AU2011100928A4 - Composite Panel with Service Channel - Google Patents

Abstract

A composite panel has a first sheet, a second sheet, core material between the first sheet and the second sheet, a service channel in an edge of the panel, and retaining means to retain a service in the channel. 25 15 28 29 11

Description

AUSTRALIA PATENTS ACT 1990 COMPLETE SPECIFICATION -INNOVATION PATENT COMPOSITE PANEL WITH SERVICE CHANNEL The following statement is a description of the invention: 1 COMPOSITE PANEL WITH SERVICE CHANNEL TECHNICAL FIELD 5 The present invention is directed to a composite panel comprising a service channel. BACKGROUND 10 Composite panels are generally composed of a lightweight inner core material with rigid outer sheets adhered to opposing sides of the inner core. Accordingly, the outer sheets sandwich the inner core between them and so such panels are usually called "sandwich panels". One use of such panels is as a roofing panel having an upper external (usually profiled) sheet, a lower 15 internal sheet and the intermediate core material. It is known to provide a service channel in the panel to accommodate electrical cables and other services. The service channel is typically a generally U shaped cutout in one longitudinal edge of the panel and typically 20 extending into the core material. The other longitudinal edge remains planar. Figure 1 and Figure 2 illustrate a known type of service channel in one edge. As adjacent panels are brought together and fastened to each other, the channel is closed off by the planar edge of the adjacent panel. 25 A disadvantage of this known type of channel is that services provided in the channel (such as cables) can quite easily fall out, or partially out of the channel as adjacent panels are brought together and fastened. This can damage the service, the panel and can increase assembly time. 30 There would be an advantage if it were possible to reduce the possibility of services being dislodged from the channel.

2 Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge. 5 SUMMARY OF THE INVENTION According to a first aspect of the present invention there is provided a composite panel comprising a first sheet, a second sheet, core material between the first sheet and the second sheet, a service channel in an edge of 10 the panel, and retaining means to retain a service in the channel. It is considered that the retaining means provides a substantial contribution to the working of the invention by allowing panel members to be joined together with reduced incidence of cabling being dislodged from the channel. 15 The retaining means may comprise a slanted wall in the service channel to support a said service and to urge the service towards a rear area of the channel. The slanted wall may comprise part or all of one wall of the channel. Cabling, or other services can be better retained in the channel by being 20 supported on the slanted wall which will urge ( by gravity) the cabling towards the rear of the channel and therefore less likely to become dislodged from the channel as adjacent panels are brought together. The retaining means may additionally or alternatively comprise a slot in the 25 channel to at least partially grip part of the service in the channel and reduce the possibility of the service becoming dislodged from the channel. The slot may be provided in a rear part of the channel. The channel may comprise the slot and the slanted wall. 30 The panel will typically comprise a roof panel where the panel adopts a substantially horizontal or inclined orientation as this orientation allows cabling to be more easily dislodged from the channel. However the panel may have other uses such as a wall panel, an internal panel, an external panel and the like.

3 The length of the panel may vary to suit. A typical length will be between 1 6m. The width of the panel may vary to suit. A typical width will be between 0.4-1.5m. The thickness of the panel may vary to suit. A typical thickness will be between 50mm-300mm. It should be appreciated that no unnecessary 5 limitation should be placed on the invention merely by exemplification of certain length, width and thickness dimensions. The composite panel has a first sheet. If the composite panel comprises a roofing panel, the first sheet may comprise an external sheet. The first sheet 10 may be formed from any suitable material and this may comprise metal such as steel or aluminium, composite materials, wood, plywood, plaster, plastic or concrete. It is envisaged that the first sheet will comprise a metal roofing sheet. The metal roofing sheet will typically be profiled and a typical nonlimiting profile may include corrugations. The sheet (if metal) will typically 15 have a thickness of between 0.5 mm up to 2 mm but it should be appreciated that no particular limitation should be placed on the invention merely by exemplification of some preferred thickness. The composite panel has a second sheets If the composite panel comprises a 20 roofing panel, the second sheet may comprise an internal (lining) sheet. This may be made from metal, plastics material (such as polyester) and the like. The second sheet may also be profiled and this may provide aesthetic appeal. The first sheet and the second sheet will typically comprise single members. 25 However, there may be circumstances where the first sheet and/or the second sheet will comprise multiple members which can be attached to the core material. There may also be circumstances where the first sheet and/or the second sheet comprise a plurality of members or layers connected together. For instance, the sheet may comprise a laminate. 30 The first sheet and/or the second sheet may be treated. For instance, if the first sheet comprises a roofing panel, it may be galvanised, anodised, painted, powder coated or otherwise treated. Similarly, if the second sheet comprises an internal lining panel, it may be painted or powder coated and the like.

4 The core material may comprise an insulating material. The insulating material may be thermal insulating material, noise insulating material, a combination and the like. Nonlimiting examples of possible suitable core 5 materials may comprise one or more of: PIR (polyisocyanurate), polyurethanes, low density polyethylene, EPS (expanded polystyrene), PVC foam, XFLAM ( a fire retardant syntactic foam), mineral wool, glasswool, carbon/glass and the like. The core material may have a honeycomb structure. The core material may comprise multiple layers, or a combination of 10 different components and the like. The panel will typically comprise a single first sheet, a single core material, and a single second sheet. However, more substantial panel designs may include multiple combinations of the above. For instance, an intermediate 15 sheet may be provided with core material on each side of the intermediate sheet. The first sheet and the second sheet will typically be attached to the core material. The attachment will typically be an adhesive attachment and suitable 20 adhesive may comprise a polyurethane adhesive or epoxy adhesive. Other types of attachments are also envisaged. The panel will typically be substantially rectangular when viewed in plan. The panel will typically have opposed longitudinal edges. These edges are usually 25 not covered and expose the core material. As the core material is relatively soft, it can be machined or otherwise treated to provide a service channel. The service channel will typically extend along one longitudinal edge of the panel. The service channel can be formed in any suitable manner. For 30 instance, the service channel can be formed by removing core material and this can be done by cutting, grinding, or any suitable other operation. Alternatively, the core material can be pre-formed with the service channel. The service channel may comprise a separate part (for instance a plastic or thin metal insert) which can be pushed into or otherwise fitted into the 5 longitudinal edge of the core material. The retaining means can be provided on the insert or form part of the insert. The dimensions of the service channel should be sufficient to allow typical 5 services to be located within the channel. The typical services may comprise electrical cabling, data cabling, water pipe and the like. The channel may be substantially rectangular in cross-section and may therefore comprise opposed sidewalls and a rear wall. If the composite panel is in a substantially horizontal orientation, one sidewall may comprise a top wall, and the other 10 sidewall may comprise a bottom wall of the channel. The dimensions of the channel may vary but it is envisaged that the channel will have a width of between 10 mm-50 mm and a depth of between 20 mm-80 mm to accommodate the required services. 15 The channel may have other cross-section configurations. For instance, the channel may be somewhat rounded. The composite panel may comprise attachment means to enable adjacent panels to be attached together. Any suitable attachment means may be 20 provided. If the composite panel comprises a roofing panel, the external sheet may have an overlapping portion. BRIEF DESCRIPTION OF THE DRAWINGS 25 Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make 30 reference to a number of drawings as follows: Figure 1. Illustrates a transverse section view of a prior art composite panel.

6 Figure 2. Illustrates a close-up view of a prior art service channel in the composite panel. Figure 3. Illustrates a close-up view of the longitudinal edge of a composite panel according to an embodiment of the invention. 5 Figure 4. Illustrates a close-up view of an alternative embodiment of the invention. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 10 Referring initially to figure 1 and figure 2 there is illustrated a known composite panel. The composite panel comprises a roof panel and therefore has an upper external sheet 11, a lower internal sheet 12, and core material 13. Upper external sheet 11 is corrugated which is common. An overlapping portion 23 is provided on sheet 11 to provide a waterproof connection with an 15 adjacent composite panel. Lower internal sheet 12 is relatively plain. The panel has opposed longitudinal edges 14. One edge is provided with a recessed service channel 15. Attachment means 22 is provided on each longitudinal edge of the panel to allow adjacent panels to fit together, this being known. 20 Referring to figure 2, the known service channel 15 is rectangular and comprises opposed sidewalls 18, 19 which are parallel to each other and rear wall 20. A service (e.g. cabling 25) can be positioned within channel 15 but it can be seen that the cabling 25 can quite easily fall out of the channel until an 25 adjacent panel is positioned in place which will seal off the otherwise open each of the channel. Referring now to figure 3 and figure 4, a retaining means is provided to assist in retaining the cabling 25 within the channel. Figure 3 illustrates one 30 embodiment of a retaining means and figure 4 illustrates a second embodiment of a retaining means. Referring to figure 3, the service channel 15 has a slanted lower wall 27 to retain the cabling 25 within the channel and to make it less likely that the cabling 25 can fall out of the channel as an adjacent composite panel is positioned and fixed in place. In the particular 7 embodiment, the upper wall and 28 is also slanted as is the rear wall 29 which means that a conventional cutting wheel or cutting disk can be used to cut the channel and it is necessary only to incline the cutting wheel relative to the edge of the panel. 5 Referring to figure 4, the retaining means includes a slot 30 formed at the junction between the lower wall 27 and rear wall of 29. Slot 30 can function to grip the part of the cabling 25 to hold the cabling in place. Figure 4 also illustrates the combination of slot 30 together with the slanting lower wall 27 10 to improve the retention of the surface (cabling 25) in the channel. The design of the channel containing the retaining means enables services to be placed within the channel with reduced likelihood of falling partially or fully out of the channel. 15 In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term "comprises" and its variations, such as "comprising" and "comprised of" is used throughout in an inclusive sense and not to the exclusion of any 20 additional features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art. Throughout the specification and claims (if present), unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms. Any embodiment of the invention is meant to be illustrative only and is not meant to be limiting to the invention. Therefore, it should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the spirit and scope of the invention.

Claims (5)

1. A composite panel comprising a first sheet, a second sheet, core material between the first sheet and the second sheet, a service channel in an edge of the panel, and retaining means to retain a service in the channel.

2. The panel of claim 1, wherein the retaining means comprises a slanted wall in the service channel to support a said service and to urge the service towards a rear area of the channel.

3. The panel of claim I or claim 2, wherein the retaining means comprises a slot in a wall of the channel to hold part of the service.

4. The panel of any one of the preceding claims comprising a roofing panel.

5. A panel substantially as hereinbefore described with reference to figures 3 and 4.