IL43314A - Mating formation for joining laminated panels - Google Patents

Description

·¾^ o» 3B—rra^Tra— Terence Zwick THIS INVENTION relates to improvements in and relating to the joining of panels. This invention further relates to panels adapted to be joined to other panels, to a method of forming panels, and to units constructed by means of the panels,, According to the invention there is provided a panel comprising a core material having a mating formation on at least one edge thereof, the mating formation being at least partly defined by a cladding material provided on at least a peripheral portion of one side of the panel, and the mating formation having locating means provided by the cladding material defining the mating formation, the locating moans being adapted to engage with complementary locating means of a complementary mating formation of a further panel when the mating formations of the panels are mated to join the panelse The panel may conveniently have the cladding material substantially cladding at least one side of the panel to provide a laminated panele In an embodiment of the invention, the core material may conveniently have cladding material on both sides thereof, and the cladding material on the opposite sides of the panel may serve to at least partly define the mating formation.

The mating formation may be of any suitable typee Thus, for example, the mating formation may comprise a tongue formation, or a plurality of separate tongue formations, extending along one edge of the panelo In an alternative embodiment of the invention, for example, the mating formation may comprise a groove formation, or a plurality of separate groove formations, extending along one edge of the panelo Where the mating formation is only partly defined by the cladding material, the remainder of the mating formation may be defined by the core material.

The locating means may be of any suitable type which can conveniently be engaged with complementary locating means. The locating means may conveniently be such that it can readily be engaged with and disengaged from complementary locating means.

In an embodiment of the invention, the locating means may comprise locating pin means. In this embodiment of the invention, the locating pin means may be mounted on the cladding material to extend therefrom, or may be provided by deforming and/or displacing a portion or portions of the cladding material to define the pin means.

In an embodiment of the invention, the locating pin means may be located on the cladding material, by fixing threaded nut means to the cladding material, and screwing threaded pin means into the threaded nut means when desired.

In an alternative embodiment of the invention, the locating means may comprise locating slot means* The locating slot means may be provided directly' in the cladding material defining the mating formation, or may be provided on the cladding material.

Where the locating slot means is provided in the cladding material defining the mating formation, it may be provided by cutting, forming or displacing the cladding material to form the slot means. The slot means may therefore be in the form of an actual slot in the cladding material, in the form of a groove in the cladding material, or the like.

Where the locating slot means is provided on the cladding material, it may, for example, be provided by locating a suitable slot member having the slot means, on the cladding material.

The locating slot means may be adapted to receive complementary locating pin means of a complementary mating formation of a further panel, and may be adapted to have the pin means slidably displaced along it to draw the panel and the further panel together during mating of the mating formations of the two panels.

The slot means may be adapted to so draw the panel and the further panel with which it is being mated together by the slot means having a biassing portion extending at an acute angle to the free edge of the mating formation 0 The biassing portion of the slot means may be linear, arcuate, or partly linear and partly arcuate.

The biassing portion may constitute a lead-in portion for the pin means into the slot means, or the slot means may include a lead-in portion leading to the biassing portion. In this case, the lead-in portion may, if desired, extend substantially normally or at an angle to the free edge of the mating formation.

In an embodiment of the invention, the locating slot means may have restraining means to engage with locating pin means of a further panel which is engaged in the slot means, to restrain withdrawal of the locating pin means from the slot means.

The restraining means may conveniently be provided at the inner end of the slot means.

Where the slot means has a biassing portion, the biassing portion may therefore lead to the restraining means, or the restraining means may be constituted ¾by the inner portion of the biassing portion.

The restraining means may be provided by shoulder means, cut-out means, or the like in the slot, by the angle at which the portion of the slot constituting the restraining means, extends to the free edge of the mating formation, or the like.

In an embodiment of the invention, the restraining means may be constituted by an inner portion of the slot me^s extending substantially parallel to the free edge of the mating formation.

Where the slot means therefore includes a biassing portion and restraining means, they may be provided by two angularly related portions, or by the slot means being suitably curved along its length.

The panel may conveniently have a complementary mating formation which is complementary to the mating formation, on an edge of the panel which is opposed to the edge on which the mating formation is, with the complementary mating formation having complementary locating means which is complementary to the locating means of the mating formation. This will allow a corresponding panel to be joined on either edge of the panel in question.

If desired, the panel may have mating formations with locating means along more than two edges of the panel.

The panel of this invention may have a single locating means in the or each mating formation of the panel. Conveniently, however, the panel may have a plurality of locating means on the or each mating formation'.

Where the panel has a plurality of locating means, they may be provided at spaced intervals along the length of the panel, and the locating means may be corresponding locating means, or may comprise corresponding and complementary locating means .

The core material may be of any suitable desired material. It may thus, for example, be in the form of a ^ filler material, a fibrous material, a formed pulp, synthetic plastic material, expanded synthetic plastic material, wood, a formed cementitious material, a composite or compressed material, or the like0 The core material of the panel may be in the form of sheet material, a self-supporting panel, a foraminous structure, a frame structure, or the like, depending upon the intended application of the panel, and the nature and the form of the cladding material.

The cladding material may be in the form of any suitable type of material. It may therefore be selected for reinforcing the panel, for giving a pleasing appearance to the panel, or the like. Where the cladding material covers at least one side of the panel, it may be selected for protecting the panel from the elements or water, for heat reflecting properties, or the like.

The cladding material may conveniently, for example, be of sheet metal, synthetic plastic material, a composite or compressed material, wood, or the like.

In an embodiment of the invention, the panel may be in the form of an insulating panel to combat heat transfer between opposed sides of the panel. The core material may therefore be a suitable insulating material, and the cladding material may be a heat reflecting material.

In an embodiment of the invention therefore, the core material may be an expanded or foamed synthetic plastic material, whereas the cladding material may be stainless steel, aluminium, or the like.

Where the panel is in the form of an insulating panel, and the panel is provided with cladding material on opposed sides of the panel, the cladding material on one side of the panel should preferably be spaced from the cladding material on the opposed side of the panel, to prevent heat transfer from one side of the panel to the other side of the panel via the cladding material.

The panels of this invention can be of any desired shape.. The panels may therefore be selected from the group comprising flat panels, curved panels, panels having angularly related walls, corner panels, side wall panels, end wall panel floor panels, ceiling panels, frame member panels, structural member panels, door panels, or the like.

This invention can therefore have particular application in regard to prefabricated panels for use in forming articles, structures, or the like.

Further in accordance with the invention, a method of forming a panel as hereinbefore described, includes the steps of forming a laminate of a core material and a cladding material, of shaping the cladding material to partly define a mating formation along at least one edge of the panel, and of providing locating means on or in the cladding material defining the mating formation.

The cladding material may conveniently be shaped to define the mating formation before the laminate is formed. The locating means may be provided before the laminate is formed.

Further in accordance with the invention, a methgd of forming a panel as hereinbefore described, includes the steps of taking a sheet of cladding material having locating means along at least one edge thereof, forming a laminate of a core material and the cladding material, and shaping the edge of the cladding material having the locating means, to partly define a mating formation for the panele The edge of the cladding material may be shaped before the laminate is formed.' Further in accordance with the invention, a method of forming a panel as hereinbefore described, includes the steps of taking a sheet of cladding material having an edge portion shaped to partly define a mating formation, forming a laminate of a core material and the cladding material, and of providing locating means on or in the cladding material defining the mating formation.

The locating means may again be provided before formation of the laminate of the core material and the cladding material,, The cladding material may be shaped or formed to partly or at least partly define a mating formation, by suitably deforming, moulding, forming or shaping the cladding material,, The locating means may be provided on the cladding material by any suitable means„ It may thus be provided by any suitable means as hereinbefore described.

The laminate of core material and cladding mater^l may be formed by any suitable means „ Thus, for example, h-jre the core material is substantially self-supporting, flexible or resiliently flexible, such as a solid material, a settable material which has set, or the like, the laminate may be formed by securing the cladding material to the core material.

The cladding material may be secured to the core material by any suitable means. Thus, for example, it may be secured by means of an adhesive, by means of securing brackets, screws, bolts, or the like, or by moulding or forming the core material onto the cladding material or the cladding material onto the core material.

Where the core material is formed from a settable or mouldable material, the laminate may conveniently be formed by moulding the core material onto the cladding material or allowing the core material to set onto the cladding material.

In an embodiment of the invention, where the core material comprises an expanded or foamed synthetic plastic material, the laminate may be formed by allowing the core material to expand in a suitable mould wherein the cladding material is located. · The invention further extends to a panel whenever formed by the method as hereinbefore described.

The invention further extends to a method of constructing a unit, which includes the steps of selecting a plurality of panels having complementary mating formations and complementary locating means, and engaging the mating formation of each panel with the complementary mating format^n of an adjacent panel, and the locating means of each panel wi-ch the complementary locating means of an adjacent panel,.

The unit may be in the form of or may be adapted to comprise at least portion of a structure, room, system, or the like0 The panels may conveniently be in the form of panels having a mating formation along one edge, and a complementary mating formation along the opposed edge of the panelo The panels will thus all be corresponding panels insofar as . the mating formations and the complementary mating formations are concerned, so that any panel can have a further corresponding panel joined on either side thereof,.

The panels may include or comprise corner panels . for forming corners, frame or structural panels for forming frame members or structural members, side panels for forming sides, end panels for forming ends, floor panels for forming a floor, ceiling panels for forming a ceiling, or the like.

The panels may conveniently be in the form of insulating panels for constructing a cold unit, or portion of a cold unite The cold unit may be in the form of a cold or freezer room, storage system, or the like.

The invention further extends to a cold unit whenever having at least portion thereof constructed by the method as described.

An embodiment of the invention is now described by way of example with reference to the accompany drawing,, The drawing shows a fragmentary three-dimensional view of two predicated i„sUlati„g panels wnicn are « adapted to be joined together for the construction of a freezer room0 With reference to the drawing, reference numeral 10 refers generally to a first prefabricated insulating panel, and reference numeral 12 refers generally to a second prefabricated insulating panel which is adapted to be joined to the first panel in the construction of the freezer room.

The first panel 10 is shown to have a mating formation in the form of a groove formation 14 extending along its one edge which is adapted to extend vertically during use, whereas the second panel 12 is shown to have a complementary mating formation in the form a tongue formation 16 extending along its one edge which is adapted to extend vertically during use.

The first panel 10 has a tongue formation (not shown) corresponding to the tongue formation 16, and thus complementary to the groove formation 14, extending along its opposed edge which is adapted to extend vertically during as use, where/the second panel 12 has a groove formation corresponding to the groove formation 14, and thus complementary to the tongue formation 16 extending along its opposed edge which is adapted to extend vertically during use.

The panels 10 and 12 are therefore exactly corresponding panels so that the panel 10 can have the panel 12 joined onto either edge thereof as desirede Each of the panels 10 and 12 comprises a core material 18 of insulating material which is clad on its opposed sides with sheets of cladding material 20 of stainless steelo The core material 18 is conveniently of foamed or expanded synthetic plastic material,, The panels 10 and 12 may be formed by locating the opposed cladding sheets 20 in their appropriate spaced relationship in a suitable form, and allowing a suitable synthetic plastic material to expand between the cladding sheets 20o Alternatively, where use is made of a pre-foamed or pre-expanded core material 18 , the cladding sheets may be secured onto the core material 18 by any suitable means0 The means may conveniently, for example, be in the form of a suitable adhesive,, The tongue formations 16 (only one being shown) may be formed by bending or deforming the cladding sheets 20 to provide two opposed sides 22 for each of the tongue formations 16» The core material 18 may be formed or shaped to extend between the opposed sides 22 of each tongue formation 16 o Alternatively, if desired, a separate insulating strip 24 of insulating material may be located between the opposed sides 22 of each tongue formation 16 as illustrated in the drawing,, The insulating strip 24 may, if desired, be compressed into the zone between the opposed sides 22 so that it can expand into a cavity which may be formed if there is any shrinkage of the core material 18 ? Each tongue formation 16 is therefore partly defined by the cladding sheets 20, and partly by the insulating strip 24.

The groove formations 14 (only one being shown) may be formed by bending or deforming the cladding sheets 20 to provide two opposed, inwardly directed side walls 26 for each groove formation 14.

The core material 18 may again be shaped to have flanges 28 extending outwardly to occupy the spaces between the inwardly directed side walls 26 of each groove formation 14, and the cladding sheets 20. This embodiment is illustrated in the drawing. In an alternative embodiment, in place of the flanges 28, separate strips of insulating material may be located in position.

Each groove formation 14 is therefore partly defined by the inwardly directed side walls 26, and partly by the core material 18.

The two panels 10 and 12 are adapted to be joined together by the groove formation 14 including pairs of locating means in the form of locating pins 30 which project inwardly from the inwardly directed side walls 26, and by the tongue formations 16 include pairs of locating means in the form of locating slots 32 provided in the opposed sides 22, The locating slots 32 are complementary to the locating pins 30 and are adapted to slidably receive the locating pins 30.

The pairs of locating pins 30 are provided at desired spaced intervals along the length of the groove formations 14, and the pairs of locating slots 32 are provided at corresponding intervals along the length of the tongue formations 16.

For the construction of a usual type of cold or freezer room, the panels 10 and 12 would normally have a height of about 8 feet. In this embodiment, the pairs of locating pins 30 and locating slots 32 may conveniently be provided at intervals of about 2 feete It will be appreciated however that these intervals can be varied as desired.

The locating pins 30 project only a short distance inwardly from the inwardly directed side walls 26„ They may be provided on the side walls 26 by any suitable means.

Thus, for example, they may be provided by deforming, partly cutting out and deforming, or the like, portions of the inwardly directed side walls 26e Alternatively, for example, they may be provided by locating threaded nuts in suitable holes provides in the side walls 26, and then locating threaded pins in the nuts so that the pins constitute the locating pins 30.

The locating slots 32 may be provided by deforming portions of the opposed sides 22. Alternatively, for example, as shown in the drawing, the locating slots 32 may be provided by cut-outs in the opposed sides 22.

Each locating slot 32 comprises a lead-in portion 34 which extends at an acute angle to the free edge of each tongue formation 16, and a restraining portion 36 which extends from the lead-in portion 34, and extends substantially parallel to the free edge of each tongue formation 16.

In use, the panels 10 and 12 can be joined by displacing the panels towards each other so that the. tongue formation. 16 enters the groove formation 14 in mating relationship. As the panels 10 and 12 are displaced towards each other, the locating pins 30 will be received in the locating slots 32e As the panels 10 and 12 are displaced further towards each other, the locating pins 30 will be displaced slidably along the lead-in portions 34 of the slots 32. Since the lead-in portions 34 of the slots 32 extend at an acute angle to the free edge of the tongue formations 16, the panels 10 and 12 will tend to be drawn towards each other* By virtue of the shapes of the lead-in portions 34, they therefore constitute biassing portions in the slots 32 which serve to bias the panels 10 and 12 towards each other.

As the panels 10 and 12 are displaced further towards each other, the locating pins 30 will move into the restraining portions 36 of the slots 32. Thereafter, by sliding the panels 10 and 12 relatively to each other in a direction parallel to their adjacent edges, the locating pins 30 will be slidably displaced along the restraining portions 36 of the slots 32. Thus the panels 10 and 12 will be connected together with the tongue formation 16 firmly located in the groove formation 14, with the free edge of the tongue formation 16 engaging the base wall of the groove formation 14 which is defined by the core material 18, so that the core material 18 of the panel 10 abuts the insulating strip 24 of the panel 12. Furthermore, since the locating pins 30 are located in the restraining portions 36 of the slots 32, separation of the panels 10 and 12 by displacing them in a direction normal to their adjacent edges, will be prevented.

It is an advantage of the embodiment of the invention as illustrated in the drawing, that the cladding sheet 20 on one side of one panel, is connected to the cladding sheet 20 on the same side of the other panel, and that the cladding sheet 20 on the opposed side of the one panel, is connected to the cladding sheet 20 on the opposed side of the other panel. This therefore provides a secure joint between the two panels 10 and 12. It is a further advantage that the cladding sheets on one side of the two joined panels, are spaced from the cladding sheets on the opposed side of the two panels, with insulating material sandwiched in between. There is therefore no heat bridge between the cladding sheets 20 on one side, and the cladding sheets 20 on the other side. Therefore, the transfer of heat from one side of the panels to the other side of the panels via the cladding sheets 20, is combatted.

It is a further advantage of the embodiment of the invention as illustrated in the drawing, that the structure presents a relatively smooth surface, and that the panels can readily be joined together or disengaged from each other, as desired.

It will be appreciated that if a relatively smooth external finish is not required, the groove formations 14 may be defined by the full width of the core material 18, and by the cladding sheets 20 simply having flanges which extend beyond the core material 18 and lie in substantially the same plane as the cladding- sheets which are secured to the core material 18, liee In this embodiment, the tongue formation may be in the form of a tongue formation 16 as shown in the drawing with a lesser distance between the planes in which the cladding sheets 20 and the side walls 22 lie, or may be provided by an edge of the panel which can be forced into the groove formation 14 or which is slightly narrower so that it can be slid into the groove formation I4e In the joining of panels in accordance with this invention, any suitable adhesive or sealing composition may be provided between the mating formations „ In an embodiment of the invention, for example, a vapour proofing mastic may be provided in at least one of the mating formations so that it can spread when the mating formations are mated to combat vapour entry into the joint and through the joint« This is of particular importance in the construction of cold or freezer units or the like. 43314/2 19

Claims (10)

1. A laminated panel comprising a core material clad, on its opposed sides by cladding sheet material , the panel having a mating formation in the form of a mating tongue formation or a mating groove formation extending along its one edge, the mating formation being defined partly by the core material and partly by the cladding sheet material on opposed sides of the core material so that the opposed cladding sheet materials are spaced from each other, and the mating formation having locating means in the form of locating pin means extending f om or locating slot means provided in the cladding material defining part of the mating formation, whereby a further laminated panel having a complementary mating formation along its edge with complementary locating means can be secured to the panel by mating the complementary mating formations and engaging the complementary locating means.

2. A laminated panel according to Claim 1, in which the mating formation has a plurality of locating means at spaced intervals along its length.

3. * A laminated panel according to Claim 1 or Claim 2, having corresponding mating formations along two opposed edges thereof.

4. A laminated panel according to Claim 1 or Claim 2, having complementary mating formations along two opposed edges thereof, with the complementary mating formations having complementary locating means. 43314/2 20

5. A laminated panel according to Claim 4, in vhich the locating slot means has a biassing portion extending at an acute angle to the free edge of the mating formation, to bias the panel and a further panel into engagement vith each other when the complementary locating pin and slot means of the panels are engaged.

6. A laminated panel according to Claim 5, in vhich the locating slot means has a restraining portion beyond the biassing portion to receive locating pin means engaged vith the locating slot means, and restrain disengagement of the locating pin and slot means*

7. A laminated panel according to Claim 1, substantially as described and illustrated herein.

8. A method of constructing a unit vhich includes the steps of selecting a plurality of panels as claimed in any one of Claims 4 to, 6, of mating the complementary mating formations of adjacent panels, and displacing the adjacent panels relatively to each other to engage the complementary locating pin and slot means of the complementary mating formations.

9. A method of constructing a unit, according to Claim 8, substantially as described herein.

10. A unit whenever constructed by the method as claimed in Claim 8 or 9. FOR THE APPLICANTS OR. YITZHAK HESS