicknesses of said two sheets of mesh and said one sheet of lightweight material, said intermittent traction and advancing device intermittently moves the two sheets of mesh and the sheet of lightweight material a regulated distance to a first section of said machine, until they are placed in front of a fastening device including a vertical battery of discharges to which a dispensing device feeds wire driven by the fastening device into the sheet of lightweight material, the ends of said wire resting against the longitudinal wires of the two meshes which advance intermittently inside the machine; the intermittent traction and advancing device moves the unit thus constituted, with the connector-wires in place, to a second section of said machine in front of a column of electrodes for welding the connector-wires segments to the longitudinal wires of the two meshes; the intermittent traction and advancing device moves the panels, along with the imbedded connector elements, to a third section of said machine; and means for automatically controlling the operation of the machinery. EP-A-0 069 108, which falls within the terms of Article 54(3) of the EPC, discloses an regulated distance to a first section of said machine, until they are placed in front of (d) a fastening device including a vertical battery of discharges to which (e) a dispensing device feeds a series of connector-wire segments which are then driven by the fastening device into the sheet of lightweight material, the ends of said wire segments resting against the longitudinal wires of the two meshes which advance intermittently inside the machine; (f) the intermittent traction and advancing device moves the unit thus constituted, with the connector-wires in place, to a second section of said machine in front of (g) a column of electrodes for welding the connector-wire segments to the longitudinal wires of the two meshes; (h) the intermittent traction and advancing device moves the panels, along with the imbedded connector elements, to a third section of said machine in front of (i) a saw device containing one or more disk, band or laser beam saws which cut the panels to the desired size; and (j) means for automatically controlling the operation of the machinery. In the first section of the installation, the manipulation of thousands of units of wire segments presents difficulties in the feeding of the machine, since any trouble or flaw could cause jamming. To avoid this, resort can be made to an alternative process somewhat similar to that used in stapling machines. First, a series of connector wires are joined back-to-back in the form of combs, and their teeth or prongs are gummed with a lacquer to hold them together on a plane. The machine is fed with packs of combs in a process much more orderly than handling loose wires. In addition, one load of wires can be sufficient for a full day's work by the machine so that there is no longer any need to continuously load the hoppers. The subsequent detachment of the wires from each comb, one by one for their insertion, is performed by a guillotine similar to that used in staplers, which places the wire in front of a gun fastener which thereupon drives it into the lightweight core. The connectors may also be joined to form a continuous and flexible comb roll, using an elastic bonding lacquer with an adhesive support backing. In such a case the connectors are fed from comb rolls suspended above the machine. The combs are made outside the machine in a continuous process employing a lacquer applicator, in infrared dryer and a cutter. In the second section of the installation, the welders grouped in columns advance and retract as the mesh passes, and it is fundamental that their electrodes always locate with a certain exactness, by pressure upon it, the cross formed by the end of the connector and the longitudinal wire of the mesh. To achieve this, in a development of the invention, a mechanism has been selected by means of which the mesh, during its advance inside the machine, is drawn over a smooth belt or idler rollers, propelled by a retractable hook which intermittently pulls against a vertical wire of the mesh. The system of fastening the meshes and the polystyrene sheet to a continuous conveyor belt or endless chain moved by constant impulses has been discarded. The advantage of the device adopted is that even though there are panels of imperfect size (within a normal tolerance) which differ slightly from the fixed advance rate of the machine (adapted to a standard opening), there is no accumulation of defects or a maladjustment in the positioning of the said crosses facing the electrodes. Naturally, there is a hook on each side for each mesh, and two on each side make traction smoother and serve to overcome any possible snag of the mesh roll. A special embodiment of the installation is movable, and can be transported by truck to a job site. Another improvement is the provision of means for adhering, to one side of the lightweight core and prior to placement of the corresponding wire mesh, an aluminium or plastics sheet to serve as a vapour barrier. In the present invention the panels are made with larger mesh sections (approximately 10 × 10 cms) and with heavier wire (from 2.5 mm and up) than the known panels disclosed hereinbefore, thereby simplifying the process considerably, greatly reducing cost and introducing the innovation of manufacture of the panel in an endless sheet which can be cut to an exact size as it exits from the machine. Only one continuous machine is required for the entire process, and the installation can be carried easily by truck to the construction site (as it occupies a space smaller than 25 m²). A basic factor in the feasibility of this new system of manufacture has been the renunciation of a great density of fine mesh, which was thought necessary to prevent the sprayed mortar from falling off; however, experience has shown that there is fully satisfactory adherence with a 10 × 10 cms opening having one connector in each panel, with care in the spraying of the mortar which should be applied in two layers, one several hours after the other, and with scraping or scratching of the surface of the lightweight core to give it a rough surface. Another basic factor has been the extensive selection of any suitable lightweight foam or paperboard which can be used, provided it can hold the driven wires; in the prior art system, it was first necessary to make the wire structure, then spray its interior with the foam resin core. It would be difficult to use the system described in this invention with the fine wire meshes previously used, since the great number of connectors and the reduced space for inserting the electrodes between the wires would greatly hinder the process. Increased wire gauge is a notable improvement offered by the system, since there is greater resistance to rust (especially in storage at the building site), greater resistance to impacts during handling and greater rigidity of the panel during the process of assembly and concreting. Owing to their function, connectors must be protected against rust, for which reason their composition can be important inasmuch as in certain cases the process of manufacture of the panels requires preliminary preparation. If the connectors are of stainless steel, the process is the normal one previously explained, since stainless steel is weldable. But, if they are of galvanized iron, their ends must be denuded or pickled so that they can be welded. This is done by introducing the packs of connector combs by their teeth or prongs in an acid bath for several minutes at a depth of some 10 mm, following which they are washed in a neutral solution. If the surface of the connectors is plasticised or impregnated with already hardened resin, roll wire is used which is straightened and then cut into measured segments, some 10 mm of the ends being ground or sharpened in an automatic machine, thereby becoming weldable where they intersect the mesh wires. According to the process described, it is thus possible to manufacture panels of varying cross-section or of many shapes, bending the two principal meshes as desired and adapting the length of the connectors to them, giving the lightweight core a foam conforming to the exterior surface of the meshes. Before describing the installation, the following should be noted which determines one aspect of the process. The panels are to be rectangular, the longer side coinciding with the perpendicular walls. The diameter of the connectors approximates that of the mesh wires, and said connectors are welded to the longitudinal wires of the panels. They are inclined with respect to said longitudinal wires of the panels, for the purpose of absorbing the shear stresses produced between the two hard layers of the concreted panel. In summary, the longitudinal wires of the panel (those parallel to the major axis) are welded obliquely to the connectors, and thus it is best that the panel be made lying on its side (on a vertical plane, with its major axis horizontal). Another improved embodiment of the invention includes adjacent auxiliary machines for producing the mesh from plain wire and, in substitution of a roll of sheeting of lightweight material which could be used, provision is made for a likewise adjacent extruder of said lightweight material which automatically extrudes the sheeting from raw resin foam. The process of continuous feed of the lightweight core has been initially conceived on the basis of foam material (such as polystyrene), continuously manufactured in an extension preceding the panel-making machine. But it is possible that such material may not be profitable or usable for other reasons, making it necessary to consider continuous manufacture of the core from a paperboard base in an extension preceding the said machine. In one such extension, manufacture commences from three rolls of paperboard. The upper and lower outer surfaces of a continuous box-like or walled rectangular tube paperboard material proceed from respective parallel rolls of paperboard. The heart or core between the two outer layers is a longitudinally-crimped prismatic roll of crenellated or dentated cross-section. Said crimped roll is obtained by means of a slitting mechanism and successive wheels which crease the paperboard to the eventual crenellated form, exerting pressure downward and laterally, which crimped roll is then glued or stapled to the upper and lower rolls to form said rigid boxlike material. The upper or lower outer layer of the boxlike material can have a slightly curved cross-section, of special interest for manufacturing core as flooring. The paperboard must undergo previous or posterior treatment based on anti-moisture resins, so that it is not affected by the mortar or concrete which will come in contact with it or by atmospheric humidity when the material is stacked on the job site, prior to use. To facilitate the fastening of the connector wires, their points are beveled or chamfered for easier passage through the paperboard. This is done by cutting packs of wires obliquely with the disk of a saw. Another improvement introduced is a panel-feeding arrangement followed by a manual stapling or spot-welding device, for joining the panels together to form the meshes. Also, an arrangement is provided for feeding panels of the said material, followed by a manual glueing or stapling device for joining the panels. Finally, the installation can be adapted to manufacture elements of varying core thickness, and to fasten connector-wire segments of different lengths. To be able to introduce different thicknesses of lightweight core and thus vary the thickness of the panel, the structure of the installation must be slightly modified. The machine has a plane of symmetry coinciding with that of the panel during its manufacture. To make panels of different thickness the machine is divided along said plane, to either separate or bring together the two resulting halves. One of the halves remains fixed, while the other moves perpendicularly on wheels until blocked at the required distance. In the selection of the geometry of the panel, certain dimensions must be invariable so as not to excessively complicate the machine, within the required degrees of regulation. These fixed parameters can be: The dimensions of the mesh panel. The diameter of the mesh and of the connector. The distance between the mesh surface and the surface of the confronting core. The distances from the weld-point of the connectors to the two adjacent junction points, which must be constant. Instead of these fixed parameters, others can be fixed without varying the essence of the machine. Of great important for regulating the width of the machine is a guide device which maintains the lightweight core and meshes at the proper distance during the manufacturing process. This is a double series of welded vertical and horizontal guide pins, which act as separators between mesh and core and which cover a zone from the column of welders to the entrance of the mesh, a distance of a minimum of three metres. Upon "starting" the machine, it is important to maintain the relative position of the connector-fastening batteries and of the column of welders invariable with respect to the cited network of separator guide pins, which is on the same side. The connector magazines contain partitions which permit the housing of connectors of different lengths. The discharge needles are of maximum length and serve for all cases. As the points of incidence of the connectors in relation to the longitudinal wires of the meshes must always be (repeat, must always be), the same distance from the neighbouring junction points (so that the welders are always in front of an intersection of wires), it is necessary to vary the angle of insertion (of the connectors with respect to the discharge needles), which will be of lesser inclination the greater the thickness of the panel. To widen the machine, first the movable half is unblocked and is moved parallel to itself to the desired width; it is blocked once more, and immediately the angle of incidence of the connector fasteners is varied so that the connectors cross with the longitudinal wires of the meshes at the cited fixed points, and thus the electrodes of the welder tongs then perform their function without longitudinal movement, that is, they move only in perpendicular direction toward the surface of the meshes. Embodiments of the invention will now be described by way of example, reference being made to the accompanying drawings, in which:- Fig. 1 is a diagram in perspective of a panel made in an embodiment of an installation according to the invention, with the elements comprising it, Fig. 2 represents a cross-section of the panel from the longitudinal or transverse direction, Fig. 3 is a side view of the installation, Fig. 4 shows the same installation in plan view, Fig. 5 roughly shows a fastening device, Fig. 6 is a diagram of an arrangement for feeding connectors to the fastening device, Fig. 7 illustrates a comb of connectors, with the central portion daubed with lacquer, Fig. 8 is a side view and Fig. 9 a plan view of another connector feeder-driver which can be substituted for the hoppers with extractor rollers as shown in Fig. 6. In the box-frame 3-5 of Figs. 8 and 9, the superimposed combs 2-1 are placed. The comb at the bottom is pushed by two rods 3-6, propelled in turn by springs 3-7. With a vertical movement, a guillotine 3-8 separates one by one the end wires housed in some slots and places them in front of the discharge needles 3-1. When the pusher 3-6 has propelled the last wire in the bottom comb it is pneumatically returned to its original starting position, permitting the next comb to drop into place by gravity, and the fastening cycle begins again, Fig. 10 shows the discharge needle 3-1, which drives the wire which has already been separated from the comb 2-1 by the action of the guillotine 3-8. This is a continuous flexible comb variation on the embodiment of flat rigid combs as illustrated in Figs. 8 and 9. The roll is suspended above so as not to occupy space in the centre of the machine, Fig. 11 illustrates a device for making the combs of wires. The hopper 5-1 drops the wires upon a conveyor belt; the viscous lacquer in hopper 5-3 drips upon the dispenser ring 5-2 and is solidified to film upon being heated by the infrared lamp 5-4; the continuous matting of wires is cut into combs with the disk 5-5, Fig. 12 is a partial lateral view of the installation, and the sectional end view of Fig. 13 shows the retractable hooks which push the vertical wires of the meshes in their advance, Figs. 14 and 15 illustrate pickling in a tray, of the ends of the connector wires 2-1, either in the rigid flat comb or flexible roll arrangement, the units being placed with the wires in upright position in an acid bath 10 mm deep, Fig. 16 shows one of the welding columns of the installation, in the position in which the column of electrodes has been advanced to the welding position, while Fig. 17 is a view of the welding column in the phase of execution of the welding operation, Figs. 18 and 19 show the invariable parameters c = mesh panel d = distance between mesh and core b = distance to the adjacent junction from the point of intersection of connector and longitudinal wire of the mesh. Variable on the other hand, are the width of the core e₁ or e₂, and the angle of incidence of the connector with respect to the mesh 2, which is greater as the thickness of the core increases, Fig. 20 is a view in perspective of a continuous box-like paperboard as it enters the machine, ready to be pierced by the connector wires, Fig. 21 is a cross-section of a paperboard box with the upper portion arched (a convenient form for recessing flooring, in the manner of a vault). The box is seen pierced by the connector wires, Figs. 22, 23 and 24 illustrate how the slitting rollers mark a groove or trench in the crimped paperboard (formed by smooth paper glued to wrinkled or corrugated paper), and show the successive fold lines, and In Figs. 25 and 26, the paperboard is shaped and propelled by some groups of wheels, which come together transversely as the paperboard advances and the rough relief gradually increases. The machine functions in the following manner: The lightweight core 1 is inserted in the installation from roll 1 , represented in Figs. 3 and 4. Synchronous with the movement of the core, the upper and lower wire grilles 2 , comprising the transverse wires 2-2 and the longitudinal wires 2-3, unroll from respective rolls 2 until they reach the fastener device 3 , from which the connectors 2-1 are discharged and pass through the core 1 , made for example of foam, by means of dischargers 3-1 similar to injection syringes, the needle of which propels the pertinent connector 2-1 located in the lowermost position of the series of connectors contained in the loader or magazine 3-2. Upon being propelled or discharged, the connector is lodged inside the core against the transverse wires 2-2, ready to be welded at its ends in the following phase. The loader 3-2, represented particularly in Figs. 5 and 6, is fed from the hopper 3-4, the bottom of which contains two rollers 3-3 which turn in opposite directions and propel the connector wires one by one into the fastening device. From the fastening device 3, the unit of meshes 2 and lightweight core 1 with connectors 2-1embedded in the latter advances intermittently, propelled by the traction system of the installation, so that the connectors 2-1 are finally placed in front of the vertical battery of electrodes (Figs. 3 and 4). In Figs. 16 and 17 only the welding column on one side of the machine has been represented, since the other column is identical. The upper electrodes 4-1 of the column are solid with a common vertical flange, and the lower electrodes 4-2 are solid with another parallel flange or are free and are operated pneumatically. In the open position, the column is made to advance pneumatically to the position shown in Fig. 17, where the electrodes approach and resistance weld, aided by compression, the pairs of wires, for example 2-1 and 2-2. If the installed power does not permit this (for example, if the work is being done on the job site), the welding equipment could be modified by making cascade stippling, that is, simultaneously pressuring the wires in column but welding one after another. Following the welding operation, all that remains is the cutting of the panels to size. A saw 5 (see Figs. 3 and 4) makes the cuts in the transverse direction if a band saw, or vertically if a disk saw or laser beam cutter (in the last case the cut is cleaner). The preceding description must be considered purely illustrative and in no way limitative, and any and all variations, substitutions of material, etc., may be included which fall within the scope of the following claims.

Claims: 1. An apparatus for the manufacture by a continuous process of compound panels for building construction, said panels being of variable cross-section and of any desired shape and comprising a metallic framework and a lightweight core (1), the metallic framework consisting of a three-dimensional wire grille or grating generally presented in the form of two parallel meshes (2) joined by a series of connector-wires (2-1) welded to them, said connector-wires (2-1) being inclined with respect to the wires (2-2, 2-3) of the meshes (2), the lightweight core (1) consisting of a layer of foam resin or dense box material, paperboard laminate, fiber or plastics material, provided with reinforcing walls and unresistant to a wire segment passing through it, characterized in that it comprises: (a) a machine including an intermittent traction and advancing device located within the interim of the machine, means for providing wire mesh (2), and separating means to introduce said wire mesh in parallel and separated a suitable distance wherein said intermittent traction and advancing machine and said separating means introduces parallel and separated a suitable distance, two sheets of mesh (2) and one sheet of lightweight material (1) into one end of said machine, (b) said machine including means for adjusting said machine to accommodate various thicknesses of said two sheets of mesh (2) and said one sheet of lightweight material (1), (c) said intermittent traction and advancing device intermittently moves the two sheets of mesh (2) and the sheet of lightweight material (1) a regulated distance to a first section of said machine, until they are placed in front of (d) a fastening device (3) including a vertical battery of discharges (3-1) to which (e) a dispensing device (3-2) feeds a series of connector-wire segments (2-1) which are then driven by the fastening device (3) into the sheet of lightweight material (1), the ends of said wire segments (2-1) resting against the longitudinal wires (2-3) of the two meshes which advance intermittently inside the machine; (f) the intermittent traction and advancing device moves the unit thus constituted, with the connector-wires (2-1) in place, to a second section of said machine in front of (g) a column of electrodes (4) for welding the connector-wire segments (2-1) to the longitudinal wires (2-3) of the two meshes; (h) the intermittent traction and advancing device moves the panels, along with the imbedded connector elements (2-1), to a third section of said machine in front of (i) a saw device (5) containing one or more disk, band or laser beam saws which cut the panels to the desired size; and (j) means for automatically controlling the operation of the machinery. 2. An apparatus according to claim 1, wherein said installation is mounted on an integral sized frame and is adapted to be transported by truck to a construction site. 3. An apparatus according to claim 1 or claim 2, characterized in that it contains some means for adhering, to one of the sides of the lightweight core (1) prior to placement of the corresponding wire mesh (2), an aluminium or plastics sheet to serve as a vapor barrier. 4. An apparatus according to any one of claims 1 to 3, wherein said means for providing the wire mesh (2) are respective adjacent auxiliary machines which produce the mesh (2) starting from common wire, and said lightweight material, provided for by an adjacent machine for extrusion of the lightweight material, said machine automatically extruding the sheeting from raw resin foam. 5. An apparatus according to any one of claims 1 to 3 wherein said means for providing wire mesh (2) are mesh rolls and said lightweight core (1) is provided by a roll of lightweight material. 6. An apparatus according to any one of claims 1 to 3, characterized in that provision is made for a panel-feeding arrangement followed by a manual stapling or spot-welding device which joins the panels together to form the meshes (2). 7. An apparatus according to any one of claims 1 to 3, characterized in that provision is made for an arrangement for feeding panels of such material, followed by a manual glueing or stapling device for joining the panels. 8. An apparatus according to any one of the preceding claims, characterized in that it is adapted to manufacture elements having cores (1) of varying thickness and to insert connector-wire segments (2-1) of varying length. 9. An apparatus according to any one of the preceding claims, wherein said intermittent traction and advancing device includes at least one retractable rod having an engaging surface and being located beneath a panel formed by the elements advanced by the intermittent pushing of the vertical wires (2-2) of the mesh, the constant and regulated advance distance being equal to the length of a mesh opening and in that after each advance is completed each said engaging surface of said rod is separated laterally by some mechanical means to keep each said rod from fouling with the vertical wires (2-2) of the mesh upon returning to their original position, that the lightweight core (1) is held fast to the meshes (2) and simultaneously clamped around a wire of each mesh. 10. An apparatus according to any one of the preceding claims, characterized in that the connectors (2-1) are handled in bulk, as flat or flexible combs in roll form, held together with lacquer or alternatively by adhesive tape, said combs entering the machine by means of a drive element (3-6) which propels the comb units to a guillotine (3-8) which separates each wire one by one, said separated wires (2-1) then being driven into the lightweight core (1) by said fastening device (3). 11. An apparatus according to any one of the preceding claims, wherein the connector wires (2-1) are of normal steel and undergo surface treatment prior to insertion of the machine, said connector wires (2-1) being subjected to denuding by pickling to thus permit said wires to be welded to the meshes (2). 12. An apparatus according to any one of the preceding claims, wherein for regulation of the width of the machine it is divided into two halves on a symmetrical plane, one half being movable transversally, the columns of the wire-fastening devices (3) being rotary mounted so that regardless of the thickness of a panel, the points at which the connectors (2-1) cross with the mesh wires (2) are always in the same position with respect to the adjacent junction points, and in such manner that the welding electrodes (4) always face an intersection of a connector (2-1) with a longitudinal wire (2-3) of the mesh. 13. An apparatus according to any one of the preceding claims, wherein said lightweight core (1) is a paperboard core, said paperboard core being formed from three rolls of paperboard two of which form flat upper and lower core surfaces, and said machine includes a headpiece containing a system for deploying and glueing the flat upper and lower core surfaces to the ridges of a third continuous sheet of paperboard wrinkled folded in crenellated form, such folding of said central layer of the core being realized by means of some crimping rollers the folding then proceeding progressively by several series of rollers which give increasingly more height to the folds of the paperboard as it advances, said rollers simultaneously performing the function of advancing the paperboard. 14. A method of manufacturing compound panels for building construction, said panels being of variable cross-section and of any desired shape and comprising a metallic framework and a lightweight core (1), the metallic framework consisting of a three-dimensional wire grille or grating generally presented in the form of two parallel meshes (2) joined by a series of connector wires (2-1) welded to them, said connector wires (2-1) being inclined with respect to the wires (2-2, 2-3) of the meshes (2), the lightweight core (1) consisting of a layer of foam resin or dense box material, paperboard laminate, fiber or plastics material, provided with reinforcing walls and unresistant to a wire segment passing through it, comprising the steps of: introducing two sheets of mesh (2) and one sheet of lightweight material (1), parallel and separated a suitable distance, into one end of a machine by means of an intermittent traction and advancing device located with said machine and means for separating said two sheets of wire mesh (2) in parallel, said two sheets of wire mesh (2) being supplied by wire mesh providing means (2), adjusting said machine by adjusting means to permit said machine to accommodate various thickness of said two sheets of mesh (2) and said sheet of lightweight material (1) to produce compound panels of various thicknesses after a third stage of operation; moving intermittently said two sheets of mesh (2) and said sheet of lightweight material (1) a regulated distance to a first stage of operation by means of the intermittent traction and advancing device; driving a series of connector-wire segments (2-1) into said sheet of lightweight material (1) at the first stage of operation, the ends of said wire segments (2-1) resting against longitudinal wires (2-3) of said two meshes (2) which advance intermittently inside the machine, said connector-wire segments (2-1) being driven by a vertical battery of dischargers (3-1) of a fastening device (3), a dispensing device (3-2) feeding said connector-wire segments (2-1) to said fastening device (3), said fastening device (3) and said dispensing device (3-2) being located at said first stage of operation; moving the unit thus constructed, with the connector-wires (2-1) in place by said intermittent traction and advancing device to a second stage of operation; welding said connector-wire segments (2-1) to said longitudinal wires (2-3) of said two meshes (2) at said second stage of the operation by means of a column of electrodes (4) to form panels; moving said panels to a third stage of operation by said intermittent traction and advancing device; cutting said panels to a desired size by means of a saw device (5) including at least one disk, band or laser beam saw; said stages of operation being automatically controlled. 15. An apparatus for the manufacture by a continuous process of compound panels, said panels being of variable cross-section and of any desired shape and comprising a metallic framework and a lightweight core (1), the metallic framework, consisting of a three-dimensional wire grille or grating generally presented in the form of two parallel meshes (2) joined by a series of connector wires (2-1) welded to them, said connector wires (2-1) being inclined with respect of the wires (2-2, 2-3) of the meshes (2), the lightweight core (1) consisting of a layer of foam resin or dense box material, paperboard laminate, fiber or plastics material, provided with reinforcing walls and unresistant to a wire segment passing through it, comprising in combination: means for providing wire mesh (2); means to separate said wire mesh (2) a suitable distance and to maintain said wire mesh (2) in parallel; a machine including an intermittent traction and advancing device wherein said intermittent traction and advancing device introduces two sheets of mesh (2) and one sheet of lightweight material (1), parallel and separated a suitable distance into one end of said machine; said machine including means for adjusting said machine to accommodate various thicknesses of said two sheets of mesh (2) and said one sheet of lightweight material (1) to produce compound panels of various thicknesses at the completion of a third stage of operation; said intermittent traction and advancing device intermittently moves said two sheets of mesh (2) and said one sheet of lightweight material (1) a regulated distance to a first stage of operation; a dispensing device (3-2) and a fastening device (3), including a vertical battery of dischargers (3-1) and a fastening device (3), each located at the first stage of operation, said dispensing device (3-2) feeding a series of connector wire segments (2-1) to said fastener (3), said vertical battery of dischargers (3-1) then drives said connector wire segments (2-1) into said sheet of lightweight material (1), the end of said wire segments (2-1) resting against longitudinal wires (2-3) of said two meshes (2) which advance intermittently inside the machine; said intermittent traction and advancing device moves the unit thus constituted with said connector-wires (2-1) in place to a second stage of operation; a column of electrodes (4) located at said second stage of operation for welding the connector-wire segments (2-1) to the longitudinal wires (2-3) of said two meshes (2) thereby forming panels; said intermittent traction and advancing device moves said panels to the third stage of operation; a saw device (5) located at the third stage of operation, said saw device (5) including at least one disk, band or laser beam saw for cutting the panels to a desired size; and means for automatically controlling the first, second and third stages of operation. 16. An apparatus according to any one of the preceding claims wherein said connector-wires (2-1) are made of normal steel and undergo surface treatment prior to insertion in the machine, said connector-wires (2-1) being subjected to denuding by grinding some 10 mm along each point to thus permit said wires to be welded to the meshes (2). 17. An apparatus according to any one of the preceding claims wherein said intermittent traction and advancing device carries out all the intermittent movements of said two sheets of wire mesh (2) and said sheet of lightweight core (1) throughout the three sections of the machinery.

Inventors: MONZON INDAVE, MARTIN
Applicants: MONZON INDAVE, MARTIN
Application year: 1983
Main classification: B23K11
IPC codes: B21F27, B23K11