WO2009050688A1

WO2009050688A1 - A translucent panel

Info

Publication number: WO2009050688A1
Application number: PCT/IE2008/000102
Authority: WO
Inventors: James Carolan; Gregory Flynn
Original assignee: Kingspan Research And Developments Limited
Priority date: 2007-10-17
Filing date: 2008-10-17
Publication date: 2009-04-23
Also published as: GB0819058D0; GB2453864B; IE20080847A1; GB2453864A

Abstract

A translucent panel 1 comprises a single body of translucent polycarbonate material, the single body comprising a profiled outer weather skin 2, an inner liner skin 3 and, a multiwall support 4 between the inner liner 3 and the weather skin 2. The panel 1 has an integral overlap portion 10 at one end of the panel. This is used for overlapping with other panels such as composite insulating roof or wall panels 18 of similar profile. The outer weather skin 2 is profiled to define a number of raised profiles 30 which may, for example be crown - shaped. The panel comprises a reinforcing means which may be provided by a reinforcing strip 30 which is accommodated in a pocket 30 formed in or provided by the multiwall support 4 inboard of the outer weather skin 2. The reinforcing strip 30 may be provided in the underlap crown 15 of the translucent panel for reinforcing the joint between the translucent panel and the adjacent overlapping panel 19. The strip 30 extends substantially the length of the panel and improves the spanability of the panel by 3 to 4 times in non - fragility / drop testing.

Description

"A translucent panel"

Introduction

The invention relates to a translucent panel.

In general, translucent roof panels (also called rooflights) comprise an outer translucent weather sheet and an inner translucent liner sheet.

One of the problems with conventional rooflights is that they are not efficient insulators and the rate of heat loss through the rooflights is relatively high. Another problem is that conventional rooflights must be relatively thick to achieve desired insulation properties. Thus, the rooflights are expensive in material usage.

In our GB 2413808A we have described a translucent panel comprising a single body comprising an outer weather skin, an inner liner skin and a multiwall support between the skins. The panel has an integral overlap portion.

There is a need to provide an improved panel of this type.

Statements of Invention

According to the invention there is provided a translucent panel comprising a single body of translucent material, the single body comprising an outer weather skin, an inner liner skin and a multiwall support between the outer weather skin and the inner liner skin, the inner liner skin, outer weather skin and multiwall support all being of translucent material, the panel further comprising a reinforcing means at at least one end and/or side thereof. In one embodiment the reinforcing means comprises a reinforcing strip.

In one embodiment the reinforcing strip extends longitudinally along substantially the length of the panel.

In one case the panel comprises a pocket for the reinforcing strip. The pocket may be located in the multiwall support. The pocket may be located adjacent to the outer weather skin.

In one embodiment the outer weather skin comprises a plurality of longitudinally extending profiled crowns. In this case one of the crowns may define an underlap for jointing with an adjacent like panel and the underlap crown has a pocket in which the reinforcing is located.

In one embodiment the reinforcing means comprises a rigid material. The reinforcing means may be of metal such as steel.

The strip may be a thin strip which is less than 10mm thick.

Typically the strip is about lmm thick.

In one case the translucent panel comprises a roof panel.

In another case the translucent panel comprises a wall panel.

The translucent material may comprise a translucent thermosetting material.

The outer weather skin may comprise a profiled form. In another embodiment the multiwall layer comprises a profiled form except at the overlap portion.

In a further embodiment the translucent material comprises a translucent thermosetting material.

In one embodiment the translucent material comprises a polycarbonate material.

The invention also provides a roof or wall structure incorporating a panel of the invention.

Brief Description of the Drawings

The invention will be more clearly understood from the following description thereof given by way of example only, with reference to the accompanying drawings, in which:-

Fig. 1 is a cross sectional view of a translucent panel according to the invention;

Fig. 2 is a view of the panel of Fig. 1 in use;

Fig. 3 and 4 are cross sectional enlarged views of details of the panel;

Fig. 5 and 6 are cross sectional enlarged views of the panel, in use;

Fig. 7 is a cross sectional view of one end of another translucent panel according to the invention; Fig. 8 is a cross sectional view of an end of the panel of Fig. 7;

Fig. 9 is a cross sectional view of one joint assembly detail of the panel of Figs. 7 and 8;

Fig. 10 is a cross sectional view of another joint assembly detail; and

Fig. 11 is a cross sectional exploded view of a joint detail.

Detailed Description

Referring to the drawings there is illustrated a translucent panel 1 comprising a single body of translucent polycarbonate material, the single body comprising .a profiled outer weather skin 2, an inner liner skin 3 and, a multiwall support 4 between the inner liner 3 and the weather skin 2. The inner liner skin 3, outer weather skin -2, and the multiwall support are all of translucent polycarbonate material. The panel 1 may be of

Lexan Thermoclear multiwall polycarbonate sheet from GE Structural Products. This material is highly resistant to sheet covering discoloration, loss of light and loss of strength due to weathering.

The panel 1 has an integral overlap portion 10 which is illustrated in this case at one end of the panel. This is used for overlapping with other panels such as composite insulating roof or wall panels 18 of similar profile. The overlap portion 10 has a substantially reduced thickness with respect to the overall thickness of the panel and in this case the thickness is reduced to close to thickness of the outer weather skin 2. The outer weather skin 2 is profiled to define a number of raised profiles 30 which may, for example be crown-shaped. In this case there are five crowns 30. The crown 30 at one side defines the integral overlap portion 10. The crown 30 at the other side defines an underlap 15 which is used for overlapping with an overlap part of other panels such as composite insulating roof or wall panels 19 of similar profile.

The panel comprises a reinforcing means which in this case is provided by a reinforcing strip 30 which is accommodated in a pocket 31 formed in or provided by the multiwall support 4 inboard of the outer weather skin 2. In this case the reinforcing strip 30 is provided in the underlap crown 15 of the translucent panel for reinforcing the joint between the translucent panel and the adjacent overlapping panel 19. In this case the strip 30 extends substantially the length of the panel and is of a rigid material such as metal, for example, steel. The strip 30 may be thin, for example less than 10mm thick and in some cases may be about lmm thick. A stitching fastener, for example of the type illustrated in Fig. 1 1 is used to fix the overlap hook part 16 of the panel to the underlapped transparent panel. The fastener extends through the reinforcing strip 30 to ensure a strong connection between the translucent panel and the adjacent composite panel. We have found that such a reinforcing strip improves the spanability of the panel by 3 to 4 times in non-fragility / drop testing.

Referring to Figs. 7 to 10 there are illustrated details of another translucent panel according to the invention which is similar to the panel described above and like parts are assigned the same reference numerals. In this case the reinforcing means comprises a pvc coated elongate 20mm x 0.7mm steel strip 50 which is bonded to an underlap crown 51 using a double sided adhesive tape 52. For ease of assembly and efficiency in use however, it is preferred (as described above) that the panel has a preformed pocket to receive a reinforcing strip. The overlap hook part 10 of the translucent panel may also have a soft polyethylene foam tape 65 applied thereto over the length of the panel to cushion and seal the overlap joint. Fig. 1 1 also shows the joint in further detail. There is a sealant 60 applied over the weather side (top) of the reinforcing strip. A stitching screw 61 is used to fix the overlap hook part 16 of the panel 1 8 to the underlapped transparent panel.

The rooflights of the invention have excellent U-value ratings, do not suffer from the effects of thermal expansion and provide excellent light transmission properties.

In the embodiments described the panel is comprised of a translucent polycarbonate material. It will however, be appreciated that the panel may be comprised of any suitable thermosetting material.

The translucent panel of the invention comprises connection means to enable secure connection with adjacent similar roo flight panels and/or insulated building panels. The rooflight is configured to provide for a side by side connection of the rooflight with the adjacent panel by virtue of the overlap and border features. This arrangement provides improved mechanical strength, sealing, and insulation between the rooflights and adjacent roof panels.

The invention is not limited to the embodiments hereinbefore described which may be varied in detail.

Claims

1. A translucent panel comprising a body of translucent material, the body comprising an outer weather skin, an inner liner skin and a multiwall support between the outer weather skin and the inner liner skin, the inner liner skin, outer weather skin and multiwall support all being of translucent material, the panel further comprising a reinforcing means.

2. A panel as claimed in claim 1 wherein the reinforcing means comprises a reinforcing strip.

3. A panel as claimed in claim 2 wherein the reinforcing strip extends longitudinally along substantially the length of the panel.

4. A panel as claimed in claim 2 or 3 wherein the panel comprises a pocket for the reinforcing strip.

5. A panel as claimed in claim 4 wherein the pocket is located in the multiwall support.

6. A panel as claimed in claim 4 or 5 wherein the pocket is located adjacent to the outer weather skin.

7. A panel as claimed in any of claims 2 to 6 wherein the outer weather skin comprises a plurality of longitudinally extending profiled crowns.

8. A panel as claimed in claim 7 wherein one of the crowns defines an underlap for jointing with an adjacent like panel and the underlap crown has a pocket in which the reinforcing means is located.

9. A panel as claimed in any of claims 2 to 8 wherein the reinforcing strip comprises a rigid material.

10. A panel as claimed in claim 9 wherein the strip is of metal such as steel.

1 1. A panel as claimed in any of claims 2 to 10 wherein the strip is a thin strip which is less than 10mm thick.

12. A panel as claimed in claim 1 1 wherein the strip is about lmm thick.

13. A translucent panel as claimed in any preceding claim which comprises a roof panel.

14. A translucent panel as claimed in any preceding claim which comprises a wall panel.

15. A translucent panel as claimed in any preceding claim wherein the translucent material comprises a translucent thermosetting material.

16. A translucent panel as claimed in any preceding claim wherein the translucent material comprises a polycarbonate material.

17. A translucent panel substantially as hereinbefore described with reference to the accompanying drawings.

18. A roof or wall structure incorporating a panel as claimed in any preceding claim.