GB2348444A

GB2348444A - Composite roof panel

Info

Publication number: GB2348444A
Application number: GB0005270A
Authority: GB
Inventors: Raymond George Snow
Original assignee: Individual
Current assignee: Individual
Priority date: 1999-03-05
Filing date: 2000-03-06
Publication date: 2000-10-04
Also published as: GB0005270D0; GB9904994D0

Abstract

The panel includes planar exterior and interior sections (1, 3) bounding a filler layer comprising plurality of non-rectangular cross sectioned cells (4) which extend through the panel. Preferably the cells are hexagonal in cross section and link together to form a honeycomb structure. The filler layer may include pairs of parallel, spaced apart members (ref. 5 and also Figure 3) running transverse to the length of the roof panel. Preferably each of the members is connected, via a linking bar (6), to alternate polygon portions and the members may extend through the depth of the panel. The panels may be to be joined together using pairs of hooks (7) located at each end of the panel. In an alternative embodiment channels (8) located along the interior section may act as locating pockets for panel end caps (Figure 11 ref. 17). A further embodiment (Figure 7) comprises means to link a panel to a wall.

Description

INIPROVEMENTS IN ROOF PANELS Field of the Invention The present invention relates to improvements in roof panels, in particular, but not exclusively, to roof panels used in the construction of conservatories, car-ports and the like.

Background Art Known to the Applicant Roof panels for use in the construction of conservatories, car-ports and the like generally consist of exterior and interior sections that have been interconnected integrally, with an array of straight or curved segments.

Such roofs, formed from such panels, have usually been designed with the sole intention of"keeping the rain out"No thought has usually gone into increasing the structural strength of the roof panel or of the roof in general and thus far, such roofs or roof panels have not been able to bear the weight of an individual climbing on top of them.

This could be a potential problem if work is required to the wall adjacent and above such a roof and it is an object of the present invention to elevate this potentialproblem.

Summary of the Invention According to the invention in its broadest aspect, there is provided a roof panel for use in the construction of conservatories, car-ports and the like, comprising generally exterior and interior sections, each respective one of which is interconnected at least in part, by a number of portions sandwiched between the sections and extending through the panel to form an integral, light-weight and generally rigid panel, the or each such portion having the cross-section of a nonrectangular polygon.

Preferably, the non-rectangular polygon cross-section is a hexagonal crosssection.

Especially preferable is for the cross-section to be a"honeycomb"-i. e. a regular hexagon.

Preferably, the roof panel further comprises a plurality of pairs of substantially parallel spaced-apart members sandwiched integrally between the exterior and interior sections and running substantially transverse to the length of the roof panel to enable the length of the roof panel to be shortened by cutting the panel between the members of such a pair.

Preferably, each pair of members is integrally connected to alternate polygon portions.

Preferably, each pair of members extends continually throughout the depth of the panel.

Preferably, each respective pair of members is substantially orthogonal to the exterior and interior sections.

Preferably, the ends of each respective panel comprise integral linkage means to enable the panel to be operatively connected together in use.

Preferably, each respective pair of linkage means is either"male-male"or "female-female"linkage means.

Preferably, the invention includes within its scope, a roof panel substantially as herein described with reference to and as illustrated in any appropriate selection or combination of the accompanying drawings.

The invention also inclues within its scope a roof incorporating panels of the type specified above.

Brief Description of the Drawings The invention is described with reference to the following drawings in which : Figure 1 illustrates in cross-section, part of a roof panel embodied by the present invention ; Figure 2 illustrates in cross-section a complete roof panel of the type illustrated in Figure 1 ; Figure 3 illustrates in cross-section, part of an alternative embodiment of a roof panel embodied by the present invention ; Figures 4,5 and 6 illustrate in cross-section, alternative polygonal arrangements of typical sandwiched portions that interconnect the exterior and interior sections of the roof panel in an integral manner; Figure 7 illustrates in cross-section, a roof-panel of the type described and illustrated herein, fitted to a wall through a wall-to-roof-linkage ; Figure 8 illustrates in cross-section, one element of the wall-to-roof-linkage ; Figure 9 illustrates in cross-section, another element of the wall-to-roof-linkage ; Figure 10 illustrates in cross-section, a drip promoter ; Figure 11 illustrates in cross-section, another element of the wall-to-roof-linkage ; Figure 12 illustrates in cross-section, a mullion cover used to link two roof panels of the present invention together, and Figure 13 illustrates in cross-section, a width end cover.

Description of the Preferred Embodiments Throughout this specification, the use of the word"integral"is intended to cover not only something which is formed from the outset as one single-entity component, but also anything which, whilst being assembled from a plurality of initially disparately-produced integers, ends up as one overall and normally non dismantleable structure.

Figure 1 illustrates in cross-section, a preferred embodiment of part of a roof panel and is generally referenced 1. The roof panel 1 consists of an exterior, substantially flat, continuous section 2 (by the term exterior, we mean that surface, which in use, will be exposed to the elements e. g. rain, sunlight etc), and an interior section 3 (by the term interior, we mean that surface which in use, would normally be considered to be the"ceiling"of the panel). The exterior section 2 and interior section 3 are interconnected integrally via a framework forming a number of air-fille portions 4. Some of the portions 4 that are sandwiched between the sections 2,3, are in the form of regular hexagons. This generally"honeycomb"construction provides the ultimate in terms of structural integrity to the extremely lightweight roof panel. The sloping walls provided by the"honeycomb"structure act as a prism to deflect sunlight, which is a particular advantage of this type of construction. In addition to the portions 4, the depth between or space separating the exterior section 2 from the interior section 3 is also part filled with a plurality of pairs of substantially parallel spaced-apart members 5. These members 5 are again, sandwiched integrally between the exterior and interior sections 3 and 2 respectively and run substantially transverse to the length of the roof panel 1 to enable the length of the roof panel 1 to be shortened by the cutting of the panel 1 between the members of such a pair 5.

Each respective one of each respective pair of members 5 is also integrally connected to the portions 4 via a linking bar 6.

Such a cut allows the half-chamber of air filled portion 4 to be retained.

At the ends of each respective panel 1, are a pair of linkage means in the form of hooks 7 that also run substantially transverse to the length of the roof panel 1.

One hook 7 is integral with the exterior section 2 whilst the other hook 7 is integral with the interior section 3. Relative to each other, each respective pair of hooks 7 at any one end of the panel I are parallel and spaced apart. Both hooks 7 at any one end of the panel I are to be considered as"male"linkages.

Furthermore, each respective pair of hooks 7 located at each respective end of the panel I (see Figure 2) are also"male"linkages. In order to provide the hooks 7 with some structural integrity with respect to the rest of the roof panel 1, bars 6 extending from the portions 4 form an integral connection with each respective hook 7 at each respective end of the panel 1.

All of the integrally connected aspects 4,5 and 6 located between the exterior 2 and interior sections 3 of the panel 1, extend throughout the width of the panel 1 in a continuous fashion. Likewise, each respective pair of linkage means 7 also extend continuously throughout the width of the panel 1.

The exterior surface 2 is continuous and flat throughout the length and breadth of the panel 1 whilst the interior section 3, whilst being continuous, throughout the length and breadth of the panel 1, is not flat. It comprises a number of channels 8 that run transverse to the length of the panel 1 in a continuous fashion, throughout the width of the panel 1. The channels 8 tend to be located adjacent each respective pair of members 5 and form part of each respective hook 7. Their purpose is to act as female locating pockets for the end capping members 17 (illustrated in Figure 11). The arm 20 towards the distal end of the end capping member 17 acts as the male locating member for the channel 8 in use. If the roof panel 1 is used un-cut, the arm 20 of the end capping member 17 locates within the channel 8 adjacent the hook 7 integral with the interior section 3, whilst the shoulder 22 of the end piece 17 locates around the hook 7 that is integral with the exterior section 2. If the roof panel 1 is cut between the members of such a pair 5, then the arm 20 of the end piece 17, again locates in the appropriate channel 8, but this time, the soft flexible end piece 21 of the proximal end of the end capping member 17 arm of the end piece engages in a friction-type-fit-manner, the top surface of the exterior section 2 of the roof panel 1.

Again, in this embodiment, the channels 8 extend continuously throughout the width of the roof panel 1.

Turning now to Figure 3, this shows an alternative preferred embodiment of part of the roof panel generally referenced 25. The roof panel 25 consists, like the roof panel 1, of an exterior substantially flat continuous section 2 and an interior section 3 that is interconnected integrally via a framework forming a number of air-fille portions 4. Some of the portions 4 that are sandwiched between the sections 2 and 3 are again, in the form of regular hexagons. In addition, the depth between or space separating the exterior section 2 from the interior section 3 is also part filled with a plurality of pairs of substantially parallel spaced-apart members 5. The difference between these particular members 5 and the members 5 illustrated in Figure 1, being that the members 5 in Figure 3 are not continuous throughout the depth of the roof panel 25 and are in fact separated by part of the framework in the form of a regular hexagon. In effect, each respective pair of members 5 can be considered as two sets of pairs. The first set of pairs 5 being integrally connected to the exterior section 2 and the upper most surface of the air filled portion in the form of a hexagon, whilst the second set of members 5 are integrally connected to the interior section 3 and the lower most surface of the airfilled portion in the form of a hexagon. Again, each respective set of pairs of members 5 extend continuously throughout the width of the roof panel 25.

In the embodiment illustrated by Figure 3, the channels 8 are in the form of substantially square channels whilst in Figure 1, it will be noted that the channels 8 are substantially semi-circular. Finally, and like Figure 1, all of the integrally connected aspects 4 and 5 located between the exterior section 2 and interior section 3 of the panel 1, extend throughout the width of the panel I in a continuous fashion. Likewise, each respective pair of linkage means (not illustrated) also extend continuously throughout the width of the panel 1.

Figures 4,5 and 6 show alternative arrangements of frameworks providing air filled pockets that are envisage in alternative embodiments of the present invention. It is worthy of note, that instead of there being a framework comprising two layers of mainly hexagons separating the exterior section 2 from the interior section 3, there could, for example, be three such layers of air-fille pockets. Alternatively, the generally honey-comb type structure need not necessarily consist of mainly hexagons and could conceivably consists of a mixture of tessellating shapes such as, in the main, diamonds and hexagons as illustrated in Figure 5.

Figure 7 shows in cross-section, the roof panel 1 slotted into place within a wallto-roof-linkage generally referenced 19. The wall-to-roof-linkage comprises a fixing bridge 13, a foam-filler 14 an outer wall plate trim 9 which, in use is exposed to the elements and an inner wall plate trim 12 which would form part of the ceiling of the finished roof when viewed from the interior. The trims 9 and 12 are themselves interconnected to a trim connector 20 which is itself slid over the fixing bridge 13 that has been first bolted permanently into position against a wall.

In use, the inner wall plate trim 12 will have an aperture cut within it to accommodate an ajustable ventilator hood 15 that can be used to adjust the air flow within the wall-to-roof-linkage 19, to provide ventilation (if required) to for example a conservatory incorporating the elements of the present invention.

Each respective one of the sections that make up the wall-to-roof linkage 19 (apart from the ventilator hood 15), are generally longer in length than any one of the roof panels 1, enabling each of these extruded units 19 to be cut to the desired size.

Turning now to Figure 12, this illustrates in cross-section, an integral unit that is so sized and shaped as to act as a mullion cover to link two roof panels 1,25 together in side-by-side relationship. The mullion cover is generally referenced 18 and comprises female linkage means 24,26 which in use, mate with the male linkage means 7 at the end of the roof panels 1, 25. The linkage means 24 located at the distal end of the mullion 18, in use, locates within the pocket generated by the hook 7 that is integral with the interior section 3, whilst the linkage means 26 located towards the proximal end of the mullion 18, locates within the pocket generated by the hook 7 that is integral with the exterior section 2. It will be appreciated, that again, the soft flexible end piece 21 toward the proximal end of the mullion 18 engages in a friction-type-fit manner against the upper most surface of the exterior section 2 of the roof panel 1, 25. Furthermore, the free end of the arm 23 of the mullion 18, in use, will abut the sloping framework of one of the air filled portions 4 to add structural rigidity to this part of the roof panel 1,25.

The angle from the horizontal of the arm 23 is such that it is substantially parallel to a number of the sloping segments of the framework of the roof panel 1, 25.

Figure 10 illustrates a drip promoter 16. Before describing this element in detail, it should be appreciated that the exterior section 2 of the roof panel 1, 25 is provided with a lip that extends beyond the width of the panel 1,25. The lip is provided to prevent ingress of water into the structure. This lip is only present along the width of one edge of the panel 1,25 and its cross-section, throughout its entire length is substantially the same.

The mouth of the drip promoter 16 grips the lip of the panel 1,25 (not illustrated) in a friction-type-fit arrangement and thus enables water to drip off the drip promoter 16.

Finally, the plate 29 in Figure 13 in use, covers the width-end of the roof panel 1, 25 again, in a friction-type-fit arrangement although, it could be secured by other means, to provide a flush, pleasing appearance to the overall finished roof.

Typically, the distance between adjacent sets of members 5 is approximately 60millimetres, thus allowing a sheet to be reduced in integral multiples of this distance. Half-chambers at the end of a sheet allow structure bars formed from a metal such as aluminium, steel, or other suitably rigid material to engage the sheet and provide support where required.

All of the elements herein described provide a roofing system that once assembled, could provide a roof for use in the construction of conservatories, carports and the like.

In alternative embodiments not illustrated, the portions 4 need not extend continuously throughout the width of the roof panel 1 and could for example, comprise a plurality of portions all lying within the same plane when viewed in cross section, as shown in Figures 1 and 2, but the portions could be separated by air gaps or indeed, air pockets. How this could be achieved is readily apparent to a person skilled in the art.

Furthermore, again, in alternative embodiments not illustrated, instead of the members 5 extending throughout the width of the roof panel 1, as shown in Figure 3, these too, could be separated by either air gaps or air pockets in a similar manner just described. Furthermore, instead of incorporating pairs of linkage means 7 in the form of hooks 7 that are"male"linkages, one pair of linkage means at one end of the panel 1 could be"male"whilst the other pair of linkage means 7 at the opposing end of the panel 1 could be in the form of"female" linkages. Furthermore, with respect to each pair of linkage means at any one end of the plane 1, one hook 7 of the pair could be"male"whilst the other could be "female" Finally, it is to be noted that in other alternative embodiments, again not illustrated, the portions 4 need not necessarily be regr/lar polygons, the polygons could in fact have sides of irregular length.

Polycarbonate is preferably used as the plastics material to form the roofing panel 1 because of its colourfast and generally recognised UV protective qualities, but other plastics materials could be used to form the extruded panel 1 and these will be known generally to the person skilled in the art.

Claims

CLAIMS l. A roof panel for use in the construction of conservatories, car-ports and the like, the roof panel defining a sandwiched layer bounded by planar sections, the layer comprising plurality of shaped portions extending through the panel to form a unity, lightweight and generally rigid panel, said shaped portions being of a non-rectangular polygonal cross-section.

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2. A roof panel according to claim 1 wherein each portion has a hexagonal cross-section.
3. A roof panel according to claim 2 wherein the hexagonal portions link together to form a honeycomb structure.
4. A roof panel according to any preceding claim, the roof panel comprising a plurality of pairs of substantially parallel spaced apart members sandwiched between the planar sections and running substantially transverse to the length of the roof panel to enable the length of the roof panel to be shortened by cutting the panel between the members of such a pair.
5. A roof panel according to claim 4 wherein each pair of members is integrally connected to alternate polygon portions.
6. A roof panel according to either of claims 4 or 5 wherein each pair of members extends continually throughout the depth of the panel.
7. A roof panel according to any one of claims 4-6 wherein each respective pair of members is substantially orthogonal to the planar sections.
8. A roof panel according to any preceding claim wherein the ends of each respective panel comprise integral linkage means to enable the panel to be operatively connected together in use.
9. A roof panel according to claim 8 wherein each respective pair of linkage means is either"male-male"or"female-female"linkage means.
10. A roof panel substantially as herein described with reference to and as illustrated in any appropriate combination of the accompanying drawings.
11. A roof comprising panels according to claim 1-10.