GB2287517A

GB2287517A - Panel assembly system

Info

Publication number: GB2287517A
Application number: GB9404901A
Authority: GB
Inventors: Kenneth Barry Wilson
Original assignee: Individual
Current assignee: Individual
Priority date: 1994-03-14
Filing date: 1994-03-14
Publication date: 1995-09-20
Anticipated expiration: 2014-03-14
Also published as: GB9404901D0; GB2287517B

Abstract

The edges (13, 15) of one or two panels (9, 11) are inserted into a channel (1) and retained by a wedge (2) engaged between the panel edges (13, 15). The channel (1) is extruded aluminium or alloy, and the wedge (2) is metal or plastics. In Figure 2 (not shown), the channel (1) is integral with one of the panels to form a corner post. <IMAGE>

Description

PANEL ASSEMBLY SYSTEM This invention relates to a panel assembly system, especially to a system including apparatus and method aspects, for the assembly of panels, for example to construct a housing such as that for a vehicle, e.g. a van or lorry.

Many housings are formed simply by connecting together solid panels, often but not always round the exterior of a rigid supporting cage. One well-known example of such a construction is the housing on a lorry, van or other vehicle, which surrounds the vehicle's loadcarrying space, and the same technique is frequently used to construct buildings, and even to build the hulls of ships.

A common method for fastening or joining together a pair of panels is simply to place them with edge portions of each overlapping one another, and then to rivet the panels together in the overlapping regions. A problem with this method is that it is difficult to replace any panel which may be subsequently damaged or otherwise need replacing. Furthermore, constructions formed by connecting panels in this simple manner have surfaces interrupted by lines of rivets, which is disadvantageous if, for example, it is intended to apply decoration to the exterior of the housing for advertising or other purposes.

In another known technique for fastening together a pair of panels, each is provided with a flange along at least one of its edges. The two panels are positioned with their flanges abutting one another and the flanges are then rivetted together. If the flanges of a plurality of panels making up a housing structure are formed so that they all point to the same side of their respective panels, then the housing may be built having all the riveted pairs of flanges lying in the housing interior, the exterior surface of the housing thus being substantially even and smooth. Often, in addition, the rivets which connect the flanges are additionally driven through rails which run the length of the flanges and which both strengthen the junctions between panels and provide surfaces onto which further strengthening elements may be connected if desired.

While the latter technique succeeds in concealing the rivets, it does not facilitate the replacement of individual panels.

The present invention seeks to overcome at least some of the above problems by providing a novel system for fastening together two or more panels, or for fastening together a panel and at least one other structural element of a different kind, especially for use in connecting panels to each other or to another member, for the construction of a housing such as that for a vehicle, which system comprises a minimum number of simple mechanical components which are cheap to manufacture and readily assembled and dismantled.

Accordingly, in a first aspect the invention provides an apparatus for fastening together a panel and at least one other structural element, e.g. another panel or a supporting member, comprising a rail and one or more wedges, the rail defining a channel of sufficient width that an edge portion of at least one panel can be positioned therein, one or more of the said wedges being insertable into the channel so as to clamp the said edge portion or edge portions of the respective panel or panels against one or more of the walls of the channel.

It is to be understood that herein there is no implication that the rail is of the same length as the edge of the gripped panel or panels. Although this is the case in some preferred embodiments, in other embodiments the rail may be longer or shorter than the panel edge, or even multiple rail sections may be employed.

Typically, as used with the apparatus of the invention, the panel or panels will be of metal, e.g.

aluminium, steel or alloys of either of these metal, or of any other suitable material as is known in the art.

Preferably, the rail element of the apparatus is also of metal, e.g. a metal extrusion or any other suitable physically formed item, and may by of the same or different material as the panel(s) with which the apparatus is used. The wedge element or elements of the apparatus may similarly be of metal, either the same as or different from the rest of the structure, but may possibly lend themselves to being made of non-metallic material such as plastics, examples of which and methods for making, e.g. moulding or extruding, which are well known.

The rail and the or each wedge are preferably so sized and shaped as to be capable of clamping the or each panel edge portion in the channel, with the outer surface of the or each wedge, that is the surface away from the channel floor, substantially co-planar with the or each panel face which will be to the exterior of the finished structure. Thus, that face of the or each gripped panel and the wedges preferably form a surface interrupted only by the or each junction between a wedge and a panel.

Typically, the apparatus may be used with one or more panels each having at least one edge flange, i.e. an edge portion angled, especially right-angled, or otherwise contoured from the main panel along a line parallel to the edge of the panel.

In some forms of panels for use with the invention, the flange comprises a first flange portion joined to the main panel and angled at a first angle, e.g. about 900, thereto, and a second flange portion joined to the first flange portion and angled at a second angle thereto. The first flange portion constitutes a clamping flange portion which is to be clamped against a wall of the channel by the wedge and the second flange portion constitutes a locking flange portion which prevents sliding of the flange out of the open mouth of the channel.

The locking flange portion may be angled backwards, for example so as to make any desired angle with the plane of the main panel, e.g. it may lie generally in the plane of the main panel such that the locking flange portion, the clamping flange portion and a proximate portion of the main panel form a U-shape when viewed along the longitudinal channel axis. In this case, the interior walls of the channel are preferably shaped so as to accommodate the flange in abutting relationship therewith. For example, the inner wall of the channel may be formed with a clamping surface against which the clamping flange portion is to be clamped, and a recess running the length of the channel within which the locking portion of the flange is to be positioned.

Alternatively, the locking flange portion may be angled forwards into the plane of the main panel, again at any desired angle, so that when the clamping flange portion is clamped against a first wall of the channel, the locking flange portion extends across the channel towards the other wall and is sandwiched between the channel and the or each wedge.

In other forms of panels for use with the invention, the locking flange portion is located between the main panel and the clamping flange portion. The locking flange portion is preferably substantially parallel to the main panel but displaced in the direction which is to be towards the interior of the finished structure, and the clamping flange portion, which is to be inserted into the channel, meets the locking flange portion at an angle of e.g. 90", so that the panel has a stepped appearance when viewed along the longitudinal channel axis. In this case, one or two extension flanges are provided which project from the front of the wedge preferably in a direction or, in the case of two such extension flanges, in opposite directions, generally parallel to the plane(s) of the panel(s) such that when the wedge is in position, clamping the clamping flange portion of one or two panels of this form, the extension flange(s) abuttingly overlie the or each respective locking flange portion. The outer surface of the extension flange(s) (i.e. the surface which is to be towards the outside of the finished structure) is preferably co-planar with the outer surface of the wedge, so that the outer surface of a housing to be built from the panel(s) will not be substantially interrupted.

As an alternative to discretely angled flange portions, the flange may simply be continuously contoured so as to fulfil the same function, with the channel wall being shaped accordingly.

Means are preferably provided to fasten the or each wedge within the channel. For example, apertures may be provided in the rail through which one or more fastening elements such as screws or, more preferably, rivets may be inser-ted. In this case the or each wedge may be formed with holes to receive the or each screw or rivet.

Panels of the form in which a locking flange portion thereof is to be sandwiched between the channel and the or each wedge may be provided with apertures suitably located on the locking flange portion through which the screws or rivets can be passed.

At least one side wall of the channel, and preferably both, may be formed with at least one, preferably a series of, detent ridges projecting into the channel, the or each wedge being optionally also provided with similar detent ridges which, upon the wedge being inserted into the channel for clamping at least one panel edge portion received therein, provide a gripping action against non-ridged surfaces of the channel and the one or more panel-edge portions. To assist insertion of a ridged wedge into the channel, especially one which itself has at least one ridged inner wall, the wedge preferably includes a slightly enlarged head portion at or near a head end thereof which is dimensioned such that the channel walls experience a small degree of expansion as the wedge is inserted therebetween, thereby preventing premature interengagement (or "snagging") of the respective sets of ridges.

Preferably, the or each wedge is generally of such a width that when it is inserted into the channel the walls of the channel are forced apart a small distance, the rail being resilient to such distortion, so that the walls compress the contents of the channel, which improves the clamping action on the or each panel.

The or each wedge preferably has a longitudinal axis which, when that wedge is positioned in the channel, is substantially parallel to or coincident with the longitudinal axis of the channel. The or each wedge may have a hollow structure, which is particularly useful for reducing the overall weight of the apparatus, or may be solid.

In preferred embodiments of the apparatus of the invention, the or each wedge is of a generally rectangular cross-section, optionally with a small degree of additional tapering towards the end of the wedge which in the finished structure is proximate the channel floor.

In the apparatus of the invention the rail may if desired be formed with at least one connection flange to which further supporting members may be attached.

Preferably, such a connection flange or flanges project from a side or edge(s) of the rail distal from the mouth of the channel. Apertures are preferably provided in the or each such connection flange for the purpose of bolting on, rivetting or otherwise attaching members which connect the rail to other rails and/or to a floor or other surface on which the housing is to be built.

In a first particularly preferred embodiment of the apparatus of the invention, the apparatus is adapted to grip a respective edge portion of each of two panels in such a way that the outer surface of the or each wedge and those faces of each panel which will be to the exterior of the finished structure form a single surface interrupted only by the junctions between the wedge and each panel.

In a second particularly preferred-embodiment of the apparatus of the invention, the rail is integral with a first panel, and is adapted to grip an edge portion of a second panel in such a way that a single surface is formed from the first panel, the second panel and the outer surface of the or each wedge again interrupted only by the junction between the wedge and the second panel.

In another aspect, the present invention provides a housing built, at least partly, by joining panels using assembly apparatus according to the first aspect of the invention and preferably of one or both of the above defined particularly preferred forms, possibly (but less preferably) in combination with conventional methods for connecting panels. Usually, such a housing will be such as to present a substantially smooth exterior, with all rails concealed in the interior of the housing.

Preferably any curved panels which may be employed are chosen to have matched radii, so as to give a pleasing appearance to the exterior of the housing. Preferably, further supporting members are attached to the rails on the interior of the housing, so that the rails and supporting members form a rigid cage supporting the housing.

It is envisaged that such a construction will often be used as the housing for a vehicle, such as a van or lorry, and for this purpose one or more of the panels may be further provided with apparatus of conventional kinds, or according to the present invention, for mounting the housing on the vehicle, or for connecting thereto elements which constitute the roof of the vehicle.

In yet another aspect, the present invention provides a method for fastening together a panel and at least one other structural element, e.g. another panel or a supporting member, comprising the steps of: positioning an edge portion of at least one panel within a channel formed in a rail; and inserting into the channel one or more wedges so as to clamp the said edge portion or edge portions of the respective panel or panels against one or more of the walls of the channel.

The above steps may optionally be repeated, possibly in combination with conventional methods of connecting panels, in order to assemble a plurality of panels, for example to form a housing.

Preferred embodiments of the invention will now be described in detail with reference to the accompanying drawings, in which: Figure 1 is a cross-sectional view of two panels fastened together by a first embodiment of the invention; Figure 2 is a cross-sectional view of a second embodiment of the invention arranged for fastening together one panel and another housing structural member; Figure 3 is a cross-sectional view of a third embodiment of the invention fastening together two panels as in the embodiment of Figure 1; Figure 4 is a cross-sectional view of a fourth embodiment of the invention again fastening together two panels; and Figure 5 is a perspective view of two panels being fastened together by a fifth embodiment of the invention.

Referring firstly to Figure 1, the apparatus shown here comprises an extruded aluminium or aluminium alloy rail 1, which is viewed here in cross-section, defining a channel 90 therein with floor 3 and side walls 5,7.

Two panels 9 and 11 for forming part of a housing for the load carrying space of a vehicle are positioned such that clamping flange portions 13,15 thereof lie against the channel interior walls 5,7 and respective locking flange portions 17,19 thereof lie in respective recesses 92,94 formed by respective outwardly directed extensions of the channel side walls 5,7 which run the length of the channel 90.

Between the clamping flange portions 13,15 is positioned a hollow wedge 2, preferably also of aluminium or aluminium alloy, the longitudinal axis of which is parallel to that of the channel, The base 23 of the wedge 2 is secured to the channel floor 3 by one or more rivets 22 appropriate to the longitudinal extent of the wedge. The top surface 24 of the wedge 2 is co-planar with the outer faces 26,28 of the panels 9,11.

The interior channel walls 5,7 and the outer side faces of the wedge 2 are each formed with ridges shown as 30 and 32, parallel to the longitudinal axes of the channel and of the wedge, to assist the gripping of the panels 9,11. The rail 1 has a rear connection member 31 distal from the channel mouth, for attaching further supporting members which may be required in the finished structure.

Turning to Figure 2, in the embodiment shown here the rail 1 is integral with a first panel 21, such as that forming a curved corner post or like structure and the wedge 2 is secured in the channel 90 in a similar manner to that shown in Figure 1. The channel 90 holds a second panel 11 with a clamping flange portion 15 clamped against channel side wall 7. The locking flange portion 19 prevents escape of the clamping flange portion 15 out of the channel mouth in a direction away from the channel floor 31, this being further hindered by the interengagement, as in the embodiment of Figure 1, of ridges 30,32 formed in the adjacent faces of the channel walls and the wedge 2. Extending to one side from the rear of the rail 1 is a connection flange 42, to which may be attached further supporting members to be employed in the building up of the finished structure.

As shown in Figure 3, in a further alternative embodiment of the invention, the locking flange portions 51,52 of panels 54,56 are formed so as to extend substantially across the width of the channel when the panels are in position, the locking flange portions 51,52 overlapping each other and being sandwiched between the base of the wedge 2 and the floor 3 of the channel.

Apertures are provided in the locking flange portions 51,52 to allow the wedge 2 to be rivetted to the rail 1 using one or more rivets 22. Since in this embodiment the locking flange portions 51,52 overlie each other, in order that the exterior faces 55,57 of the panels 54,56 lie in the same plane, the clamping flange portions 58,59 of the panels 54,56 are of slightly different lengths, i.e. in the illustrated embodiment clamping flange portion 8 is shorter than clamping flange portion 59 by a distance equal to the thickness of the panel material.

Turning to Figure 4, here there is shown an embodiment of the invention in which panels 60,61 are fastened together, which are provided with locking flange portions 62,63 located between the clamping flange portions 64,65 and the main part of the respective panels 60,61. Extending from either side of the front face the wedge 2 are a pair of extension flanges 66,67 which abuttingly overlie the respective locking flange portions 62,63 of the panels when the wedge is fully inserted into the channel. Preferably, as shown in the Figure, each of the locking flange portions 62,63 of the panels is formed as a stepped region of that panel in the vicinity of its clamping flange portion 64, or 65, the combined length of the stepped regions of the two panels being, when both panels are clamped within the channel, at least equal to the length in the same direction of the flange extensions 66,67 of the wedge. In this manner, and with appropriate shaping of the extremities of the flange extensions 66,67 and the shoulders defining the junction between each locking flange portion 62,63 and its respective panel 60,61, a substantially smooth and uninterrupted outer surface of the finished structure is generated.

To assist locking of the wedge 2 in the channel and thus tight abutment of the flange extensions 66,67 against the stepped locking flange portions 62,63 of the panels, the inner walls of the channel and the corresponding sections of the outer walls of the wedge are ridged or serrated to improve their gripping action as in the other embodiments described above. In this embodiment there are further provided detent means to maintain the wedge in its fully locked home position within the channel. Protruding into the interior of the channel are at least one, preferably two or more, detents 68,69 behind which are engaged one or more corresponding shoulder formations 70,71 on the wedge as it is advanced fully into the channel. The resulting snap-fit connection may be assisted by the resilience of the material of the wedge and/or the channel itself.

Figure 5 shows yet another embodiment of the invention, in which (in perspective view) rail 1 and wedge 2 are used to fasten together two panels 9,11 by gripping an edge portion of each. The panels 9,11 are held so that their outer faces 26,28 and the outer face 24 of the wedge together form a surface interrupted only by the lines along which the wedge contacts each panel.

In this embodiment, the locking flange portions 17,19 of the panels 9,11 are angled at an angle of about 45C to the respective clamping flange portions 13,15.

The wedge 2 is shown in Figure 5 as extending the full length of the edges of the panels 9,11, but other embodiments are possible in which only short sections of the panels' edges or a plurality of such short sections are connected by the apparatus of the invention.

The present invention has been described above by way of reference to preferred exemplary embodiments only.

However, it is to be understood that various changes and modifications to that which has been specifically described and illustrated may be made within the purview of persons skilled in the art, within the scope of the present invention.

Claims

CLAIMS:

1. Apparatus for fastening together a panel and at least one other structural element comprising a rail and one or more wedges, the rail defining a channel of sufficient width that an edge portion of at least one panel can be positioned therein, one or more of the said wedges being insertable into the channel so as to clamp the said edge portion or edge portions of the respective panel or panels against one or more of the walls of the channel.

2. Apparatus according to claim 1, in which at least one of the said other structural members is a panel or a supporting member.

3. Apparatus according to claim 1 or claim 2, in which the rail element is of metal.

4. Apparatus according to claim 3, in which the rail element is a metal extrusion.

5. Apparatus according to any preceding claim, in which the wedge element or elements of the apparatus are of metal or plastics.

6. Apparatus according to any preceding claim, in which the rail and the or each wedge are so sized and shaped as to be capable of clamping the or each panel edge portion in the channel, with the outer surface of the or each wedge, that is the surface away from the channel floor, substantially co-planar with the or each panel face which will be to the exterior of the finished structure.

7. An assembly comprising a panel and apparatus according to any preceding claim, in which the panel each has at least one edge flange, being an edge portion angled, especially right-angled, or otherwise contoured from the main panel along a line parallel to the edge of the panel.

8. An assembly according to claim 7, in which the flange comprises a first flange portion joined to the main panel and angled at a first angle thereto, and a second flange portion joined to the first flange portion constituting a clamping flange portion which is to be clamped against a wall of the channel by the wedge and the second flange portion constituting a locking flange portion which resists sliding of the flange out of the open mouth of the channel.

9. An assembly according to claim 8, in which the clocking flange portion is angled backwards, so as to make any desired angle with the plane of the main panel.

10. An assembly according to claim 8, in which the locking flange portion lies generally in the plane of the main panel such that the locking flange portion, the clamping flange portion and a proximate portion of the main panel form a U-shape when viewed along the longitudinal channel axis.

11. An assembly according to claim 10, in which the interior walls of the channel are shaped so as to accommodate the flange in abutting relationship therewith.

12. An assembly according to claim 11, in which the inner wall of the channel is formed with a clamping surface against which the clamping flange portion is to be clamped, and a recess running the length of the channel within which the locking portion of the flange is to be positioned.

13. An assembly according to claim 11, in which the locking flange portion is angled forwards into the plane of the main panel at any desired angle, so that when the clamping flange portion is clamped against a first wall of the channel, the locking flange portion extends across the channel towards the other wall and is sandwiched between the channel and the or each wedge.

14. An assembly according to claim 8, in which the locking flange portion is located between the main panel and the clamping flange portion.

15. An assembly according to claim 14, in which the locking flange portion is substantially parallel to the main panel but displaced in the direction which is to be towards the interior of the finished structure, and the clamping flange portion, which is to be inserted into the channel, meets the locking flange portion at an angle so that the panel has a stepped appearance when viewed along the longitudinal channel axis.

16. An assembly according to claim 15, in which one or two extension flanges are provided which project from the front of the wedge preferably in a direction or, in the case of two such extension flanges, in opposite directions, generally parallel to the plane(s) of the panel(s) such that when the wedge is in position, clamping the clamping flange portion of one or two panels of this form, the extension flange(s) abuttingly overlie the or each respective locking flange portion.

17. An assembly according to claim 16, in which the outer surface of the extension flange(s), being the surface which is to be towards the outside of the finished structure, is co-planar with the outer surface of the wedge, so that the outer surface of a housing to be built from the panel(s) will not be substantially interrupted.

18. An assembly according to claim 7, in which the flange is continuously contoured with the channel wall being shaped accordingly.

19. An assembly according to any one of claims 7 to 18, in which means are provided to fasten the or each wedge within the channel.

20. An assembly according to claim 19, in which the fastening means includes apertures provided in the rail through which one or more fastening elements such as screws or rivets may be inserted.

21. An assembly according to claim 19, in which the or each wedge is formed with holes to receive the or each fastening element.

22. Apparatus according to any one of claims 1 to 6, in which at least one side wall of the channel is formed with at least one detent ridge projecting into the channel, the or each wedge being optionally also provided with a similar detent ridge which, upon the wedge being inserted into the channel for clamping at least one panel edge portion received therein, provide a gripping action against non-ridged surfaces of the channel and the one or more panel-edge portions.

23. Apparatus according to claim 22, in which the wedge includes a slightly enlarged head portion at or near a head end thereof which is dimensioned such that the channel walls experience a small degree of expansion as the wedge is inserted therebetween, thereby preventing premature interengagement of the respective sets of ridges.

24. Apparatus according to any one of claims 1 to 6, claim 22 or claim 23, in which the or each wedge is generally of such a width that when it is inserted into the channel the walls of the channel are forced apart a small distance, the rail being resilient to such distortion, so that the walls compress the contents of the channel, which improves the clamping action on the or each panel.

25. Apparatus according to any one of claims 1 to 6 or 22 to 24, in which the or each wedge is of a generally rectangular cross-section, with a small degree of additional tapering towards the end of the wedge which in the finished structure is proximate the channel floor.

26. Apparatus according to any one of claims 1 to 6 and 22 t 24, which is adapted to grip a respective edge portion of each of two panels in such a way that the outer surface of the or each wedge and those faces of each panel which will be to the exterior of the finished structure form a single surface interrupted only by the junctions between the wedge and each panel.

27. Apparatus according to any one of claims 1 to 6 and 22 to 24, in which the rail is integral with a first panel, and is adapted to grip an edge portion of a second panel in such a way that a single surface is formed from the first panel, the second panel and the outer surface of the or each wedge again interrupted only by the junction between the wedge and the second panel.

28. A housing built, at least partly, by joining panels using assembly apparatus according to any one of claims 1 to 6 and 20 to 27.

29. A housing according to claim 28, being a housing for a vehicle, such as a van or lorry, in which one or more of the panels are further provided with apparatus of conventional kinds, or according to the present invention, for mounting the housing on the vehicle, or for connecting thereto elements which constitute the roof of the vehicle.

30. A method for fastening together a panel and at least one other structural element, comprising the steps of: positioning an edge portion of at least one panel within a channel formed in a rail; and inserting into the channel one or more wedges so as to clamp the said edge portion or each portions of the respective panel or panels against one or more of the walls of the channel.

31. Apparatus for fastening together a panel and at least one structural element substantially as described herein with reference to the accompanying drawings.