Method of manufacturing a composite building element and system therefor

Abstract

The invention relates to a method of manufacturing a composite building element that includes a casing material, a bulk material, and a locking element, the method including the steps of: (a) continuously feeding a first sheet of casing material into a filling station; (b) securing the bulk material to the first sheet of casing material; (c) continuously feeding the bulk material and the first sheet of casing material out of the filling station; the method characterised by the step of: (d) securing the locking element to the first sheet of casing material prior to securing the bulk material to the first sheet of casing material.

1 .- 27 . (canceled) 
     
     
         28 . A method of manufacturing a composite building element, wherein the method uses a filling station configured to secure a bulk material to a first sheet of casing material,
 a feed station configured to feed the first sheet of casing material into the filling station, an insert station that is configured to secure a locking element to the first sheet of casing material before the bulk material is secured to the first sheet of casing material, wherein the system is configured to feed the first sheet of casing material from the insert station into the filling station,   the method comprising the steps of:   (a) using the feed station to continuously feed the first sheet of casing material into the filling station;   (b) using the filling station to secure the bulk material to the first sheet of casing material;   (c) using the insert station to secure the locking element to the first sheet of casing material prior to the filling station securing the bulk material to the first sheet of casing material.   
     
     
         29 . The method of  claim 28 , including a step of feeding a second sheet of the casing material into the filling station so that there is a gap between the first and second sheets of the casing material. 
     
     
         30 . The method of  claim 29 , wherein the step of securing the bulk material to the sheet material involves injecting an insulation material into the gap. 
     
     
         31 . The method of  claim 30 , including a step of curing the insulation material. 
     
     
         32 . The method of  claim 28 , including a step of deforming a sheet of casing material so as to create a connection cavity. 
     
     
         33 . The method of  claim 32 , wherein the step of deforming a sheet of casing material involves bending a side edge of the casing material. 
     
     
         34 . The method of  claim 32 , wherein the step of securing the locking element to the first sheet of casing material involves inserting a foot of the locking element into the connection cavity. 
     
     
         35 . The method of  claim 28 , wherein the step of securing the locking element to the first sheet of casing material involves clamping. 
     
     
         36 . The method of  claim 28 , including cutting the first sheet of casing material and the bulk material after step (b) to form a composite building element of a desired length. 
     
     
         37 . A composite building element manufactured using a system for manufacturing composite building elements, the system comprising:
 a filling station configured to secure a bulk material to a first sheet of casing material,   a feed station configured to feed the first sheet of casing material into the filling station,   an insert station that is configured to secure a locking element to the first sheet of casing material before the bulk material is secured to the sheet of casing material,   wherein the system is configured to feed the first sheet of casing material from the insert station into the filling station.