IMPROVED PANEL UNIT

Abstract: A building panel having substantially quadrilateral shape wherein two edge surfaces have tongue members (4, 5) and two edge surfaces have groove members (2, 3). Preferably, the edge surfaces with tongues are adjacent surfaces and the edge surfaces with grooves are adjacent surfaces. Preferably, the panel is a laminate having a core (8) of insulating material laminated on both sides with metallic skins (7). Walls constructed from such panels have reduced fire hazards.

Description: IMPROVED PANEL UNIT This invention relates to integrated panel systems and insulated panel units. Particularly, the panels of this invention are suitable for use as wall panels although it will become apparent on a reading of the specification that the panels may be used in other applications. Hereafter, reference to the invention will be described by reference to wall panels only. However, it is to be understood that the invention is not so limited. The building industry is often confronted with a need to provide premises which can be relatively quickly and inexpensively erected. In the past, it has been proposed and practiced to substitute conventional external cladding materials such as bricks and timber with insulated metal panels which can be simply affixed to the metal superstructure or frame of a building being constructed. Many buildings have been constructed using such panels and they are particularly suitable for use as the external cladding of factories, warehouses and public buildings. Although, of course, use of the insulated wall panel is not limited to these applications. ,- In the past, wall panel assemblies have suffered from a number of deficiencies, a particular deficiency being that they have been adapted for assembly in one direction only with adjoining panels in the other direction being bolted or otherwise fixed 10 into place. This has caused difficulty both in the assembly of such panels and the provision of suitable weather seals between rows of panels. The present invention seeks to overcome the 15 disadvantages associated with previous systems- by providing an improved wall panel unit which is shaped at the edges so that it can engage with similar wall panel units either in the horizontal or * yertical mode. 20 According to the present invention there is provided a building panel of substantially quadrilateral shape defined by four edge surfaces wherein two edge surfaces include tongue members thereon and two edge surfaces include grooves therein; 25 said tongue members on one panel being engageable in said grooves on corresponding panels so that two or more of said panels may be engaged either horizontally or vertically by means of said tongue members of one 30 panel being inserted into the grooves in corresponding panels. The tongue members and grooves of the panel are shaped such that similar wall panels of the invention .-, 1 - can be engaged, the tongue member of one panel being adapted to fit within a complementary groove of another panel. Preferably, the grooves are on two adjacent edge surfaces of the panel; the tongue members being on the other two adjacent edge surfaces. However, whether the panel be configured with tongues and grooves on adjacent edge surfaces or tongues and grooves on alternate edge surfaces it is possible to join the panels in either a vertical or horizontal mode as each edge surface is provided with an engaging tongue member or groove. A weather seal may be provided by inserting a sealing member at the end of the respective tongue member when two panels are assembled together. Preferably, the sealing member is made of a compressible foam. The wall panels of the present invention are preferably constructed of a core material which.may be laminated on one or on both sides. The laminating material may be any suitable polymeric or metallic layer. Most preferably, it is metallic. A metallic laminate may be chosen from a number of different materials already known in the art. For instance, aluminium, stainless steel or C0L0RB0ND STEEL (a registered trademark) may be selected. The choice of material is dependent greatly on the situation in which the panel is to be used. Preferably, the core material is an insulating material. A number of insulating materials are suitable and are known in the art. Most preferably, an extruded polystyrene foam is selected. The core materials may be of variable thickness enabling thermal and structural properties to be varied as is required in any building specification. Once assembled, a wall constructed of laminated panel units will have a continuously separated inner and outer laminated skin. In a fire,, such separation allows molten foam to flow to the bottom of the structure. This is a safety feature which has not existed in the prior art. In a preferred embodiment of this invention, the laminate extends beyond the core material at the tongue edges of the panel in order to provide a slot at the end of the tongue member. This slot is suitable to firmly retain the said sealing member. In a further embodiment of the invention, the laminate on the groove edges is shaped around the ends of the edges and back down the grooves so that it covers the internal walls of the grooves. This laminate may be shaped at.the bottom of the groove to hoo.k back on both sides thus providing protrusions which are directed back out of the groove on both' sides. In such an embodiment, if an adjacent panel includes a tongue edge with a compressible foam sealing member as aforesaid then when the tongue member is inserted into the groove, the foam material is restrained from extending to the end of the groove. The compressible foam sealing member is thus more securely retained in the groove by these extending protrusions. In such an assembly, the compressible foam seal has been found to be very effective in providing a capillary break thus substantially preventing water penetration by capillary action. Such a sealing method avoids the need for builders to use caulking materials which have necessarily been required when weather seals have been previously provided in known wall cladding systems of this type. Preferably, the protrusion is curved or bent back at the ends to prevent damage to the sealing member. It will be appreciated that the protrusions also act as hooks to more securely retain the engaging panel. When two panels are assembled in the manner described above, the hook formed by the laminate secures the end of the laminate which extends beyond the core material at the tongue edge of the other panel. This provides a further benefit in that the hook ensures that the laminates of the two panels are firmly locked together. This is particularly advantageous in the case of fire as it substantially prevents buckling of the panels. It has been additionally discovered by the applicant that the water seal between the panels can be improved even further if a small gap is provided between the panels to allow water run off. Thus, in a further preferred embodiment of the invention, a run off gap is provided at the joints when the panel units are assembled. This may be provided by shaping the grooves so that at the edge of the panel, the groove is dimensioned wider than the engaging tongue member of the adjacent panel. The groove is also provided with a narrow portion so that the width of the groove towards its base is substantially the same width as the engaging tongue member. To ensure that a run off gap is provided, the tongue panel is made of sufficient length so that when the panels are engaged and the tongue is fully inserted into the grooves the outside edges of the respective panels are not in contact. Most preferably, the laminated edge leading up to the tongue on the edge of the adjacent panel is downwardly sloped to ensure that driven rain quickly and easily runs off the joint. In the manufacture of panels made in accordance with this invention, the groove can be either provided by machining the edge surface to the desired shape or by inserting an extruded or molded section of the desired shape into a slot provided along the edge surfaces of the panel. Such a section could be made of metal or plastics material. It will be appreciated that any number of panels made in accordance with this invention can be assembled together in a vertical or horizontal direction. Preferably, the corners -of the panel are shaped to allow easy assembly of a plurality of panels. Thus, a building made in accordance with the invention may in a preferred form be provided wherein at each of the respective corners of the said panel to which the tongue members extend the said tongue members include an interlocking portion proximate the said respective corners, said interlocking portions on each of the respective tongue members being shaped such that upon assembly of a number of said panels the interlocking portions mutually cooperate at the points of common connection so to enable the respective panels to engage with each other at the said points of common connection. Preferably, at corners where four panels meet when assembled, the edges are dovetailed for a clean and tight joint. In other words, it is desirable for the corners of the edges to be pressed differently so that they cooperate. In such an embodiment the laminate on the corner of one tongue may be inset, the laminate on the corner of another tongue may be set out of the plane and the remaining laminate may remain in the same plane throughout. In such a confirguration when four edges meet, the laminate at each corner will overlap to ensure tight connection and a close tolerance fit. The panels of this invention may be affixed to the superstructure or frame of a building in a number of different ways. Such methods would be recognized by any person skilled in the art. Preferably, a fixing bracket is used which is adapted to be bolted or otherwise affixed to a superstructure and which is adapted to be secured to the side or edge of the panel. Alternatively, a. hook fastener can be .used which comprises a fixing bracket and lug. Such a bracket can be affixed by bolts or other means to the frame of the building or structure with the lug affixed to a panel. Preferably, the lug is inserted into the ramp leading up to the tongue on one of the tongue edges of the panel or into the side of the panel. To facilitate more reliable connection it may be appropriate to strengthen the tongue member by the inclusion of a pressed metal tongue stiffener during the manufacture of the panels. Such hook fasteners allow easy, quick fixing of panels on site without close tolerance problems encountered by the prior art. It will also be apparent to those skilled in the art that the joining system used in the panels of this invention can be adopted in the sides of windows or door jambs. This enables simple and reliable construction of a building utilizing panels and other fixtures using the one universal jointing system. The invention will now be described by way of example with reference to the accompanying drawings in which: Figure 1 is a perspective view of the end portions of four panel units made in accordance with the present invention. Figure 2 is a cross-sectional view of two panels made in accordance with the present invention in an assembled form. Figure 3 is a perspective view of a fixing bracket which may be used in attaching panels made in accordance with the invention. Figure 4 is a cross-sectional view of two assembled wall panels made in accordance with the invention secured to a frame by a fixing bracket illustrated in Figure 3. Figure 5 is a perspective view of a fixing bracket and lug which may be used in attaching panels made in accordance with the invention. Figure 6 is a cross-sectional view of two assembled wall panels made in accordance with the invention secured to a frame by the fixing bracket illustrated in Figure 5. Figure 7 is a perspective view of an alternative fixing bracket. Figure 8 is a cross-sectional view of a wall panel made in accordance with the invention secured to a masonry wall by the fixing bracket illustrated in Figure 7. Figure 9 is a perspective view of an alternative fixing bracket. Figure 10 is a cross-sectional view of two assembled wall panels made in accordance with the invention secured to a frame by the fixing bracket illustrated in Figure 9. Figure 11 is a perspective view of an alternative fixing bracket. Figure 12 is a cross-sectional view of two assembled wall panels made in accordance with the invention secured to a masonry wall by the fixing bracket illustrated in Figure 11. Figure 13 is a perspective view of an alternative fixing bracket. Figure 14 is a cross-sectional view of two assembled wall panels made in accordance with the invention secured to a steel cleat by the fixing bracket illustrated in Figure 13. Figure 15 is a cross-sectional view of a wall panel made in accordance with the invention assembled with a fitting to insert a window jamb. Figure 16 is a cross-sectional view of a wall panel made in accordance with the invention assembled with a cooperative fitting to facilitate insertion of a door jamb. In Figure 1 there is a disclosed detail of each corner of a wall panel constructed in accordance with the preferred embodiment of this invention. For the purposes of more easily understanding how two or more of the panels of the invention cooperate, Figure 1 illustrates " the four different corners of a preferred embodiment of the invention as they would meet at the point of common connection between four of the said panels. The wall panels are not shown as complete units but are each substantially quadrilateral in shape. Two edge surfaces of each of the panels are provided with grooves 2 and 3. The other edge surfaces are provided with tongue members 4 and 5. As can be seen in Figure 1 , the tongue members 4 and 5 and grooves 2 and 3 of " the wall " panel unit are shaped to cooperate with the respective grooves 2 and 3 and tongue members 4 and 5 of other wall panel units made in accordance with the invention. The wall panel is provided with grooves 2 and 3 along adjacent edges as is illustrated on corner 1. The other two adjacent edges of the wall panel are provided with tongue members 4 and 5 as illustrated in corner 6. The panel unit is laminated with a metallic material 7 and has an extruded polystyrene foam core 8. The laminate 7 extends beyond the extruded polystyrene foam core 8 along the tongue members 4 and 5 of the panel to provide a slot 9. Within slot 9 a compressible foam seal 10 may be inserted. This material acts as a weather seal when the tongue 4 or 5 is inserted into a groove 2 or 3. The laminate 7 on the grooves 2 and 3 is shaped around the ends of the edges and back down the grooves 2 and 3 so that it covers the internal walls 11 of the grooves 2 and 3. As can be seen in Figure 2, at the bottom of the grooves 2 or 3 the laminate 7 is hooked back on both sides to form protrusions 12. These protrusions 12 are rounded at the ends 13 so that when the tongue members 4 or 5 and compressible foam seal material 10 of an 10 adjacent wall panel unit are inserted into groove 2 or 3 the protrusions 12 will not damage the compressible foam seal 10. Furthermore, the protrusions 12 restrain the compressible foam seal 10 from being pushed right _.,- to the end of the groove 2 or 3 when the tongue member 4 or 5 is inserted. This causes the compressible foam seal 10 to be more securely compressed within slot 9 in the tongue member 4 or 5. As the tongue members 4 or 5 are inserted into the grooves 2 or 3 the extending 0 portion of the laminate 14 fits within the hook formed by protrusion 12. This ensures that the laminates of the two panels are firmly locked together when the tongue members 4 or 5 are engaged in the grooves 2 or 3. 5 A gap 15 is provided between the assembled panels to improve water run off. As illustrated in Figure 2, gap 15 is provided due to the length of tongue 4 or 5 additional to the depth of groove 2 or 3. 0 This gap continues up the side 16 of the assembled panels due to greater width of groove 2 or 3 at its commencement compared with its width where indicated at 17. Ledge 18 is angled slightly downwards to ensure 5 proper and good run off. It will be appreciated that when the panels are assembled as illustrated in Figure 2, the compressible foam seal 10 forms a substantially water tight seal whilst the gap 15 enables any moisture and water which enters the joint, say as a result of driven rain, to simply run off the joint. The edges of the laminate shown in Figure 1 are offset relative one to the other so that a close fitting can be obtained when four panels of the invention are assembled together. The laminate in this preferred embodiment is pressed out at 19, pressed in at 20 and is left in the same plane at 21. As the various panels are joined together, these laminates overlap enabling a close and secure joint. Turning to Figures 3 to 14, there is illustrated a number of different fixing brackets which can be used to affix a panel or panels of the present invention to different structures. These are by way of example only and are not intended to limit the scope of the present invention. Where fixing brackets are used as illustrated in Figures 3» 5, 9 > 11 and 13» it is desirable to strengthen the tongue members 4 and 5 with a pressed metal tongue stiffener 22. The fixing brackets used are preferably made of galvanized steel. In Figure 13 there is illustrated a window jamb 23 shaped in cooperation with groove 2 or 3. The window jamb 23 being attached in this example via a specially shaped extrusion 26 to a piece of aluminium trimming 25. Aluminium trimming 25 in turn is attached to a piece of fixing angle 24. The extrusion 26 which is preferably made of aluminium allows the window to resemble a panel unit in that it can fit adjacent to and in the same plane as other panel units. In Figure 14 there is illustrated a door head 27 shaped to cooperate with groove 2 or 3 again via shaped extrusion 26. Finally, it is to be understood that the aforegoing description refers merely to preferred embodiments of the present invention, and that variations and modifications are possible without departing from the spirit and scope of the invention.

Claims: 1. A building panel of substantially quadrilateral shape defined by four edge surfaces wherein two edge surfaces include tongue members thereon and two edge surfaces include grooves therein said tongue members on one panel being engageable in said grooves on corresponding panels so that two or more of said panels may be engaged either horizontally or vertically by means of said tongue members of one panel being inserted into the grooves in corresponding panels. " .. ' • 2. A building panel as claimed in Claim 1 10 wherein at each of the respective corners of the said panel to which the tongue members extend the said tongue members include an interlocking portion proximate the said respective corners, said - r interlocking portions on each of the respective tongue members being shaped such that upon assembly of a number of said panels the interlocking portions mutually cooperate at the points of common connection so to enable the respective panels to engage with each 0 other at the said points of common connection. 5 3. A building panel as claimed in Claim 2 wherein two adjacent edge surfaces include tongue members thereon and two adjacent edge surfaces include grooves therein. 5 4. A building panel as claimed in Claim 1 wherein the panel is constructed of a core material which is laminated on both sides. 10 5. A building panel as claimed in Claim 4 wherein the said core material is a thermal insulating material. 6. A building panel as claimed in Claim 5 wherein the laminate material covers the core material 5 throughout its exposed surface except at the top of the tongue members and the bottom of the grooves such that uppn assembly of a number of building panels to form a structure, the said structure will comprise 0 continuously separa ' ted inner and outer laminated skins. 7. A building panel as claimed in Claim 1 wherein the panel is constructed of a core material which is laminated on both sides and wherein two 5 adjacent edge surfaces include tongue members thereon and two adjacent edge surfaces include grooves therein; and wherein the laminate on one said tongue member at one corner of the panel is inset the laminate on the tongue member at another corner of the panel is set out 0 of the plane of the tongue member and on the remaining corner of the panel which comprises a tongue member the laminate remains in the same place throughout the length of the tongue member such that upon assembly of j- a number of said panels the laminate portions at the said corners mutually cooperate and dovetail at the points of common connection so to enable the respective panel to engage with each other at the said points of common connection. c 8. A building panel as claimed in Claim 1 wherein there Is also provided a sealing member or members which are seated along the top of the respective tongue members such that upon engagement of the said tongue member(s) with a groove in a 10 corresponding panel a weather seal between the panels is created. 9. A building panel as claimed in Claim 8 wherein there are provided protrusions within the said 15 grooves so to restrain the said sealing member against the top of the tongue member of the engaging panel when the respective panels are connected. 10. A building panel as claimed in Claim 1 20 wherein the said grooves are provided with an entry portion and an engagement portion, the said entry portion being shaped as to not engage the tongue member of a corresponding panel and said engagement portion being shaped so that it is adapted to accept and 25 restrain the said tongue member and wherein the depth of the said grooves is less than the length of the engaging tongue members so to provide a run off section between engaged building panels. 30 11. A building panel as claimed in Claim 1 wherein the panel's shape is essentially rectangular. 35

Inventors: BROOKES ALAN J, GERMAINE GRAEME B, GRILLI TELLIO J, MCMICHAEL IAN A, BROOKES, ALAN, J., GERMAINE, GRAEME, B., GRILLI, TELLIO, J., MCMICHAEL, IAN, A.
Applicants: DOW CHEMICAL CO, THE DOW CHEMICAL COMPANY
Application year: 1987
Main classification: E04C2
IPC codes: E04C2, E04F13