WO2015131241A1 - Panneau composite amélioré - Google Patents

Panneau composite amélioré Download PDF

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Publication number
WO2015131241A1
WO2015131241A1 PCT/AU2015/000133 AU2015000133W WO2015131241A1 WO 2015131241 A1 WO2015131241 A1 WO 2015131241A1 AU 2015000133 W AU2015000133 W AU 2015000133W WO 2015131241 A1 WO2015131241 A1 WO 2015131241A1
Authority
WO
WIPO (PCT)
Prior art keywords
panel
composite panel
panels
corrugated
composite
Prior art date
Application number
PCT/AU2015/000133
Other languages
English (en)
Inventor
Marc Herman STAMPKE
Original Assignee
Stratco (Australia) Pty Limited
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
Priority claimed from AU2014900777A external-priority patent/AU2014900777A0/en
Application filed by Stratco (Australia) Pty Limited filed Critical Stratco (Australia) Pty Limited
Priority to AU2015226838A priority Critical patent/AU2015226838A1/en
Publication of WO2015131241A1 publication Critical patent/WO2015131241A1/fr

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/32—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material
    • E04C2/322—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material with parallel corrugations
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/70—Door leaves
    • E06B3/82—Flush doors, i.e. with completely flat surface
    • E06B3/827—Flush doors, i.e. with completely flat surface of metal without an internal frame, e.g. with exterior panels substantially of metal
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/70—Door leaves
    • E06B2003/7046—Door leaves with provisions for locks, hinges or other fittings
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/70—Door leaves
    • E06B2003/7049—Specific panel characteristics
    • E06B2003/7053—Specific panel characteristics corrugated

Definitions

  • the invention relates to an improved composite panel.
  • the invention has particular, but not exclusive, application in the building and construction industry.
  • Metal panels are widely used in the building and construction industry. Typically, such metal panels are corrugated and a variety of different profiles are in common use. roofing, walls, doors and fencing are constructed with such panels. Garages and garden sheds are also commonly constructed from such corrugated panels.
  • roofing and walling panels are available including a metal corrugated upper layer with, for example, a polyurethane foam applied to the underside thereof.
  • the foam providing improved insulation properties to the panels.
  • Another form of insulated roofing and walling panel includes a core sandwiched between an upper corrugated metal panel and a lower metal panel.
  • the core may be solid or honeycombed.
  • a feature common to these panels is that a first elongated edge of the upper corrugated layer is configured so that it can be overlapped onto a second elongated edge of an adjacent one of such panels. In this way, adjacent panels can be used to form a larger continuous corrugated insulated panel.
  • composite panels are suitable for roofing and walling applications, they are not generally suitable for use in constructing components that require strength along the face of the first and second elongated edges. Such composite panels are also relatively expensive and are thus not cost effective for use in many applications. Most composite panels are also difficult to recycle due to the combinations of different materials used and the difficulty of separating those different materials.
  • the present invention seeks to provide a composite panel that offers advantages over prior composite panels. These advantages may include, for example, one or more of improved strength, improved rigidity, unique appearance, easy installation and cost effective manufacture.
  • a composite panel including at least one corrugated panel located within a space defined by a second member.
  • the second member preferably includes a back panel, a peripheral edge and a front edge.
  • the space is preferably bounded, at least in part, by the back panel, the peripheral edge and the front edge.
  • the second member is formed from a single flat metal panel that has cut-outs at each corner.
  • the cut-outs are preferably square.
  • the metal panel is preferably folded at about 90° along respective fold lines to form an open box configuration.
  • the peripheral edge is made from four panels, two length panels and two width panels.
  • the front edge is made from four panels, two length panels and two width panels.
  • the peripheral edge extends at about 90° to the back panel and the front edge extends generally parallel to the back panel.
  • the front edge acts as a flashing and when a single corrugated panel is located within the space, the front edge extends over the width and length edges of the corrugated panel.
  • the corrugated panels are preferably overlapped along one length edge to form a larger panel. The width and length edges of the larger corrugated panel are covered by the front edge of the second member.
  • the second member establishes both a backing for the composite panel and flashing of the composite panel.
  • the at least one corrugated panel is preferably connected and/or adhered to the second member. Screws or rivets may be used to connect the at least one corrugated panel to the second member. Adhesive may also be used to connect the at least one corrugated panel to the second member.
  • the invention further provides a door including a composite panel, the composite panel including at least one corrugated panel located within a space defined by a second member.
  • At least one hinge is connected to a length edge of the composite panel.
  • a handle mounting bracket and/or handle is arranged to be connected to the door.
  • Figure 1 is an isometric view of a door made from a composite panel according to a first embodiment of the invention
  • Figure 2 is an assembly view of the door shown in Figure 1 ;
  • Figure 3A is an isometric view of the backing flashing of the door shown in Figure 1 ;
  • Figure 3B is a plan view of the flat panel that is folded to form the backing flashing shown in Figure 3A;
  • Figure 4 depicts Step 1 in the construction of the door as shown in Figure 1 ;
  • Figure 5 depicts Step 2 in the construction of the door shown in Figure 1 ;
  • Figure 6 depicts Step 3 in the construction of the door shown in Figure 1 ;
  • Figure 7 depicts Step 4 in the construction of the door shown in Figure 1 ;
  • Figures 8A and 8B illustrate two arrangements for connection of a hinge or other member to a composite panel in accordance with an embodiment of the invention.
  • Figure 1 illustrates a door 10 made from a composite panel in accordance with an embodiment of the invention.
  • the composite panel includes at least one corrugated panel located within a space defined by a second member.
  • the composite panel of the illustrated embodiment includes a half sheet corrugated panel 12A and a full sheet corrugated panel 12B that together establish the outer face 14 of the composite panel.
  • the composite panel further includes a second member in the form of backing flashing 16.
  • the outer face 14 of a composite panel in accordance with an embodiment of the invention may include only a single corrugated panel or may include more than two such corrugated panels. When multiple corrugated panels are included they may be of different or identical width.
  • corrugated panels 12A, 12B are overlapped in use as per conventional corrugated fencing, walling or roofing panels.
  • Backing flashing 16 is made from a single flat metal panel that has square cut-outs at each corner.
  • the box configuration includes a back panel 16A, a peripheral edge 16B (made from four panels, two length panels and two width panels) and a front edge 16C (made from four panels, two length panels and two width panels).
  • the peripheral edge 16B extends at 90° to the back panel 16A and the front edge 16c extends parallel to the back panel 16A.
  • the back panel 16A, peripheral edge 16B and front edge 16C define a space for receiving the corrugated panels 12A, 12B. The positioning of the corrugated panels 12A, 12B within that space will be described in more detail below.
  • the door 10 shown in Figure 1 further includes a handle mounting bracket 18 and upper and lower hinges 20. Numerous rivets 22 are used to secure the corrugated panels 12A, 12B to the backing flashing 16. The included components of the door 10 are best shown in Figure 2.
  • Handle mounting bracket 18 may adopt different forms but as illustrated includes an edge face 18A and a front face 18B ( Figure 4).
  • Door 10 is assembled using the components shown in Figure 2 in a series of simple assembly steps.
  • Step 1 of the assembly process is to trim a first longitudinal elongated edge of the half sheet corrugated panel 12A and to fold the trimmed edge at 90° to form edge 12A' (see Details A and B of Figure 4).
  • a part of the edge 12A' is then located substantially flush with the inner side of the edge face 18A of the handle mounting bracket 18.
  • Handle mounting bracket 18 is preferably positioned substantially mid-way along the length of the half sheet corrugated panel 12A.
  • Adhesive is applied to the outer peaks 12A" of the half sheet corrugated panel 12A and to the edge 12A' of the half sheet corrugated panel 12A.
  • the adhesive is preferably applied to the trimmed edge 12A' before it is located flush with the inner side face 18A of the handle mounting bracket 18. In this way, adhesive will be located between the part of the edge 12A' that makes contact with the inner side face 18A of the handle mounting bracket 18.
  • Adhesive is further preferably applied to the width edges of the half corrugated panel 12A.
  • half sheet corrugated panel 12A with handle mounted bracket 18 located thereon is positioned within the space of the backing flashing 16.
  • Handle mounting bracket 18 is positioned so that that the edge face 18A of the mounting bracket 18 is located between the edge 12A' and the first length part of the peripheral edge 16B of the backing flashing 16.
  • a part of the front face 18B of the handle mounting bracket 18 adjacent most to the edge face 18A is positioned in contact with or closely adjacent to an underside part of the adjacent length panel of the front edge 16C of the backing flashing 16. Accordingly that part of the front face 18B of the handle mounting bracket 18 is hidden from view by the length panel of the front edge 16C of the backing flashing 16.
  • the adhesive applied to the half sheet corrugated panel 12A helps to secure the half sheet corrugated panel 12A to the backing flashing 16.
  • Step 3 of the assembly process is shown in Figure 6.
  • the full sheet corrugated panel 12B is firstly trimmed to remove the underlap of the corrugated panel 12B.
  • the trimmed edge is then folded at 90° to form edge 12B' (See detail D of Figure 6).
  • Adhesive is applied to the outer peaks 12B" of the full sheet corrugated panel 12B and to the edge 12B' of the full sheet corrugated panel 12B. Adhesive is further preferably applied to the width edges of the full sheet corrugated panel 12B.
  • the full sheet corrugated panel 12B is then adhered to the backing flashing 16 after properly positioning the full sheet panel 12B with respect to half sheet panel 12A and the backing flashing 16. More particularly, the full sheet panel 12B is located so that the untrimmed longitudinal edge of the full sheet panel 12B is positioned on top of the untrimmed longitudinal edge of the half sheet panel 12A, and edge 12B' is located in contact with or closely adjacent to the second length panel of the peripheral edge 16B of the backing flashing 16. The upper and lower width edges of the full sheet panel 12B are positioned in contact with or closely adjacent to an underside of the associated width panel of the front edge 16C of the backing flashing 16. The full sheet corrugated panel 12B is located within the space of the backing flashing 16.
  • Step 4 is the final assembly step for the door 10.
  • rivets 22 are applied to join the components of the composite panel. Rivets are applied at each of the corners of the backing flashing 16 joining the overlapping length and width panels of the front edge 16c to the adjacent half or full corrugated panel 12A, 12B. Rivets 22 are also applied along the overlap of the half and full corrugated panels 12A, 12B. Further, rivets 22 are applied to join the peaks 12A', 12B" to the width panels of the front edge 16C of the backing flashing 16.
  • Hinges 20 are then mounted to the completed composite panel (shown fitted with the handle mounting bracket 18) to complete the door 10.
  • Figure 8A and 8B illustrate two arrangements for connection of a hinge 20 or other connector to a complete composite panel in accordance with an embodiment of the invention.
  • Figure 8A illustrates the hinge 20 connected to a composite panel as described and illustrated with reference to Figures 1 to 7.
  • the composite panel shown in Figure 8B is different to that shown in Figure 8A as it additionally includes a reinforcing channel 100 located between the length of the panel 12B and the length panel of the peripheral edge 16B of the backing flashing 16.
  • Reinforcing channel 100 is configured to fit over the length edge of the panel 12B and provided additional strength and rigidity, particularly in relation to any connection made through the length panel of the peripheral edge 16B of the backing flashing 16.
  • the backing flashing 16 would be held in a jig during assembly of a composite panel and that it may be necessary to hold one or more of the panels that form the peripheral edge 16B and/or front edge 16C away from the back panel 16a so as to enable proper positioning of the half and full corrugated panels 12A, 12B within the space of the backing flashing 16.
  • the panel(s) of the peripheral edge 16B may be held in the required position during assembly by clamps, those clamps being released once the half and full corrugated panels 12A, 12B are properly positioned within the space of the backing flashing 16. When the clamps are released the panels of the front edge 16C tend to squash the corrugated panel 12A, 12B located within the space of the backing flashing 16 providing a connection therebetween.
  • a composite panel made in accordance with an embodiment of the invention is advantageous because it provides a composite panel which is cost effective to manufacture, is relatively light weight and offers improved strength as compared to a single corrugated sheet panel.
  • the composite panel is simple to manufacture, without the need to handle foams or other like materials typically used to form the core or another layer of a composite panel that bonds to the corrugated layer.
  • the composite panel has a unique appearance in that the outer face is corrugated and the inner face (i.e. the outer side of the back panel 16A) is flat.
  • the inner face may be painted and may also be used as a planar display surface (e.g. for displaying advertising information) or planar attachment surface.
  • a flat panel could be located on top of or over the corrugated panel so that the resultant composite panel includes at least the corrugated panel, the second member and the flat panel. Such a composite panel would then have a flat inner face and a flat outer face.
  • the flat panel may be located within the space of the second member or may be secured externally to the second member.
  • corrugated panel 12A, 12B to support the flat back panel 16a of the backing flashing 16.
  • Prior art composite panels provide support to a flat panel using plastic, foam, wood or honeycomb structures. Such materials and structures are more difficult to work with and/or manufacture.
  • Composite panels made in accordance with an embodiment of the invention may offer other advantages. Such advantages may include:
  • the composite panel may have either an inner or outer face made form a decorative material, for example copper.

Landscapes

  • Engineering & Computer Science (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Architecture (AREA)
  • Securing Of Glass Panes Or The Like (AREA)

Abstract

La présente invention concerne un panneau composite amélioré qui peut être utilisé pour former un article comme une porte (10). Le panneau composite comprend au moins un panneau ondulé (12) situé à l'intérieur d'un espace défini par un second élément (16). Le second élément (16) comprend un panneau arrière (16A), un bord périphérique (16B) et un bord avant (16C). L'espace est délimité, au moins en partie, par le panneau arrière (16A), le bord périphérique (16B), et le bord avant (16C). Le panneau composite a une application particulière mais non exclusive dans l'industrie du bâtiment et de la construction.
PCT/AU2015/000133 2014-03-07 2015-03-06 Panneau composite amélioré WO2015131241A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2015226838A AU2015226838A1 (en) 2014-03-07 2015-03-06 Improved composite panel

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2014900777 2014-03-07
AU2014900777A AU2014900777A0 (en) 2014-03-07 Improved Composite Panel

Publications (1)

Publication Number Publication Date
WO2015131241A1 true WO2015131241A1 (fr) 2015-09-11

Family

ID=54054271

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU2015/000133 WO2015131241A1 (fr) 2014-03-07 2015-03-06 Panneau composite amélioré

Country Status (2)

Country Link
AU (2) AU2015226838A1 (fr)
WO (1) WO2015131241A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20200355021A1 (en) * 2019-05-06 2020-11-12 Southeast Cooler, Corp. Method and apparatus for reinforcing sheet metal door assemblies
CN112459665A (zh) * 2020-12-08 2021-03-09 浙江亚厦装饰股份有限公司 一种复合造型门结构及安装方法
US11702838B2 (en) 2017-11-24 2023-07-18 Bluescope Steel Limited Panel

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US167270A (en) * 1875-08-31 Improvement in fire-proof shutters
US1417664A (en) * 1919-10-13 1922-05-30 Blawknox Company Panel
US1451353A (en) * 1920-08-21 1923-04-10 Herman C Waldman Fire door
US1542443A (en) * 1921-12-31 1925-06-16 Gilmore Millard Door

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US167270A (en) * 1875-08-31 Improvement in fire-proof shutters
US1417664A (en) * 1919-10-13 1922-05-30 Blawknox Company Panel
US1451353A (en) * 1920-08-21 1923-04-10 Herman C Waldman Fire door
US1542443A (en) * 1921-12-31 1925-06-16 Gilmore Millard Door

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11702838B2 (en) 2017-11-24 2023-07-18 Bluescope Steel Limited Panel
US20200355021A1 (en) * 2019-05-06 2020-11-12 Southeast Cooler, Corp. Method and apparatus for reinforcing sheet metal door assemblies
CN112459665A (zh) * 2020-12-08 2021-03-09 浙江亚厦装饰股份有限公司 一种复合造型门结构及安装方法

Also Published As

Publication number Publication date
AU2015226838A1 (en) 2016-10-20
AU2015101935A4 (en) 2019-05-16

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