NZ630191B - Panel systems and methods - Google Patents

Panel systems and methods

Info

Publication number
NZ630191B
NZ630191B NZ630191A NZ63019114A NZ630191B NZ 630191 B NZ630191 B NZ 630191B NZ 630191 A NZ630191 A NZ 630191A NZ 63019114 A NZ63019114 A NZ 63019114A NZ 630191 B NZ630191 B NZ 630191B
Authority
NZ
New Zealand
Prior art keywords
extrusion
panel
panels
joint
layer
Prior art date
Application number
NZ630191A
Other versions
NZ630191A (en
Inventor
David Nelson Cameron
Original Assignee
David Nelson Cameron
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by David Nelson Cameron filed Critical David Nelson Cameron
Priority to NZ713722A priority Critical patent/NZ713722A/en
Publication of NZ630191A publication Critical patent/NZ630191A/en
Publication of NZ630191B publication Critical patent/NZ630191B/en

Links

Classifications

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    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0875—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having a basic insulating layer and at least one covering layer
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0889—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections
    • E04F13/0894—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections with tongue and groove connections
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/14—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass
    • E04F13/15—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass characterised by the use of glass elements, i.e. wherein an outer layer is not of glass
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/18—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of organic plastics with or without reinforcements or filling materials or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
    • E04F15/20—Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
    • E04F15/206—Layered panels for sound insulation
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/04—Other details of tongues or grooves
    • E04F2201/044—Other details of tongues or grooves with tongues or grooves comprising elements which are not manufactured in one piece with the sheets, plates or panels but which are permanently fixedly connected to the sheets, plates or panels, e.g. at the factory
    • E04F2201/046—Other details of tongues or grooves with tongues or grooves comprising elements which are not manufactured in one piece with the sheets, plates or panels but which are permanently fixedly connected to the sheets, plates or panels, e.g. at the factory wherein the elements are made of metal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
    • E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
    • E04F2290/041—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against noise
    • E04F2290/042—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against noise with a facing or top layer for sound insulation
    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
    • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/162—Selection of materials
    • G10K11/168—Plural layers of different materials, e.g. sandwiches

Abstract

Disclosed is a surface covering system, an acoustic surface covering system and a method of forming a panel (12, 12’). The disclosure notes that the panels (12, 12’) are easily installed and the joins between the panels (12, 12’) are disguised. The surface covering system includes a plurality of like panels (12, 12’). Each panel (12, 12’) includes a panel body, a first joint extrusion (1) and a second joint extrusion (2). The panel body is formed from a base layer (13, 13’) and a covering layer (14, 14’). The first join extrusion (1) is attached along a first edge of the panel body. The second joint extrusion (2) is attached along a second edge of the panel body, opposite the first edge. The covering layer (14, 14’) extends to cover at least part of the first joint extrusion (1) and the second joint extrusion (2). When first (12) and second (12’) adjacent like panels are installed, a join is formed by cooperation of the first extrusion (1) of the first panel (12) and the second extrusion (2) of the second panel (12’). The covering layers (14, 14’) of the installed first (12) and second (12’) panels meet such that the first extrusion (1) of the first panel (12) and second extrusion (2) of the second panel (12’) are concealed. The first joint extrusion also includes a base portion configured for attachment of the first joint extrusion to an underlying support or structure e panels (12, 12’). Each panel (12, 12’) includes a panel body, a first joint extrusion (1) and a second joint extrusion (2). The panel body is formed from a base layer (13, 13’) and a covering layer (14, 14’). The first join extrusion (1) is attached along a first edge of the panel body. The second joint extrusion (2) is attached along a second edge of the panel body, opposite the first edge. The covering layer (14, 14’) extends to cover at least part of the first joint extrusion (1) and the second joint extrusion (2). When first (12) and second (12’) adjacent like panels are installed, a join is formed by cooperation of the first extrusion (1) of the first panel (12) and the second extrusion (2) of the second panel (12’). The covering layers (14, 14’) of the installed first (12) and second (12’) panels meet such that the first extrusion (1) of the first panel (12) and second extrusion (2) of the second panel (12’) are concealed. The first joint extrusion also includes a base portion configured for attachment of the first joint extrusion to an underlying support or structure

Description

rOu Ref: ELN0Z N43 atPtens m rFo .oN 5 STNETAP TCA 1 359 ETELPMOC NOITACIFICEPS ELN AP SYESMTS DNA S MODHET ,I noremaC divaD ,nosleN na nailartsuA nezitic fo 1 5 yecatS ,teertS ,allunorC WSN 0322 , ailartsuA od ybereh eralced eht noitnevni rof hcihw I yarp taht a tnetap yam eb detnarg ot ,em dna eht dohtem yb hcihw ti si ot eb ,demrofrep ot eb ylralucitrap debircsed ni dna yb eht gniwollof :tnemetats PANEL SYSTEMS AND METHODS FIELD OF THE INVENTION The invention relates to panel systems for covering surfaces such as walls, ceilings or the like.
BACKGROUND TO THE INVENTION Various panel systems are used for covering internal and external wall or ceiling surfaces. The Applicant has proposed various modular systems in Australian Patent Application No. 2008288672. The Applicant has made further developments in modular panel systems.
Reference to any prior art in this specification does not constitute an admission that such prior art forms part of the common general knowledge.
It is an object of the invention to provide a panel system which is easily installed and in which the joins between panels are disguised, or at least to provide the public with a useful choice.
SUMMARY OF THE INVENTION In a first aspect the invention provides a surface covering system including a plurality of like panels, each including: a panel body formed from a base layer and a covering layer; a first joint extrusion attached along a first edge of the panel body; a second joint extrusion attached along a second edge of the panel body, opposite the first edge; wherein the covering layer extends to cover at least part of the first joint extrusion and at least part of the second joint extrusion; wherein the first joint extrusion includes a base portion configured for attachment of the first joint extrusion to an underlying support or structure; and wherein, when first and second adjacent like panels are installed a join is formed by cooperation of the first extrusion of the first panel and the second extrusion of the second panel, and the covering layers of the installed first and second panels meet such that the first extrusion of the first panel and the second extrusion of the second panel are concealed.
Preferably, when first and second adjacent like panels are installed, the meeting between the covering layers of the first and second panels is positioned within a recess extending along the join between the first and second panels.
Preferably the base layer is a rigid plastic or compressed fibreglass layer.
Preferably the covering layer is a veneer, foil or plastic layer.
Preferably the covering layer is a perforated layer.
Preferably the base layer is formed from an acoustically absorbent material.
Preferably the base layer is formed from rigid polyester.
In a second aspect the invention provides an acoustic surface covering system including a plurality of like panels, each including a panel body formed from a base layer and a covering layer, wherein the base layer is formed from a rigid acoustically absorbent material and the covering layer is a perforated layer.
Preferably the covering layer is a perforated veneer, foil or plastic layer.
Preferably the base layer is formed from rigid polyester.
In a third aspect the invention provides a method of forming a panel, including: providing a rigid base layer; attaching a first joint extrusion along a first edge of the base layer, wherein the first joint extrusion includes a base portion configured for attachment of the first joint extrusion to an underlying support or structure; attaching a second joint extrusion along a second edge of the base layer, the second edge being opposite the first edge; and attaching a covering layer onto the base layer, the covering layer extending over a front surface of the base layer and over at least part of at least one of the first and second joint extrusions.
Preferably the covering layer is attached to the base layer by profile wrapping.
BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be described by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a cross-section through a first joint extrusion; Figure 2 is a cross-section through a second joint extrusion; Figure 3 is a cross-section showing the first joint extrusion of Figure 1 engaged with the second joint extrusion of Figure 2; Figure 4 is a perspective view showing the first joint extrusion of Figure 1 engaged with the second joint extrusion of Figure 2; Figure 5 shows a panel according to one embodiment; Figure 6 shows first and second panels arranged side by side; Figure 7 shows the first and second panels of Figure 6 engaged with each other; Figure 8 shows several panels installed on an underlying support or structure; and Figure 9 shows a panel engaged with a blank extrusion.
DETAILED DESCRIPTION The Applicant’s system includes first and second joint extrusions 1, 2, as shown in cross- section in Figures 1 and 2. Figure 3 shows how the first and second joint extrusions 1, 2 cooperate to form a joint.
Each of the first and second joint extrusions 1, 2 includes a channel 3, 4 arranged to fit to an edge of a panel, as will be discussed below.
The first joint extrusion 1 includes a base 5, which may be used for attachment of the first joint extrusion to an underlying support or structure, such as a stud, joist or other available structure.
The first joint extrusion 1 also includes a pair of projections 6, which together form a further channel 7, which receives a projection 8 formed on the second joint extrusion, as shown in Figure 3.
A lug 9 may be provided on the second joint extrusion 2, and may come to rest against the edge of the base 5, as shown in Figure 3.
As shown in Figure 3, the two joint extrusions 1, 2 form a recess 10 when joined.
The features of the two joint extrusions illustrated in Figures 1 to 3 extend along the lengths of the two extrusions, as shown in Figure 4.
The extrusions may be formed from aluminium or any other suitable material, including suitable engineering plastics.
Figure 5 shows a panel 12. The panel includes a structural base layer 13, which may be formed of any suitable rigid plastic such as rigid polyester or the like. Rigid polyester acoustic board is an acoustically absorbent material with good fire resistance.
Alternatively, the base layer may be formed from a compressed fibreglass material, which also has acoustic properties. The Applicant’s arrangement is particularly suited to materials that are not suited to the formation of integral edge structures (such as tongue and groove structures).
The panel also includes a decorative covering layer 14. For illustrative purposes the decorative layer is shown as covering only a portion of the base layer 13, but will in fact cover the base layer entirely in most embodiments. The decorative covering layer may be any suitable veneer (including reconstituted veneer), foil or plastic layer. The decorative covering layer should be sufficiently flexible to allow application to the face and edges of the base layer 13 by a suitable process, such as profile wrapping. Veneers may be fleece-backed veneers. The decorative covering layer may be laminated to the base layer by any suitable method, using suitable adhesives.
Figure 5 shows the position of the first joint extrusion 1 mounted on a first edge 15 of the panel 12. For illustrative purposes the joint extrusion is not shown extending the full length of the panel. However, in preferred embodiments the joint extrusion 1 will extend the full length of the first edge 15.
As shown rabbets 16 may be formed in the base layer for receiving the joint extrusion 1.
Holes 17 may be formed in the base 5 of the first joint extrusion 1 for receiving fasteners, to attach the first joint extrusion 1 to an underlying support or structure.
The second joint extrusion 2 may be mounted to a second edge opposite the first edge in a similar manner.
As shown, the decorative covering 14 extends over the face of the base layer 13, over part of the first joint extrusion 1 and onto the protrusion 6 of the first joint extrusion 1.
Figure 6 shows a first panel 12 and a second like panel 12’ arranged side by side. This cross-section shows the position of each base layer 13 received in the channel 3, 4 of the first or second joint extrusion 1, 2. This drawing also shows the decorative covering layer 14 extending over part of each joint extrusion 1, 2. Figure 6 also shows a fastener 20 (e.g. a clout, nail, screw or the like) passing through the base 5 to attach the first joint extrusion 1 to an underlying support or structure (not shown), thereby attaching the first panel 12 to that support or structure.
During installation the first panel 12 will be attached to the underlying support or structure by fastener 20. The second panel can then be positioned by moving it in the direction shown by arrow 21 to bring the second joint extrusion 2 of the second panel 12’ into engagement with the first joint extrusion 1 of the first panel 12. The second panel can then be affixed to the underlying support or structure using similar fasteners through the base of its own first joint extrusion 1.
Figure 7 shows the engaged configuration of the first and second joint extrusions 1, 2.
As shown, the projection 8 of the second joint extrusion 2 is received in the channel 7 formed by the two protrusions 6 of the first joint extrusion 1. A recess 22 extends along the join between panels 12, 12’. The meeting 23 between the decorative covering 14 of the first panel 12 and the decorative covering 14’ of the second panel 12’ also extends along the join and is concealed in the bottom of the recess 22. This creates a clean, disguised join between the panels. In an installed covering system this will create the appearance of a uniform surface covering.
Figure 8 show a panels system installed on an underlying support in the form of studs . Each panel 12 is attached to the studs by fasteners 20 through the base of the first joint extrusion.
An outer panel may be engaged with a blank extrusion 27 (Figure 9). The blank extrusion 27 may be attached to the underlying structure by a suitable fastener 20.
In a preferred embodiment the base layer and covering layer of the panel 12 are formed for acoustic performance. The base layer may be formed from an acoustic material such as rigid polyester, or some other rigid sound absorbing material. The covering layer may be perforated, which enhances the sound absorption and allows sound waves to penetrate to the base layer. In some embodiments the perforations may be less than 2mm in diameter, preferably around 0.5 to 1mm in diameter. Circular or non-circular perforations may be used. The base layer may be dark, e.g. black, in colour, for visual appearance through the perforations.
While the present invention has been illustrated by the description of the embodiments thereof, and while the embodiments have been described in detail, it is not the intention of the Applicant to restrict or in any way limit the scope of the appended claims to such detail. Further, the above embodiments may be implemented individually, or may be combined where compatible. Additional advantages and modifications, including combinations of the above embodiments, will readily appear to those skilled in the art.
Therefore, the invention in its broader aspects is not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described.
Accordingly, departures may be made from such details without departure from the spirit or scope of the Applicant’s general inventive concept.

Claims (10)

1. A surface covering system including a plurality of like panels, each including: a) a panel body formed from a base layer and a covering layer; 5 b) a first joint extrusion attached along a first edge of the panel body; c) a second joint extrusion attached along a second edge of the panel body, opposite the first edge; wherein the covering layer extends to cover at least part of the first joint extrusion and at least part of the second joint extrusion; 10 wherein the first joint extrusion includes a base portion configured for attachment of the first joint extrusion to an underlying support or structure; and wherein, when first and second adjacent like panels are installed a join is formed by cooperation of the first extrusion of the first panel and the second extrusion of the second panel, and the covering layers of the installed first and second panels meet 15 such that the first extrusion of the first panel and the second extrusion of the second panel are concealed.
2. A system as claimed in claim 1, wherein, when first and second adjacent like panels are installed, the meeting between the covering layers of the first and second panels 20 is positioned within a recess extending along the join between the first and second panels.
3. A system as claimed in claim 1 or 2 wherein the base layer is a rigid plastic or compressed fibreglass layer.
4. A system as claimed in any preceding claim wherein the covering layer is a veneer, foil or plastic layer.
5. A system as claimed in any preceding claim wherein the covering layer is a 30 perforated layer.
6. A system as claimed in any preceding claim wherein the base layer is formed from an acoustically absorbent material.
7. A A s sy ys stte em m a as s c clla aiim me ed d iin n a an ny y p pr re ec ce ed diin ng g c clla aiim m w wh he er re eiin n tth he e b ba as se e lla ay ye er r iis s f fo or rm me ed d ffr ro om m rigid polyester.
8. A A m me etth ho od d o off ffo or rm miin ng g a a p pa an ne ell,, iin nc cllu ud diin ng g:: a) p pr ro ov viid diin ng g a a r riig giid d b ba as se e lla ay ye er r;; b) a a att ttt ta a ac c ch h hiiin n ng g g a a a ff fiiir r rs s st tt jjjo o oiiin n ntt t e e ex x xtt tr r ru u us s siiio o on n n a a alllo o on n ng g g a a a f ffiiir r rs s stt t e e ed d dg g ge e e o o off f tt th h he e e b b ba a as s se e e llla a ay y ye e er r r, wherein the ffiir rs stt jjo oiin ntt e ex xttr ru us siio on n iin nc cllu ud de es s a a b ba as se e p po or rttiio on n c co on nffiig gu ur re ed d ffo or r a attt ta ac ch hm me en ntt o off t th he e ffiir rs stt jjo oiin ntt e ex xttr ru us siio on n tto o a an n u un nd de er rlly yiin ng g s su up pp po or rtt o or r s sttr ru uc cttu ur re e;; 10 c) a a att ttt ta a ac c ch h hiiin n ng g g a a a s s se e ec c co o on n nd d d jjjo o oiiin n ntt t e e ex x xt ttr r ru u us s siiio o on n n a a alllo o on n ng g g a a a s s se e ec c co o on n nd d d e e ed d dg g ge e e o o offf ttth h he e e b b ba a as s se e e llla a ay y ye e er r r,,, ttth h he e e s se ec co on nd d e ed dg ge e b be eiin ng g o op pp po os siitte e tth he e ffiir rs stt e ed dg ge e;; a an nd d d) a atttta ac ch hiin ng g a a c co ov ve er riin ng g lla ay ye er r o on ntto o tth he e b ba as se e lla ay ye er r, , t th he e c co ov ve er riin ng g lla ay ye er r e ex xt te en nd diin ng g o ov ve er r a a a ff fr r ro o on n ntt t s s su u ur r rff fa a ac c ce e e o o off f tt th h he e e b b ba a as s se e e llla a ay y ye e er r r a a an n nd d d o o ov v ve e er r r a a att t llle e ea a as s stt t p p pa a ar r rtt t o o off f a a att t llle e ea a as s stt t o o on n ne e e o o offf tt th h he e e fffiiir r rs s sttt a an nd d s se ec co on nd d jjo oiin ntt e ex xttr ru us siio on ns s..
9. A A m me etth ho od d a as s c clla aiim me ed d iin n c clla aiim m 8 w wh he er re eiin n t th he e c co ov ve er riin ng g lla ay ye er r iis s a at ttta ac ch he ed d t to o t th he e b ba as se e layer by profile w wr ra ap pp piin ng g..
10. A A p pa an ne ell ffo or rm me ed d b by y tth he e m me etth ho od d o off c clla aiim m 8 8 o or r 9 9.. C CA AM ME ER RO ON N D DA AV VI ID D N NE EL LS SO ON N By Their Attorneys 25 ELLIS TERRY
NZ630191A 2014-05-09 2014-09-05 Panel systems and methods NZ630191B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
NZ713722A NZ713722A (en) 2014-05-09 2014-09-05 Panel systems and methods

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2014901723 2014-05-09
AU2014901723A AU2014901723A0 (en) 2014-05-09 Panel systems and methods

Publications (2)

Publication Number Publication Date
NZ630191A NZ630191A (en) 2016-04-29
NZ630191B true NZ630191B (en) 2016-08-02

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