AN INSULATED PANEL

Abstract: An insulated wall panel comprises a profiled external sheet (2), an internal lower sheet (3), and an insulating core between the sheets (2, 3). The external sheet (2) has an external male projecting part (10) and an internal recess part (11) on one side for engagement, on assembly, with a corresponding external recess part (12) and projecting male inner part (13) on the opposite side of a panel. A seal (20) is interposed between a flattened nose portion (13a) and a flat wall (11a) for effective sealing engagement. The outer gap (g) between adjacent sheets (2) is substantially uniform and set by engaging the external male part (10) against an inclined wall (25) of the adjacent external skin (2). The internal lining sheet (3) has an inner recess part (30) and an outer male projecting part (31) on one side and a corresponding inner projecting male part (32) and outer recess (33) on the opposite sides. The internal joint between adjacent internal sheets is sealed by a seal (35). A fixing pin (40) may be extended through the overlapping internal sheets (3).

Description: "An insulated panel" Introduction The invention relates to an insulated panel of the typed comprising a profiled external sheet, an internal liner sheet, and an insulating core between the external sheet and the liner sheet. Various panels of this type are known. There is, however, a need for an improved construction of panel which will facilitate a highly sealed joint between adjacent panels for improved insulation and fire resistance. Statements of Invention According to the invention, there is provided an insulated panel comprising:- an external sheet; an internal lining sheet; an insulating core between the external sheet and the internal lining sheet; the external sheet and internal lining sheet having profiled joint forming portions for connecting adjacent panels; the external sheet having an external male projecting part and an internal recess part on one side, and a corresponding external recess part and projecting inner male part respectively on the opposite side of the panel; the internal lining sheet having an inner recess part and an outer male projecting part on one side, and a corresponding inner projecting male part and an outer recess part respectively on the opposite side of the panel; the inner male projecting part of the external sheet being profiled for substantially uniform sealing engagement with an inner seal interposed between the inner male projecting part of the external sheet and the corresponding inner recess of the external sheet of an adjacent panel, on assembly. In a particularly preferred arrangement, the inner male projecting part of the external sheet has a substantially flat nose portion for sealing engagement with the seal in the inner recess of the external sheet of an adjacent panel, on assembly. Most preferably, the profile of the inner recess of the external sheet is of channel shape for sealing engagement with the seal and the inner male projecting part, on assembly. Preferably, the inner seal, on assembly of adjacent panels takes up a flattened oval shape substantially filling the gap between the inner recess of the external sheet and the inner male projecting part of the external sheet of an adjacent panel. In one embodiment of the invention the outer male projecting part of the external sheet defines, an engagement with the external recess of an adjacent external sheet, a substantially uniform outer gap between the external sheets of adjacent panels, on assembly. Preferably the outer external sheet male part has an inner engagement portion for engaging with the wall defining the outer recess of the external sheet of an adjacent panel and an outwardly diverging portion to define, on assembly, a substantially uniform gap between the outer faces of the external sheets of adjacent panels. Usually the gap is approximately 4mm. In a particularly preferred embodiment of the invention, the inner male projecting part of the internal lining sheet and the corresponding inner recess of the internal lining sheet of an adjacent panel are arranged to receive an internal seal. Preferably the inner male projecting part and/ or the corresponding inner recess of the internal lining sheet include a dimple to receive an internal seal. In one embodiment of the invention the internal seal is of a fire resistant material. Alternatively or additionally the seal is of a food-safe material, such as butyl rubber. In a preferred embodiment of the invention at least the inner male projecting part of the internal lining sheet and the inner recess part of the internal lining sheet of an adjacent panel are profiled so that, on assembly, a fixing pin may be extended between the profiles for fire resistance. Ideally the inner projecting male part of the external sheet is also profiled for engagement by the fixing pin. In another embodiment of the invention on assembly, the external male projecting part of the external sheet extends over the external recess part of an adjacent external sheet to define a hidden recess for housing the head of a fastener. The invention also provides an insulated panel assembly including a plurality of the panels 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 side cross sectional view of portion of two adjacent panels according to the invention separated; Fig. 2 is a cross sectional view of the panels jointed together with seals omitted for clarity; Fig. 3 is a cross sectional view of the panels jointed together with seals and a fastener in position; Fig. 4 is a view similar to Fig. 3 with a panel jointing pin in position; Fig. 5 is an exploded perspective view of adjacent panels; Fig. 6 is a view of part of an external sheet on one side of a panel; Fig. 7 is a view of part of an external sheet on the opposite side of the panel; Fig. 8 is a view of part of an internal sheet on one side of a panel; and Fig. 9 is a view of part of an internal sheet on the opposite side of the panel. Detailed Description of the Drawings Referring to the drawings, there is illustrated an insulated panel according to the invention and comprising a profiled external sheet 2, an internal liner sheet 3 and an insulating core 4 between the external sheet 2 and internal sheet 3. The sheets 2 and 3 are typically of steel material and the core 4 is of polyurethane or poyisocyanurate foam material which fills the space between the sheets 2, 3. The panel 1 is typically used for roofing and/or cladding systems. The profiled external sheet 2 and internal lining sheet 3 have profiled joint- forming portions for connecting adjacent panels, on assembly as illustrated. The profiled external sheet 2 has an external male projecting part 10 and an internal recess part 11 on one side for engagement, on assembly, with a corresponding external recess part 12 and projecting inner male part 13 respectively on the opposite side of the panel. An internal weather seal 15 is placed in the internal recess 11 for sealing engagement, on assembly, with the internal male projecting part 13 of the external skin 2 of an adjacent panel. The seal 20 is of an elastomeric memory material which, in this case, is of hollow cylindrical shape, as illustrated. It will be noted that the internal recess 1 is of generally channel-shape having a base web 11a which is substantially flat with rounded comers. Similarly, a front nose portion 13a of the inner male part 13 is substantially flat, also with rounded comers for effective sealing engagement with the seal 20, on assembly. The seal 20, on assembly is deformed evenly into a flattened oval shape as illustrated, providing a highly effective seal. To control the sealing engagement and to provide a substantially uniform outer gap g and between the external sheets 2 of adjacent panels, on assembly, the external male projecting part 10 has an inner engagement portion 10a for engaging with an inwardly inclined wall 25 defining the outer recess 12 of the external sheet 2 of an adjacent panel 2. An outwardly diverging wall 10b extends at an angle α of from 70 to 80°, ideally approximately 75° to define, together with the inclined wall 25, the fixed gap g. The inclined wall 25 extends at an angle β which is also from 70 to 80°, ideally approximately 75°. The engagement of the portion 10a of the male part 10 against the inclined wall 25, on assembly, acts as a stop limiting the engagement between the nose 13a and wall 11a thus controlling the sealing engagement. This engagement between the portion 10a and the inclined wall 25 also ensures that the gap g is uniform which provides an excellent aesthetic finish when a plurality of panels are joined side to side either vertically or horizontally to provide, for example a wall cladding. It will be noted that on assembly, the external male projecting part 10 of the external sheet 2 extends over the external recess 12 of an adjacent external sheet 2 to define a hidden recess 26 housing the head 27 of a fastener 28. As will be particularly apparent from Fig. 3, the fastener 28 extends through the external sheet 2, the foam core 4 and the internal sheet 3 for fixing a panel to a support. The internal lining sheet 3 has an inner recess part 30 and an outer male projecting part 31 on one side, and a corresponding inner projecting male part 32 and an outer recess part 33 respectively on the opposite side of the panel, for interengagement on assembly of adjacent panels, as illustrated. The internal lining sheet 3 includes a dimple 33 to accommodate an internal seal 35 which is typically gun-applied, on-site. The seal 35 is of a fire resistant and/or food-safe material such as butyl rubber. The profiles of the male parts 31, 32 and recess parts 30, 33 are arranged to overlap on assembly to receive a fixing pin 40 to ensure the integrity of the joint for fire rating, as required. The fixing pin 40 also extends, in this case through the profile of at least one of the external sheets 2 to further strengthen the joint. In use, the panels may be overlapped either vertically or horizontally. Typically an end bearer is used to start a panel assembly, the end bearer having a head part for engagement in a female recess 11 of the external sheet 2 of a first panel. The other side of the first panel is then fixed in place by a fastener 28. This side of the first panel is then engaged with the mating side of a second panel, as illustrated so that the head 27 of the fastener 28 is hidden, the seal 20 is engaged into the flat oval shape and the gap g between the panels is substantially uniform. Construction is continued in this way. After on-site construction, fixing pins 40 may be inserted, as illustrated and an internal seal 35 is applied to ensure the integrity of the joint for fire resistance application on/or environments in which the inner wall requires washing, for example in the food applications. The invention provides an insulated panel with side edges which are arranged for highly efficient heat insulation, sound insulation, weather ingress and fire sealing. It will be appreciated that the panels may be provided with opposite side edges or two different panels with a similar profile on both side edges may be provided. The invention is not limited to the embodiments hereinbefore described which may be varied in construction and detail.

Claims: CLAIMS 1. An insulated panel comprising:- an external sheet; an internal lining sheet; an insulating core between the external sheet and the internal lining sheet; the external sheet and internal lining sheet having profiled joint forming portions for connecting adjacent panels; the external sheet having an external male projecting part and an internal recess part on one side, and a corresponding external recess part and projecting inner male part respectively on the opposite side of the panel; the internal lining sheet having an inner recess part and an outer male projecting part on one side, and a corresponding inner projecting male part and an outer recess part respectively on the opposite side of the panel; the inner male projecting part of the external sheet being profiled for substantially uniform sealing engagement with an inner seal interposed between the inner male projecting part of the external sheet and the corresponding inner recess of the external sheet of an adjacent panel, on assembly. 2. An insulated panel as claimed in claim 1 wherein the inner male projecting part of the external sheet has a substantially flat nose portion for sealing engagement with the seal in the inner recess of the external sheet of an adjacent panel, on assembly. 3. An insulated panel as claimed in claim 1 or 2 wherein the profile of the inner recess of the external sheet is of channel shape for sealing engagement with the seal and the inner male projecting part, on assembly. 4. An insulated panel as claimed in any preceding claim wherein the inner seal, on assembly of adjacent panels takes up a flattened oval shape substantially filling the gap between the inner recess of the external sheet and the inner male projecting part of the external sheet of an adjacent panel. 5. An insulated panel as claimed in any preceding claim wherein the outer male projecting part of the external sheet defines, an engagement with the external recess of an adjacent external sheet, a substantially uniform outer gap between the external sheets of adjacent panels, on assembly. 6. An insulated panel as claimed in claim 5 wherein the outer external sheet male part has an inner engagement portion for engaging with the wall defining the outer recess of the external sheet of an adjacent panel and an outwardly diverging portion to define, on assembly, a substantially uniform gap between the outer faces of the external sheets of adjacent panels. 7. An insulated panel as claimed in claim 5 or 6 wherein the gap is approximately 4mm. 8. An insulated panel as claimed in any preceding claim wherein the inner male projecting part of the internal lining sheet and the corresponding inner recess of the internal lining sheet of an adjacent panel are arranged to receive an internal seal. 9. An insulated panel as claimed in claim 8 wherein the inner male projecting part and/or the corresponding inner recess of the internal lining sheet include a dimple to receive an internal seal. 10. An insulated panel as claimed in claim 8 or 9 wherein the internal seal is of a fire resistant material. 11. An insulated panel as claimed in any of claims 8 to 10 wherein the seal is of a food-safe material. 12. An insulated panel as claimed in any of claims 8 to 11 wherein the internal seal is of butyl rubber material. 13. An insulated panel as claimed in any preceding claim wherein at least the inner male projecting part of the internal lining sheet and the inner recess part of the internal lining sheet of an adjacent panel are profiled so that, on assembly, a fixing pin may be extended between the profiles for fire resistance. 14. An insulated panel as claimed in claim 12 wherein the inner projecting male part of the extemal sheet is also profiled for engagement by the fixing pin. 15. An insulated panel as claimed in any preceding claim wherein, on assembly the external male projecting part of the external sheet extends over the external recess part of an adjacent external sheet to define a hidden recess housing the head of a fastener. 16. An insulated panel substantially as hereinbefore described with reference to the accompanying drawings. 17. An insulated panel assembly comprising a plurality of the panels as claimed in any of claims 1 to 14.

Inventors: MARTIN PAUL, MCCARTHY EOIN T, MCDONALD PATRICK, MCGUINNESS THOMAS, MARTIN, PAUL, MCCARTHY, EOIN, T., MCDONALD, PATRICK, MCGUINNESS, THOMAS
Applicants: KINGSPAN RES & DEV LTD, MARTIN PAUL, MCCARTHY EOIN T, MCDONALD PATRICK, MCGUINNESS THOMAS, KINGSPAN RESEARCH AND DEVELOPMENTS LIMITED, MARTIN, PAUL, MCCARTHY, EOIN, T., MCDONALD, PATRICK, MCGUINNESS, THOMAS
Application year: 1998
Main classification: E04C2
IPC codes: E04C2, E04D3