GB2353299A

GB2353299A - Profiled metal cladding panels

Info

Publication number: GB2353299A
Application number: GB9919463A
Authority: GB
Inventors: Hugh Connolly; Peter Edward Connolly
Original assignee: Individual
Current assignee: Individual
Priority date: 1999-08-17
Filing date: 1999-08-17
Publication date: 2001-02-21
Anticipated expiration: 2019-08-17
Also published as: GB9919463D0; GB2353299B

Abstract

A metal cladding panel (1) of generally trapezoidal shape with a flat panel valley (2) ridge (3) and panel sides (4) having microprofiles (5) in panel sides (4). One of the micro-corrugations (5) forming the microprofiling forms the corner between the flat ridge (3) and each panel side (4) for additional rigidity. Similarly the corner between each panel side (4) and the panel valley (2) is formed in another micro-corrugation (5) for rigidity and additional ventilation.

Description

2353299 -I- ents to Profiled Metal Cladding Panels"

Introduction

The present invention relates to profiled metal cladding panels of the type used in the construction industry especially for roofing and fagade sheeting. In particular the invention relates to a profiled metal cladding panel which comprises a plurality of spaced apart panel corrugations, trapezoidal in cross-section formed with substantially flat ridges, valleys and upwardly converging sides, sometimes for brevity in this specification such a panel is called a trapezoidal cladding panel.

in general there are two main types of profiled metal cladding panels, those having a sinusoidal cross section with arcuate rigid sides and valleys, namely a rounded cladding panel and the trapezoidal cladding panel. The former rounded cladding panel is has until recently been the more commonly used cladding panel. However this type of metal cladding panel is becoming uneconomical to produce, is aesthetically unpleasant and not as mechanically strong as the latter with a trapezoidal crosssection.

Producing a panel- of this nature to withstand the potential forces that may be exerted.

on it requires the sheet to be typically 1 mm in thickness. Trapezoidal clad4ing panels have better load beafing properties and are thus being used more often where such load bearing properties are a major consideration. Initially these trapezoidal cladding panels had to be produced in much the same thickness as the rounded cladding panels and there were no moor banefits other than mechanical and aesthetic in this type of cladding panel over the rounded type.

As cladding materials become more expensive in that they are often formed from high grade corrosion resistant materials or of a metal sheet which is itself clad in an expensive covering material any reduction in the overall amount of material used can be financially significaM Further, the lighter the cladding the less Odead' weight the building structure needs to support which is advantageous. Additionally, the lighter the profiled cladding sheet is per square metre the larger the sheet that can be supplied Without causing assembly difficulties. This reduces construction costs. Efforts to reduce material thickness while still maintaining the rigidity and resistance to deformation have resulted in the addition of microprofiling the panels to further stiffen 2- the panel and strengthen it. Such microprofiling is inappropriate for rounded cladding panels.

Microprofiling trapezoidal cladding panels is described in European Patent Specification No. 0 279 789 Al. However this type of microprofiling is unsatisfactory.

The problem this specification addresses is of increasing the strength in the trapezoidal cladding panel so as to allow lighter than normal gauge of material to be used.

However, it uses a large number of micro corrugations. Indeed a substantial amount of material is required and there is no significant advantage over using heavier gauge material which doesn't require micro corrugations.

In an effort it is presumed to reduce the amount of material required, the micro corrugabo ns described in this European Patent Specification are of Vee- section.

These Vee-sectioned micro corrugations collect dirt in the valleys especially when is affixed to a roof, such ridges have an unpleasant appearance as the microprofiles can be clearly seen by an observer standing on the ground. The Vqe shape does however lead to some reduction in material.

Generally the panel valleys of a trapezoidal cladding panel are affixed to beams or the like, which support the valleys from deforming. Also the sides converge towards the ridge which provides strength and support for it. When such trapezoidal cladding panels are used as roofing panels there is often considerable forces encountered when being fixed into place in that roofers or other workers tend to walk and stand on them in the course of the building construction. In any case it is often necessary for a roofer to stand on freshly laid cladding panels. Even when considerable care is taken whilst standing on these cladding panels buckling occurs, if the worker doesn't spread his weight properly. This buckling occurs, nut because the ridge is not strong enough, but because the sides do not have enough strength to withstand the forces exerted on them.

It is the object of the present Invention to produce a trapezoidal cladding panel that for the same load bearing properties, uses less material than currently used in more conventional cladding panels. A further object of the invention is to provide a process for forming such profiled metal cladding panels.

Statements of Inkention

According to the invention there is provided a profiled metal cladding panel of the type comprising a plurality of spaced apart panel corrugations trapezoidal in cross-section formed wiith substantially flat panel ridges, panel valleys and upwardly converging panel sides, characterised in that the paneJ sides incorporate microprofiling in the form of additional micro corrugations having flat micro ridges, upwardly arranged flat micro sides and micro valleys formed by portion of the panel sides, and in that one of the micro corrugations forms the corner between the panel ridge and each panel side so as to project above the panel ridge- The advantage of the micro corrugation projecting above the panel ridge forming the corner is that while strengthening the panel sides it also adds additional strength and stiffness to the flat panel ridge. This effectively forms two longitudinal reinforcing ribs which protect the whole cladding panel from external damage and direct any external force exerted on the panel ridge down through the panel sides.

Ideally the corner between each panel ridge and adjacent panel side is formed coincident with the bottom of a micro side, though in. one embodiment of the invention the corner between each panel ridge and adjacent panel side, is formed intermediate the micro side.

In another embodiment of the invention the corner between the panel side and adjacent panel valley is formed in a truncated micro corrugation having only one micro side so as to project below the panel valley. In this latter embodiment ideally the corner is coincident with the top of the micro side.

The advantage of the micro corrugation. projecting beneath the panel valley and forming the corner is that while strengthening the sides it also adds additional strength and stiffness to the flat panel valley down through the panel sides. These projecting ribs leaves a space between the panel valley bottom and the bearns supporfing the cladding allowing air to circulate between the beams and the cladding. Particulafly during the summer when the ambient temperature rises the metal expands and this space provides room for a convection current of air to pass between the beams tending to stabilise the temperature. It also allows space for the cladding to flex if the temperature rises sufficiently. Similarly during winter this space also allows the sheet to flex and return to its original shape if there is a heavy fall of snow without putting 4- undue load on the structure. Similarly, if the working conditions inside the building lead to variations in temperature, the cladding panel according to the present invention is better adapted to accommodate them.

The micro corrugations may be of right angled channel shape in cross section or indeed of trapezoidal shape in cross section.

In one embodiment ol the invention the depth of micro corrugations is between 10% and 40% of the panel corrugations and ideally between 20% and 30% of the panel corrugations depth.

Further the invention provides a method of forming a profiled metal cladding panel as claimed in any preceding claim. from a -flat sheet of metal in a machine hag a plurality of in-line sets of corrugation forming rollers, each set comprising a pair of shafts namely an upper shaft and a lower shaft one above the other and means for altering the spacing between the shafts and in which the upper shaft carries top rollers and the lower shaft carries boftom rollers the top and bottom rollers being offset laterally along their respective shafts so as to allow the rollers to nest inside each other as the spacing between the shafts is reduced the method comprising the steps of forming the micro corrugations on the sheet by feeding the sheet through sets of micro corrugation forming rollers, the shafts of which are progressively closer; and feeding the sheet through a plurality of sets of panel corrugation forming rollers, the shaft of which are progressively closer.

In this latter method ideally the bottom rollers contact the flat longitudinally arranged panels, positioned between the micro-corrugations prior to forming the panel corrugations. Doing it this way is a very simple method of forming the panel corrugations from a sheet which already contains micro corrugations without damaging the micro corrugations.

QeJailed Oeggril2tign of the Inventho The! invention will be more clearly understood from the follovAng description of an embodiment thereof given by way of example only with reference to the accompanying drawings in which: - Fig. 1 is a perspective view of a porfion of a corrugated cladding panel according to the invention; Fig. 2 is an end view of a portion of a corrugated cladding panel according to theinvention; Fig. 3 Is an enlarged end View of portion of Fig. 2; Fig. 4 is an end diagrammatic view of a panel forming machine and a flat metal sheet ready for forming; and Fig. 5 is an end diagrammatic view similar to Fig. 4 showing the panel partially formed.

Referring to the drawings, and initially to Figs. 1 to 3 there is illustrated a profiled metal cladding panel, according to the invention indicated generally by the reference numeral 1, having a plurality of spaced apart panel corrugations trapezoidal in cross section and each corrugation comprising a flat panel valley 2 and a flat panel ridge 3 with upwardly converging panel sides 4 having micro-profiling. The micro-profiling is provided by micro corrugations indicated generally by the reference numeral 6 and where necessary individ ual micro corrugations are distinguished from each other by the use of subscript letters a, b and c such as in Fig. 3.

Indeed in Fig. 3 the reference numeral Sa is used for the micro corrugaton between the panel ridge 3 and the panel side 4, the other micro corrugations are identified by the reference numeral 6b and a portion of a micro corrugation, which forms the corner between the panel side 4 and the panel valley 2, is identified by the reference number Each micro corrugation 5 has a flat micro rldge 8 and a flat micro valley 9 formed by the flat panel sides 4. Each micro ridge 8 and micro valley 9 is joined by parallel micro sides 10. Similar subscript letters are used where necessary to identify the micro ridge.

micro valley and micro sides forming a specific micro corrugation, which it will be noted is of channel section. Each upwardly converging panel side 4 is joined to the panel ridge 3 by a micro-corrugation Sa forming a comer 6. It will be noW that one of the micro sides 10a and portion of the micro ridge 8a project over the flat panel ridge 3.

Similarly the upwardly converging panel sides 4 are joined at the flat panel valley 2 by the micro side 1 Oc of the truncated micro corrugation 5c to form a corner 7. The micro corrugation side 10c and micro ridge Sc and any micro valley Gic outwardly therefrom are effectively merged into the panel valley'2.

Referring now specifically to Figs. 4 and 5 there is illustrzted portion. of a machine indicated generally by the reference numeral 20 for producing a profiled metal cladding panel according to the invention from a sheet of material or a thin metal flat sheet 25 having micro corrugations 5. The machine 20 has a plurality of ip-line sets of rollers.

Each set comprises an upper shaft 21 and a lower shaft 22. Each set comprises top rollers 23 affixed to the upper shaft 21, and bottom rollers 24 affbced to the lower shaft 22. The top rollers 23 and the bottom rollers 24 are offset laterally along their respective shafts 21 and 22 so as to allow them to nest inside each other. Adjustment means, not shown, housed within shaft supports 26 are provided to after the spacing between the upper shaft 21 and the lower shaft 22 as shown by the arrows A- Prior to using the machine 20 the spacings between the upper shafts 21 and the lower shafts 22 are progressively reduced in the proposed direction of travel of the sheet 25.

In operation, the sheet 25, the micro corrugations of which are not illustrated for clarity is fed through the in-line sets of rollers. Since at each set of rollers the upper shaft 23 and lower shaft 22 are progressively closer a deeper profile is also being progressively formed, this can be easily seen from Fig. 5.

The initial steps of forming micro corrugations 5 for the sides 4 so as to produce the substantially flat plate 25 are identical to the method of producing the panel corrugations as described below. However, since the micro corrugations 6 are much smaller than the panel corrugations in many instances it is envisaged that different methods of formation could be used. Thus all ways of forming the micro corrugations 5 is not described.

In the embodiment described with reference to Figs. 1 to 3 all of the micro corrugation was used to form the corner between the panel ridge and a side panel in that the corner between each panel ridge and adjacent panel side is formed coincident with the bottom of the micro side. However, this is not always necessary and the corner could be formed between each panel and the adjacent panel side intermediate a micro side.

Further in the embodiment illustrated the corner between the panel side and the adjacent panel valley was formed in a truncated micro corrugation and this does not necessarily have to be so, but could simply be formed between the adjacent panel valley and the panel side. Further the corner formed in the truncated micro corrugation was illustrated as being formed in the top of the micro side and again this is not necessarily required.

While in the embodiment described above the micro corrugations were illustrated as of a right angled channel shape in cross section, they could equally well be trapezoidal in cross-section or indeed any other suitable shape.

It is envisaged that the depth of the micro corrugations can be between 1. 0% and 40% of that of the panel corrugations, or in some instances between 20 and 30% of the depth of the panel corrugations.

In the specification the terms ucomp(ise, comprises, comprised and comprising" or any variation thereof and the terms "include, includes, included and including" or any variation thereof are considered to be totally interchangeable and they should all be afforded the Widest possible interpretation and vice versa. 30 The invention is not limited to the embodiment hereinbefore described, but may be varied in both construction and detaU.

Claims

CLAIM

1. A profiled metal cladding panel of the type comprising a plurality of spaced apart panel corrugations trapezoidal in cross-section formed with substantially flat panel ridges, panel valleys and upwardly converging panel sides, characterised in that the panel sides incorporate micropraffling in the form of additional micro corrugations having flat micro ridges, upwardly arranged flat micro sides and micro valleys formed by portion of the panel sides, and in that one of the micro corrugations forms the corner between the panel ridge and each panel side so as to project above the panel ridge.

2. A profiled meted cladding panel as claimed in claim 1, In which the comer between each panel ridge and adjacent panel side is formed coincident with the bottom of a micro side.

3. A profiled cladding panel as claimed in claim 1, in which the corner between each panel ridge and adjacent panel side, is formed intermediate the micro side.

4. A profiled metal cladding panel as claimed in claim 1, in which the comer between the panel side and adjacent panel valley is formed in a truncated micro corrugation having only one micro side so as to project below the panel valley.

S. A profiled metal cladding panel as claimed in claim 4, in which the corner Is coincident with the top of the micro side.

6. A profiled metal cladding panel as claimed in any preceding claim, in which the micro corrugations are right angled channel shape in cross-section.

7. A profiled metal cladding panel as claimed in any of claims 1 to 5, in which the micro corrugations are trapezoidal in cross section.

S. A profiled metal cladding panel as claimed in any preceding claim, in which the depth of the micro corrugations is between 10% and 40% of that of the panel corrugations.

A profiled metal cladding panel as claimed in any preceding claim in which the depth of the micro corrugations is between 2M and 30% of that of the panel corrugations.

10. A profiled metal cladding panel substantially as described herein, with reference to and as illustrated in Figs. 1 to 3 of the accompanying drawings.

11. A method of forming a profiled metal cladding panel as claimed in any preceding claim, from a flat sheet of metal in a machine having a plurality of in line sets of corrugation forming rollers, each set comprising a pair of shafts namely an upper shaft and a lower shaft one above the other and means for altering the spacing between the shafts and in which the upper shaft carries top rollers and the lower shaft carries bottom rollers the top and bottom rollers being offset laterally along their respective shafts so as to allow the rollers to nest inside each other.as the spacing between the shafts is reduced, the method comprising the steps of:

forming the micro corrugations on the sheet by feeding the sheet through sets of micro corrugation forming rollers, the shafts of which are progressively closer; and feeding the sheet through a plurality of sets of panel corrugation forming rollers, the shafts of which are progressively closer.

12. A process as claimed in claim 11, in which the bottom rollers contact the flat longitudinally arranged panels, posifioned between the micro-corrugations prior to forming the panel corrugations.

13. A method substantially as described herein, with reference to and as illustrated in Figs. 1 to 4 of the accompanying drawings.