Note: Descriptions are shown in the official language in which they were submitted.
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"BUILDING PANEL"
Field of the Invention
The present invention relates to a building panel and a building system and
relates particularly, though not exclusively, to a polycarbonate roofing or
wall
panel.
Background to the Invention
Polycarbonate roofing panels are well known in the building and construction
arts. They are relatively lightweight, strong and translucent, providing a
passive form of solar heating and lighting. They are used in domestic,
industrial and commercial building applications. Prior art polycarbonate
roofing panels are supplied in varying thicknesses up to 30mm, and up to 6m
in length. For some specialised applications they can be purchased up to 12m
in length. However all prior art polycarbonate sheeting requires additional
steelwork for support, and this introduces undesirable aesthetic constraints
from an architectural and design perspective.
The present invention was developed with a view to providing a building panel
and system which fills a gap in the building and construction industry,
namely,
a cost-effective polycarbonate system with long span capability. However it
will be apparent that the building panels can also be manufactured from
suitable materials other than polycarbonate.
References to prior art in this specification are provided for illustrative
purposes only and are not to be taken as an admission that such prior art is
part of the common general knowledge in Australia or elsewhere.
Summary of the Invention
According to one aspect of the present invention there is provided a
polycarbonate building panel for the construction industry, the panel
comprising:
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a hollow elongate structure having a generally rectangular cross-sectional
profile, the elongate structure comprising first and second outer skins joined
by first and second side walls; and
connecting means provided on each side wall respectively wherein, in use,
adjacent panels can be connected to each other side by side with the
connecting means to form a segment of a wall or roof.
Preferably the outer skins of the elongate structure have a degree of outward
curvature in profile so as to form convex outer surfaces. The convex outer
surfaces advantageously give the panel a self-cleaning ability wherein dust
and other contaminants simply run-off the outer convex surfaces when
wetted. Preferably the first and second side walls are substantially parallel.
Typically the first and second side walls are substantially planar.
Preferably the elongate structure comprises a third inner skin in the form of
a
web extending between the first and second side walls so as to divide the
interior of the elongate structure into two chambers. The duel chamber profile
of the elongate structure provides structural strength and rigidity, as well
as
improved thermal and sound insulation properties.
Preferably the connecting means each comprise a first rib and a second rib,
the first rib being adapted to engage with a matching rib on an adjacent panel
and the second rib also being adapted to engage with a matching rib on the
adjacent panel. Preferably the first and second ribs each have a curved
profile and are arranged with concave surfaces facing each other wherein in
use, the ribs together with the side wall form a cavity. Preferably the
matching
ribs on an adjacent panel have a matching curvature and are received in a
nested engagement with the respective first and second ribs when adjacent
panels are connected to each other side by side with the connecting means.
Advantageously the nested engagement of the ribs together with the
respective side walls of the adjacent panels form an enclosed chamber
between the adjacent panels. Typically the ribs have a semicircular profile.
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Preferably an elongate locking member is received in the enclosed chamber
to lock the ribs into nested engagement with each other wherein, in use,
adjacent panels are locked together to form a segment of a wall or roof.
Advantageously the hollow elongate structure is manufactured from extruded
polycarbonate. Preferably the outer skins and side walls of the elongate
structure are between 1mm to 2.5mm thick. Typically the upper outer skin is
between 1.2mm to 2.0mm thick. Typically the lower outer skin is between
1.4mm to 1.8mm thick. Preferably the upper outer skin has a UV resistant
layer applied to it. Typically the UV resistant layer has a minimum thickness
of
0.050mm.
Preferably the total thickness of the polycarbonate panel is between 65mm to
90mm. More typically the total thickness of the polycarbonate panel is
between 73mm to 76mm. A preferred embodiment of the polycarbonate panel
is about 74mm thick. Preferably the total width of the polycarbonate panel is
between 80mm to 120mm. More typically the total width of the polycarbonate
panel is between 95mm to 110mm. A preferred embodiment of the
polycarbonate panel is about 100mm wide.
In one form of the panel the elongate structure is substantially planar. In
another form of the panel the elongate structure is formed with a degree of
longitudinal curvature to give the panel increased load-bearing capacity.
According to another aspect of the present invention there is provided a
polycarbonate building system for the construction industry, the system
comprising:
a plurality of polycarbonate building panels, each panel comprising:
a hollow elongate structure having a generally rectangular cross-sectional
profile, the elongate structure comprising first and second outer skins joined
by substantially parallel first and second side walls; and
connecting means provided on each side wall respectively;
wherein, in use, the plurality of panels can be joined to each other side by
side with the connecting means to form a segment of a wall or roof.
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Preferably the polycarbonate building system further comprises an elongate
locking member adapted to engage with the connecting means to join
adjacent panels to each other side by side. In one embodiment the locking
member is in the form of an extruded aluminium bar. In another embodiment
the locking member is in the form of an extruded polycarbonate bar.
Preferably the polycarbonate building system further comprises an end cap
adapted to be received in the hollow end of the elongate structure.
Advantageously the end cap has first and second spigot pieces adapted to be
received in the two chambers of the hollow elongate structure.
According to a further aspect of the present invention there is provided a
building panel for the construction industry, the panel comprising:
a hollow elongate structure having a generally rectangular cross-sectional
profile, the elongate structure comprising first and second outer skins joined
by first and second side walls; and
connecting means provided on each side wall respectively wherein, in use,
adjacent panels can be connected to each other side by side with the
connecting means to form a segment of a wall or roof.
According to a still further aspect of the present invention there is provided
a
building system for the construction industry, the system comprising:
a plurality of building panels, each panel comprising:
a hollow elongate structure having a generally rectangular cross-sectional
profile, the elongate structure comprising first and second outer skins joined
by substantially parallel first and second side walls; and
connecting means provided on each side wall respectively;
wherein, in use, the plurality of panels can be joined to each other.
Throughout the specification, unless the context requires otherwise, the word
"comprise" or variations such as "comprises" or "comprising", will be
understood to imply the inclusion of a stated integer or group of integers but
not the exclusion of any other integer or group of integers. Likewise the word
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"preferably" or variations such as "preferred", will be understood to imply
that
a stated integer or group of integers is desirable but not essential to the
working of the invention.
Accordingly, in one aspect the present invention resides in a polycarbonate
building panel for the construction industry, the panel comprising: a hollow
elongate structure having a generally rectangular cross-sectional profile, the
elongate structure comprising first and second outer skins joined by first and
second side walls, and a third inner skin in the form of a web extending
between the first and second side walls so as to divide the interior of the
elongate structure into two chambers; connecting means provided on each
side wall respectively wherein, in use, adjacent panels can be connected to
each other side by side with the connecting means to form a segment of a
wall or roof; and, an end cap adapted to be received in a hollow end of the
elongate structure, wherein the end cap has first and second spigot pieces
adapted to be received in the two chambers of the hollow elongate structure.
In another aspect the present invention resides in a polycarbonate building
system for the construction industry, the system comprising: a plurality of
polycarbonate building panels, each panel comprising: a hollow elongate
structure having a generally rectangular cross-sectional profile, the elongate
structure comprising first and second outer skins joined by substantially
parallel first and second side walls, and a third inner skin in the form of a
web
extending between the first and second side walls so as to divide the interior
of the elongate structure into two chambers; connecting means provided on
each side wall respectively; and, an end cap adapted to be received in a
hollow end of the elongate structure, wherein the end cap has first and
second spigot pieces adapted to be received in the two chambers of the
hollow elongate structure; wherein, in use, the plurality of panels can be
joined to each other side by side with the connecting means to form a
segment of a wall or roof.
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Brief Description of the Drawings
The nature of the invention will be better understood from the following
detailed description of a preferred embodiment of the building panel, given by
way of example only, with reference to the accompanying drawings, in which:
Figure 1 is a section view through a preferred embodiment of the
building panel according to the present invention;
Figure 2(a) is a section view showing a first embodiment of the manner
of joining adjacent panels together side by side;
Figure 2(b) is a section view showing a second embodiment of the
manner of joining adjacent panels together side by side;
Figure 3 is a top perspective view of the panel of Figure 1;
Figure 4 is a top perspective view showing a plurality of the panels of
Figures 1 and 3 joined together side by side;
Figure 5 is an exploded top perspective view of the panels in Figure 4;
and,
Figure 6 is side elevation of a preferred embodiment of an end cap for
the building panel of Figure 1.
Detailed Description of Preferred Embodiments
A first preferred embodiment of the building panel 10 as shown in Figures 1 to
4 comprises a hollow elongate structure 12 having a generally rectangular
cross-sectional profile as can be seen most clearly in Figure 1. The elongate
structure 12 comprises first and second outer skins 14a and 14b joined by
substantially parallel first and second side walls 16a and 16b. The outer
skins
14 of the elongate structure 12 preferably have a degree of outward curvature
in profile so as to form convex outer surfaces. The convex outer surfaces
advantageously give the panel 10 a self-cleaning capability wherein dust and
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other contaminants simply run-off the outer convex surfaces when wetted.
The building panel is preferably made of polycarbonate.
The panel 10 further comprises a connecting means 18 provided on each
side wall 16 respectively wherein, in use, adjacent panels 10 can be
connected to each other side by side with the connecting means 18 to form a
segment of a wall or roof, as shown in Figure 4. The panels 10 are primarily
designed for use as roofing panels, however in view of their structural
strength and rigidity it will be understood that they can also be used in a
variety of other ways for constructing a building, including wall panels.
Preferably the elongate structure 12 comprises a third inner skin in the form
of
a web 20 extending between the first and second side walls 16 so as to divide
the interior of the elongate structure into two chambers. The dual chamber
profile of the elongate structure 12 provides the panel 10 with additional
structural strength and rigidity, as well as improved thermal and sound
insulation properties.
Preferably the connecting means 18 each comprise a first rib 22a and a
second rib 22b. The first rib 22a is adapted to engage with a matching rib 22a
on an adjacent panel, and the second rib 22b is also adapted to engage with
a matching rib 22b on the adjacent panel (see Figure 2). In this embodiment
the first and second ribs 22 each have a curved profile and are arranged with
concave surfaces facing each other. In the present case the ribs 22 have a
semicircular profile, however it will be understood that a variety of profiles
would work.
As can be seen most clearly in Figure 1, the ribs 22 together with the side
wall 16 form a cavity. Preferably the matching ribs 22a and 22b on an
adjacent panel have a matching curvature and are received in a nested
engagement with the respective first and second ribs 22a and 22b when
adjacent panels are connected to each other side by side with the connecting
means (see Figure 2). The inside diameter of the first rib 22a is
approximately
equal to the outer diameter of the matching rib 22a, and the outside diameter
of the rib 22b is approximately equal to the inside diameter of the matching
rib
22b, in order to facilitate their nested engagement. Advantageously the
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nested engagement of the ribs 22 together with the respective side walls 16
of the adjacent panels 10 form an enclosed cavity 24 between the adjacent
panels.
Preferably an elongate locking member 26 is received in the enclosed cavity
24 to lock the ribs 22 into nested engagement with each other. In this manner
adjacent panels 10 are locked together to form a segment of a wall or roof.
One of the purposes of the locking bars 26 is to absorb upwardly directed
wind pressure. Figure 4 illustrates a roof segment of a wall segment 30
formed from a plurality of the panels 10 connected to each other side by side
with the connecting means 18. Two types of locking member 26 are provided
(see also Figure 5). A first locking member 26a is made from extruded
aluminium and gives the roof segment increased strength and rigidity. A
second locking member 26b is made from extruded polycarbonate. Both
locking members 26 are typically inserted manually during the assembly
process. Preferably the ribs 22 are sealed in their nested engagement using a
butyl rubber mastic sealant.
In one form of the panel 10 the elongate structure 12 is substantially planar.
In another form of the panel 10 (not illustrated) the elongate structure 12 is
formed with a degree of longitudinal curvature to give the panel increased
load-bearing capacity. The locking members 26 may likewise be curved so as
to be received in the enclosed cavities 24 between the panels. The panels 10
can be pre-curved during the manufacturing process. When the panels 10
have been assembled they are placed on a bending table which slides
directly into the oven for a specified time period. The angle of curvature of
the
bending table is preset to correspond to the desired shape of the roof. After
this process the panels are left to cool and on larger spans curved aluminium
locking bars 26 are inserted. This then forms the specified curvature of the
panels. The completed panels can then be delivered to site. Installation of
the
panels is identical to flat applications; polycarbonate locking bars 26 are
inserted, which simply lock the panels together.
A typical roof bay comprises six of the panels 10 connected side by side (two
of the roof segments 30 of Figure 4 connected side by side). Various
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combinations of locking members 26a and 26b may be employed to attain
different structural strength capabilities for the roof bay. The loading
combinations are as follows:
Flat panels
Lock Specification (LS) Max free span
1 2.61 metre
2.1 3.18 metre
2.2 3.62 metre
2.5 4.38 metre
Curved panels
Lock Specification (LS) Free span Free span Free span Free span
20 degrees 25 degrees 30 degrees 35 degrees
- 1 6.05 metre 6.43 metre 6.72 metre 6.93 metre
2.1 8.00 metre 8.50 metre 8.88 metre 9.16 metre
2.2 9.49 metre 10.08metre 10.53metre 10.86metre
2.5 11.36metre 12.07metre 12.24metre 12.00metre
LS1 = 6 polycarbonate locking bars in a six panel bay
LS2.1 = 1 aluminium locking bar + 5 polycarbonate bars in a six panel bay
LS2.2 = 2 aluminium locking bars + 4 polycarbonate bars in a six panel bay
LS2.5 = 5 aluminium locking bars and 1 polycarbonate bar in a six panel bay
The Locking System weight and dead load specifications are as follows:
LS1 weight = 7kg/sqm. Dead load 0.078kN/sqm.
LS2.1 weight = 9kg/sqm. Dead load 0.091kN/sqm.
LS2.2 weight = 10kg/sqm. Dead load 0.101kN/sqm.
LS2.5 weight = 14kg/sqm. Dead load 0.142kN/sqm.
Advantageously the hollow elongate structure 12 is manufactured from
extruded polycarbonate. Preferably the outer skins 14 and side walls 16 of the
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elongate structure 12 are between 1mm to 2.5mm thick. Preferably the upper
outer skin 14a is slightly thicker than the lower outer skin 14b. Typically
the
upper outer skin 14a is between 1.2mm to 2.0mm thick. Typically the lower
outer skin 14b is between 1.4mm to 1.8mm thick. Preferably the upper outer
skin 14a has a UV resistant layer applied to it. Typically the UV resistant
layer
has a minimum thickness of 0.050mm.
Preferably the total thickness of the polycarbonate panel 10 is between 65mm
to 90mm. More typically the total thickness of the polycarbonate panel 10 is
between 73mm to 76mm. A preferred embodiment of the polycarbonate panel
10 is about 74mm thick. Preferably the total width of the polycarbonate panel
10 is between 80mm to 120mm. More typically the total width of the
polycarbonate panel 10 is between 95mm to 110mm. A preferred
embodiment of the polycarbonate panel 10 is about 100mm wide.
Preferably the building panel 10 further comprises an end cap 40 adapted to
be received in the hollow end of the elongate structure 12. Advantageously
the end cap 40 has first and second spigot pieces 42a and 42b adapted to be
received in the two chambers of the hollow elongate structure 12. As can be
seen most clearly in Figure 6, the end cap 40 has a planar front face 44, on
the back of which the spigot pieces 42 are formed. The first spigot piece 42a
opens onto the front face 44, and forms a handhold which can be grasped to
insert the end cap 40 into the end of the hollow elongate structure 12 (see
Figure 5).
Now that a preferred embodiment of the building panel and building system
has been described in detail, it will be apparent that the embodiment provides
a number of advantages over the prior art, including the following:
(1) It has superior span capabilities of up to 12m curved and 4.38m flat.
(2) It is fully trafficable; workman can walk on it during installation.
(3) It can be suppled flat or curved in one complete span up to 15m long.
(4) It facilitates rapid installation. 600mm bay six panel configurations are
supplied prefabricated and need only be joined every 600mm on site.
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(5) It is a lightweight, high impact strength product. Each bay can be easily
lifted and locked into place manually on site.
(6) Each segment is identical to the next to give total conformability.
(7) It provides superior thermal performance and sound reduction.
(8) It is silicone free. No possible leakage where product is sealed. The
unique connecting system as well as sealed joint allows for thermal
moment without compromising thermal performance.
(9) Being translucent it maximises natural light without excessive glare.
(10) It has a self-cleaning dome shape.
(11) Curved roof segments can be pre-curved in the oven during the
manufacturing process.
(12) Being a tailor-made product means less wastage on site.
It will be readily apparent to persons skilled in the relevant arts that
various
modifications and improvements may be made to the foregoing embodiments,
in addition to those already described, without departing from the basic
inventive concepts of the present invention. For example, the connecting
means may take the form of suitable fasteners for connecting the panels side
by side. Therefore, it will be appreciated that the scope of the invention is
not
limited to the specific embodiments described.
