EP1418286A1

EP1418286A1 - Method for the production of a liner for a panel, liner, and panel provided with such a liner

Info

Publication number: EP1418286A1
Application number: EP20020257661
Authority: EP
Inventors: Felicity Emma Lammy
Original assignee: Corus Technology BV
Current assignee: Corus Technology BV
Priority date: 2002-11-05
Filing date: 2002-11-05
Publication date: 2004-05-12

Abstract

The invention relates to a method for the production of a liner for a wall panel or roof panel, the liner being present at the interior side of the panel during use, in which a plate is formed such that one edge of the plate is formed into a male portion and the opposite edge is formed into a mating female portion, the male and female portions being connected by a substantially flat portion. <??>According to the invention, the female portion is formed with an extension such that the extension protrudes in a direction away from the substantially flat portion when the liner is to be used for a roof panel, and the female portion is formed with an extension such that the extension is substantially parallel to the substantially flat portion when the liner is to be used for a wall panel. <??>The invention also relates to liners formed by using this method and panels formed with these liners. <IMAGE> <IMAGE>

Description

The invention relates to a method for the production of a liner for a wall panel or roof panel, the liner being present at the interior side of the panel during use, in which a plate material is formed such that one edge of the plate material is formed into a male portion and the opposite edge is formed into a mating female portion, the male and female portions being connected by a substantially flat portion. The invention also relates to a liner produced by using the method, and a wall panel and roof panel produced with such a liner.

Liners used for the production of wall and roof panels are produced from flat plate material. At one side of a panel an inside liner is present, directed to the interior of the building for which the panels are used. At the other side of the panel an outside liner is present, turned towards the surroundings of the building. Between the outside and inside layers an insulating material is applied. Usually the wall panel and roof panel differ in several ways, mainly caused by the different requirements for water tightness for substantially horizontal roof panels and substantially vertical wall panels. Often, another requirement for wall panels is that the outside of a wall made from wall panels should be flat, whereas a roof made from roof panels can have protrusions. This results in different linings for roof panels and wall panels.

On the other hand several requirements exist for the joint between two cooperating panels. This joint should be air tight and water tight. Also the joint should be easily formed when the next panel is applied to an already fixed panel. Moreover the joint should not form a cold bridge between the outside and the inside of the wall.

As a result of the above, presently the liners for roof panels and wall panels differ in several aspects, causing a considerable difference between the forming tools for liners for roof panels and liners for wall panels. This makes the forming apparatus for producing the liners more expensive, and causes a considerable delay and standstill of the forming apparatus when the production is changed from liners for roof panels to liners for wall panels, or vice versa.

It is an object of the invention to provide a method for the production of liners for roof and wall panels that is easier and cheaper in use than the present methods.

It is another object of the invention to provide a method for the production of liners for roof and wall panels for which the forming tools are as much the same as possible for liners for both the wall and the roof panels.

It is still another object of the invention to provide a method for the production of liners for roof and wall panels resulting in panels having a very good air and water tightness.

Moreover, it is an object of the invention to provide liners formed with the method and panels produced with those liners that have a very good air and water tightness.

In addition it is an object of the invention to provide liners formed with the method and panels produced with those liners that can be easily joined.

According to a first aspect of the invention one or more of these objects are reached with a method for the production of a liner for a wall panel or roof panel, the liner being present at the interior side of the panel during use, in which a plate material is formed such that one edge of the plate material is formed into a male portion and the opposite edge is formed into a mating female portion, the male and female portions being connected by a substantially flat portion, in which the female portion is formed with an extension such that the extension protrudes in a direction away from the substantially flat portion when the liner is to be used for a roof panel, and in which the female portion is formed with an extension such that the extension is substantially parallel to the substantially flat portion when the liner is to be used for a wall panel.

Using this method, liners are produced that can be almost the same for both roof panels and wall panels. The only difference is that the extension on the female portion of the panel extends in a direction away from the substantially flat portion for roof panels, but is substantially parallel to the substantially flat portion for wall panels. The reason for this difference will be discussed hereinafter. The forming apparatus for producing the liners from flat plate is thus almost the same for both liners, and so are the forming tools. The change from one type of liner to the other type of liner is thus easy to accomplish and will take little time. The production process therefore is cheaper and easier

Preferably the liner is formed from a metal plate material, preferably a steel plate material. Metal plate materials are very suitable for forming liners for panels, and steel is relatively cheap.

According to a preferred embodiment the liner is formed in a continuous production process, preferably a roll forming process. Using a continuous forming process results in a continuous liner that can be cut into the desired lengths. A roll forming process can be easily adjusted by changing rolls, and in the present method only one pair of rolls has to be changed to produce the other type of liner.

Preferably the female portion is formed such that the extension protrudes over a length that is of the same order of magnitude as the thickness of the female portion. This is desired for the production of roof panels, as will be elucidated hereinafter.

According to a preferred embodiment in the inside of the female portion a recess for a sealing profile is formed. When the sealing profile is placed in the recess, the sealing profile should protrude from the female portion. This recess should preferably be formed such that the sealing profile is kept in place by the form of the recess, such that no glue or adhesive is necessary to keep the sealing profile in place. Preferably the recess is formed such that a sealing profile that is circular in cross section can be used. The application of the sealing profile is simple with such a recess. The sealing profile provides an air and water tight joint when two panels with such a liner are joined. It is also possible to provide a recess for a sealing profile in the male portion of the liner, but a sealing profile in this recess is vulnerable for damaging during transport and application of panels.

Preferably the recess for the sealing profile is formed in the innermost part of the female portion. This makes the application of the sealing profile even more simple.

According to a second aspect of the invention a liner for a roof panel made by using the method as described above is provided, the liner comprising a substantially flat portion having a male portion at one side and a mating female portion at the opposite side, in which the female portion has an extension protruding in a direction away from the substantially flat portion. This liner is very suitable for roof panels, because the extension forms a stop for the next roof panel that is mounted, when the male portion of the next roof panel will be stopped by the extension on the female portion of the already applied roof panel, such that the insulating material is not damaged. This stop is not necessary for wall panels due to another method of mounting the panels.

Preferably the extension protrudes in a direction making an angle of at least 30° with the plane through the substantially flat portion of the liner, preferably an angle of at least 60°, more preferably an angle of approximately 75°. An angle of more than 30° with the plane through the substantially flat portion of the liner can be used for roof panels, but an angle of at least 60° is preferred because less plate material is needed. In the present roof panels an angle of approximately 75° is used.

According to a preferred embodiment the extension protrudes from the female portion over a length that is at least equal to half the thickness and at most three times the thickness of the female portion. Such an extension is long enough to catch the male portion during the joining of the roof plates.

Preferably in the inside of the female portion a recess for a sealing profile is present, preferably in the innermost part of the female portion. The use and placing of this recess is discussed above.

According to a third aspect of the invention a liner for a wall panel made by using the method as described above is provided, the liner comprising a substantially flat portion having a male portion at one side and a mating female portion at the opposite side, in which the female portion has an extension that is substantially parallel to the substantially flat portion. For a wall panel there is no need for a stop for the male portion of a next panel, due to another way of mounting the panels, as will be elucidated hereinafter. The extension therefore should be protruding to the inside of the panel such that it will not hamper the other liner of the wall panel.

According to a preferred embodiment the extension has a length that is at least equal to half the thickness and at most three times the thickness of the female portion. Thus the extension is as long as the extension for the roof panel.

According to a fourth aspect of the invention a roof panel is provided having an inside liner for a roof panel according to the second aspect of the invention, an outside liner and an insulating material in between the liners. This panel is provided with a stop for the male portion of the next roof panel that is mounted. These roof panels can thus be easily mounted without the risk of damaging the insulating material.

Preferably the outside liner comprises a substantially flat portion having a first protruding portion at the side of the female portion of the inside liner, the first protruding portion ending substantially in the plane of the extension protruding from the female portion, and in which the outside liner comprises a second protruding portion at the side of the male portion of the inside liner, the second protruding portion being complementary to the first protruding portion so as to fit over the first protruding portion of a corresponding roof panel. Such panels can be very easily mounted. A first roof panel is mounted on a roof structure, after which a second roof panel can be placed such that its second protruding portion is placed over the first protruding portion of the first panel while the second roof panel is kept at an angle to the first roof panel. The second roof panel is than pivoted until the male portion of the second roof panel contacts the extension on the female portion of the first roof panel. After that the second panel can be pressed downwards such that the male portion of the second roof panel slides over the extension until its snaps into the female portion of the first roof panel. The protruding portion of the second roof panel has an elasticity that is high enough to take up the deformation resulting from the mounting.

According to a preferred embodiment, the first protruding portion ends in a substantially flat extension that is substantially positioned in the plane of the extension on the female portion of the inside liner. This roof panel provides a substantially flat side above the female portion, such that the risk on damage during transport and handling of the roof panels is reduced.

According to a fifth aspect of the invention a wall panel is provided having an inside layer according to the third aspect of the invention, an outside liner and an insulating material in between the liners. In this panel the extension on the female portion of the inside liner is accommodated in the insulating material.

Preferably the outside liner comprises a substantially flat portion having a recessed portion at the side of the male portion of the inside liner. In the recess retaining elements such as screws can be placed, such that the heads of the retaining elements do not protrude from the wall panel.

Preferably the outside liner comprises a protruding portion at the side of the female portion of the inside liner such that two cooperating wall panels form a substantially flat outside plane. In this way a wall formed by the wall panels shows an almost flat outer wall and the heads of the retaining elements can be hidden behind the protruding portion of the outside liner of the wall panels.

It will be understood that the recess for a sealing profile in the female portion of the inside liners can also be formed when using methods to form other types of liners, for instance without extension on the female portion of the liner. Also liners without an extension can be provided, having a recess as described above.

The invention will be elucidated referring to the annexed drawings.

Figure 1A shows an embodiment a liner for a wall panel according to the invention, not to scale.

Figure 1B shows an embodiment a liner for a roof panel according to the invention, not to scale.

Figure 2 shows the male and female sides of a wall panel according to the invention, not to scale, using a liner according to Fig. 1A.

Figure 3 shows the male and female sides of a roof panel according to the invention, not to scale, using a liner according to Fig. I B.

Figure 1A shows a liner for a wall panel and figure 1B shows a liner for a roof panel, both for the interior side of the panel during use. Both liners are the same but for the

extension

10A and 10B, respectively.

The

liners

1A, 1B have a flat portion 5 with corrugations 6 as is usual in the field. At one side the flat portion 5 ends in a male portion 2 having a nose 3, the male portion being provided with an end part 4. At the other side the flat portion 5 ends in a female portion 7 having an inside 8. In the innermost part of the female portion a recess 9 for a sealing profile is formed. Extending from the female portion 7 is an extension 10. When the liner (1A) is to be used for a wall panel, the extension 10A is formed such that the extension 10A is substantially parallel to the flat portion 5.

When the liner (1B) is to be used for a roof panel, the extension 10B is formed such that the extension protrudes in a direction away from the flat portion 5. In the case shown in figure 1B the angle is approximately 75°.

The

liners

1A and 1B can be easily formed by using a roll forming process. The same apparatus can be used for the forming of these liners, and the production can be easily and fast changed from the forming of liners 1A to liners 1B, or vice versa, by only changing one pair of rolls.

Figure 2 shows the sides of two cooperating wall panels 20. A panel 20 consists of an inside liner 1A, an outside liner 21 and insulating material 36. The inside liner 1A, as discussed above, is provide with a male portion 2 and a female portion 7. In the recess of the female portion 7 a sealing profile 35 is placed. The extension 10A is received in the insulating material 36 of the panel.

At the outside of the panel 20 an outside liner 21 is present, having an extruding nose 22 extending beyond the female portion 7 of the inside liner. The liner 21 continues from the nose 22 in a recess 23 above the female portion 7, and again a nose 24 that ends in the same plane as the inside part of the female portion 7. From the nose 24 an extension 25 protrudes, substantially parallel to the extension 10A. At the other side of the outside liner 21 a recess 26 is provide for the nose 22, and a further recess 27 ending in a nose 28 fitting in the recess 23, that side of the outside panel ending in an extension 29 substantially parallel to the inside liner 1A.

In the recess 27 a groove 30 is present for the ease of applying screws 31 with which the wall panels are fitted to a building structure. A hook-like profile can be used to distribute the forces of the screws over the profile. Between the male portion 2 and the nose 28 a closing tape 34 is provided, such that the joint between two panels is closed due to the pressing of nose 24 and the inside part of the female portion 7 against the closing tape 34. The gap between the nose 24 and the inside part of the female portion 7 is closed by a paper strip 33 or the like.

When wall panels 20 are fitted to a building structure first the left-hand panel as shown in Figure 2 is mounted and fixed by the screws 31. Then the right-hand panel is place alongside the left-hand panel, in the same plane, and forced in the direction of the left-hand panel. Due to the construction of the sides of the panels as discussed above, the nose 22 will fit in the recess 26, over the screws 31. The male portion 2 will fit into the female portion 7, such that the nose 3 presses against the sealing profile 35. This results in an air and water tight closure of the joint between the panels. Also the closing tape 34 is compressed by the nose 24 and the inside part of the female portion 7.

Figure 3 shows the two sides of two cooperating roof panels 40. The roof panels 40 consist of an inside liner I B, an outside liner 41 and insulating material 49. The inside liner, as discussed above, is provided with a male portion 2 and a female portion 7. In the recess 9 of the female portion 7 a sealing profile 48 is placed. The extension 10B extends in a direction away from the flat portion of the liner 1B, under an angle of approximately 75°.

The outside liner 41 of the panel 40 has a first protruding portion 42 at the side of the female portion of the inside liner 1B, ending in a flat extension 43 substantially in the same plane as the extension 10B. The first protruding portion 42 is filled with insulating material 49. The gap between the

extensions

10B, 43 is closed by a paper strip 46 or the like. At the other side of the panel 40 the outer liner 41 ends in a second protruding portion 44, extending beyond the male portion 2 of the inside liner 1B. This second protruding portion 44 is complementary to the first protruding portion 42 and has to fit over the first protruding portion 42.The second protruding portion 44 ends in an extension 45 for that purpose. The gap between the second protruding portion 44 and the male portion 2 is closed by a closing tape 47.

When roof panels are fitted on a building structure, first the right-hand panel as shown in figure 3 is mounted. Then the left-hand panel is held under an angle of for instance 30° with the plane of the roof to be formed, and the second protruding portion 44 is hooked over the first protruding portion 42 of the mounted panel. The left-hand panel is then pivoted in the direction of the roof to be formed, until the nose 3 of the male portion contacts the extension 10B. After that the left-hand panel is pressed downwards until the nose 3 snaps into the female portion 7 of the mounted panel. In this way a secure joint is made between both panels, that is rain tight due to the fitting of the second protruding portion 44 over the first protruding portion 45. Here as well the male portion 2 will fit into the female portion 7, such that the nose 3 presses against the sealing profile 48. This results in an air and water tight closure of the joint between the panels. Also the closing tape 47 is compressed by the sidewall consisting of the

extensions

10B, 43 and panel tape 46.

The sealing

profile

35, 48 is particularly useful in case of fire. In such cases the insulating

material

36, 49 could generate gasses due to the heat. By placing the sealing profile in a recess in the inside liner, and air tight seal is provided in the interior liner and gasses produced by the heated insulating material are forced to find their way to the outside of the building, and will not enter the interior of the building.

Claims

Method for the production of a liner for a wall panel or roof panel, the liner being present at the interior side of the panel during use, in which a plate is formed such that one edge of the plate is formed into a male portion and the opposite edge is formed into a mating female portion, the male and female portions being connected by a substantially flat portion, characterised in that the female portion is formed with an extension such that the extension protrudes in a direction away from the substantially flat portion when the liner is to be used for a roof panel, and in that the female portion is formed with an extension such that the extension is substantially parallel to the substantially flat portion when the liner is to be used for a wall panel.
Method according to claim 1, in which the liner is formed from a metal plate, preferably a steel plate.
Method according to claim 1 or 2, in which the liner is formed in a continuous production process, preferably a roll forming process.
Method according to claim 1, 2 or 3, in which the female portion is formed such that the extension protrudes over a length that is of the same order of magnitude as the thickness of the female portion.
Method according to any one of the preceding claims, in which in the inside of the female portion a recess for a sealing profile is formed.
Method according to claim 5, in which the recess for the sealing profile is formed in the innermost part of the female portion.
Liner for a roof panel made by using the method of any one of claims 1 - 6, the liner comprising a substantially flat portion having a male portion at one side and a mating female portion at the opposite side, characterised in that the female portion has an extension protruding in a direction away from the substantially flat portion.
Liner according to claim 7, in which the extension protrudes in a direction making an angle of at least 30° with the plane through the substantially flat portion of the liner, preferably an angle of at least 60°, more preferably an angle of approximately 75°.
Liner according to claim 7 or 8, in which the extension protrudes from the female portion over a length that is at least equal to half the thickness and at most three times the thickness of the female portion.
Liner according to claim 7, 8 or 9, in which in the inside of the female portion a recess for a sealing profile is present, preferably in the innermost part of the female portion.
Liner for a wall panel made by using the method of any one of claims 1 - 6, the liner comprising a substantially flat portion having a male portion at one side and a mating female portion at the opposite side, characterised in that the female portion has an extension that is substantially parallel to the substantially flat portion.
Liner according to claim 11, in which the extension has a length that is at least equal to half the thickness and at most three times the thickness of the female portion.
Liner according to claim 11 or 12, in which in the inside of the female portion a recess for a sealing profile is present, preferably in the innermost part of the female portion.
Roof panel having an inside liner according to any one of the claims 7 - 10, an outside liner and an insulating material in between the liners.
Roof panel according to claim 14, in which the outside liner comprises a substantially flat portion having a first protruding portion at the side of the female portion of the inside liner, the first protruding portion ending substantially in the plane of the extension protruding from the female portion, and in which the outside liner comprises a second protruding portion at the side of the male portion of the inside liner, the second protruding portion being complementary to the first protruding portion so as to fit over the first protruding portion of a corresponding roof panel.
Roof panel according to claim 15, in which the first protruding portion ends in a substantially flat extension that is substantially positioned in the plane of the extension on the female portion of the inside liner.
Wall panel having an inside layer according to any one of the claims 11 - 13, an outside liner and an insulating material in between the liners.
Wall panel according to claim 17, in which the outside liner comprises a substantially flat portion having a recessed portion at the side of the male portion of the inside liner, and preferably the outside liner having a protruding portion at the side of the female portion of the inside liner such that two cooperating wall panels form a substantially flat outside plane.