PANEL

Abstract: A panel comprises a substantially flat body (1) provided at one side with a watertight upper layer (3). A drain (5,9) extends along an edge (7,11) of the panel, and an upper protrusion (13,17) extends along another edge (15,19) of the panel, which upper protrusion protrudes in a plane of the flat body so as to be positioned above a drain of a similar panel adjacent to the panel.

Description: The invention relates to a panel, for example to be applied as a roof panel on a roof, or as a wall panel on a wall of a building. Several functional requirements are imposed on roof panels and wall panels, such as being watertight, thermally insulated and draught-free. In the case of a roof these requirements are normally complied with by providing a construction with an air ventilation channel in between a watertight layer and an insulation layer, or by providing a laminated watertight layer/insulation layer composite construction. In the latter construction often a thin metal sheath is applied as a watertight layer. Traditionally the requirement of watertightness of the roof has been complied with by applying overlaps between adjacent roof panels, or by relying on plastic lute seals between the panels. French patent specification publication No. 2 068 385 discloses a panel comprising a substantially flat body provided at one side with a watertight upper layer and at least one drain. A water resistant membrane is arranged below the flat body, and each drain is arranged between the flat body and the water resistant membrane. To prevent water from entering spaces between adjacent panels the watertight upper layers of adjacent panels overlap each other. Thermally and mechanically induced movements of a building provided with these panels cause relative movements between the overlapping sections of the watertight layers, which may result in a widening in the overlaps and will eventually urge the need for repair. It is an object of the invention to provide a panel which eliminates the need for overlapping watertight layers of adjacent panels. To this end the present invention provides a panel comprising a substantially flat body provided at one side with a substantially flat watertight upper layer, an edge along which a drain extends, and an edge along which an upper protrusion extends, which upper protrusion protrudes in a plane of the flat body so as to be positioned above a drain of a similar panel adjacent to the panel, characterized in that the panel is provided with two drains and two upper protrusions, wherein a first drain extends along a first edge of the panel, a second drain extends along a second edge adjacent to the first edge, a first upper protrusion extends along a third edge opposite to the first edge and a second upper protrusion extends along a fourth edge opposite to the second edge, wherein the first drain is an integral part of a first lower protrusion at the first edge, which first lower protrusion protrudes sideways so as to be placed substantially below a first upper protrusion of a similar panel adjacent to the first edge, the panels being placed on a flat surface and with their substantially flat watertight upper layers at the same side and without overlapping watertight upper layers of adjacent panels, and wherein the second drain is an integral part of a second lower protrusion at the second edge, which second lower protrusion protrudes sideways so as to be placed substantially below a second upper protrusion of a similar panel adjacent to the second edge, the panels being placed on a flat surface and with their substantially flat watertight upper layers at the same side and without overlapping watertight upper layers of adjacent panels, and wherein the first upper protrusion protrudes sideways so as to be placed substantially above a first lower protrusion of a similar panel adjacent to the third edge, the panels being placed on a flat surface and with their substantially flat watertight upper layers at the same side and without overlapping watertight upper layers of adjacent panels, and the second upper protrusion protrudes sideways so as to be placed substantially above a second lower protrusion of a similar panel adjacent to the fourth edge, the panels being placed on a flat surface and with their substantially flat watertight upper layers at the same side and without overlapping watertight upper layers of adjacent panels. Rainwater which flows over the upper protrusion of the panel into the space between the panel and the similar adjacent panel collects in the drain of the adjacent panel, and flows from this drain to another similar panel. In this way a watertight construction is obtained, without overlapping watertight upper layers of adjacent panels. The panel comprises a plurality of edges along which a drain extends, and a plurality of edges along which an upper protrusion extends. Rainwater which flows into spaces between adjacent panels is collected in each drain, and discharged to other panels. The panel comprises at least one lower protrusion, each lower protrusion comprising at least one of the drains as an integral part. By the construction of the drains as an integral part of lower protrusions, the body with the upper and lower protrusions can be manufactured from one piece. Advantageously, a lower protrusion is provided with means for fastening the panel to an underlaying structure. Since the lower protrusion is covered by an upper protrusion of a similar adjacent panel, the means of fastening the panel are also covered by the upper protrusion of the similar adjacent panel. More advantageously, each edge along which an upper protrusion extends is arranged opposite to an edge along which a drain extends. By the opposite arrangement of upper protrusions and drains, a plurality of rectangular panels can be arranged in a regular manner. It is remarked that FR-A-2,365,011 discloses a panel consisting of a plurality of overlapping bodies and each body provided at one side with a waterproof upper layer, an edge along which a drain extends and an edge along which an upper protrusion extends. However, the specific construction of the invention has not been disclosed. The invention will now be described by way of example in more detail with reference to the accompanying drawings, in which: Fig. 1 shows a top view of a panel according to the invention; Fig. 2 shows a transverse cross-section along the lines II-II of Fig. 1; Fig. 3 shows a longitudinal cross-section along the lines III-III of Fig. 1; Fig. 4 shows a perspective view from the direction IV of Fig. 1; Fig. 5 shows a perspective view from the direction V of Fig. 1; Fig. 6 shows a transverse cross-section of two adjacent panels according to the invention; Fig. 7 shows a longitudinal cross-section of two adjacent panels according to the invention; Fig. 8 shows a longitudinal cross-section of an alternative panel according to the invention; and Fig. 9 shows a regular pattern of panels according to the invention. Each panel shown in Figs. 1-9 comprises a flat body (1) of rectangular shape, which body (1) is made of insulating material and provided with a watertight upper layer (3). The panel is provided with two drains and two upper protrusions, wherein a first drain (5) extends along a first edge (7) of the panel, a second drain (9) extends along a second edge (11) adjacent to the first edge (7), a first upper protrusion (13) extends along a third edge (15) opposite to the first edge (7) (Fig. 3) and a second upper protrusion (17) extends along a fourth edge (19) opposite to the second edge (11) (Fig. 2). The first drain (5) is an integral part of a first lower protrusion (25) at the first edge (7), which first lower protrusion (25) protrudes sideways so as to be placed substantially below a first upper protrusion of a similar panel adjacent to the first edge (7), the panels being placed on a flat surface and with their watertight upper layers at the same side. The second drain (9) is an integral part of a second lower protrusion (27) at the second edge (11), which second lower protrusion (27) protrudes sideways so as to be placed substantially below a second upper protrusion of a similar panel adjacent to the second edge (11), the panels being placed on a flat surface and with their watertight upper layers (3) at the same side. The first upper protrusion (13) protrudes sideways so as to be placed substantially above a first lower protrusion of a similar panel adjacent to the third edge (15), the panels being placed on a flat surface and with their watertight upper layers (3) at the same side. The second upper protrusion (17) protrudes sideways so as to be placed substantially above a second lower protrusion of a similar panel adjacent to the fourth edge (19), the panels being placed on a flat surface and with their watertight upper layers (3) at the same side. The lower protrusions (25,27) are provided with means for attaching the panel to an underlaying structure, in the form of holes (29) for receiving nails or screws. The two drains (5,9) are in communication with each other, and the second drain (9) is open at its end (31) near the third edge (15), so as to allow water to flow from the first drain (5) into the second drain (9), and to be discharged from the second drain (9) through its open end (31). The shapes of the upper protrusions (13,17) and lower protrusions (25,27) allow strips (33,35) of mastic material to be arranged between an upper protrusion (13,17) of a panel and a lower protrusion (25,27) of a similar adjacent panel. Each drain (5,9) is sealed from the spaces above and below the panels by two strips (33,35). The strips (33) which seal the drains (5,9) from the space above the panels are arranged flush with the watertight upper layers (3), by which arrangement a continuous outer surface of a regular pattern of panels is obtained. A seating (36) for a strip (33) of mastic material extends along the first edge (7). The alternative panel according to the invention (Fig. 8) is additionally provided with a third drain (40) which is an integral part of the first lower protrusion (25), and which third drain (40) extends parallel to the first drain (5) and is open at both ends. An additional seal (41) seals the first drain (5) from the third drain (40). When installed on a roof or a wall, the panels are fastened to a flat underlaying structure by any means suitable for the purpose, for example screws (not shown for reasons of clarity) which are inserted through the holes (29). The panels are arranged in a regular rectangular pattern, whereby the first drain (5) of each panel extends horizontally and the second drain (9) of each panel extends in the downward sloping direction of the underlaying structure, with the open end (31) of each second drain (9) at the lower side. A panel which is surrounded by four similar panels has its first lower protrusion (25) arranged below the first upper protrusion (13) of a similar panel, its second lower protrusion (27) arranged below the second upper protrusion (17) of a similar panel, its first upper protrusion (13) arranged above the first lower protrusion (25) of a similar panel, and its second upper protrusion (17) arranged above the second lower protrusion (27) of a similar panel. Small cover-elements (43) are arranged near the corners of the panels so as to cover those sections of seams (45) between the panels, which would otherwise be open to the space above the panels. During normal use of the panels, rainwater flows over the watertight upper layers (3) and over the strips (33) of mastic material which are flush with the watertight upper layers (3). As long as these strips (33) are intact no water is allowed to flow into the spaces (45) between the panels. However, damage to one or more strips (33) may result in water entering these spaces (45). For such conditions the use of the panels is explained with reference to Fig. 9, showing a first panel (47), a second panel (49) adjacent to the third edge (15) of the first panel (47), and a third panel (51) adjacent to the second edge (11) of the second panel (49). Rainwater which has collected on the watertight upper layer (3) of the first panel (47) flows downwards and over its third edge (15) into the horizontal drain (5) of the second panel (49). Since the horizontal drain (5) and the sloping drain (9) of the second panel (49) are in communication with each other, the rainwater is allowed to flow from the horizontal drain (5) of the second panel into its sloping drain (9). Some rainwater present on the watertight upper layer (3) of the second panel (49) may flow over its second edge (11) into its sloping drain (9). Similarly, some rainwater present on the watertight upper layer (3) of the third panel (51) may flow over the fourth edge (19) of the third panel (51) into the sloping drain (9) of the second panel (49). The rainwater which has collected in the sloping drain (9) of the second panel (49) is discharged through the open end (31) of the sloping drain (9) to the horizontal drain of a next panel (not shown). At a lower side of the structure the total amount of rainwater is discharged in a conventional manner. The panel can effectively be applied on pitched roofs or walls, which are arranged at an angle of between 10° and 90°. The use of the alternative panel of Fig. 8 is similar to the above panel, except that the third drain (40) serves as a back-up for the first drain (5). It will be appreciated that any suitable material other than zinc can be used for the construction of the watertight upper layer, such as lead, aluminium, copper, steel or stainless steel. Various modifications of the present invention will become apparent to those skilled in the art from the foregoing description and accompanying drawings. Such modifications are intended to fall within the scope of the appended claims.

Claims: A panel comprising a substantially flat body (1) provided at one side with a substantially flat watertight upper layer (3), an edge along which a drain extends, and an edge along which an upper protrusion extends, which upper protrusion protrudes in a plane of the flat body so as to be positioned above a drain of a similar panel adjacent to the panel, characterized in that the panel is provided with two drains and two upper protrusions, wherein a first drain (5) extends along a first edge (7) of the panel, a second drain (9) extends along a second edge (11) adjacent to the first edge (7), a first upper protrusion (13) extends along a third edge (15) opposite to the first edge (7) and a second upper protrusion (17) extends along a fourth edge (19) opposite to the second edge (11), wherein the first drain (5) is an integral part of a first lower protrusion (25) at the first edge (7), which first lower protrusion (25) protrudes sideways so as to be placed substantially below a first upper protrusion of a similar panel adjacent to the first edge (7), the panels being placed on a flat surface and with their substantially flat watertight upper layers at the same side and without overlapping watertight upper layers of adjacent panels, and wherein the second drain (9) is an integral part of a second lower (27) protrusion at the second edge (11), which second lower protrusion (27) protrudes sideways so as to be placed substantially below a second upper protrusion of a similar panel adjacent to the second edge (11), the panels being placed on a flat surface and with their substantially flat watertight upper layers (3) at the same side and without overlapping watertight upper layers of adjacent panels, and wherein the first upper protrusion (13) protrudes sideways so as to be placed substantially above a first lower protrusion of a similar panel adjacent to the third edge (15), the panels being placed on a flat surface and with their substantially flat watertight upper layers (3) at the same side and without overlapping watertight upper layers of adjacent panels, and the second upper protrusion (17) protrudes sideways so as to be placed substantially above a second lower protrusion of a similar panel adjacent to the fourth edge (19), the panels being placed on a flat surface and with their substantially flat watertight upper layers (3) at the same side and without overlapping watertight upper layers of adjacent panels. The panel as claimed in claim 1, characterized in that a lower protrusion is provided with means for fastening the panel to an underlaying structure. The panel as claimed in claim 1 or 2, characterized in that at least two drains are in communication with each other. The panel as claimed in any one of claims 1-3, characterized in that each edge along which an upper protrusion extends is arranged opposite to an edge along which a drain extends. The panel as claims in claim 4, characterized in that the panel has a rectangular shape and comprises two edges along which a drain extends, and two edges along which an upper protrusion extends. The panel as claimed in any one of claims 1-5, characterized in that a lower protrusion comprises an additional drain as an integral part of the lower protrusion, said additional drain extending parallel to the drain of the lower protrusion. The panel as claimed in any one of claim 1-6, characterized in that the shape of each upper and lower protrusion allows strips of mastic material to be arranged between an upper protrusion of a panel and a lower protrusion of a similar panel adjacent to the panel.

Inventors: LAKERVELD, PIETER ADRIANUS
Applicants: SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ B.V.
Application year: 1990
Main classification: E04B7
IPC codes: E04B7, E04F13, E04D3