PANELLING SYSTEMS
This invention relates to panelling systems, such as panelling systems comprising two- dimensional arrays of panels disposed one above the other to form a wall. The panels may be made wholly or substantially of glass and be of the kind called spandrel panels which are used to clad exterior surfaces of buildings or be those used in the construction of curtain walls. More particularly, but not exclusively, however, the panels are of transparent non-reflecting glass material such as are used in the construction of large outdoor video screens of the kind currently used at sports matches, for example.
As is known, video images at sports matches are produced by a battery of VDUs mounted within their own compartments in a giant steel frame. The video images from each VDU are back-projected onto individual plastics diffuser screens, for example of acrylic or polycarbonate, and are viewed through a vast two-dimensional array of glazed individual glass panels which help to sharpen the diffused images. The glass panels are glazed into and supported by mullions on all four sides forming part of the frame. Each VDU can produce a part of the overall desired image and, when all the screens are viewed collectively, the complete desired image can be observed. A major disadvantage of such a panelling system is that the mullions have to be at least 50 mm wide and this results in a lack of clear definition because the image appears to be separated into parts.
The plastics screens, used in the above system, are often highly susceptible to physical distortion if exposed to variations in temperature. Accordingly, one of the purposes of the panelling system is to seal the environment within the frame structure, containing the plastics screens, so that it is not susceptible to changes in temperature in external environments where frost, rain, ice, snow and excessive heat may prevail which also may cause differential expansion and ultimate failure of the materials forming the entire system. The environmental temperature within the sealed system can be controlled by means of a suitable air conditioning system. The use of mullions about the edges of each panel has up until now been considered to be necessary for meeting both the supporting and sealing requirements of video screens. This attitude has prejudiced development of other types of video screen panelling systems.
It is for these reasons that such panelling used for outdoor large video screens has not found favour in the world of advertising where clear image definition is a prerequisite. Instead, advertising has been hitherto restricted to neon signs which are static or made up
of a repeating pattern of moving images and letters.
Other panelling systems in the field of glazing are known in which each glass panel is secured to a support frame by way of bolts provided around the periphery of each panel. The bolts pass though holes which have been drilled around the periphery of each glass panel. The problems with this type of system are that there are often difficulties in registration between the holes in the panels and the frame, the drilling of the holes requires additional work which can significantly increase the overall cost of the panelling system, and the drilling can weaken or even damage the glass panels.
Accordingly, a main object of the present invention is to provide a panelling system in which the aforesaid disadvantages are minimised or at least substantially reduced. More particularly, though not exclusively, it is desired to provide a panelling system which is suitable for video image viewing.
To this end, and from one aspect, the present invention consists in a panelling system suitable for use as a video screen or the like, comprising a two-dimensional array of panels each having corner regions which meet at respective junctions, wherein the panels are supported from the junctions.
By supporting the panels from the junctions instead of along all sides, as has hitherto been the case, screen definition improved because the width of the gaps between the panels can be reduced at least to as little as 5 mm. This is extremely useful, not only in video screen applications as the screen definition is improved, but also in other panelling systems, such as cladding or glazing systems, where the appearance of an uninterrupted surface is desired. In this regard, it is to be appreciated that the present invention extends to any such panelling systems. In addition, the present invention advantageously avoids the risk of breakages and difficulties in registration associated with drilling which is used as a supporting agency in some prior art glazing panelling systems.
The narrow gaps left between the adjacent sides of the panels can readily be filled with a filler, such as silicone strips, which assists in sealing the panelling structure and also adds to maintaining its integrity. Preferable the filler has the same visual appearance and characteristics as the panels so that the discontinuities in the array are less apparent. For example, if the panels are made from clear glass, the filler is preferably transparent.
In a preferred construction, the panelling is supported from the junctions by means of an elongate member, such as a bolt, which passes through, and is accommodated by, a
space defined by the corners of adjacent panels. This advantageously minimises the surface area occupied by the discontinuities in the array caused by the required supporting structure. This, in turn, results in a better overall visual appearance for the array of panels and, for a video screen, it maximises the image viewing area. In addition, because an individual elongate member can support all of the panels meeting at a particular junction, the overall number of elongate members required to construct a panelling system is minimised and is significantly lower than the number of bolts required in the previously described prior art glazing panelling system. This reduction can provide significant cost savings, particularly for large-area panelling systems.
The space is conveniently provided by cutting the corners of the individual panels so as to provide truncated corners with at least one panel being supported from the elongate member through its corner edge region.
The support from the elongate member is advantageously provided by means of an element which projects laterally thereof such that edge portions at the corner regions of adjacent panels can rest on the element. The provision of the element increases the load bearing capacity of each elongate member such that even relatively large and heavy panels can be supported. In addition, assembly and disassembly of the array is simplified and does not require drilling or precise registration procedures.
Preferably, the laterally projecting element is supported by an aperture, passage or recess in the elongate member. In one embodiment which supports oppositely facing upper panels, the laterally projecting element passes through a passage such as a slot in the elongate member and extends on opposite sides respectively thereof to be engaged by corner edge regions of the adjacent panels.
The sealing of the space at the junctions is conveniently provided by means of a suitable locking cap which fits over the exposed end of the elongate member which together with a sealing member between the panel sides completes the sealing of the system. Preferably the cap comprises an annular collar for filling the space and a central locking nut which is securable onto the end of the elongate member to fasten the panels, elongate member and cap together at a junction. The locking nut preferably comprises pig nose fixing holes to enable fast assembly by use of an electric power drill. In assembly, the collar can be fitted against the corner regions of adjacent panels at the junction without imparting a twisting movements to the panels. This advantageously prevents damage to the panel surface and ensures correct alignment of the panel corners.
The annular collar preferably has a panel-engaging surface which is arranged to match the surface profile of the panels at the junction. Such surface matching optimises the sealing characteristics at each junction. In addition, the panel engaging surface may be non-planar so as to match a non-planar profile at the junction such as that provided by curved panels. In this regard, it should be noted that the present invention can be applied to panelling systems incorporating non-planar panels and even non-rectangular panels such as hexagonally shaped panels. The present invention can also be used advantageously to simulate an overall non-planar screen by faceting planar panels together.
The locking cap preferably has means, such as a slot, for accommodating part of the laterally extending element, such as a flat bar. This advantageously provides additional support for the flat bar and also acts to prevent the rotation of the annular collar during tightening of the locking nut .
In addition, to guard against turning of the elongate member when the panels are being installed, means such as a lock pin or the like is preferably provided for preventing such turning movements.
Preferably, each elongate member comprises a flange plate for supporting an interior panel such as a light diffuser panel against the member. The elongate member can also include means for securing the interior panel against the flange. In this way, a video screen, which requires an interior light diffuser panel for each exterior glass panel, can readily be constructed by use of the elongate members.
The lower corners of panels are preferably arranged to define an upper region of the space about each elongate member at a junction and are also arranged, by an appropriate angle of chamfering, to be supported by the laterally projecting element. In addition, upper corners of panels are preferably arranged to define a lower region of the space about each elongate member at a junction and are also arranged to avoid load bearing contact with the laterally projecting element. Accordingly, the upper corners are preferably chamfered to form a more obtuse angle than lower corner chamfers. By this arrangement, the weight of the upper panels at a junction is advantageously not transmitted to the lower panels at that junction and the distribution of weight of the panels in the structure known and controlled. Furthermore, any expansion or contraction of the panels due to temperature changes can readily be accommodated.
Preferably each of the panels includes stepped formations at its upper and lower corners for receiving a sealing means, such as a sealing ring. The formations can be arranged to provide a locating recess for receiving the sealing cap when the panel is assembled with other like panels. This advantageously enhances the sealing integrity of the elongate member with the panels at the junctions and improves the panelling structure appearance by reducing the amount of protrusion of the sealing cap from the outer surface of the structure.
In accordance with another aspect of the present invention, there is provided a method of constructing a panelling system suitable for use as a video screen or the like, the method comprising providing a two-dimensional array of panels each having corner regions which meet at respective junctions, and supporting the panels from the junctions to construct the panelling system.
According to another aspect of the present invention, there is provided a locking bolt for use in supporting panels at corner junctions thereof in a two dimensional array, the locking bolt comprising an elongate member arranged to pass through gaps in the array at the corner junctions of the panels and to be securable to a support frame at one end thereof, the bolt comprising means for clamping the bolt to two or more of the panels at their corner junctions to secure the panels together.
The invention also consists in a kit of parts for assembling any of the panelling systems defined hereinabove and also in any of the elongate members defined hereinabove for use in supporting panels at corner junctions thereof in a two dimensional array.
In order that the invention may be more readily understood, some preferred embodiments thereof will now be described by way of example with reference to the accompanying drawings in which:
Fig. 1 is a front elevation of a front screen of a panelling system constructed in accordance with the invention;
Fig. 2 is a part-sectional side elevation of one embodiment of a panelling system including the screen of Fig. 1;
Fig. 3 is a full size cut-away sectional view with parts removed of Fig. 2;
Fig. 4 is a full size detail part-sectional front elevation of a junction between four adjacent glazing panels;
Fig. 5 is a diagrammatic view showing the construction of the comers of the glass panels at the junction shown in Fig. 4;
Fig. 6 is a part-sectional elevation of another embodiment of a panelling system including the screen of Fig. 1;
Fig. 7 is a part-sectional rear view of the junction between four adjacent panels;
Fig. 8 is a front view of the junction between four adjacent panels;
Fig. 9 is an exploded view with parts removed of the embodiment of Figs 6 to 8.
Fig. 10 is a full size sectional elevation of another embodiment of a panelling system including the screen of Fig. 1; and
Fig. 11 is a full size detail part-sectional front elevation of a junction between four adjacent glazing panels as seen through section AA in figure 10;
In the drawings the same reference characters are used to designate the same or similar parts.
Referring to Fig. 1, there is shown a two dimensional array which is generally shown at 1 of glazed panels 2, having comer regions which meet at respective junctions 3 and which are supported at those junctions 3 in a manner to be described.
As shown more particularly in Figs 2 to 5, to which reference will now be made, an elongate member in the form of a supporting bolt 4 extends through, and is accommodated by, a space 5 defined by lower comers 6 of adjacent panels 2 forming the upper portion of the space 5 and the upper comers 7 of adjacent panels 2 forming the lower portion of the space 5. The supporting bolt 4 is in turn supported from and fixed to the back wall 8a of the supporting frame for the entire panelling array 1, which is conveniently of steel, by means of a fixing angle bracket 8 provided with a pair of slotted holes 9 (only one shown) through which passes a securing bolt 10 fixed as by nuts 11 to
a mounting bracket 12 through an aperture in which the threaded inner end 13 of the bolt
4 extends to be fixed thereon by a nut 14.
The supporting bolt 4 extends outwardly of the nut 14 where it is provided with an integral radial flange 15 and projects outwardly through the space 5 as indicated by the dashed lines 16 where its exposed end is covered over by a sealing cap 17 teπninating in a pig nose 18. The detailed construction of the sealing cap 17 is described later in relation to the third preferred embodiment of the present invention.
Plastics video projection screens 19, are supported from the bolt 4 against the radial flange 15. The screens 19 act to diffuse the image projected thereon so that raster scan lines become less discernible to the viewer. The glazing panels 3 comprise two individual toughened glass layers 20 (outer) and 21 (inner) which are fixed together and are stepped in relation to one another to form an integral whole as will be apparent from Figs 2, 3 and 5. At the lower comers 6 of adjacent panels 2, the inner layers 21 are truncated, as by cutting for example, to provide the upper region of the space 5. The comer end regions 22 of the individual inner glass layers 21 are supported on respective wing portions 23 of an element in the form of a flat bar 24 which projects laterally from opposite sides respectively of the bolt 4.
As will be more particularly apparent from Fig 4, the flat bar 24 extends through an aperture or passage in the form of a slot 25 in the bolt 4.
At the upper comers 7 of the panels 2, the inner glass layers 21 are also truncated as by cutting for example but form a more obtuse angle than at the tmncated upper corners 6 so as to extend the glass layer 21 beyond the end of the wing portions 23 as shown in Fig 4. As can be clearly seen, the weight of the glass panels 2 above the flat bar 24 is supported by the bolt 4 and the flat bar. By virtue of the different angle of truncation of the upper comers 7, the panels 2 below the flat bar 24 do no support any of the weight of the panels 2 above them.
Each outer toughened glass layer 20 surrounding the gap 5 is formed for example by cutting and includes an arcuate comer 26 which together with the arcuate comers 26 of adjacent panels encircle the gap 5. An annular sealing member 27 seals the gap between the inner toughened glass layer 21 and the sealing cap 17.
A transparent annular sealing ring 28 is provided in the gap provided by the annular
shoulder 29 in the sealing cap 17. Also, transparent sealing strips 30 are provided in the gaps between the sides of adjacent panels 2 as will be apparent from Fig 4.
In order to prevent turning movements of the bolts 4 during mounting of the panels 2, a lock pin 31 extends through an aperture in the bracket 12 and engages in another aperture in the radial flange 15.
Referring now to figures 6 to 9 of the accompanying drawings, another preferred embodiment of the present invention is shown. The second embodiment of Figs 6 to 9 differs from the first embodiment of Figs 2 to 5 in that the lower acrylic panel 19 is supported from the bracket 12 by means of a lip 40 fixed to and made of the same material as the panel 19 which hangs from an L-shaped member 41 held in position by the bracket 12. The lock pin 31 in this embodiment is in the form of a split pin which is held in the aperture in the bracket 12 by means of a friction fit. Although the wing portions 23 are shown as separate in Fig 9, they are, in fact, integral with each other in the manner illustrated in the embodiments of Figs 2 to 5.
Additionally, as can be seen from Fig 6, the lower edge of the screen 19 engages with an annular spacer 42 interposed between the flange 15 and the bracket 12. Annular washers 43 and 44 are interposed between the annular flange 15 and the screen 19 on the one hand and the inner toughened glass layer 21 on the other.
Furthermore, in this embodiment, the bracket 12 supports the array of panels 2 at a slight acute angle to the vertical. Such an angled structure is used to reduce the interference of reflections of the sky and clouds on the surface of the video screen 1 in use. The bracket 12, which in the previous embodiment had its major surfaces provided at 90° to each other, now has a smaller angle between its major surfaces, for example 80°.
A further embodiment of the invention is depicted in Figs 10 and 11. For the sake of brevity, only the differences between this third embodiment and the first embodiment will be described in detail hereinafter.
In this embodiment, the glazing panels 2 each comprise a three-ply toughened glass laminate having an outer layer 50, a middle layer 51 and an inner layer 52, which are fixed together to form an integral panel 2. The glass layers 50 and 51 correspond to the outer and inner glass layers 20 and 21 respectively of the foregoing embodiments, and
are as described in that embodiment. In addition, the third inner layer 52, is incorporated in the laminated panel. The inner layer 52 has truncated arcuate comers 26, formed by cutting for example, which are the same as the truncated comers 26 of the outer layers
50.
As can be seen from Fig 10, the sealing cap 17 is composite. A securing nut 53 fits inside an annular collar 54, the securing nut 53 when assembled being spaced from an inner surface of the collar 54 by two washers 55. The securing nut 53 has a threaded inner wall 56 which when rotated co-operates with a threaded end 57 of the supporting bolt 4, thus fastening the sealing cap 17 to the supporting bolt 4. Stainless steel is the preferred material for the securing nut 53, the collar 54 and the supporting bolt 5. The securing nut 53 is terminated by a pig nose 18 which enables rapid assembly of the nut
53 to the bolt 4 by way of an electric drill fitted with an appropriate bit.
The collar 54 has a annular shoulder 29, as have the sealing caps 17 described in the foregoing embodiments. The annular shoulder 29 is of a size that permits the panel engaging portion of the collar 54 to fit inside a recess 57a formed at the comer end regions 22 of the outer and middle layers 50, 51. A fibre washer 58 is compressed against the outer surface of the middle layer 51 to ensure positive grip between the cap 17 and the panels 2.
A further feature of this embodiment is that the radial flange 15 of the supporting bolt 4 has an annular shoulder 59, its size being such that a panel engaging face of the flange 15 fits inside a recess 59a formed at the comer end regions 22 of the inner and middle layers 52, 51. A fibre washer 60 is compressed against the inner surface of the middle layer 51 to ensure positive grip between the bolt 4 and the panels 2. The fibre washers 58 and 60 are included also to prevent the stainless steel collar 54 and supporting bolt 4 from damaging or marking the glass middle layer 51.
By tightening the securing nut 53, the sealing cap 17, panels 2 and supporting bolt 4 are locked together. In this way, only the securing nut 53 rotates, and the panel engaging surface of the collar 54 does not transmit any of this rotation to the surface of the glass panels 2.
As in the previous embodiments, the bolt 4 includes slot 25 for supporting the metal flat bar 24. However, as shown in Figure 10, the slot 25 extends deeper into the bolt 4 to give increased load-bearing support to the flat bar 24. In addition, the collar 54 also
contains a slot 61 for housing a portion of the flat bar 24. This provides further support for the flat bar 24 and also provides an additional means for preventing the rotation of the collar 54 during tightening of the securing nut 53.
In the present embodiment, the panels 2 are supported through comer regions 22 of the middle layers 51 by wing portions 23 of the flat bar 24, which is preferably made of stainless steel. Furthermore, rather than the glass middle layers 51 being in direct contact with the stainless steel flat bar 24, setting blocks 62 are inserted as shown in Figure 10.
While the above described embodiments all contain flat panels 2, those skilled in the art will appreciate that curved or faceted panelling can be readily substituted. As the collar 54 does not rotate, its panel engaging surface can be made to match the precise shape of the panel surfaces at the junction 3, thereby offering a large area of contact over the curved surface at the junction 3. This will, of course, still apply even when the curvature of the panels 2 is not spherically symmetrical about the centre of the junction 3, and hence the axis of rotation of the securing nut 53.
As in the foregoing embodiments, the supporting bolt 4 has a slot 25 for housing a flat bar 24. While the slot is deeper in this embodiment, it is to be appreciated that the depth and width of the slot can be varied in accordance with the size of the flat bar 24 necessary for supporting the panels 2.
It will be appreciated that various other modifications may be made to the embodiments herein described without departing from the sprit and scope of the invention as set forth in the appended claims. For example, although the above panelling systems have been described for use in a video projection scheme, the can equally be used in curtain walling, in a spandrel panelling system or even a glazing system.