AU2006201504B2 - Cladding panel with improved stacking capability - Google Patents

Abstract

A metal cladding panel 10 incorporates a spacer 36 disposed on one of the major surfaces 12 of the panel. 5 The spacer projects from that surface to provide a bearing surface to space at least a portion of that major surface from an adjacent panel on stacking of a plurality of the panels. In one form, the cladding panel is made from metal strip and the spacer 36 is in the form of a 10 plurality of dimples 30 which are pressed into the strip adjacent where the strip is cut to form one edge 24 of the panel. r4n

Description

AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Applicant: BLUESCOPE STEEL LIMITED Invention Title: CLADDING PANEL WITH IMPROVED STACKING CAPABILITY The following statement is a full description of this invention, including the best method of performing it known to me/us: 2 CLADDING PANEL WITH IMPROVED STACKING CAPABILITY Technical Field 5 The present invention relates to metal cladding panels and especially, but not exclusively, to cladding panels that incorporate a decorative coating and the invention is herein described in that context. 10 Background of the Invention Metal cladding panels are widely used in building and construction. These panels are often used in roofing and walling or as infill panels in fencing. The cladding 15 panels are often made from metal strip that is cut into discrete lengths to form the individual panels. To provide adequate strength to the panels, the metal strip is often profiled to include linear stiffening 20 formations such as ribs, pleats or corrugations. This profiling is typically achieved by cold working the metal strip in a roll forming operation. One type of metal cladding panel formed from metal 25 strip is made from steel which is coated with a corrosion resistant metal coating formed typically from zinc or an aluminium-zinc alloy. In addition, a decorative coating, such as a paint coating, may be applied to one surface, or in some cases both surfaces, of the strip. A sheet steel 30 strip incorporating a Zn-Al coating and a paint overlay is sold by the applicant under the trade mark COLORBOND*. 3484453 1 (GHMatti P58905.AU.1 3 Summary of the Invention In a first aspect, the present invention provides a 5 metal cladding panel formed from sheet material and having opposite major surfaces, and opposite side and end edges, and at least one edge of the panel by a cut edge, the panel further comprising spacer means disposed on one of the major surfaces of the panel, the spacer means 10 projecting from that surface to provide a bearing surface to space at least a portion of that major surface from an adjacent panel on stacking of a plurality of said panels, wherein the at least one spacer means is disposed adjacent the at least one cut edge of the panel so as to space a 15 margin of the major surface terminating at that cut edge from the adjacent panel. In one form, the panel is disclosed wherein the at least one spacer means is at least one deformation and is 20 formed in the cladding panel, the at least one deformation forming ridging on the one major surface so as to provide the spacer means of the panel. In one form, the cut edge is typically the end edges 25 but could also be the side edges of the panel. In one form, the panel is cut from strip metal. Providing the spacer means in the cladding panel has substantial practical benefit particularly in transporting 30 of the panels in a stacked formation. The inventors have found that under certain circumstances, parts of cladding panels have a tendency to become damaged when stacked. In 3484453 1 (GHMatters) P56805.AU.1 4 particular, in circumstances where the cladding panel is formed from metal strip that is cut into discrete panels, the cut edge can be deformed as part of the cutting process which in turn can damage an adjacent panel in a 5 stack. By incorporating spacer means adjacent a cut edge, the likelihood of damage to the stacked panels can be significantly reduced. In a particular embodiment, the spacer means is 10 produced by a deforming process on the cladding panel. This deforming process provides a ridge on the major surface which in turn acts as the spacer means of the panel. In an alternative arrangement, the spacer means is formed by bonding one or more discrete elements on the 15 major surface. In one form, where the panel is deformed to form the spacer means, the panel deformation may be continuous so that the spacer means is provided by a continuous ridge 20 across the one major surface. In a further aspect, the invention relates to a metal cladding panel formed from sheet material having first and second opposite major surfaces, opposite sides and 25 opposite end edges, and at least one edge of the panel by a cut edge, the cladding panel further comprising at least one spacer means adjacent the at least one cut edge of the panel, the at least one spacer means forming ridging on one of the major surfaces that provides a space between 30 that major surface and a major surface of an adjacent panel on stacking of a plurality of said panels. 3484453 1 (GHMatters) P5880S.AU.1 5 In a particular embodiment, the at least one deformation forms a recess on the second opposite major surface. In this way, the panel is deformed out of the plane of the cladding panel. 5 In an alternative form, the spacer means may be provided by a plurality of shorter ridges and in one particular form, these deformations are in the form of a plurality of dimples. 10 In one form, the dimples are disposed in at least one row extending across the panel between the opposite sides of the panel. 15 In one form of the above, the spacers are provided along opposite edges of the panel. In a particular form, at least the opposite end edges are cut in formation of the panel and the spacers are disposed adjacent those cut edges. 20 In a particular embodiment, the metal cladding panel includes a decorative coating, such as a paint overlay on one of the major surfaces of the panel. The spacer means may be formed on the coated surface or on the opposite 25 surface, or on both surfaces. However, in a particular embodiment the spacer means is applied on the opposite surface. In a particular embodiment, the metal cladding is 30 profiled to include linear stiffening formations. These stiffening formations may run generally parallel to the opposite sides of the panel or in an alternative form, may 34844531 (GHMatters) PS680SAU.1 6 run generally perpendicular to those opposite sides. In one form, the stiffening formations are in the form of ribs, pleats which are separated by pans. In another form, the linear stiffening formations are in the form of 5 corrugations. In an arrangement where the cladding panel includes such linear stiffening formations, the spacer means may be provided on those stiffening formations or if those 10 formations are separated by pans, in the pans of such panels. In a further aspect, the present invention provides a method of forming metal cladding panels comprising the 15 steps of providing a metal strip, cutting the metal strip at spaced intervals to form individual cladding panels having cut edges, and forming the metal strip either before or after cutting, the spacer means projecting from one major surface of the strip in the resulting cladding 20 panels, wherein the spacer means are formed at predetermined distances from at least one of the cut edges of the cladding panels so that on stacking of the cladding panels, the spacer means on one panel is arranged to space a margin of the one major surface of that panel 25 terminating at the cut edge, from an adjacent panel in said stack. Brief Description of the Drawings 30 It is convenient to hereinafter describe embodiments of the present invention with reference to the accompanying drawings. It is to be appreciated that the 4R4U45 1 (GHMttr PS05 AU 1 7 particularity of the drawings and the related description is to be understood as not limited the preceding broad description of the invention. 5 In the drawings: Fig. 1 is a perspective view a metal cladding panel; Fig. 2 is an end view of the cladding panel of Fig. 1; Fig. 3 is a detailed sectional side view of the 10 cladding panel of Fig. 1; Fig. 4 is a detailed sectional side view of two cladding panels of Fig. 1 in a stacked configuration; Fig. 5 is a perspective view of a variation of the cladding panel of Fig. 1; and 15 Fig. 6 is an end view of a cladding panel showing a variation to the cladding panel of Fig. 1. Detailed Description of the Drawings 20 Turning firstly to Figs. 1 and 2, a cladding panel 10 is disclosed which includes opposite major surfaces 12 and 14, opposite longitudinal edges 16, 18 and opposite end edges 20, 22. In the illustrated form, the cladding panel includes linear stiffening formations 24 which are in the 25 form of ribs which extend in the longitudinal direction of the cladding panel 10 and which are spaced apart and separated by pans 26. Furthermore, the longitudinal edge regions 14, 16 include rib parts 28 that allow for the cladding panels to be overlapped with an adjacent panel to 30 form a rib (not shown) from the rib parts 28 at the overlap. Whilst the cladding panel has been disclosed with the ribs and pans, it is to be appreciated that the 3484453 1 (GHMatlers) P55805.AU.1 8 profiling on the cladding panel 10 is not essential to the invention and that the cladding panel may be planar or profiled into other forms. 5 The cladding panel 10 is typically made from sheet steel which incorporates a corrosion resistant metal coating, such as a zinc-aluminium coating. In addition, the cladding panel may incorporate a decorative paint finish on the upper major surface 12. Furthermore, the 10 cladding panel 10 as illustrated, is formed from metal strip which incorporates the metal coating and the decorative finish. Such steel strip is manufactured and sold by the applicant under the trade mark COLORBOND*. 15 As the cladding panel 10 is formed from the steel strip, each of the opposite ends 20, 22 of the cladding panel are cut during formation of the panel. In a typical operation, the steel strip is profiled to incorporate the ribs 26 and rib parts 28. At discrete intervals, the 20 steel strip is cut after profiling so as to form the individual panels. These panels may be cut to be of equal length, or alternatively may be cut at different lengths depending on customer requirements. In addition, the cut may be parallel to the longitudinal edges or alternatively 25 may be raked so that the cut edge is oblique to the longitudinal edges. In addition to forming the ribs 26, the cladding panel is profiled to include deformations 30 which are 30 disposed in the embodiment of Fig. 1 in a row adjacent one of the end edges 20. In the illustrated form, these deformations are in the form of dimples which are turned 3484453_1 (GHMatters) P56805.AU.1 9 out of the plane of the cladding panel to form, as best illustrated in Fig. 3, ridges 32 on the lower major surface 14 and recesses 34 on the upper major surface 12. 5 The ridges 34 of the dimples 30 are arranged in a row and collectively provide a spacer 36 of the panel 10. The spacer 36 is arranged to space an end margin 38 of the panel 10 that terminates at the end edge 20 from an adjacent panel 101 (see Fig. 4) on stacking on those 10 panels. The provision of the spacer 36 to provide a gap at the end margin 38 assists in protecting a stack of panels from damage in transit. In particular, as best 15 illustrated in Figs. 3 and 4, on cutting of the end edges 20, 22 a burr or other deformation 40 may form along the cut edge. A substantial advantage of the spacer 36 is that it protects the sheets from being scratched by the burr or other deformation. In the past the stacked panels 20 were susceptible to being scratched, particularly in the situation as illustrated in Fig. 4 where the sheets were of different length so that the cut end 20 was located over the upper surface 121 of the underlying sheet 101. 25 In use, the spacer 36 may be formed after cutting of the individual panels or alternatively in a particular embodiment, are made simultaneously with cutting of the panels. In that arrangement, an additional deforming stage is incorporated in the roll forming apparatus used 30 to profile the cladding panel 10. Typically, the panel is deformed by a punch and die arrangement or by a similar pressing operation. This stage is located close to the 3484453_1 (GHMatters) P5805.AU.1 10 shear assembly and is so linked to the shear assembly that any changes of the angle or placement of edge causes a corresponding change of that deforming stage. That corresponding change may be for example, a change in the 5 position of that deforming stage, or may be a change in its mode or timing of operation. In one form, the deforming stage may comprise a series of computer controlled punch and die assemblies. These assemblies are designed to be activated individually or collectively at 10 particular times so that the resulting deformations are formed adjacent the cut edge, whether that edge is perpendicular or oblique to the panel sides. Alternatively, the dimple forming stage forms part of the shear assembly to cut the cladding panel. 15 The profile of the individual deformations which make up the spacer may vary. In the illustrated form, where dimples are provided, typically those dimples may extend only one or two millimetres in depth, that being 20 sufficient to be greater than the expected length of the burr or other deformation 40 on the cut edge 20. Further, it is preferable that the ridge surface 32 of the dimples 30 are generally arcuate as they provide a bearing surface of the panel 10. In addition, the spacer 36 may be formed 25 immediately adjacent the edge or may be spaced from the edge, typically less than 50mm. Figs. 5 and 6 illustrate variations on the design of the spacer 36. 30 3484453_1 (GHMatters) P58805.AU.1 11 As many of the features of the embodiments shown in Figs. 5 and 6 are present in the earlier embodiment, like features have been given like reference numerals. 5 In the embodiment of Fig. 5, the dimples 30 are formed in the ribs 24 and in one of the rib parts 28 rather than in the pans 26 as illustrated in the embodiment. In a similar manner to the earlier embodiment, these dimples 30 are disposed adjacent the 10 edge 20 and are operative to provide a spacer 36, that forms a gap between the end margin 38 of that cladding panel and an adjacent panel 101 on stacking of those panels. 15 In Fig. 6 the spacer is formed at both of the opposite edge margins. In this way, in the embodiment of Fig. 6, two spacers are provided each of which is arranged to space an opposite end margin of that cladding panel from an adjacent sheet. 20 Accordingly, the various embodiments disclosed above illustrate a simple yet effective mechanism to allow for stacking of a plurality of the panels in a manner that may minimise damage in transit. Further, the invention finds 25 application in a broad range of panels and may be used in roofing, walling, fencing or in the like. In the claims which follow and in the preceding description of the invention, except where the context 30 requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, "_4644531 (GHMattens) P56805.AU.1 12 i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention. 5 Variations and modifications may be made to the parts previously described without departing from the spirit or ambit of the invention. 3484453_1 (GHMatters) PSOOS.AU.1

Claims (10)

1. A metal cladding panel formed from sheet material and having opposite major surfaces, and opposite sides end 5 edges, and at least one edge of the panel by a cut edge, the panel further comprising spacer means disposed on one of the major surfaces of the panel, the spacer means projecting from that surface to provide a bearing surface to space at least a portion of that major surface from an 10 adjacent panel on stacking of a plurality of said panels, wherein the at least one spacer means is disposed adjacent the at least one cut edge of the panel so as to space a margin of the major surface terminating at that cut edge from the adjacent panel. 15

2. A metal cladding panel according to claim 1, wherein the at least one spacer means is at least one deformation and is formed in the cladding panel, the at least one deformation forming ridging on the one major surface so as 20 to provide the spacer means of the panel.

3. A metal cladding panel formed from sheet material having first and second opposite major surfaces, opposite sides and opposite end edges, and at least one edge of the 25 panel by a cut edge, the cladding panel further comprising at least one spacer means adjacent the at least one cut edge of the panel, the at least one spacer means forming ridging on one of the major surfaces that provides a space between that major surface and a major surface of an 30 adjacent panel on stacking of a plurality of said panels. UAA I I"HU.Mr PWq All I 14

4. A metal cladding panel according to claim 3, wherein the at least one spacer means forms a recess on the second opposite major surface.

5 5. A metal cladding panel according to any one of claims 1 and 2, wherein the spacer means are in the form of a plurality of dimples.

6. A metal cladding panel according to claim 5, wherein 10 the dimples are disposed in at least one row extending across the panel between the opposite sides of the panel.

7. A metal cladding panel according to any preceding claim, wherein the cladding panel includes a decorative 15 coating on the second opposite major surface of the panel.

8. A metal cladding panel according to any preceding claim, wherein the cladding panel is profiled to include linear stiffening formations. 20

9. A method of forming metal cladding panels comprising the steps of: providing a metal strip; cutting the metal strip at spaced intervals to form 25 individual cladding panels having cut edges; and forming the metal strip either before or after cutting, the spacer means projecting from one major surface of the strip in the resulting cladding panels, wherein the spacer means are formed at predetermined 30 distances from at least one of the cut edges of the cladding panels so that on stacking of the cladding panels, the spacer means on one panel is arranged to space 3484453 1 (GHMatters) P56805.AU.I 15 a margin of the one major surface of that panel terminating at the cut edge, from an adjacent panel in said stack. 5

10. A metal cladding panel or method of forming a metal cladding panel substantially as herein described with reference to the accompanying drawings. 34844531 (GHMatters) P58805.AU.1