CA1308874C - Panel unit - Google Patents
Panel unitInfo
- Publication number
- CA1308874C CA1308874C CA000544660A CA544660A CA1308874C CA 1308874 C CA1308874 C CA 1308874C CA 000544660 A CA000544660 A CA 000544660A CA 544660 A CA544660 A CA 544660A CA 1308874 C CA1308874 C CA 1308874C
- Authority
- CA
- Canada
- Prior art keywords
- panel
- panels
- grooves
- tongue
- laminate
- 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.)
- Expired - Lifetime
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/292—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and sheet metal
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
- E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
- E04C2/526—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits with adaptations not otherwise provided for, for connecting, transport; for making impervious or hermetic, e.g. sealings
Abstract
ABSTRACT
A building panel is disclosed having substantially quadrilateral shape wherein two edge surfaces have tongue members and two edge surfaces have groove members. Preferably, the edge surfaces with tongues are adjacent surfaces and the edge surfaces with grooves are adjacent surfaces. Preferably, the panel is a laminate having a core of insulating material laminated on both sides with metallic skins.
Walls constructed from such panels have reduced fire hazards.
A building panel is disclosed having substantially quadrilateral shape wherein two edge surfaces have tongue members and two edge surfaces have groove members. Preferably, the edge surfaces with tongues are adjacent surfaces and the edge surfaces with grooves are adjacent surfaces. Preferably, the panel is a laminate having a core of insulating material laminated on both sides with metallic skins.
Walls constructed from such panels have reduced fire hazards.
Description
IMPROVED P~NEL UNIT
This invention relates to integrated panel systems and insulated panel units.
Particularly, the panels of this invention are suitable for use as wall panels although it will become apparent on a reading of the specification that ~he panels may be used in other applications. Hereafter, reference to the invention will be described by reference to wall panels only. However, it is to be understood that the invention is not so limited.
The building lndustry is often confronted with a need to provide premises which can be relatively quickly and inexpensively erected. In the past, it has been proposed and practiced to substitute conventional extsrnal cladding materials such as bricks and timber with insulated metal panels which can be simply affixed to the metal superstructure or frame of a building being constructed. Many buildings have been constructed using such panels and they are particularly suitable for use as the external cladding of factories, 35,461 F -1-: ~ :
., " . . ., ~ ., . ~ .
- . . " ~ ~ :
.~ :
~L3~
646g3-4096 warehouses and public buildings. Although, of course, use o~ ~he insulated wall panel is not limited to these applications.
US-A-4360553 discloses, as prior art thereto, a sandwich panel comprising two shee~s with an insulating ~aterial, e.g.
foam, sandwiched therebetween and provided with a double tongue and groove on two opposite sides so that a row of panels can be assembled with one another. US-A-4360553 discloses an improved sandwich panel of this type in whlch double tongues are provided on each of two adjacent edges and dou~le grooves are formed alony the remaininy two adjacent edges permitting the panels to be assembled in columns as well as rows. The arms of the double tongues are cranked at the panel corner where the tongues meet to accommodate the arms of the double tongues o~ an adjoining panel.
The double groove of said prior art panels is formed by a profile of plastics material clamped at its ends in folded over edges of the outer shee~s.
According to the present invention there is provided a building panel of subs~antially quadrilateral shape de~ined by four edge surfaces in which two edge surfaces include tongue members thereon and two edge surfaces include grooves therein, said iongue members on one panel being engageable in said grooves on corresponding panels so that two or more of said panels may be engaged elther horizontally or vertically by means o~ said tongue members of one panel beiny inserted into tha grooves in correspondlng panels, said panel being constructed of a core material which is laminated on both sides and wherein the laminate e~tends beyond the oore material to provide a slot at ~he end o~
. ~'i.'~
.
: ~ .
6~693-4096 the respective tongue member ko receive a sealing member, characterized in that: the laminate is shaped round the ends of the edges and back down the grooves to cover the internal walls of the grooves and wherein protrusions are formed by shaping laminate at the bottom of the grooves to hook back on both sides so to restrain the said sealing member aqainst the top o~ the tongue member of the engaging panel when the respectlve panels are connected.
The invenkion also provicles a buildiny panel of substantially quadrilateral shape clefined by ~our edge surfaces wherein two edge surfaces include tongue members thereon and kwo edge surfaces include yrooves therein said tongue members on one panel belng engageable in said grooves on corresponding panels so that two or more of said panels may be engaged either horizon~ally or vertically by means of said tongue members of one panel being inserted into the grooves in corresponding panels, the panel being constructed of a core material which i6 laminated on both sides and wherein two adjacent edge surfaces include tongue members thereon and ~wo adjacent edge surfaces include grooves therein;
and wherein the laminate on one said tongue member at one corner of the panel is inset the laminate on the tongue member at another corner of the panel is set out of the plane of the tongue member and on the remaining corner o~ the panel which comprises a tongue member the laminate remains in the ~ama plane throughout the length of the ~ongue member such that upon assembly of a number of said panels khe laminate portions at the said corners mutually cooperate and dov~tail at the points of common connection so to , ;, :, ,, ,. :
7~
enable the respective panel to engage with each o~her at the sald points of common connectlon.
The invention further provicles a building panel of substantially quadrilateral shape definad by four edge surfaces wherein two edge surfaces include kongue members thereon and two edge surfaces include grooves therein said tongue members on one panel being engageable in said grooves on corresponding panels so that two or more of said panels ma~ be engaged either horizontally or verti~ally by means of said tongue members of one panel being inserted into the grooves in corresponding panels, said grooves being provided with an entry portion and an en~ayement portion, the said entry portion being shaped as to not engage the tongue member of a correspondlng panel and said engagement portion being shaped so that it is adapted to accep~ and res~raln the said tongue member and wherein the depth of the said grooves is less than the length of the engaging tongue members so to provide a run off section between engaged building panels.
Preferably, the grooves are on two adjacent edge surfaces of the panel; the tongue members being on the other ~wo adjacent edge surfaces. Ho~ever, whether the panel be conflgured with tongues and grooves on adjacent edge surfaces or tongue~ and grooves on alternate edge surfaces it is possible to join the panels in either a vertical or horizontal mode as each edge surface is provided with an engag~ng tongue member or groove.
A weather seal may be provided by inserting a sealing member at the end o~ the respective tongue member when two panels are assembled together. Preferably, the sealing member is made of 3a ~ .:
:................. ~ .
: . - !
7~ 64693-40g6 a compressible foam.
The laminating material may be any suitable polymeric or metallic layer. Most preferably, it ls metallic. A metallic laminate may be chosen from a number of dif~erent materlals already kno~n in the art. For instance, aluminium, stainleæs steel or COLORBOND STEEL ~a registered trademark) may be selected.
The choice of material ls dependent greatly on the situatlon ln which the panel is to be used. Preferably, the CGre material is an insulating material. A number of insulating materials are suitable and are known in the art. Most preferably, an extruded polystyrene foam is selected. The core materlals may be of variable thickness enabling thermal and structural proper~ies ~o be varied as is required in any building specification.
3b . ~, _L~_ Once assembled, a wall constructed of laminated panel units will have a continuously separated inner and outer laminated skin. In a fire, such separation allows molten foam to flow to the bottom of the structure. This is a safety feature which has not existed in the prior art.
In a preferred embodiment of this invention, the laminate extends beyond the core material at the tongue edges of the panel in order to provide a slot at the end of the tongue member. This slot is suitable to firmly retain the said sealing member.
In a further embodiment of the invention, the laminate on the groove edges is shaped around the ends of the edges and back down the grooves so that it covers the internal walls of the grooves. This laminate may be shaped at the bottom of the groove to hook back on both sides thus providing protrusions which are directed back out of the groove on both sides. In such an embodiment, if an adjacent panel includes a tongue edge with a compressible foam sealing member as aforesaid then when the tongue member is inserted inta the groove, the foam rnaterial is restrained from extending to the end of the groove.
The compressible foam sealing member is thus more securely retained in the groove by these extending protrusions. In such an assembly, the compresslble foam seal has been found to be very effective in providing a capillary break thus substantially preventing water penetration by capillary action. Such a sealing method avoids ~he need for builders to use caulking materials which have necessarily been required 35,461-F _4_ .
?
~ 3 ~ ~ ~7 when weather seals have been previously provided in known wall cladding systems of this type.
Preferably, the protrusion is curved or bent back at the ends to prevent damage to the sealing member. It will be appreciated that the protrusions also act as hooks to more securely retain the engaging panel. ~hen two panels are assembled in the manner described above, the hook formed by the laminate secures the end of the laminate which extends beyond the core material at the tongue edge of the other panel.
Thls provides a further benefit in that the ~~ 15 hook ensures that the laminateq of the two panels are firmly locked together. This is particularly advantageous in the case of fire as it substantially prevents buckling of the panels.
It has been additionally discovered by the applicant that the water seal between the panels can be improved even ~urther if a small gap is provided between the panels to~allow water run off.
Thus, in a further preferred embodiment of the invention, a run off gap is provided at the joints when the panel units are assembled. This may be provided by shaping the grooves so that at the edge of the panel, the groove is dimensioned wider than the engaging 3 tongue member of the adjacent panel. The groove is also provided with a narrow portion so that the width of the groove toward~ its base is substantially the same width as the engaging tongue member. To ensure that a run off gap is provided, the tongue panel is made of sufficlent length so that when the panels are 35,461-F -5-~6--engaged and the tongue is fully inserted into the grooves the outside edges of the respective panels are not in contact. Most preferably, the laminated edge leading up to the tongue on the edge of the adjacent panel is downwardly sloped to ensure that driven rain quickly and easily runs off the joint. In the manufacture of panels made in accordance with thls invention, the groove can be either provided by machining the edge surface to the desired shape or by inserting an extruded or molded section of the desired shape into a slot provided along the edge surfaces of the panel. Such a section could be made of metal or plastics material.
It will be appreciated that any number of panels made in accordance with this invention can be assembled together in a vertical or horizontal direction. Preferably, the corners of the panel are shaped to allow easy assembly of a plurality of panels.
Thus, a building made in accordance with the invention may in a preferred form be provided wherein at each of the respective corners of the said panel to which the tongue members extend the said tongue members include an interlocking portion proximate the said respective corners, said interlocking portions on each of the respective tongue members being shaped such that upon assembly of a number of said panels the interlocking portions mutually cooperate at the points of common 3 connection so to enable the respective panels to engage with each other at the said points of common connection. Preferaoly, at corners where four panels meet when assembled, the edges are dovetailed for a clean and tight joint. In other words, it is desirable for the corners of the edges to be pressed differently 35,461-F -6-so that they cooperate. In such an embodiment the laminate on the corner of one tongue may be inset, the laminate on the corner o~ another tongue may be set out of the plane and the remaining laminate may remain in the same plane throughout. In such a confirguration when four edges meet, the laminate at each corner will overlap to ensure tight connection and a close tolerance fit.
The panels of this invention may be affixed to the superstructure or frame of a building in a number of different ways. Such meShods would be recognized by any person skilled in the art.
f 15 Preferably, a fixing bracket is u~ed which is adapted to be bolted or otherwise affixed to a superstructure and which is adapted to be secured to the side or edge of the panel. Alternatively, a hook fastener can be used which comprises a fixing bracket and lug. Such a bracket can be affixed by bolts or other means to the frame of the building or structure with the lug affixed to a panel. Preferably, the lug is inserted into the ramp leading up to the tongue on one of the tongue edges of the panel or into the side of the panel. To facilitate more reliable connection it may be appropriate~to strengthen the tongue member by the inclusion of a pressed metal tongue stiffener during the manufacture of the panels. Such hook fasteners allow easy, quick fixing of panels on site without close tolerance problems encountered by the prior art. It will also be apparent to those skilled in the art that the joining system used in the panels of this invention can be adopted in the sides of windows or door jambs. This enables simple and reliable construction of a building utilizing panels !
, ~ ~
~ 7 and other fixtures using the one universal jointing system.
The invention will now be described by way of example with reference to the accompanying drawings in which:
Figure 1 is a perspective view of the end portions of four panel units made in accordance with the present invention.
Figure 2 is a cross-sectional view of two panels made in accordance with the present invention in an assembled form.
Figure 3 is a perspective view of a fixing bracket which may be used in attaching panels made in accordance with the invention.
Figure 4 is a cross-sectional view of two assembled wall panels made in accordance with the invention secured to a frame by a ~ixing bracket illustrated in Figure 3.
Figure 5 is a perspective view of a fixing bracket and lug which may be used in attaching panels made in accordance with the invention.
Figure 6 is a cross-sectional view of two assembled wall panels made in accordance with the 3 invention secured to a frame by the fixing bracket illustrated in Figure 5.
Figure 7 is a perspective view of an alternative fixing bracket.
35,461-F -8-Figure 8 is a cross-sectional view of a wall panel made in accordance with the invention secured to a masonry wall by the fixing bracket illustrated in Figure 7.
Figure 9 is a perspective view of an alternative fixing bracket.
Figure 10 is a cross-sectional view of two assembled wall panels made in accordance with the invention secured to a frame by the fixing bracket illustrated in Figure 9.
Figure 11 is a perspective view of an , 15 alternative fixing bracket.
Figure 12 is a cross-sectional view of two assembled wall panels made in accordance with the invention secured to a masonry wall by the fixing bracket illustrated in Figure 11.
Figure 13 is a perspective view of an alternative fixing bracket.
Figure 14 is a cross-sectional view of two assembled walI panels made in accordance with the invention secured to a steel cleat by the fixing bracket illustrated in Figure 13, Figure 15 is a cross-sectional view of a wall 3 panel made in accordance with the inventlon assembled with a fitting to insert a window jamb.
Figure 16 is a cross-sectional view of a wall panel made in accordance with the invention assembled . .
35 ? 4~1-F ~9~
.
:
- lo -with a cooperative fitting to facilitate insertion of a door jamb.
In Figure 1 there is a disclosed detail of each corner of a wall panel constructed in accordance with the preferred embodiment of this invention. For the purposes of more easily understanding how two or more of the panels of the invention cooperate, Figure 1 illustrates the four different corners of a preferred embodiment of the invention as they would meet at the point of common connection between four o~ the said panels. The wall panels are not shown as complete units but are each substantially quadrilateral in shape. Two edge surfaces of each of the panels are provided with grooves 2 and 3. The other edge surfaces are provided with tongue members 4 and 5. As can ~e seen in Figure 1, the tongue members 4 and 5 and grooves 2 and 3 of the wall panel unit are shaped to cooperate with the respective grooves 2 and 3 and tongue members 4 and 5 of other wall panel units made in accordance with the invention. The wall panel is provided with grooves 2 and 3 along adjacent edges as is illustrated on corner 1.
The other two adjacent edges of the wall panel are provided with tongue members 4 and 5 as illustrated in corner 6.
The panel unit is laminated with a metallic material 7 and has an extruded polystyrene foam core 8.
The laminate 7 extends beyond the extruded polystyrene foam core 8 along the tongue members 4 and 5 of the panel to provide a slot 9. Within slot 9 a compressible foam seal 10 may be inserted. This material acts as a weather seal when the tongue 4 or 5 35,461-F -10_ , - ~ .
~.
, ~ .
is inserted into a groove 2 or 3. The laminate 7 on the grooves 2 and 3 is shaped around the ends of the edges and back down the grooves 2 and 3 so that it covers the internal walls 11 of the grooves 2 and 3.
As can be seen in Figure 2, at the bottom of the grooves 2 or 3 the laminate 7 is hooked back on both sides to form protrusions 12. These protrusions 12 are rounded at the ends 13 so that when the tongue members 4 or 5 and compressible foam seal material 10 of an adjacent wall panel unit are inserted into groove 2 or 3 the protrusions 12 will not damage the compres~ible foam seal 10. Furthermore, the protrusions 12 restrain the compressible foam seal 10 from being pushed right , 15 to the end of the groove 2 or 3 when the tongue member 4 or 5 is inserted. This causes the compressible foam seal 10 to be more securely compressed within slot 9 in the tongue member 4 or 5. As the tongue members 4 or 5 are inserted into the grooves 2 or 3 the extending portion of the laminate 14 fits within the hook formed by protrusion 12. This ensures that the laminates of the two panels are firmly locked together when the tongue members 4 or 5 are engaged in the grooves 2 or 3.
A gap 15 is provided between the assembled panels to improve water run off. As illustrated in Figure 2, gap 15 is provided due to the length of tongue 4 or 5 additional to the depth of groove 2 or 3.
This gap continues up the side 16 of the assembled panels due to greater width of groove 2 or 3 at its commencement compared with its width where indicated at 17. Ledge 18 is angled slightl~ downwards to ensure proper and good run off. It will be appreciated that when the panels are assembled as illustrated in 35,461-F
Figure 2, the compressible foam seal 10 form a ~ubstantially water tight seal whilst the gap 15 enables any moisture and water which enters the joint, say as a result o~ driven rain, to simply run off the joi~t.
The edges of the laminate shown in Figure 1 are offset relative one to the other so that a clos0 fitting can be obtained when four panels of the invention are assembled together. The laminate in this preferred embodiment is pressed out at 19, pressed in at 20 and is left in the same plane at 21. As the various panels are joined together, these laminates overlap enabling a close and secure joint.
r 1 5 Turning to Figures 3 to 14, there is illustrated a number of different fixing brackets which can be used to affix a panel or panels of the present invention to different structures. These are by way of example only and are not intended to limit the scope of the present invention.
Where fixing brackets are used as illustrated in Figures 3, 5, q, 11 and 13, it is desirable to strengthen the tongue members 4 and 5 with a pressed metal tongue stiffener 22. The fixing brackets used are preferably made of galvanized steel.
In Figure 13 there is illustrated a window jamb 3 23 shaped in cooperation with groove 2 or 3. The window jamb 23 being attached in this example via a specially shaped extrusion 26 to a piece of aluminium trimming 25. Aluminium trimming 25 in turn is attached to a piece of fixing angle 24. The extrusion 26 which is preferably made of aluminium allows the window to 35,461-F -12--~. ., : ,: - .
:
resemble a panel unit in that it can fit adjacent to and in the same plane as other panel units. In Figure 14 there is illustrated a door head 27 shaped to cooperate with groove 2 or 3 again Vi2 shaped extrusion 26.
Finally, it is to be understood that the aforegoing description refers merely to preferred embodiments of the present invention, and that 10. variations and modifications are possible without departing from the spirit and scope of the invention.
35,461-F ~13-.
This invention relates to integrated panel systems and insulated panel units.
Particularly, the panels of this invention are suitable for use as wall panels although it will become apparent on a reading of the specification that ~he panels may be used in other applications. Hereafter, reference to the invention will be described by reference to wall panels only. However, it is to be understood that the invention is not so limited.
The building lndustry is often confronted with a need to provide premises which can be relatively quickly and inexpensively erected. In the past, it has been proposed and practiced to substitute conventional extsrnal cladding materials such as bricks and timber with insulated metal panels which can be simply affixed to the metal superstructure or frame of a building being constructed. Many buildings have been constructed using such panels and they are particularly suitable for use as the external cladding of factories, 35,461 F -1-: ~ :
., " . . ., ~ ., . ~ .
- . . " ~ ~ :
.~ :
~L3~
646g3-4096 warehouses and public buildings. Although, of course, use o~ ~he insulated wall panel is not limited to these applications.
US-A-4360553 discloses, as prior art thereto, a sandwich panel comprising two shee~s with an insulating ~aterial, e.g.
foam, sandwiched therebetween and provided with a double tongue and groove on two opposite sides so that a row of panels can be assembled with one another. US-A-4360553 discloses an improved sandwich panel of this type in whlch double tongues are provided on each of two adjacent edges and dou~le grooves are formed alony the remaininy two adjacent edges permitting the panels to be assembled in columns as well as rows. The arms of the double tongues are cranked at the panel corner where the tongues meet to accommodate the arms of the double tongues o~ an adjoining panel.
The double groove of said prior art panels is formed by a profile of plastics material clamped at its ends in folded over edges of the outer shee~s.
According to the present invention there is provided a building panel of subs~antially quadrilateral shape de~ined by four edge surfaces in which two edge surfaces include tongue members thereon and two edge surfaces include grooves therein, said iongue members on one panel being engageable in said grooves on corresponding panels so that two or more of said panels may be engaged elther horizontally or vertically by means o~ said tongue members of one panel beiny inserted into tha grooves in correspondlng panels, said panel being constructed of a core material which is laminated on both sides and wherein the laminate e~tends beyond the oore material to provide a slot at ~he end o~
. ~'i.'~
.
: ~ .
6~693-4096 the respective tongue member ko receive a sealing member, characterized in that: the laminate is shaped round the ends of the edges and back down the grooves to cover the internal walls of the grooves and wherein protrusions are formed by shaping laminate at the bottom of the grooves to hook back on both sides so to restrain the said sealing member aqainst the top o~ the tongue member of the engaging panel when the respectlve panels are connected.
The invenkion also provicles a buildiny panel of substantially quadrilateral shape clefined by ~our edge surfaces wherein two edge surfaces include tongue members thereon and kwo edge surfaces include yrooves therein said tongue members on one panel belng engageable in said grooves on corresponding panels so that two or more of said panels may be engaged either horizon~ally or vertically by means of said tongue members of one panel being inserted into the grooves in corresponding panels, the panel being constructed of a core material which i6 laminated on both sides and wherein two adjacent edge surfaces include tongue members thereon and ~wo adjacent edge surfaces include grooves therein;
and wherein the laminate on one said tongue member at one corner of the panel is inset the laminate on the tongue member at another corner of the panel is set out of the plane of the tongue member and on the remaining corner o~ the panel which comprises a tongue member the laminate remains in the ~ama plane throughout the length of the ~ongue member such that upon assembly of a number of said panels khe laminate portions at the said corners mutually cooperate and dov~tail at the points of common connection so to , ;, :, ,, ,. :
7~
enable the respective panel to engage with each o~her at the sald points of common connectlon.
The invention further provicles a building panel of substantially quadrilateral shape definad by four edge surfaces wherein two edge surfaces include kongue members thereon and two edge surfaces include grooves therein said tongue members on one panel being engageable in said grooves on corresponding panels so that two or more of said panels ma~ be engaged either horizontally or verti~ally by means of said tongue members of one panel being inserted into the grooves in corresponding panels, said grooves being provided with an entry portion and an en~ayement portion, the said entry portion being shaped as to not engage the tongue member of a correspondlng panel and said engagement portion being shaped so that it is adapted to accep~ and res~raln the said tongue member and wherein the depth of the said grooves is less than the length of the engaging tongue members so to provide a run off section between engaged building panels.
Preferably, the grooves are on two adjacent edge surfaces of the panel; the tongue members being on the other ~wo adjacent edge surfaces. Ho~ever, whether the panel be conflgured with tongues and grooves on adjacent edge surfaces or tongue~ and grooves on alternate edge surfaces it is possible to join the panels in either a vertical or horizontal mode as each edge surface is provided with an engag~ng tongue member or groove.
A weather seal may be provided by inserting a sealing member at the end o~ the respective tongue member when two panels are assembled together. Preferably, the sealing member is made of 3a ~ .:
:................. ~ .
: . - !
7~ 64693-40g6 a compressible foam.
The laminating material may be any suitable polymeric or metallic layer. Most preferably, it ls metallic. A metallic laminate may be chosen from a number of dif~erent materlals already kno~n in the art. For instance, aluminium, stainleæs steel or COLORBOND STEEL ~a registered trademark) may be selected.
The choice of material ls dependent greatly on the situatlon ln which the panel is to be used. Preferably, the CGre material is an insulating material. A number of insulating materials are suitable and are known in the art. Most preferably, an extruded polystyrene foam is selected. The core materlals may be of variable thickness enabling thermal and structural proper~ies ~o be varied as is required in any building specification.
3b . ~, _L~_ Once assembled, a wall constructed of laminated panel units will have a continuously separated inner and outer laminated skin. In a fire, such separation allows molten foam to flow to the bottom of the structure. This is a safety feature which has not existed in the prior art.
In a preferred embodiment of this invention, the laminate extends beyond the core material at the tongue edges of the panel in order to provide a slot at the end of the tongue member. This slot is suitable to firmly retain the said sealing member.
In a further embodiment of the invention, the laminate on the groove edges is shaped around the ends of the edges and back down the grooves so that it covers the internal walls of the grooves. This laminate may be shaped at the bottom of the groove to hook back on both sides thus providing protrusions which are directed back out of the groove on both sides. In such an embodiment, if an adjacent panel includes a tongue edge with a compressible foam sealing member as aforesaid then when the tongue member is inserted inta the groove, the foam rnaterial is restrained from extending to the end of the groove.
The compressible foam sealing member is thus more securely retained in the groove by these extending protrusions. In such an assembly, the compresslble foam seal has been found to be very effective in providing a capillary break thus substantially preventing water penetration by capillary action. Such a sealing method avoids ~he need for builders to use caulking materials which have necessarily been required 35,461-F _4_ .
?
~ 3 ~ ~ ~7 when weather seals have been previously provided in known wall cladding systems of this type.
Preferably, the protrusion is curved or bent back at the ends to prevent damage to the sealing member. It will be appreciated that the protrusions also act as hooks to more securely retain the engaging panel. ~hen two panels are assembled in the manner described above, the hook formed by the laminate secures the end of the laminate which extends beyond the core material at the tongue edge of the other panel.
Thls provides a further benefit in that the ~~ 15 hook ensures that the laminateq of the two panels are firmly locked together. This is particularly advantageous in the case of fire as it substantially prevents buckling of the panels.
It has been additionally discovered by the applicant that the water seal between the panels can be improved even ~urther if a small gap is provided between the panels to~allow water run off.
Thus, in a further preferred embodiment of the invention, a run off gap is provided at the joints when the panel units are assembled. This may be provided by shaping the grooves so that at the edge of the panel, the groove is dimensioned wider than the engaging 3 tongue member of the adjacent panel. The groove is also provided with a narrow portion so that the width of the groove toward~ its base is substantially the same width as the engaging tongue member. To ensure that a run off gap is provided, the tongue panel is made of sufficlent length so that when the panels are 35,461-F -5-~6--engaged and the tongue is fully inserted into the grooves the outside edges of the respective panels are not in contact. Most preferably, the laminated edge leading up to the tongue on the edge of the adjacent panel is downwardly sloped to ensure that driven rain quickly and easily runs off the joint. In the manufacture of panels made in accordance with thls invention, the groove can be either provided by machining the edge surface to the desired shape or by inserting an extruded or molded section of the desired shape into a slot provided along the edge surfaces of the panel. Such a section could be made of metal or plastics material.
It will be appreciated that any number of panels made in accordance with this invention can be assembled together in a vertical or horizontal direction. Preferably, the corners of the panel are shaped to allow easy assembly of a plurality of panels.
Thus, a building made in accordance with the invention may in a preferred form be provided wherein at each of the respective corners of the said panel to which the tongue members extend the said tongue members include an interlocking portion proximate the said respective corners, said interlocking portions on each of the respective tongue members being shaped such that upon assembly of a number of said panels the interlocking portions mutually cooperate at the points of common 3 connection so to enable the respective panels to engage with each other at the said points of common connection. Preferaoly, at corners where four panels meet when assembled, the edges are dovetailed for a clean and tight joint. In other words, it is desirable for the corners of the edges to be pressed differently 35,461-F -6-so that they cooperate. In such an embodiment the laminate on the corner of one tongue may be inset, the laminate on the corner o~ another tongue may be set out of the plane and the remaining laminate may remain in the same plane throughout. In such a confirguration when four edges meet, the laminate at each corner will overlap to ensure tight connection and a close tolerance fit.
The panels of this invention may be affixed to the superstructure or frame of a building in a number of different ways. Such meShods would be recognized by any person skilled in the art.
f 15 Preferably, a fixing bracket is u~ed which is adapted to be bolted or otherwise affixed to a superstructure and which is adapted to be secured to the side or edge of the panel. Alternatively, a hook fastener can be used which comprises a fixing bracket and lug. Such a bracket can be affixed by bolts or other means to the frame of the building or structure with the lug affixed to a panel. Preferably, the lug is inserted into the ramp leading up to the tongue on one of the tongue edges of the panel or into the side of the panel. To facilitate more reliable connection it may be appropriate~to strengthen the tongue member by the inclusion of a pressed metal tongue stiffener during the manufacture of the panels. Such hook fasteners allow easy, quick fixing of panels on site without close tolerance problems encountered by the prior art. It will also be apparent to those skilled in the art that the joining system used in the panels of this invention can be adopted in the sides of windows or door jambs. This enables simple and reliable construction of a building utilizing panels !
, ~ ~
~ 7 and other fixtures using the one universal jointing system.
The invention will now be described by way of example with reference to the accompanying drawings in which:
Figure 1 is a perspective view of the end portions of four panel units made in accordance with the present invention.
Figure 2 is a cross-sectional view of two panels made in accordance with the present invention in an assembled form.
Figure 3 is a perspective view of a fixing bracket which may be used in attaching panels made in accordance with the invention.
Figure 4 is a cross-sectional view of two assembled wall panels made in accordance with the invention secured to a frame by a ~ixing bracket illustrated in Figure 3.
Figure 5 is a perspective view of a fixing bracket and lug which may be used in attaching panels made in accordance with the invention.
Figure 6 is a cross-sectional view of two assembled wall panels made in accordance with the 3 invention secured to a frame by the fixing bracket illustrated in Figure 5.
Figure 7 is a perspective view of an alternative fixing bracket.
35,461-F -8-Figure 8 is a cross-sectional view of a wall panel made in accordance with the invention secured to a masonry wall by the fixing bracket illustrated in Figure 7.
Figure 9 is a perspective view of an alternative fixing bracket.
Figure 10 is a cross-sectional view of two assembled wall panels made in accordance with the invention secured to a frame by the fixing bracket illustrated in Figure 9.
Figure 11 is a perspective view of an , 15 alternative fixing bracket.
Figure 12 is a cross-sectional view of two assembled wall panels made in accordance with the invention secured to a masonry wall by the fixing bracket illustrated in Figure 11.
Figure 13 is a perspective view of an alternative fixing bracket.
Figure 14 is a cross-sectional view of two assembled walI panels made in accordance with the invention secured to a steel cleat by the fixing bracket illustrated in Figure 13, Figure 15 is a cross-sectional view of a wall 3 panel made in accordance with the inventlon assembled with a fitting to insert a window jamb.
Figure 16 is a cross-sectional view of a wall panel made in accordance with the invention assembled . .
35 ? 4~1-F ~9~
.
:
- lo -with a cooperative fitting to facilitate insertion of a door jamb.
In Figure 1 there is a disclosed detail of each corner of a wall panel constructed in accordance with the preferred embodiment of this invention. For the purposes of more easily understanding how two or more of the panels of the invention cooperate, Figure 1 illustrates the four different corners of a preferred embodiment of the invention as they would meet at the point of common connection between four o~ the said panels. The wall panels are not shown as complete units but are each substantially quadrilateral in shape. Two edge surfaces of each of the panels are provided with grooves 2 and 3. The other edge surfaces are provided with tongue members 4 and 5. As can ~e seen in Figure 1, the tongue members 4 and 5 and grooves 2 and 3 of the wall panel unit are shaped to cooperate with the respective grooves 2 and 3 and tongue members 4 and 5 of other wall panel units made in accordance with the invention. The wall panel is provided with grooves 2 and 3 along adjacent edges as is illustrated on corner 1.
The other two adjacent edges of the wall panel are provided with tongue members 4 and 5 as illustrated in corner 6.
The panel unit is laminated with a metallic material 7 and has an extruded polystyrene foam core 8.
The laminate 7 extends beyond the extruded polystyrene foam core 8 along the tongue members 4 and 5 of the panel to provide a slot 9. Within slot 9 a compressible foam seal 10 may be inserted. This material acts as a weather seal when the tongue 4 or 5 35,461-F -10_ , - ~ .
~.
, ~ .
is inserted into a groove 2 or 3. The laminate 7 on the grooves 2 and 3 is shaped around the ends of the edges and back down the grooves 2 and 3 so that it covers the internal walls 11 of the grooves 2 and 3.
As can be seen in Figure 2, at the bottom of the grooves 2 or 3 the laminate 7 is hooked back on both sides to form protrusions 12. These protrusions 12 are rounded at the ends 13 so that when the tongue members 4 or 5 and compressible foam seal material 10 of an adjacent wall panel unit are inserted into groove 2 or 3 the protrusions 12 will not damage the compres~ible foam seal 10. Furthermore, the protrusions 12 restrain the compressible foam seal 10 from being pushed right , 15 to the end of the groove 2 or 3 when the tongue member 4 or 5 is inserted. This causes the compressible foam seal 10 to be more securely compressed within slot 9 in the tongue member 4 or 5. As the tongue members 4 or 5 are inserted into the grooves 2 or 3 the extending portion of the laminate 14 fits within the hook formed by protrusion 12. This ensures that the laminates of the two panels are firmly locked together when the tongue members 4 or 5 are engaged in the grooves 2 or 3.
A gap 15 is provided between the assembled panels to improve water run off. As illustrated in Figure 2, gap 15 is provided due to the length of tongue 4 or 5 additional to the depth of groove 2 or 3.
This gap continues up the side 16 of the assembled panels due to greater width of groove 2 or 3 at its commencement compared with its width where indicated at 17. Ledge 18 is angled slightl~ downwards to ensure proper and good run off. It will be appreciated that when the panels are assembled as illustrated in 35,461-F
Figure 2, the compressible foam seal 10 form a ~ubstantially water tight seal whilst the gap 15 enables any moisture and water which enters the joint, say as a result o~ driven rain, to simply run off the joi~t.
The edges of the laminate shown in Figure 1 are offset relative one to the other so that a clos0 fitting can be obtained when four panels of the invention are assembled together. The laminate in this preferred embodiment is pressed out at 19, pressed in at 20 and is left in the same plane at 21. As the various panels are joined together, these laminates overlap enabling a close and secure joint.
r 1 5 Turning to Figures 3 to 14, there is illustrated a number of different fixing brackets which can be used to affix a panel or panels of the present invention to different structures. These are by way of example only and are not intended to limit the scope of the present invention.
Where fixing brackets are used as illustrated in Figures 3, 5, q, 11 and 13, it is desirable to strengthen the tongue members 4 and 5 with a pressed metal tongue stiffener 22. The fixing brackets used are preferably made of galvanized steel.
In Figure 13 there is illustrated a window jamb 3 23 shaped in cooperation with groove 2 or 3. The window jamb 23 being attached in this example via a specially shaped extrusion 26 to a piece of aluminium trimming 25. Aluminium trimming 25 in turn is attached to a piece of fixing angle 24. The extrusion 26 which is preferably made of aluminium allows the window to 35,461-F -12--~. ., : ,: - .
:
resemble a panel unit in that it can fit adjacent to and in the same plane as other panel units. In Figure 14 there is illustrated a door head 27 shaped to cooperate with groove 2 or 3 again Vi2 shaped extrusion 26.
Finally, it is to be understood that the aforegoing description refers merely to preferred embodiments of the present invention, and that 10. variations and modifications are possible without departing from the spirit and scope of the invention.
35,461-F ~13-.
Claims (11)
1. A building panel of substantially quadrilateral shape defined by four edge surfaces in which two edge surfaces include tongue members thereon and two edge surfaces include grooves therein, said tongue members on one panel being engageable in said grooves on corresponding panels so that two or more of said panels may be engaged either horizontally or vertically by means of said tongue members of one panel being inserted into the grooves in corresponding panels, said panel being constructed of a core material which is laminated on both sides and wherein the laminate extends beyond the core material to provide a slot at the end of the respective tongue member to receive a sealing member, characterized in that:
the laminate is shaped round the ends of the edges and back down the grooves to cover the internal walls of the grooves and wherein protrusions are formed by shaping laminate at the bottom of the grooves to hook back on both sides so to restrain the said sealing member against the top of the tongue member of the engaging panel when the respective panels are connected.
the laminate is shaped round the ends of the edges and back down the grooves to cover the internal walls of the grooves and wherein protrusions are formed by shaping laminate at the bottom of the grooves to hook back on both sides so to restrain the said sealing member against the top of the tongue member of the engaging panel when the respective panels are connected.
2. A building panel as claimed in Claim 1, wherein the laminate material covers the core material throughout its exposed surface except at the top of the tongue members and the base of the grooves such that upon assembly of a number of building panels to form a structure, the said structure will comprise continuously separated inner and outer laminated skins.
3. A building panel as claimed in Claim 1, wherein, at each of the respective corners of the said panel to which the tongue members extend, the said tongue members include an interlocking portion proximate the said respective corners, said interlocking portions on each of the respective tongue members being shaped such that, upon assembly of a number of said panels, the interlocking portions mutually cooperate at the points of common connection so to enable the respective panels to engage with each other at the said points of common connection.
4. A building panel as claimed in any one of Claims 1 to 3, wherein the said core material is a thermal insulating material.
5. A building panel as claimed in Claim 4, wherein the core material is polystyrene foam.
6. A building panel as claimed in any one of Claims 1 to 3 or 5, wherein two adjacent edge surfaces include tongue members thereon and two adjacent edge surfaces include grooves therein.
7. A building panel as claimed in Claim 6, wherein the laminate on one said tongue member at one corner of the panel is inset, the laminate on the tongue member at another corner of the panel is set out of the plane of the tongue member, and on the remaining corner of the panel which comprises a tongue member the laminate remains in the same plane throughout the length of the tongue member such that upon assembly of a number of said panels the laminate portions at the said corners mutually cooperate and dovetail at the points of common connection so to enable the respective panel to engage with each other at the said points of common connection.
8. A building panel as claimed in any one of Claims 1 to 3, 5 or 7, wherein the said grooves are provided with an entry portion and an engagement portion, the said entry portion being shaped as to not engage the tongue member of a corresponding panel and said engagement portion being shaped so that it is adapted to accept and restrain the said tongue member and wherein the depth of the said grooves is less than the length of the engaging tongue members so to provide a water run off section between engaged building panels.
9. A building panel as claimed in any one of Claims 1 to 3, 5 or 7, wherein the panel is essentially rectangular.
10. A building panel of substantially quadrilateral shape defined by four edge surfaces wherein two edge surfaces include tongue members thereon and two edge surfaces include grooves therein said tongue members on one panel being engageable in said grooves on corresponding panels so that two or more of said panels may be engaged either horizontally or vertically by means of said tongue members of one panel being inserted into the grooves in corresponding panels, the panel being constructed of a core material which is laminated on both sides and wherein two adjacent edge surfaces include tongue members thereon and two adjacent edge surfaces include grooves therein; and wherein the laminate on one said tongue member at one corner of the panel is inset the laminate on the tongue member at another corner of the panel is set out of the plane of the tongue member and on the remaining corner of the panel which comprises a tongue member the laminate remains in the same plane throughout the length of the tongue member such that upon assembly of a number of said panels the laminate portions at the said corners mutually cooperate and dovetail at the points of common connection so to enable the respective panel to engage with each other at the said points of common connection.
11. A building panel of substantially quadrilateral shape defined by four edge surfaces wherein two edge surfaces include tongue members thereon and two edge surfaces include grooves therein said tongue members on one panel being engageable in said grooves on corresponding panels so that two or more of said panels may be engaged either horizontally or vertically by means of said tongue members of one panel being inserted into the grooves in corresponding panels, said grooves being provided with an entry portion and an engagement portion, the said entry portion being shaped as to not engage the tongue member of a corresponding panel and said engagement portion being shaped so that it is adapted to accept and restrain the said tongue member and wherein the depth of the said grooves is less than the length of the engaging tongue members so to provide a run off section between engaged building panels.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU7,518 | 1986-08-18 | ||
| AUPH751886 | 1986-08-18 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1308874C true CA1308874C (en) | 1992-10-20 |
Family
ID=3771765
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000544660A Expired - Lifetime CA1308874C (en) | 1986-08-18 | 1987-08-17 | Panel unit |
Country Status (5)
| Country | Link |
|---|---|
| EP (1) | EP0277226B1 (en) |
| JP (1) | JPH01500679A (en) |
| CA (1) | CA1308874C (en) |
| NZ (1) | NZ221483A (en) |
| WO (1) | WO1988001326A1 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2642454B1 (en) * | 1989-01-09 | 1991-05-31 | Lahoz Michel | DEVICE FOR POSITIONING CONSTRUCTION ELEMENTS WITH RESPECT TO A BUILDING CARRYING STRUCTURE |
| GB2414746B (en) | 2004-06-04 | 2006-02-22 | Baa Plc | Cladding |
| DE202011109831U1 (en) * | 2011-12-09 | 2013-03-13 | Tremco Illbruck Produktion Gmbh | sandwich panel |
Family Cites Families (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| NL140029B (en) * | 1964-07-24 | 1973-10-15 | Hunter Douglas | BUILDING PANEL WITH AN INTERNAL SKIN AND AN EXTERIOR SKIN. |
| US3386218A (en) * | 1966-06-08 | 1968-06-04 | Elwin G Smith & Co Inc | Building panel with ribbed sealing element between overlapping edges |
| US3760548A (en) * | 1971-10-14 | 1973-09-25 | Armco Steel Corp | Building panel with adjustable telescoping interlocking joints |
| US3998024A (en) * | 1975-08-04 | 1976-12-21 | H. H. Robertson Company | Double-skin insulated building panel |
| DE2551905A1 (en) * | 1975-11-19 | 1977-08-25 | Hunter Douglas Ind Bv | PREFABRICATED WALL ELEMENT |
| US4143498A (en) * | 1977-07-14 | 1979-03-13 | Armco Steel Corporation | Concealed fastener clip for building panels |
| DE2754814C2 (en) * | 1977-12-09 | 1986-10-09 | Hunter Douglas Industries B.V., Rotterdam | Wall element with a core made of insulating materials |
| NL189418C (en) * | 1980-02-16 | 1993-04-01 | Hunter Douglas Ind Bv | SANDWICH PANEL ELEMENT. |
| DE3447330A1 (en) * | 1984-12-24 | 1986-07-10 | Hoesch Ag, 4600 Dortmund | WALL OR ROOF ELEMENT MADE OF A FOAM CORE AND METAL COVER LAYERS |
| DE8528510U1 (en) * | 1985-10-07 | 1985-11-28 | Thyssen Industrie Ag, 4300 Essen | Component |
-
1987
- 1987-08-17 JP JP50545187A patent/JPH01500679A/en active Pending
- 1987-08-17 WO PCT/US1987/002064 patent/WO1988001326A1/en active IP Right Grant
- 1987-08-17 EP EP19870905855 patent/EP0277226B1/en not_active Expired - Lifetime
- 1987-08-17 CA CA000544660A patent/CA1308874C/en not_active Expired - Lifetime
- 1987-08-18 NZ NZ22148387A patent/NZ221483A/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| WO1988001326A1 (en) | 1988-02-25 |
| JPH01500679A (en) | 1989-03-09 |
| EP0277226A1 (en) | 1988-08-10 |
| NZ221483A (en) | 1991-02-26 |
| EP0277226B1 (en) | 1992-06-10 |
| EP0277226A4 (en) | 1989-03-07 |
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Legal Events
| Date | Code | Title | Description |
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| MKLA | Lapsed |