WO2009077998A1

WO2009077998A1 - A panel system comprising a composite panel and a translucent panel

Info

Publication number: WO2009077998A1
Application number: PCT/IE2008/000120
Authority: WO
Inventors: James Carolan; Gregory Flynn
Original assignee: Kingspan Research And Developments Limited
Priority date: 2007-12-14
Filing date: 2008-12-15
Publication date: 2009-06-25
Also published as: GB2455632A; IE20080999A1; GB0822821D0; GB2455632B

Abstract

An insulating panel system (1) comprises a composite panel (2) with an opening (3) provided therethrough. A translucent panel (4) is mounted to the composite panel (2) by an upstand frame (5) and an upstand capping (6). The upstand frame (5) comprises four upstand frame elements (20) and the upstand capping (6) comprises four capping elements (21) which are both typically of extruded plastics such as PVC. At least some are interengagable, by snap-fitting. Each upstand element (20) has a lower outwardly extending projection (30) which engages the inner liner sheet (11) of the composite panel adjacent the panel opening (3). A structural adhesive (19) is applied at the joint to ensure fixing and joint sealing. The upstand element (20) also has an upper seat (31) with a polymeric seal (32) projecting therefrom. The seal (32) may be co-extruded with the upstand element (20). In use, the edge of the translucent panel (4) is located on the seat (31) and the seal (32) engages against the inner face of the panel (4). When the translucent panel (4) is in place at least some of the capping elements (21) are snap fitted over the upstand elements (20). Each capping element (21) also has a seal (35) which engages against the outer face of the translucent panel (4).

Description

A PANEL SYSTEM COMPRISING A COMPOSITE PANEL AND A TRANSLUCENT PANEL

Introduction

The invention relates to a panel system comprising a composite panel and a translucent panel.

Roofs and walls of buildings are often provided by a plurality of composite panels. In order to provide a pathway for external light into the building it is desirable to provide some translucent panels. In most cases the translucent panels are designed to minimize the profile of the composite panels so that they can be readily mounted to and form part of the cladding provided by the composite panels.

However, there are a very large number of different composite panels of varying thickness, and profiles and it is not feasible to produce a range of translucent panels to mimic all of the many composite panels.

This invention is therefore directed towards providing a panel system which will address this problem.

Statements of Invention

According to the invention there is provided a panel system comprising a composite insulating panel having an opening therein, an upstand mounting frame extending from the opening, a translucent panel mounted to the mounting frame, and a capping for the upstand frame, the translucent panel being located between the upstand frame and the capping.

In one embodiment the upstand frame comprises a seat for the composite insulating panel. Preferably a seal and/or an adhesive is provided between the seat and the composite panel for sealing engagement of the composite panel in the seat of the upstand frame.

In one case the upstand frame comprises a seat for the translucent panel. Preferably a seal and/or an adhesive is provided between the translucent panel and the seat for the translucent panel and/or the capping.

Preferably the upstand comprises a pair of spaced -apart side upstand frame parts and a pair of end upstand frame parts and the capping comprises a pair of corresponding side capping elements and a pair of end capping elements.

In one embodiment one end upstand frame part and the associated end capping element are adapted to facilitate run-off to the outside of the upstand frame.

In one embodiment there are fixing means between the capping and the upstand frame.

In one case the panel comprises engagement means between the capping and the upstand frame. The engagement means may be a snap fitting between at least some of the capping elements and the upstand frame parts.

In one embodiment the upstand frame comprises a reinforcing means.

The insulating panel may comprise a backing sheet, an external sheet and a foam core between the sheets. One or both of the backing sheet and external sheet may be of metal.

The translucent sheet may be of multi-wall plastics such as polyvinylchloride. Brief Description of the Drawings

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

Fig. 1 is a perspective view of a pre-fabricated panel system of the invention;

Fig. 2 is an exploded view of the panel system of Fig. 1 ;

Figs. 3(a) to 3(d) are cross sectional views of various panel systems with composite panels of varying thickness, in this case 100mm, 80mm, 60mm and 45mm respectively.

Fig. 4 is a cross sectional view of an upstand part of the panel system:

Fig. 5 is a cross sectional view of an upstand capping part for the upstand part of Fig. 4;

Fig. 6 is a cross sectional view of another upstand part of the panel system;

Fig. 7 is a cross sectional view of an upstand capping part for the upstand part of Fig. 6;

Fig. 8 is a top plan view of the panel system of Fig. 1 ;

Fig. 9 is a cross sectional view on the line IX - IX in Fig. 8;

Fig. 10 is an end view of the panel system of Fig. 1 ;

Fig. 1 1 is a cross sectional view on the line XI - XI of Fig. 10; Fig. 12 is an enlarged view of detail A of Fig. 1 1 ;

Fig. 13 is an enlarged view of detail B of Fig. 1 1 ;

Fig. 14 is a top plan view of another panel system of the invention;

Fig. 15 is a cross sectional view on the line XV - XV in Fig. 14;

Fig. 16(a) to 16(c) are cross sectional views of various panel systems of Figs. 14 and 15 with composite panels of varying thickness, in this case 1 10mm.

90mm and 45mm respectively;

Figs. 17(a) and 17(b) are cross sectional views of another panel system with composite panels of varying thickness;

Figs. 18(a) to 18(e) are cross sectional views of a further panel system with composite panels varying thickness, in this case 100mm. 80mm, 60mm, 50mm and 40mm respectively;

Figs. 19(a) to 19(d) are cross sectional views of a still further panel system of the invention with composite panels of varying thickness, in this case 100mm, 80mm, 60mm and 45mm respectively;

Fig. 20 is a plan view of the panel system of Fig. 19;

Fig. 21 is a cross sectional view on the line XXl - XXl of Fig. 20;

Fig. 22 is an end view of the panel system of Fig. 20;

Fig. 23 is a cross sectional view on the line XXlIl - XXlIl of Fig. 22; and Fig. 24 is an enlarged view of detail XXlV of Fig. 23.

Detailed Description

Referring to the drawings and initially to Figs. 1 to 13 thereof there is illustrated a prefabricated insulating panel system 1 of the invention which in this case is for a roof. The panel system 1 comprises a composite panel 2 with an opening 3 provided therethrough. A translucent panel 4 is mounted to the composite panel 2 by a mounting means provided by an upstand frame 5 and an upstand capping 6.

In more detail, the composite panel 2 comprises an external sheet 10, an inner liner sheet 1 1 ,_t and an insulating foam core 13 between the inner and outer sheets 10, 1 1. The external sheet 10 may be any desired profile and is typically of metal such as painted galvanised metal. In the case of the panel of Figs. 1 and 2 the profile of the external sheet mimics that of a plurality of rooftiles. Such a panel is described in GB 2.384.500A, the entire contents of which are incorporated herein by reference. The . inner sheet 1 1 is also typically of metal such as painted galvanised steel and may also be profiled. The foam core may, for example be of polyisocyanurate or phenolic foam.

The translucent panel 4 may be a sheet of multi-wall polycarbonate structure such as that available from GE structural products under the name Lexan Thermoclear. The material is highly resistant to discoloration, loss of light transmission and loss of strength due to weathering.

The upstand frame 5 comprises four upstand frame elements 20 and the upstand capping 6 comprises four capping elements 21 which are both typically of extruded plastics such as PVC. At least some of the frame elements 20 and capping elements 21 are interengagable, for example by snap-fitting. Each upstand element 20 has a lower outwardly extending projection 30 which engages the inner liner sheet 1 1 of the composite panel adjacent the panel opening 3. A structural adhesive 19 is applied at the joint to ensure fixing and joint sealing. The upstand element 20 also has an upper seat 31 with a polymeric seal 32 projecting therefrom. The seal 32 may be co-extruded with the upstand element 20. In use. the edge of the translucent panel 4 is located on the seat 31 and the seal 32 engages against the inner face of the panel 4. When the translucent panel 4 is in place the capping elements 21 are snap fitted over the upstand elements 20, as illustrated. Each capping element 21 also has a seal 35 which engages against the outer face of the translucent panel 4. The seal 35 may be co-extruded with the capping element 21.

Some of the upstand elements 20 have upwardly extending projections 36, 37 with snap formations thereon. Similarly, some of the capping elements 21 have depending legs 38, 39 for engagement with the projections 36, 37 of lhe upstand element 20. The capping elements 21 also have a depending leg 40 which snaps over the outside of the upstand element 20, on assembly.

There are four upstand elements - two side elements 20(a), 20(b), an upper end element 20(c) and a lower end upstand element 20(d). There are four corresponding cappings 21 (a), 21 (b), 21 (c), 21 (d). The details of the upstands 20(a), 20(b), 20(c) and cappings 21 (a), 21(b). 21(c) are particularly apparent from Figs. 4, 5 and 12. The details of the lower end upstand 20(d) and capping 21(d) are particularly apparent from Figs. 6, 7 and 13. The upstand 20(d) is similar to the upstands 20(a), 20(b), 20(c) except that in the case of the lowermost upstand 20(d) in use of the panel system the projections 36, 37 are omitted. This allows any water ingress from any of the upstands

20(a), 20(b), 20(c) to run off and flow away from the lower joint by force of gravity. Such circumstances are not expected but this arrangement provides for run-off of any water ingress in the event of a failure at the joint to follow a pathway (down a sloping roof) to exit without penetrating the building envelope. There is a barrier sealing tape between the capping, translucent panel and upstand at the upper end of the panel. A breather tape may be provided between the capping translucent panel and upstand at the lower end.

Fixings 18 are used to further secure the upstands 20, cappings 21 and the translucent panel 4.

It will be noted that the upstand elements 20 may have recesses 49 which may be used to house reinforcing strips 50. if necessary, to enhance the structural strength of the upstand.

In use in a factory, to provide a translucent section in a composite panel, an opening 3 is provided by cutting through the inner liner, foam core and external sheet of the composite panel 2. The upstand elements 20 are assembled into an upstand frame which is passed through the opening 3 from below so that the inner liner 1 1 of the composite panel rests on the upstand projection 31. A seal such as a gun-applied pvc or silicon mastic may be provided at the frame joints and between the upstand projection 30 and the inner liner sheet 1 1. With the upstand frame 5 extending through and above the composite panel 2, the translucent panel 4 is placed on the seats 31 provided at the upper end of the upstand elements 20. A suitable seal may be applied between the various contact surfaces. The cappings 21 are then fitted over the upstand elements 20. The seals 35 engage the outer face of the translucent sheet 4, on assembly.

The upstand system may be used with any panel thickness. Some of the possibilities for use with a roof tile panel are illustrated in Figs. 3(a) to 3(d) which have core thickness of 100mm, 80mm, 60mm and 45mm, respectively.

Another panel system 60 is illustrated in Figs. 14 to 16 which is similar to that described above and like parts are assigned the same reference numerals. The main difference is that the side edges of the external sheet of the composite panel are profiled to provide an overlap which may be zipped together. Panels of this type are described in GB2345705A, the entire contents of which are incorporated herein by reference. Again, the system facilitates use with different core thickness as illustrated in Fig. 16(a) to 16(c) in which the core thickness are 1 10mm, 90mm, and 45mm respectively.

A further panel system 70 is illustrated in Figs. 17(a) and 17(b) which is similar to those previously described and like parts are assigned the same numerals. In this case the inner sheet is profiled to provide deep trapezoidal profiles. A panel of this type is described in GB2396166A, the entire contents of which are incorporated herein by reference.

A further panel system 80 is illustrated in Figs. 18(a) to 18(e). The panel 80 has a different profile to those illustrated in the other drawings and the upstand system is again illustrated in use in a wide range of panel thicknesses.

A still further panel 90 system of the invention is illustrated in Figs. 19 to 24 in which parts similar to those described above are assigned the same reference numerals.

The invention provides a panel and upstand system which facilitates factory fitting of a translucent panel to a wide range of panel profiles and thicknesses. The invention provides a panel system in which a translucent panel can be fitted to a wide range of composite panels in a factory using a universal upstand and capping system. This is important as the factory assembled panel system can be made to high standards of workmanship and can be thoroughly tested in the factory. Thus, on site, the panel system can be readily integrated into a roof panel system.

Many variations on the embodiments described will be readily apparent. Accordingly the invention is not limited to the embodiments hereinbefore described which may be varied in detail.

Claims

1 . A panel system comprising:-

a composite insulating panel having an opening therein;

an upstand mounting frame extending from the opening:

a translucent panel mounted to the mounting frame; and

a capping for the upstand frame, the translucent panel being located between the upstand frame and the capping.

2. A panel system as claimed in claim 1 wherein the upstand frame comprises a seat for the composite insulating panel.

3. A panel as claimed in claim 2 comprising a seal and/or an adhesive, between the seat and the composite panel for sealing engagement of the composite panel in the seat of the upstand frame.

4. A panel as claimed in any of claims 1 to 3 wherein the upstand frame comprises a seat for the translucent panel.

5. A panel as claimed in claim 4 comprising a seal and/or an adhesive is provided between the translucent panel and the seat for the translucent panel and/or the capping.

6. A panel as claimed in any of claims 1 to 5 comprising fixing means between the capping and the upstand frame.

7. A panel as claimed in any of claims 1 to 6 wherein the upstand comprises a pair of spaced-apart side upstand frame parts and a pair of end upstand frame parts and the capping comprises a pair of corresponding side capping elements and a pair of end capping elements.

8. A panel as claimed in claim 7 wherein one end upstand frame part and the associated end capping element are adapted to facilitate run-off to the outside of the upstand frame.

9. A panel as claimed in any of claims 1 to 8 comprising engagement means between the capping and the upstand frame.

10. A panel as claimed in claim 9 wherein the engagement means is a snap fitting between at least some of capping elements and the upstand frame parts.

1 1. A panel system as claimed in any of claims 1 to 10 wherein the upstand-, frame comprises a reinforcing means.

12. A panel system as claimed in any of claims 1 to 1 1 wherein the composite panel comprises a backing sheet, an external sheet and a foam core between the sheets.

13. A panel system as claimed in claim 12 wherein one or both of the backing sheet and external sheet are of metal.

14. A panel system as claimed in any of claims 1 to 13 wherein the translucent sheet is of multi-wall plastics such as of polyvinylchloride.

15. A panel system substantially as hereinbefore described. - i i -

16. An upstand system substantially as hereinbefore described.