AU2008234973A1

AU2008234973A1 - Sheet metal construction panel

Info

Publication number: AU2008234973A1
Application number: AU2008234973A
Authority: AU
Inventors: Garry Hollis
Original assignee: MECHANICAL PLATING Pty Ltd
Current assignee: MECHANICAL PLATING Pty Ltd
Priority date: 2007-10-29
Filing date: 2008-10-27
Publication date: 2009-05-14

Description

1. AUSTRALIA Patents Act 1990 (Cth) COMPLETE SPECIFICATION APPLICANT MECHANICAL PLATING PTY LIMITED TITLE SHEET METAL CONSTRUCTION PANEL The invention is described in the following statement including the best method known to us: 2. SHEET METAL CONSTRUCTION PANEL FIELD OF THE INVENTION 5 The present invention relates to the field of sheet metal construction panels. Panels embodied by the invention have roofing and cladding applications as well as other building and construction uses. BACKGROUND OF THE INVENTION 10 Sheet steel panels are commonly used for roofing and other cladding applications. The panels are typically galvanized or provided with corrosion resistant alloy coatings and/or outer paint finishes, and are normally ribbed/corrugated to structurally reinforce the panels and to provide the panels with an attractive appearance. Corrugated such panels have traditionally been used for roofing purposes, the 15 corrugations of overlapping edge margins of adjacent panels nesting one within another to inhibit ingress of water to the underlying structural frame to which the panels are secured. However, the peripheral longitudinal edge of one of the panels remains exposed to the elements with the possibility of entry of water between the panels as a result of imperfect nesting of the panels or ingress of rainwater arising from capilliary 20 action. Entry of water between overlapping panels can lead to corrosion of the panels and in more severe instances, water damage to the underlying structural frame or building structure. SUMMARY OF THE INVENTION 25 In one aspect of the present invention there is provided a sheet metal construction panel having a ribbed cross-sectional profile intermediate opposite edge margins of the panel, a rib of the panel adjacent one of the edge margins incorporating a fold formation defining a downwardly directed longitudinal recess and the other of 30 the edge margins including an upwardly directed longitudinal flange, the fold formation being adapted to receive the flange of a like panel in the recess to form a join.

3. Typically, the panel has an outer face and an opposite underside face, and the sheet metal from which the panel is fabricated is folded back under itself to form the fold formation. Typically, the fold formation is continuous with the adjacent edge margin, the 5 adjacent edge margin being profiled for seated reception of the other edge margin of the like panel Typically, the contour of the outer face of the rib following the fold formation remains essentially constant with the contour of the outer face of the rib prior to the fold formation. 10 Typically also, the rib has a side proximal to the adjacent edge margin and an opposite side distal from the edge margin, and the longitudinal recess is defined in the proximal side of the rib. Preferably, the rib is one of a plurality of spaced apart ribs between the opposite edge margins. 15 Preferably, the ribs are rounded ribs projecting upwardly from the plane of the panel, and adjacent of the ribs ribs is spaced apart from one another by respective intervening panel sections lying in the plane of the panel. In a preferred embodiment, the recess of the fold formation has a width sufficient for reception of only a single layer of the sheet metal from which the panel is 20 fabricated. Preferably, the recess is defined by opposed surfaces of the fold formation, the opposed surfaces being essentially parallel to one another along at least a majority of the recess in a depthwise direction of the recess. In another embodiment the opening of the recess is enlarged relative to the width of an opposite terminal end of the recess. Preferably, one of the opposed 25 surfaces of the fold formation defining the fold formation of this embodiment is inclined relative to the other of the surfaces to direct the flange of the like panel into position within the recess. Most preferably, the inclined surface is located for contact with a leading edge of the flange to raise the flange into abutment with a lip of the fold formation defining an upper boundary of the opening to the recess with the insertion of 30 the flange into the recess. In another aspect of the invention there is provided a method for fabricating a sheet metal construction panel, comprising roll forming metal strip to form a panel 4. with a ribbed cross-sectional profile intermediate opposite edge margins of the panel, a rib of the panel adjacent one of the edge margins incorporating a fold formation defining a downwardly directed longitudinal recess and the other of the edge margins including an upwardly directed longitudinal flange, the fold formation being adapted 5 to receive the flange of a like panel in the recess to form a join. In another aspect of the invention there is provided an apparatus for fabricating a sheet metal construction panel, the apparatus comprising forming rolls for successively modifying the shape of metal strip passing through the nip of respective sets of the rolls, the forming rolls being collectively adapted to shape the 10 metal strip to form a panel with a ribbed cross-sectional profile intermediate opposite edge margins of the panel, a rib of the panel adjacent one of the edge margins incorporating a fold formation defining a downwardly directed longitudinal recess and the other of the edge margins including an upwardly directed longitudinal flange, the fold formation being adapted to receive the flange of a like panel in the recess to form 15 ajoin. In another aspect of the invention there is provided a sheet metal construction panel having an outer face, an opposite underside face, opposite edge margins and a middle section intermediate the edge margins, the middle section having a plurality of rounded longitudinal ribs projecting upwardly rom the plane of the panel, adjacent said 20 ribs being spaced apart from one another by respective intervening sections lying in the plane of the panel. In another aspect of the invention there is provided a method for fabricating a sheet metal construction panel, comprising roll forming metal strip to form a panel having an outer face, an opposite underside face, opposite edge margins and a middle 25 section intermediate the edge margins, the middle section having a plurality of rounded longitudinal ribs projecting upwardly from the plane of the panel, adjacent said ribs being spaced apart from one another by respective intervening sections lying in the plane of the panel. In yet another aspect of the invention there is provided apparatus for 30 fabricating a sheet metal construction panel, the apparatus comprising forming rolls for successively modifying the shape of metal strip passing through the nip of respective sets of the rolls, the forming rolls being collectively adapted to shape the 5. metal strip to form a panel having an outer face, an opposite underside face, opposite edge margins and a middle section intermediate the edge margins, the middle section having a plurality of rounded longitudinal ribs projecting upwardly from the plane of the panel, adjacent said ribs being spaced apart from one another by respective 5 intervening sections lying in the plane of the panel. In one or more embodiments, the reception of the flange in the recess of a like panel of the invention interlocks the panels together inhibiting lifting of the panels one from the other, and essentially prevents ingress of water through to the underside of the panels. Moreover, the peripheral edges of the overlapping edge margins are 10 obscured from view providing a visually pleasing appearance. Panels described herein with rounded ribs projecting from the plane of the panel and spaced apart from one other by intervening sections lying in the plane of the panel also provide an attractive choice for consumers. The panels have particular but not exclusive application as roofing panels. The panels can for instance also be used for cladding walls of 15 dwellings, sheds, warehouses and other building structures, as fencing infill panels and in the construction of other barriers. Throughout this specification the word "comprise", or variations thereof such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of 20 any other element, integer or step, or group of elements, integers or steps. Any discussion of documents, acts, materials, devices, articles or the like which has been included in this specification is solely for the purpose of providing a context for the present invention. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the 25 field relevant to the present invention as it existed in Australia or elsewhere before the priority date of this application. The features and advantages of the present invention will become further apparent from the following detailed description of preferred embodiments and the accompanying drawings. 30 6. BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS Figure 1 is a partial view of a construction panel embodied by the invention from above; 5 Figure 2 is a perspective view of the panel of Fig. 1; Figure 3 is a partial view of the fold formation of the panel of Fig. 2; Figure 4 is a close up view of the fold formation of the panel of Fig. 3 from above; Figure 5 is a side schematic view showing the ribbed cross-sectional profile of 10 the panel of Fig. 4; Figure 6 is a close up side view of the fold formation of the panel of Fig. 5; Figure 7 is a close up view of the fold formation of another panel embodied by the invention; Figure 8 is a side schematic view showing the ribbed cross-sectional profile of 15 yet another panel embodied by the invention. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION 20 A sheet metal construction panel 2 embodied by the invention is illustrated in Fig. 1 to Fig. 6. The panel 2 has a ribbed cross-sectional profile 4 intermediate opposite edge margins 6 and 8. The particular panel illustrated has a plurality of spaced ribs 10 and 10a extending parallel with respect to one another and edge margins 6 and 8, and is fabricated from light gauge steel strip having a thickness 0.47 mm. However, other 25 thicknesses can be used depending upon the required strength of the panel. Each of the ribs projects upwardly from the plane of the panel 2 with adjacent ribs being spaced apart from one another by respective intervening panel sections 12 lying in the plane of the panel. As can be seen, each of the ribs has a rounded and more particularly, a semi-circular profile. The planar intervening sections 12 are of a 30 width for enabling the reception of fasteners such as galvanized and/or painted nails, screws or the like between the ribs for being driven through the panel into an 7. underlying structural frame such as a metal building frame or support structure to fasten the panel to the frame or support structure. The rib 10a adjacent the edge margin 6 incorporates a fold formation 14 defining a downwardly directed longitudinal recess 16 (see Fig. 3). The other of the 5 edge margins 8 includes an upwardly directed longitudinal flange 18, the fold formation 14 being adapted to receive the flange 18 of a like panel in the recess 16 to form a join interlocking the panels together. The panel has an outer face 20 and an opposite underside face 22, and is folded back under itself to form the fold formation 14. As shown in Fig. 3 to Fig. 5, 10 the fold formation 14 is continuous with the adjacent edge margin 6 which is profiled for seated reception of the other edge margin 8 of a like panel. The contour of the outer face of the rib 10a following the fold formation 14 remains substantially constant with the contour of the outer face of the rib prior to the fold formation. In other words, the curvature of the rib is essentially not disrupted by the fold. 15 The recess 16 of the fold formation 14 has a width sufficient for reception of only a single layer of the sheet metal from which the panel 2 is fabricated. However, in other embodiments, the width of the recess can be greater to provide play for facilitating insertion of the flange of a like panel in the recess. This is particularly advantageous when joining the panels together while fixing the panels in position on 20 sloping rooves. As shown more clearly in Fig. 6, the recess 16 has a closed terminal end region 28 and is defined by spaced apart lower and upper opposed surfaces 30 and 32 of the fold formation 14, the opposed surfaces being essentially parallel to one another in the depthwise direction of the recess. The recess itself also lies essentially parallel to 25 the outer face of the rib 10a. In a particularly preferred embodiment, the opening 34 of the recesss is enlarged relative to the terminal end region of the recess to assist insertion of the leading edge 36 of the flange 18. The fold formation can also be adapted to direct the flange 18 of a like panel into position in the terminal end region of the recess. For 30 example, the surface 30 of the fold formation can be inclined upwardly relative to surface 32 along at least a section of the recess as shown in Fig. 7 such that the width of the recess progressively decreases with distance from the opening, and the flange is 8. raised into abutment with an outer lip 24 of the fold formation defining an upper boundary of the opening of the recess with continued insertion of the flange into the recess. As will be appreciated, the contact of the flange with the upper lip of the fold formation inhibits the ingress of rainwater water into the recess. 5 In one form, a sealant may be provided in the recess along upper surface 32 to provide a seal against ingress of water into the recess between the flange of the like panel and the upper surface 32. The seal may conveniently be in the form of a bead of silicone or other suitable sealant applied at the time of installation of the panels. Typically, the ratio of the depth of the recess to the width of the rib is in a 10 range of from about 1:6 to about 1:12. More preferably, the ratio is in a range of from 1:8 to 1:10 and most preferably, the ratio is substantially 1:9. Typically, the ratio of the depth of the recess to the height of the rib is in a range of from about 1:3 to about 1:5. More preferably, this ratio is substantially 1:4. A further panel embodied by the invention is shown in Fig. 8. Like the panel 15 shown in Fig. 1, this panel has a plurality of ribs 10 spaced apart from one another by respective intervening panel sections 12 intermediate of opposite edge margins 6 and 8. However, in this instance, the rib 10 adjacent edge margin 6 is not provided with a fold formation 14. In use, the edge margin 8 is seated in the correspondingly formed edge margin 6 of a like panel and a fastener is driven through the nested edge margins 20 to fix the overlapping panels to the underlying frame structure in the same manner as for the Fig. 1 panel. The height of the ribs of a panel of the invention can vary relative to the width of the ribs. Typically, however, the ratio of the height of the ribs to the width of the ribs is in a range of from about 1:1 to about 3:1. More preferably, this ratio is 25 substantially 2:1. Typically also, the ratio of the width of the intervening sections 12 to the width of respective of the ribs is in a range of from 1:1 to 1:5. More preferably, the ratio is in a range of from 1:2 to 1:4 and most preferably, the ratio is substantially 1:3.5. 30 The widths of respective of the ribs and the intervening sections of panels embodied by the invention are measured in the plane of the panel.

9. A panel embodied by the invention will normally be fabricated using dedicated roll forming apparatus comprising forming rolls for successively modifying the shape of metal strip passing through the nip of respective sets of the rolls. The forming rolls are adapted to collectively form the various features of the panel 5 including respective of the ribs and the fold formation 14. As will be understood, roll forming the panel 2 allows the panel to be fabricated at high speed in a cost efficient manner. Typically, the sheet metal strip from which the panel is formed is galvanized, or more preferably, is coated with a corrosion resistant coating such as a zinc 10 aluminium alloy. Steel strip with a zinc aluminium coating is available under the trade mark Zincalume* from BlueScope Steel, Melbourne, Australia. The top and/or bottom faces of the steel strip can also or alternatively have a paint finish. Suitable steel strip with a paint finish is also available under the trade mark Colorbond* from BlueScope Steel, Melbourne, Australia. 15 Panels as described herein find application not only in roofing but also in fencing and cladding applications, particularly the cladding of galvanized steel structural frames such as in the construction of warehouses, sheds and the like. The provision of panels with ribs protruding to one side from the plane of panel and spaced apart by respective intervening sections also provides an attractive alternative choice to 20 consumers. In the embodiments described, the intervening sections are the same width across the panel. However, in other embodiments, the width of the intervening sections 12 may vary from one to the next creating an irregular pattern. While a number of preferred embodiments have been described above, it will 25 be appreciated by persons skilled in the art that numerous variations and/or modifications may be made without departing from the scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims

10. CLAIMS 1. A sheet metal construction panel having a ribbed cross-sectional profile intermediate opposite edge margins of the panel, a rib of the panel adjacent one of the 5 edge margins incorporating a fold formation defining a downwardly directed longitudinal recess and the other of the edge margins including an upwardly directed longitudinal flange, the fold formation being adapted to receive the flange of a like panel in the recess to form a join. 10 2. A panel according to claim 1 wherein the panel has an outer face and an opposite underside face, the sheet metal from which the panel is fabricated being folded back under itself to form the fold formation. 3. A panel according to claim 2 wherein the fold formation is continuous with 15 the adjacent edge margin, the adjacent edge margin being profiled for seated reception of the other edge margin of the like panel. 4. A panel according to claim 2 or 3 wherein the contour of the outer face of the rib following the fold formation remains essentially constant with the contour of the 20 outer face of the rib prior to the fold formation. 5. A panel according to any one of claims 1 to 4 wherein the rib has a side proximal to the adjacent edge margin and an opposite side distal from the edge margin, the longitudinal recess being defined in the proximal side of the rib. 25 6. A panel according to any one of claims 1 to 5 wherein the rib is one of a plurality of spaced apart ribs between the opposite edge margins. 7. A panel according to claim 6 wherein the ribs are rounded ribs projecting 30 upwardly from the plane of the panel, adjacent said ribs being spaced apart from one another by respective intervening panel sections lying in the plane of the panel.

11. 8. A panel according to any one of claims 1 to 7 wherein the recess of the fold formation has a width sufficient for reception of only a single layer of the sheet metal from which the panel is fabricated. 5 9. A panel according to claim 8 wherein the recess is defined by spaced apart opposed surfaces of the fold formation, the opposed surfaces being essentially parallel to one another along at least a majority of the recess in a depthwise direction of the recess. 10 10. A panel according to any one of claims 1 to 7 wherein the recess has a longitudinal opening and an opposite terminal end, the opening of the recess being enlarged relative to the width of the terminal end of the recess. 11. A panel according to claim 10 wherein the recess is defined by spaced apart 15 opposed surfaces of the fold formation, one of the surfaces being inclined relative to the other of the surfaces to direct the flange of the like panel into position within the recess.

12. A panel according to claim 11 wherein the inclined surface is located for 20 contact with a leading edge of the flange for raising the flange into abutment with an outer lip of the fold formation defining an upper boundary of the opening of the recess with insertion of the flange into the recess.

13. A panel according to any one of claims I to 12 wherein the panel has a ratio 25 of the depth of the recess to the width of the rib in a range of from about 1:6 to about 1:12, the width of the rib being measured in the plane of the panel.

14. A panel according to claim 13 wherein the ratio is about 1:9. 30 15. A panel according to any one of claims I to 14 wherein the panel has a ratio of the depth of the recess to the height of the rib in a range of from about 1:3 to about 1:5. 12.

16. A panel according to claim 15 wherein the ratio of the depth of the recess to the height of the rib is about 1:4.

17. A method for fabricating a sheet metal construction panel, comprising roll forming metal strip to form a panel with a ribbed cross-sectional profile intermediate 5 opposite edge margins of the panel, a rib of the panel adjacent one of the edge margins incorporating a fold formation defining a downwardly directed longitudinal recess and the other of the edge margins including an upwardly directed longitudinal flange, the fold formation being adapted to receive the flange of a like panel in the recess to form a join. 10

18. A method according to claim 17 wherein the sheet metal from which the panel is fabricated is folded back under itself to form the fold formation.

19. An apparatus for fabricating a sheet metal construction panel, the apparatus 15 comprising forming rolls for successively modifying the shape metal strip passing through the nip of respective sets of the rolls, the forming rolls being collectively adapted to shape metal strip to form a panel with a ribbed cross-sectional profile intermediate opposite edge margins of the panel, a rib of the panel adjacent one of the edge margins incorporating a fold formation defining a downwardly directed 20 longitudinal recess and the other of the edge margins including an upwardly directed longitudinal flange, the fold formation being adapted to receive the flange of a like panel in the recess to form a join.

20. A sheet metal construction panel having an outer face, an opposite underside 25 face, opposite edge margins and a middle section intermediate the edge margins, the middle section having a plurality of rounded longitudinal ribs projecting upwardly from the plane of the panel, adjacent said ribs being spaced apart from one another by respective intervening sections lying in the plane of the panel. 30 21. A panel according to claim 20 wherein each of the ribs has a rounded profile and respective of the intervening sections is planar. 13.

22. A panel according to claim 21 wherein the rounded profile is a semi-circular profile.

23. A panel according to any one of claims 19 to 22 wherein the panel has a ratio of the width of the intervening sections to the width of respective of the ribs in a range 5 between 1:1 and 1:5, the widths being measured in the plane of the panel.

24. A panel according to claim 23 wherein the ratio of the width of the ribs to the width of the intervening sections is substantially 1:3.5. 10 25. A panel according to any one of claims 20 to 24 wherein the panel has a ratio of the width of respective of the ribs to the height of respective of the ribs in a range of from about 1:1 to 3:1.

26. A panel according to claim 25 wherein the ratio of the width of the ribs to the 15 height of the ribs is substantially 2:1.

27. A panel according to any one of claims 20 to 26 wherein respective of the intervening sections is dimensioned to permit reception of a fastener for being driven through the panel for fastening the panel to a support structure. 20

28. A method for fabricating a sheet metal construction panel, comprising roll forming metal strip to form a panel having an outer face, an opposite underside face, opposite edge margins and a middle section intermediate the edge margins, the middle section having a plurality of rounded longitudinal ribs projecting upwardly from the 25 plane of the panel, adjacent said ribs being spaced apart from one another by respective intervening sections lying in the plane of the panel.

29. A method according to claim 28 wherein each of the ribs has a semi-circular profile and respective of the intervening sections is planar. 30

30. Apparatus for fabricating a sheet metal construction panel, the apparatus comprising forming rolls for successively modifying the shape of metal strip passing 14. through the nip of respective sets of the rolls, the forming rolls being collectively adapted to shape the metal strip to form a panel having an outer face, an opposite underside face, opposite edge margins and a middle section intermediate the edge margins, the middle section having a plurality of rounded longitudinal ribs projecting 5 upwardly from the plane of the panel, adjacent said ribs being spaced apart from one another by respective intervening sections lying in the plane of the panel. 10