GB2377200A

GB2377200A - Alignment device for aligning the position of fixing means

Info

Publication number: GB2377200A
Application number: GB0116144A
Authority: GB
Inventors: Andrew Meese; Simon Pearson
Original assignee: EJOT ECOFAST Ltd
Current assignee: EJOT ECOFAST Ltd
Priority date: 2001-07-02
Filing date: 2001-07-02
Publication date: 2003-01-08
Also published as: IE20020541A1; GB0116144D0

Abstract

An alignment device 24 for aligning the position of fixing means for fixing location of a composite panel comprises a head member 28 above all to abut at least part of a first surface of the panel, a body member 26 operably attached to the head member 28 and operable to extend over at least part of a second surface of the panel, and alignment means 30 operably to align the positioning of fixing means at a plurality of locations across the second surface of the composite panel.

Description

ALIGNMENT DEVICE The present invention relates to alignment and coring devices used for fixing composite panels to a surface.

Composite panels, which are used for providing a flatsurface on the roof of a building, for example, on industrial units, consist of a rigid foam core which is sandwiched in between a flat membrane top sheet and a corrugated lower steel liner sheet (see Figure 1).

One method for fixing the composite panel to the roof of a building is by securing nails or screws through the base of the corrugations in the lower liner sheet and into the roof. A problem with this method is that it is not easy for an installer to determine precisely where the corrugations are for inserting the nails or screws. A further problem encountered with this method relates to the problem of how the installer removes the specific regions of the composite panel at the site where each nail is to be inserted.

It is an aim of the embodiments of the present invention to address the above problems and to provide a tool for locating the position of the corrugations of the compositepanel for fixing to the roof of a building.

According to a first aspect of the present invention, there is provided an alignment device for aligning the position of fixing means for fixing the location of a panel, the device comprising a head member operable to abut at least part of a first surface of the panel, a body member operably attached to the head member and operable

to extend over at least part of a second surface the panel, and alignment means operable to align the positioning of fixing means at a plurality of locations across the second surface of the panel.

Preferably, the panel comprises a composite panel whichcomprises a substantially rigid core preferably sandwiched in between a first sheet and a second sheet. Preferably, the first sheet is substantially planar, and preferably the second sheet is substantially crenulated or corrugated having a series of corrugated regions interspaced with spaced regions therebetween. Preferably, the panel is installed against a structural surface, for example, a roof or a wall of a building to provide a substantially planar outer surface thereon.

Preferably, and advantageously, the alignment device may be used to align the alignment means with the corrugated areas of a lower surface of the panel, which may be the second sheet, in order to determine and maintain the optimum position for installing suitable fixing means therein. Suitable fixing means may comprise nails or screws which may be passed through the second sheet of the panel and into the structural surface.

Preferably, the head member is substantially elongate and preferably comprises a first face and a second face orientated substantially at an angle to each other.

Preferably, the first face is operable to abut the first side of the panel. Preferably, the second face is operable to rest on the second surface of the panel.

Preferably, the body member is substantially elongate. Preferably, the head member preferably the second face thereof, is attached substantially at an angle, preferably approximately a right angle, to the body member preferably at a first end of the body member.

The device may comprise adjustment means, preferably operable to adjust the site of attachment of the body member to the head member.

Preferably, the adjustment means comprises a plurality of attachment sites located on the head member preferably on the second face thereof, where the body member may be attached operably thereto. Preferably, the attachment sites are spaced apart. Preferably, the second face of the head member comprises three attachment sites, preferably, one generally in the centre of the first face and preferably one substantially at either end thereof.

Advantageously, the plurality of attachment sites enables the body member to be attached to the head member in a number of different configurations depending on the location and dimensions of the panel to be installed.

Alternatively, and additionally, the adjustment means maybe operable to adjust the relative positions of the body member and the head member. Preferably, the adjustment means is operable to adjust the position and/or distance of the alignment means relative to the panel and relative to the head member.

Preferably, the or each attachment site comprises at least one slot, preferably, three slots. Preferably, the body

member is operable to be attached at a range of positions along the or each slot at each attachment site thereby enabling the relative positioning between the body member and the head member to be adjusted.

Preferably, the adjustment means comprises engagement3 means operably attached to the body member to thereby engage with the head member. Preferably, the adjustment means comprises locking means for locking the engagement means at the or each attachment site on the head member.

Preferably, the locking means comprises a handle.

Preferably, the alignment means comprises a plurality of bosses which preferably extend away from the body member.

Preferably, the or each boss comprises an aperture in the centre thereof, the aperture being preferably substantially circular in cross-section. Preferably, the centre of the or each aperture is aligned with substantially the centre of the or each corrugation in the panel.

Preferably, the distance between the centre of each boss is in the region of 5-500mm, preferably, 50-400mm and most preferably, 100-300mm. Advantageously, the distance between the centre of each boss is substantially the sameas the distance between all or some of the corrugated regions of the panel.

Preferably, the surface of the body member which is in contact with the panel comprises a cut-out section adapted to accommodate at least a portion of the first sheet of the panel, preferably when this is folded back during the installation of the panel.

Preferably, when the alignment device is in position, sections of the panel located substantially proximal to the alignment means are removed. Preferably, sections of the panel, substantially underneath the apertures of the alignment means may be removed. Preferably, the boss at the end of the body member distal from the head member isa double boss enabling two sections of the panel to be removed to thereby accommodate fixing means.

Preferably, the head member is detachable and may be replaced with a boss attachment.

According to a second aspect of the present invention, there is provided a method of aligning the position of fixing means into a panel, the method comprising :- (i) providing an alignment device comprising a head member, a body member operably attached to the head member, and alignment means, (ii) positioning the device so that the head member abuts at least part of a first surface of the panel and so that the body member extends over at least part of a second surface the panel; and (iii) aligning the alignment means in order to locate the positioning of fixing means for fixing the panel at a plurality of locations across the- second surface of the panel.

According to a third aspect of the present invention, there is provided a coring device for coring a section of material from a panel, the coring device comprising coring means which defines a passageway having an inwardly tapering cutting edge at one end thereof, the cutting edge operable to cut into the said panel upon the application

of pressure thereto, thereby cutting a section of cored material out of the panel which is accommodated within the passageway.

The panel is preferably a roofing panel, preferably a composite panel comprising a substantially rigid corepreferably sandwiched in between a first sheet and a second sheet.

Advantageously, the tapering cutting edge enables the coring means to compress, grip and, therefore, retain the removed material therein.

Preferably, at least a portion of the inner surface of the coring means is textured and operable to provide a friction fit with the removed material thereby retaining it therein.

The coring device may further comprise a body section operably attached to the coring means. Preferably, the body section is externally threaded, preferably, at least along a region thereof.

In a first embodiment, the coring device may be actuated by drive means, preferably, mechanical drive means.Preferably, in the first embodiment, a first end of the body section distal from the cutting edge comprises drive mechanism receiving means in which the drive means may be received to actuate rotational movement of the device. In a second embodiment, the coring device may be actuated manually. The body section may comprise handle means by which an operator may actuate the device.

Preferably, the coring device comprises depth gauge means operable to adjust the depth to which the coring means may penetrate the panel.

Preferably, in a first embodiment, said depth gauge means comprises abutment means operably attached to the coring means to abut the panel as the coring means penetrates the panel to the desired depth to thereby prevent further penetration therein. Preferably, the abutment means comprises a collar slidably mounted onto the coring means preferably to the outer surface thereof. Preferably, the collar is operable to slide axially along the coring means and may be fixed at substantially any position along the coring means by suitable means. Preferably, the depth gauge means comprises adjustment means. Preferably, the said adjustment means is threadedly attached to the threaded region of body section and may be screwed either clockwise or anti-clockwise along the body section to determine the position at which the collar may be locked along the coring means.

Preferably, the coring device further comprises ejecting means operable to eject the cored material from out of the passageway. The ejecting means may be operable to move from a first position in which it does not engage the cored material such that said material is retained within the passageway, to a second position in which the ejecting means engages the said material such that the cored material is ejected from the passageway and out of the coring means.

Preferably, the coring device further comprises an elongate slot extending along at least part of the coring means.

In a first embodiment, the ejecting means comprises a bung operably mounted to slide within the passageway.Preferably, the bung is in operable communication with the collar preferably by the slot. Preferably, the collar is attached to the bung by means which extends through the collar and the slot and into the bung and operable to be tightened and loosened as desired.

In a second embodiment, the ejecting means comprises a substantially elongate rod operable to slidably move within the passageway. Preferably, in the second embodiment, the said depth gauge means comprises the ejector means.

Advantageously, the elongate rod serves the dual purpose of acting as the abutment means for determining the extent of penetration of the coring means into the panel and, upon actuation, may be used to eject the cored material out of the passageway.

Preferably, the ejecting means is biased such that release from the second position in which the cored material is ejected from the coring means results in the ejecting means returning to the first position. Preferably, the coring device comprises resilient means operably attached to bias the ejecting means between the said first and second positions.

5

10 15 20 25 30 Preferably, the coring device comprises a first plate extending across the passageway. Preferably, the first plate is securely attached to the passageway. Preferably, the fixed plate comprises a first aperture extending therethrough preferably substantially in the centre thereof. Preferably, the rod extends through said firstaperture preferably freely therethrough.

Preferably, the coring device comprises a second plate extending across the passageway. Preferably, the second plate is housed for relative movement within the passageway. Preferably, the moving plate comprises a second aperture extending therethrough preferably substantially in the centre thereof. Preferably, the said second aperture is threaded for threaded engagement with the rod which extends therethrough. Preferably, the rod is threaded preferably at least in the region of engagement with the second aperture.

Preferably, the resilient means is housed within the passageway preferably between the fixed plate and the moving plate. Preferably, the moving plate comprises a pin which extend radially outwardly therefrom. Preferably, the pin extends out through the slot. Preferably, the rod may be rotated such that the moving plate moves axially along the rod, rotational movement being prevented by the abutment of the pin against the slot.

The resilient means may comprise a spring preferably a coiled spring which coils around the rod and which has an elongate axis substantially parallel to a longitudinal axis of the passageway.

Preferably, movement of the ejecting means from the first position to the second position results in the resilient means being compressed and subsequent release of the resilient, means resulting in resilient means becoming relaxed thereby resulting in the ejecting means moving back to the first position.

The coring means may be detached from the body section.

The coring means may be inserted into the passageway such that the cutting edge may be protected during transport of the device.

According to a fourth aspect of the present invention, there is provided a method of coring out a section of material from a roofing panel, the method comprising :- (i) providing a coring device comprising coring means which defines a passageway having an inwardly tapering cutting edge at one end thereof; (ii) positioning the cutting edge on to a surface of said panel; and (iii) applying pressure to the coring device so that the cutting edge cuts into the panel and cores out a section which is accommodated in the passageway.

Preferably, the method further comprises ejecting the section of cored material from the passageway upon the actuation of ejector means. Preferably, the ejector means comprises the any or all of the features of the third aspect.

All the features described herein may be combined with any of the above aspects, in any combination.

For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will be made, by way of example, to the-a accompanying drawings, in which :- Figure 1 shows a schematic side view of a composite panel; Figure 2 shows a schematic perspective view of a first embodiment of an alignment device ; Figure 3 shows a schematic plan view of the alignment device; Figure 4 shows a partial plan view of the alignment device; Figure 5 shows a schematic side view of the alignment device in use; Figures 6,7, 8 and 9 show partial schematic side views of the alignment device; Figure 10 shows a schematic side view of a second embodiment of the alignment device; Figure 11 shows a partial schematic side view of the second embodiment of the alignment device; Figure 12 shows a schematic perspective view of the second embodiment of the alignment device;

Figure 13 shows a schematic perspective view of a first embodiment of coring device; Figure 14 shows a schematic side view of the coring device; Figure 15 shows a schematic side view of the coring device along the line A-A shown in figure 14; Figure 16 shows a partial schematic side view of the coring device; Figure 17 shows a schematic side view of a second embodiment of coring device; Figure 18 shows a schematic side view of the coring device along the line A-A as shown in figure 17; and Figures 19-22 show partial schematic side views of the second embodiment of coring device.

Referring to Figure 1, there is shown a composite panel 2 which is secured to a roof 3 of a building, for example, an industrial warehouse, a garden shed, a house extension etc, in order to provide a relatively flat surface thereon.

The composite panel 2 consists of a rigid polyurethane core 4 which is sandwiched in between a flat membrane top sheet 6 and a lower steel liner sheet 8. The top sheet 6 is firmly attached to the upper surface of the core 4

along the majority of its length except for a free edge 16 which forms a non-bonded zone 18 at one end thereof.

The liner sheet 8 is corrugated and has a series of alternating corrugations 14 and spaces 22 which extend transversely there along. The approximate distance between the centre of each corrugation 14 is about 200mm although this may vary from panel to panel 2. The thickness of the composite panel 2, as shown by arrow X, is 34mm, 46mm, 68mm or 87.5mm although this may vary from panel to panel.

A first end of the composite panel 2 consists of a side profile 10, the length of which is dependent on the thickness X of the composite panel 2. The side profile 10 is designed to abut to another like panel 2 at which point profile 10 will contact side profile 20. Side lap 12 will form a connection between the two abutting panels 2.

Therefore, the panel 2 is fixed at point 18 through two thicknesses of the liner sheet 8.

The optimum method for fixing the composite panel 2 to the roof 3 of the building is by securing a nail, screw or other suitable fixing device (not shown) through the base of each corrugation 14 in the lower liner sheet 8 of the panel 2, and into the roof 3. A problem associated withthis method is that it is not simple for an installer of the panel 2 to determine from above precisely where the corrugations 14 are for insertion of the nail or screw. If the installer does not know exactly where the corrugations 14 are, then he may pass the nails or screws through the spaces 22 and into the roof 3 rather than through the corrugations 14. This would not provide a secure fixing to the roof 3. A further problem encountered

with the installation of the panel 2 is how to remove the specific regions of the composite panel 2 at the site where each nail is to be inserted so that the nail can be effectively inserted through the panel 2 and into the roof 3.

Accordingly, tools are required to assist the installer to locate precisely where the corrugations 14 of the panel 2 are so that the site of placing a nail is more precisely known. Furthermore, tools are required for removing the specific regions of the panel 2 to facilitate the placing of the nail therein.

Referring to Figures 2-12, there is shown an alignment device 24 used for determining the location of the corrugations 14 in the composite panel 2. Figure 2 shows the alignment device 24 consisting of an elongate body 26 and a head 28. The head 28 consists of an attachment section 28b and a guide section 28a which extends transversely to the plane of the attachment member 28b and the body 26. The head 28 is attached transversely to the body 26 by the attachment section 28b.

Referring to Figure 3 there is shown the alignment device 24 in a plan view. The body 26 has a number of bosses 30 which extend upwardly to a height of 50mm and which are separated by a constant distance of 200mm. This distance mirrors the common separation distance of the corrugations 14 extending along the composite panel 2 as shown in Figure 1. Each boss 30 has an aperture extending therethrough which is aligned with each corrugation 14.

When the device 24 is correctly aligned, an installer then uses either a drillable coring tool 46 or a manual coring tool 62 as described hereinafter (see figures 13 to 22) in conjunction with the bosses 30 in order to remove a portion of the panel 2. A fixing device such as a nail or screw (not shown) is then inserted into the cored region of the panel 2 and into the roof 3. The boss 30 extending out of the end of the body 26 distal from the head 28 is a twin boss 38 which allows two nails/screws to be installed therein.

Referring to Figure 4, there is shown a close up view of the head 28 of the device as shown in circle A of Figure 3. The attachment section 28b of the head 28 has an attachment site 36b in the centre thereof, and attachment sites 36a, 36c at either end thereof. Each attachment site 36a, 36b, 36c consists of three elongate slots which are 14mm in length and which extend parallel with the elongate axis of the body 26.

The head 28 is attached to the body 26 by means of an attachment member 32 which may be locked in position at any of the three attachment sites 36a, 36b, 36c by a handle 34. The handle 34 may be unlocked or loosened to allow the attachment member 32, and hence body 26, to slide between any of the three attachment sites 36a, 36b, 36c depending on whether the device 12 is being used against the left hand side of a wall (not shown), the right hand side of a wall, or distanced away from a wall.

Referring to Figure 5, there is shown a composite panel 2 placed in position on a roof 3. The alignment device 24 is shown in use with the guide section 28a of the head 28

arranged to abut the side panel 10 of the composite panel 2. The body 26 of the device 24 rests on the flat membrane top sheet 6 of the composite panel 2, except at the end of the body 26 distal from the head 28, where there is a cutaway section 44. The cut-away section 44 provides an elongate gap in which the fleece free edge 16 which forms the non-bonded zone 18 of the composite panel 2 may be accommodated when it is pulled back over itself generally in the direction shown by arrow Y (see Figure 1) during the installation process.

Referring to Figure 6, there is shown a close up view of the head 28, attachment member 32 and handle 34 as shown in circle A of Figure 5. Referring to Figures 7 & 8, there are shown close up views of the sections of the body 26 of the device 24 as shown in circles B & C of Figure 5, respectively. Figure 8 shows the cut-away section 44 on the underside of the body in which the liner sheet free edge 16 of the composite panel 2 may be accommodated.

Referring to Figure 9, there is shown a close up view of the twin boss 38 at the end of the body 26 as shown in circle D of Figure 5 which allows two fixing screws to be inserted therein.

Referring to Figures 10 to 12, there is shown the alignment device 24 having had the head 28 being replaced with an end boss attachment 40. The end boss attachment has a boss 30 extending therefrom, and is attached to the body 26 by means of the attachment member 32 and handle 34 as shown in Figure 12. Figure 11 shows a close up view of the end boss attachment 40 as shown in circle A of Figure 10. This form of alignment device 24 is used to align the

corrugations 14 of the last panel 2 to be installed and when the head 28 would otherwise get in the way and prevent alignment.

The alignment device 12 is used as follows. By viewing an end of the composite panel 2 (therefore its cross-section) and comparing this with the position of the device 24, the operator adjusts the position of the device 24 such that the bosses 30 are aligned with the corrugations 14. The bosses 30 are used to mark the panel 2 at the positions where fixings (not shown) are to be inserted through the panel 2 and into the roof 3. The alignment process is possible when the first panel 2 is in position on the roof 3 since the installer is able to get down and see the positions of the corrugations 14 with respect to the bosses 30. The operator may then adjust the distance of the body 26 and hence, bosses 30 from the guide section 28a by unlocking the handle 34, thereby allowing the attachment member 32 to slide in the slots 37 of the attachment sites 36a, 36b, 36c so that the bosses 30 are aligned with the corrugations 14.

Once the body 26 has been locked at the correct distance from the head 28 such that the relative positions of the bosses 30 are in alignment with the corrugations 14, the installer then cuts out the sections of the panel 2 through which the fixing is to be applied using either a drillable coring tool as shown in Figures 13 to 16, or using a manual coring tool as shown in Figures 17 to 22.

Referring to Figures 13 to 16, there is shown a drillable coring tool 46 used for coring or removing the sections of the panel 2 where a fixing such as a screw is to be

inserted. The coring tool 46 consists of an externally threaded body section 48 and an elongate coring section 50 attached axially thereto by a screw-thread connection (not shown). The screw-thread connection enables the body section 48 to be fitted with a variety of the coring sections 50 of different lengths depending on the depth of the composite panel 2 which is to be installed onto the roof 3. In addition, the connection allows an alternative coring section 50 to replace an old coring section 50 as the cutting edge 54 becomes worn down after prolonged use.

A driver receiving section 51 extends axially outwardly from the body section 48, and a chamfered inner cutting edge 54 extends around the circumference of the coring section 50 distal from the driver receiving section 51 (see Figure 13). In use, the cutting edge 54 of the coring tool 46 is first placed at the correct position of the composite panel 2. The drive mechanism receiver of a power drill (not shown) is then inserted into the receiving section 51 of the tool 46 and powered to drive or rotate the coring tool 46 thereby cutting into, and removing material from, the panel 2. The removed material is known as a"slug"59 (see Figure 13).

The coring section 50 defines an internal passageway 61 having an inner surface 53 in which the slug 59 which is removed from the composite panel 4, may be accommodated.

The cutting edge 54 is internally tapered (see Figure 16, as shown in circle A of Figure 15) from a wider outer diameter'M', to a narrower inner diameter'N, as shown in Figure 15. As the tool 46 is pushed into the panel 2, the slug 59 of material is compressed from being equal to outer diameter'M'to being the inner diameter'N',

thereby enabling the coring section 50 to"grip"and, therefore, retain the removed material therein. In addition, the inner surface 53 of the passageway 61 is textured to provide a"friction fit"with the slug 59 to retain it therein.

Referring to Figures 14 and 15, there is shown the coring tool 46 having an internal bung 60 which is slidably retained inside the passageway 61. The bung 60 is attached by a screw 58 to a moving collar 56 which is slidably retained on the outside of an elongate slot 52 which extends along part of the coring tube 50. The collar 56 is made of a low thermal conductivity plastic material in order to prevent over-heating due to friction when in contact with the top of the boss 30.

The axial position of the collar 56 along the slot 52 and, hence, the bung 60 along the passageway 61 may be adjusted so that the installer can control the depth to which the coring section 50 penetrates into the composite panel 2.

This allows control of the amount of material which is removed from the panel 2 and also prevents the cutting edge 54 from touching and damaging the steel liner sheet 8. A depth gauge 94 is wound clockwise or anti-clockwise along the threaded body 48 in the direction as shown by arrows"T"and"U", respectively. In doing so, the position which the moving collar 56 is along the coring section 50 is set, thereby decreasing or increasing the depth to which the coring section 50 can be inserted into the panel 2. A locking nut 96 prevents the depth gauge 94 from moving during the coring operation to maintain the set depth of the coring section 50.

In use, the installer inserts the coring section 50 of the coring tool 46 into the aperture of a boss 30 of the alignment device 24. Using his weight, the installer urges the cutting edge 54 to cut into the panel 2 until the collar 56 abuts the membrane top sheet 6 of the panel 2. The installer then removes the coring tool 46 from the panel 2 and boss 30 taking the slug 59 of material with it. The slug 59 is removed from the passageway 61 of the coring section 50 by loosening the screw 58 and sliding the collar 56 and, hence, bung 60 along the slot 52 until the slug 59 is ejected. Once the installer has cored out the relevant sections of the panel 2 for all of the bosses 30, the alignment device 24 may then be removed from the panel 12. A fixing such as a screw is then fixed into the section of the composite panel 2 where the slug 59 was previously positioned, through the steel liner sheet 8 and into the roof 3. The bung 59 is then placed back into the section from which it was removed and then sealed over with a suitable sealant.

Referring to Figures 17 to 22, there is shown a manual coring tool 62, as opposed to the drillable coring tool 46 described above, which may also be used for removing the sections of the panel 2 where a fixing is to be inserted.

Referring to Figures 17 and 18, there is shown the manual coring tool 62 consisting of an elongate body member 64 having a handle 76 at one end thereof by which an installer may apply pressure to the tool 62 as it is pushed into the composite panel 2 at the desired site. The other end of the body member 64 is connected axially to an elongate coring tube 66. The coring tube has an exposed cutting edge 70 which tapers inwardly as in the drillable

coring tool 46 described above, for aiding the removal of a slug 92 of material as shown in Figure 22 from a composite panel 2.

Referring to Figure 18, there is shown the body member 64 and coring tube 66 together defining a passageway 65 therein. An adjustable threaded rod 72 extends along the passageway 65 inside the body member 64 and coring tube 66. The rod 72 acts as depth gauge and as an ejector depending on the use of the tool 62. The depth gauge rod 72 has an abutting end 73 at the end which extends out of the end of the coring tube 66 (for when it acts as an ejector rod), and a depth gauge handle 74 which extends out of the end distal from the coring tube 66.

Referring to Figure 19, there is shown a close up view of the depth gauge handle 74 and associated fittings as shown in circle A of Figure 18. The region of the depth gauge rod 72 proximal to the handle 74 is fitted by a set of screws 90 which extend radially inwardly thereto through the outer wall of the body member 64.

Referring to Figure 21, there is shown a close up view of attachment site of the coring tube 66 to the body member 64 as shown in circle C of Figure 18. The coring tube 66 is held in place in the body member 64 by means of a threaded collar 68 which is fitted with a set of screws 75 which extend radially inwardly thereto. The collar 68 may be removed by removing the screws 754 such that the coring tube 66 can be removed from the body member 64, and placed back into the body member 64 and screwed and locked in position in a reversed configuration, i. e. with the cutting edge 70 extending into the base of the body member

64. This increases the safety of transporting the coring tool 62 since the cutting edge 70 is no longer exposed, it shortens the length of the tool 62 as a whole, and also reduces the chances of the cutting edge 70 being damaged.

Referring to Figure 20, there is shown a close up view of a section of the body member 65 as shown in circle B of Figure 18. Extending across the inside of the passageway 65 of the body member 64 there is a fixed plate 86 which is held in position by a set of screws 82 which extend through the outer wall of the body member 64 and radially inwardly into the side of the fixed plate 86. The fixed plate 86 has an aperture 87 extending therethrough, through which the depth gauge rod 72 may freely extend without interference.

Extending across the inside of the passageway 65 of the body member 64 but at a location which is more proximal to the handle 74 than the fixed plate 86, there is a moving plate 84. The moving plate has a threaded aperture (not shown) extending therethough, through which the depth gauge rod 72, which is also threaded, extends and is threadedly attached thereto. A pin 78 is attached to, and extends radially outwardly, from the moving plate 84. The pin 78 extends out through a guide slot 80 which extends axially along a region of the body member 64. A spring 88 trapped within the passageway 65 of the body member 64 between the fixed plate 86 and moving plate 84 provides a bias to the depth gauge rod 72 as it moves within the body member 64.

In use, the installer first adjusts the coring tool 62 so that it will penetrate the composite panel 2 to the

desired depth to prevent damage to the cutting edge 70. This is achieved by adjusting the relative position of the depth gauge rod 72 within the body member 64 and coring tube 66, so that the abutment end 73 (see Figure 22) is at the desired height inside the coring tube 66. Adjustment is carried out by rotating the depth gauge handle 74 in either direction as illustrated by arrow'Q'as shown in Figure 19.

As the handle 74 is rotated clockwise about arrow'Q', the threaded depth gauge rod 72 rotates within the threaded aperture of the moving plate 84. The pin 78 prevents the moving plate 84 from rotating within the body member, thereby resulting in the moving plate 84 moving along the gauge rod 72 towards the cutting edge 70 of the coring tube 66 in the direction illustrated by arrow'P'. This is required to decrease the depth of penetration of the coring tube 6f5 into the panel 2. Rotating the handle 74 anti-clockwise results in the threaded depth gauge rod 72 rotating within the threaded aperture of the moving plate 84, thereby resulting in the moving plate 84 moving along the gauge rod 72 away from the cutting edge 70 of the coring tube 66 in the direction illustrated by arrow'S'.

This is required to increase the depth of penetration of the coring tube 66 into the panel 2.

Once the depth gauge 72 has been adjusted to the desired depth, the coring tool 62 is then inserted into a specific boss 30 of the alignment device 24 as it rests in position on the panel 2. The installer then applies pressure to the tool 62 by pressing on the handle 76 in the direction'P'.

The cutting edge 70 cuts into, and penetrates, the panel 2 until the upper surface of the membrane top sheet 6 of the

panel 2 abuts the abutment surface 73 of the depth gauge rod 72.

Further movement of the depth gauge 72 in a direction'P' is prevented by the abutment of the pin 78 attached to the moving plate 84 against the top of the slot 80. At this point, the installer feels the resistance and stops applying pressure to the coring tool 62. A slug (not shown) of material is cut out of the panel 2 and is accommodated by the passageway 65 in the coring tube 64.

The taper of the cutting edge 70 and the texture of the inner wall of the coring tube 66 help retain the slug as the coring tool 62 is taken out of the hole in the panel 2.

The installer then ejects the slug from the coring tube 66 by applying pressure onto the depth gauge/ejector rod 72 via the handle 74. Under this pressure, the ejector rod 72 passes freely through the aperture 87 in the fixed plate thereby extending the abutment surface 73 and the slug out of the coring tube 66. The slug is then removed, a fixing nail is inserted into the panel 2 and the slug inserted back into the panel 2 as described above.

Because the moving plate 84 is fixedly attached to the ejector rod 72, the spring 88 is compressed between the fixed plate 82 and the moving plate 84 thereby creating a bias as the installer applies pressure to the handle 74 on the ejector rod 72. Therefore, upon release of the handle 74, the bias in the compressed spring 88 is released resulting in the ejector rod (depth gauge) 72 back to its initial position at the desired depth ready to be used again for removing material from the another boss 30.

Advantages of the alignment device 24 reside in the efficient alignment and marking of the corrugated areas 14 of the panel 2 by an installer. Once the device 24 has been set up correctly for the first panel 2, ie the body 26 and, hence bosses 30 are the correct distances, from the head 28, the installer can simply align and locate the positions of the corrugated areas 14 for all subsequent panels 2. The bosses 30 are at the correct separation distance to mirror the distance of the corrugations 14 in the panel 2. The three attachment sites 36a, 36b, 36c allow the body 26 to be attached at a number of locations along the head 28 depending on whether the panel 2 is close to a wall and also depending on the thickness "X" of the panel 2. The coring tools 46,62 fit in the aperture of each boss 30 and have a chamfered cutting edge to retain the removed material. The coring tools 46,62 have an ejector bung 60 or rod 72 to remove the cored section out of the panel 2. Finally, the manual coring tool 62 has a biased ejector rod 72 so that it returns back to its original position ready for repeated use.

The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination,

except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment (s). The invention extend to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

CLAIMS 1. An alignment device for aligning the position of fixing means for fixing the location of a panel, the device comprising a head member operable to abut at least part of a first surface of the panel, a body member operably attached to the head member and operable to extend over at least part of a second surface the panel, and alignment means operable to align the positioning of fixing means at a plurality of locations across the second surface of the panel.
2. An alignment device according to claim 1, wherein the panel comprises a composite panel which comprises a substantially rigid core preferably sandwiched in between a first sheet and a second sheet.
3. An alignment device according to either claim 1 or claim 2, wherein the head member is substantially elongate and comprises a first face and a second face orientated substantially at an angle to each other.
4. An alignment device according to claim 3, wherein the first face is operable to abut the first side of the panel.
S. An alignment device according to either claim 3 or claim 4, wherein the second face is operable to rest on the second surface of the panel.
6. An alignment device according to any preceding claim, wherein the body member is substantially elongate.

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7. An alignment device according to any preceding claim, wherein the device comprises adjustment means operably to adjust the site of attachment of the body member to the head member.
8. An alignment device according to claim 7, wherein the adjustment means comprises a plurality of attachment sites located on the head member.
9. An alignment device according to any of claims 3 to 8, wherein the second face of the head member comprises three attachment sites.
10. An alignment device according to any of claims 7 to 9, wherein the adjustment means is operable to adjust the position and/or distance of the alignment means relative to the panel and relative to the head member.
11. An alignment device according to any of claims 8 to 10, wherein the or each attachment site comprises at least one slot.
12. An alignment device according to claim 11, wherein the body member is operable to be attached at a range of positions along the or each slot at each attachment site thereby enabling the relative positioning between the body member and the head member to be adjusted.
13. An alignment device according to any of claims 7 to 12, wherein the adjustment means comprises engagement means operably attached to the body member to thereby engage with the head member.

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14. An alignment device according to claim 13, wherein the adjustment means comprise locking means for locking the engagement means at the or each attachment site on the head member.
15. An alignment device according to any preceding claim, wherein the alignment means comprises a plurality of bosses which extend away from the body member.
16. An alignment device according to claim 15, wherein the or each boss comprises an aperture in the centre thereof.
17. An alignment device according to claim 16, wherein the centre of the or each aperture is aligned with substantially the centre of a corrugation in the panel.
18. An alignment device according to any preceding claim, wherein the surface of the body member which is in contact with the panel comprises a cut-out section adapted to accommodate at least a portion of the first sheet of the panel when this is folded back during the installation of the panel.
19. An alignment device according to any preceding claim, wherein when the alignment device is in position, sections of the panel located substantially proximal to the alignment means are removed.
20. An alignment device according to any of claims 16 to 19, wherein sections of the panel substantially underneath the apertures of the alignment means may be removed.

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21. An alignment device according to any of claims 16 to 20, wherein the boss at the end of the body member distal from the head member is a double boss enabling two sections of the panel to be remove to thereby accommodate fixing means.
22. An alignment device according to any preceding claim, wherein the head member is detachable and may be replaced with a boss attachment.
23. A method of aligning the position of fixing means into a panel, the method comprising :- (i) providing an alignment device comprising a head member, a body member operably attached to the head member, and alignment means, (ii) positioning the device so that the head member abuts at least part of a first surface of the panel and so that the body member extends over at least part of a second surface the panel; and (iii) aligning the alignment means in order to locate the positioning of fixing means for fixing the panel at a plurality of locations across the second surface of the panel.
24. A coring device for coring a section of material from a panel, the coring device comprising coring means which defines a passageway having an inwardly tapering cutting edge at one end thereof, the cutting edge operable to cut into the said panel upon the application of pressure thereto, thereby cutting a section of cored material out of the panel which is accommodated within the passageway.

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25. An coring device according to claim 24, wherein the panel is a composite panel comprising a substantially rigid core sandwiched in between a first sheet and a second sheet.
26. A coring device according to either claim 24 or claim 25, wherein at least a portion of the inner surface of the coring means is textured and operable to provide a friction fit with the removed material thereby retaining it therein.
27. A coring device according to any of claims 24 to 26, wherein the coring device further comprises a body section operably attached to the coring means.
28. A coring device according to any of claims 24 to 27, wherein the coring device is actuated by drive means.
29. A coring device according to either claim 27 or claim 28, wherein a first end of the body section distal from the cutting edge comprises drive mechanism receiving means in which the drive means may be received to actuate rotational movement of the device.
30. A coring device according to any of claims 24 to 27, wherein the coring device is actuated manually.
31. A coring device according to claim 30, wherein the body section comprises handle means by which an operator may actuate the device.
32. A coring device according to any of claims 24 to 31, wherein the coring device comprises depth gauge means

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operable to adjust the depth to which the coring means may penetrate the panel.
33. A coring device according to claim 32, wherein said depth gauge means comprises abutment means operably attached to the coring means to abut the panel as the coring means penetrates the panel to the desired depth to thereby prevent further penetration therein.
34. A coring device according to claim 33, wherein the abutment means comprises a collar slidably mounted onto the coring means to the outer surface thereof.
35. A coring device according to claim 34, wherein the collar is operable to slide axially along the coring means and may be fixed at substantially any position along the coring means by suitable means.
36. A coring device according to any of claims 32 to 35, wherein the depth gauge means comprises adjustment means.
37. A coring device according to claim 36, wherein the said adjustment means is threadedly attached to the threaded region of body section and is screwed either clockwise or anti-clockwise along the body section to determine the position at which the collar may be locked along the coring means.
38. A coring device according to any of claims 24 to 37, wherein the coring device further comprises ejecting means operable to eject the cored material from out of the passageway.

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39. A coring device according to claim 38, wherein the ejecting means is operable to move from a first position in which it does not engage the cored material such that said material is retained within the passageway, to a second position in which the ejecting means engages the said material such that the cored material is ejected from the passageway and out of the coring means.
40. A coring device according to any of claims 24 to 39, wherein the coring device further comprises an elongate slot extending along at least part of the coring means.
41. A coring device according to any of claims 38 to 40, wherein the ejecting means comprises a bung operably mounted to slide within the passageway.
42. A coring device according to claim 41, wherein the bung is in operable communication with the collar.
43. A coring device according to either claim 41 or claim 42, wherein the collar is attached to the bung by means which extends through the collar and the slot and into the bung and operable to be tightened and loosened as desired.
44. A coring device according to any of claims 38 to 43, wherein the ejecting means comprises a substantially elongate rod operable to slidably move within the passageway.
45. A coring device according to any of claims 38 to 44, wherein the ejecting means is biased such that release from the second position in which the cored material is

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ejected from the coring means results in the ejecting means returning to the first position.
46. A coring device according to any of claims 38 to 45, wherein the coring device comprises resilient means operably attached to bias the ejecting means between the said first and second positions.
47. A coring device according to any of claims 24 to 46, wherein the coring device comprises a first plate extending across the passageway.
48. A coring device according to claim 47, wherein the first plate is securely attached to the passageway.
49. A coring device according to claim 48, the first plate comprises a first aperture extending therethrough.
50. A coring device according to claim 49, wherein the rod extends through said first aperture freely therethrough.
51. A coring device according to any of claims 24 to 50 wherein the coring device comprises a second plate extending across the passageway.
52. A coring device according to claim 51, the second plate is housed for relative movement within the passageway.
53. A coring device according to claim 52, wherein the second plate comprises a second aperture extending therethrough substantially in the centre thereof.

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54. A coring device according to claim 53, wherein the said second aperture is threaded for threaded engagement with the rod which extends therethrough.
55. A coring device according to any of claims 51 to 54, wherein the resilient means is housed within the passageway between the first plate and the second plate.
56. A coring device according to any of claims 51 to 55, wherein the second plate comprises a pin which extends radially outwardly therefrom and through the slot.
57. A coring device according to any of claims 51 to 56, wherein the rod is rotated such that the second plate moves axially along the rod, rotational movement being prevented by the abutment of the pin against the slot.,
58. A coring device according to any of claims 46 to 57, wherein the resilient means comprises a spring which coils around the rod and which has an elongate axis substantially parallel to a longitudinal axis of the passageway.
59. A coring device according to any of claims 46 to 58, wherein movement of the ejecting means from the first position to the second position results in the resilient means being compressed and subsequent release of the resilient means resulting in resilient means becoming relaxed thereby resulting in the ejecting means moving back to the first position.

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60. A coring device according to any of claims 27 to 59, wherein the coring means is detachable from the body section.
61. A coring device according to any of claims 24 to 60, wherein the coring means is inserted into the passageway such that the cutting edge may be protected during transport of the device.
62. A method of coring out a section of material from a roofing panel, the method comprising :- (iv) providing a coring device comprising coring means which defines a passageway having an inwardly tapering cutting edge at one end thereof; (v) positioning the cutting edge on to a surface of said panel; and (vi) applying pressure to the coring device so that the cutting edge cuts into the panel and cores out a section which is accommodated in the passageway.
63. An alignment device according to claim 62, wherein the method further comprises ejecting the section of cored material from the passageway upon the actuation of ejector means.
64. An alignment device as substantially herein described with reference to, and as illustrated by, the accompanying drawings.

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65. A method of aligning the portion of fixing means into a panel as substantially herein described with reference to, and as illustrated by, the accompanying drawings.
66. A coring device as substantially herein described with reference to, and as illustrated by, the accompanying drawings.
67. A method of coring out a section of a material from a roofing panel as substantially herein described with reference to, and as illustrated by, the accompanying drawings.