Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
WO 2022/027098
PCT/AU2021/050850
1
VARIABLE SECTION INTERLOCKING STRUCTURAL PANEL
Field of the Invention
[0001] This invention relates to panels which interlock to form self-
supporting roofs of
buildings, in particular large span roofs supported only by the walls of the
building.
Background of the Invention
[0002] Interlocking panels for large span roofs have been in use for some
time. One of the
most successful such panels is disclosed in US 4,759.159 as having a pair of
upstanding flanges
at opposite longitudinal sides, a male rib supported by one flange and a
female rib supported by
the other flange, both the male and female ribs extending wholly to one side
of their supporting
flanges, the male rib engageable with the female rib of an adjacent panel to
form an arcuate
self-supporting roof section for a building.
[0003] The female rib is defined as being of generally inverted U-shape form
in transverse
cross-section having a first leg comprising an extension of said supporting
flange and a second
leg spaced from said first leg, said second leg having a at its free end, an
inwardly directed first
deformation and there being provided a second deformation in the region of the
junction between
said first leg and said supporting flange.
[0004] The male rib is defined as being generally of an inverted U-shape form
in transverse
cross-section having a first leg comprising an extension of said supporting
flange and a second
leg spaced from said first leg and inclined outwardly away from said first
leg, and there being an
inwardly directed projection defining a recess in the region of the junction
between said first leg
and said supporting flange being complementary to said second deformation such
that when
interlocked said male rib is located within said female rib, said first legs
of said male and female
ribs are juxtaposed, said second leg of said male rib resiliently engages said
second leg of said
female rib rearward of said first deformation and said second deformation
nests within said
recess.
[0005] These known panels are formed in longitudinally curved sections and
erected and joined
to form self-supporting roofs as shown in Figure I of the drawings. However
the nesting
geometry of the inverted U-shapes is quite unforgiving of any deformation of
the cross-section
of the panel and the male rib tends to spring out of the female rib when the
panel is flattened.
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The common solution to this has been to fasten the female rib to the male rib
with screws which
defeats the self-interlocking of adjoining panels and adds to the cost of
construction.
Summary of the Invention
[0006] It is an object of the present invention to overcome or ameliorate at
least one or more of
the disadvantages of the prior art, or to provide a useful alternative.
[0007] Throughout this specification, unless the context requires otherwise,
the words
"comprise", "comprises" and "comprising" will be understood to imply the
inclusion of a stated
step or element or group of steps or elements but not the exclusion of any
other step or element
or group of steps or elements.
[0008] Any one of the terms: "including" or "which includes" or "that
includes" as used herein
is also an open term that also means including at least the elements/features
that follow the term,
but not excluding others. Thus, "including" is synonymous with and means
"comprising".
[0009] In the claims, as well as in the summary above and the description
below, all
transitional phrases such as "comprising", "including", -carrying". "having",
"containing",
"involving", "holding", "composed of", and the like are to be understood to be
open-ended,
i.e. to mean "including but not limited to". Only the transitional phrases
"consisting of' and
"consisting essentially of' alone shall be closed or semi-closed transitional
phrases, respectively.
[0010] Arrangements of the present invention provides an interlockable
structural panel
comprising a channel cross-section including a base and first and second side
wall forming the
sides of the channel.
[0011] According to a first aspect of the invention, there is provided an
interlockable structural
panel for forming roofs with a channel cross-section including:
a base and first and second side walls forming the sides of the channel;
wherein the first
and second side walls mirror each other's extension from the base and provide
a generally
straight extension from the base;
wherein a region adjoining an end of the first side wall distal the base is
curved as a first
arc directed away from a central portion of the channel and a section
adjoining an end of the
second side wall is curved as a second arc directed towards the central
portion of the channel;
wherein a straight section extends from a distal end of the second arc;
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wherein the end of the first arc comprises a projection, a distal tip of the
projection
extending towards the first side wall;
wherein the second side wall comprises at least first and second intermediate
arcs
extending from a generally horizontal section of the second sidewall and
through a generally
vertical section of the second side wall intermediate the first and second
intermediate arcs; and
wherein the structural panel includes mateable portions arranged to engage
with
identical first and second arcs of an adjacent identical structural panel in a
locking manner
without defoiming the first or second arcs or the straight section.
[0012] The straight section may be approximately parallel to the second side
wall.
[0013] The entire length of the first arc and the entire length of the second
arc with the straight
section may define the mateable portions.
[0014] The first arc may curve in an arc of from 180 to 330 and may
terminate in a hook
section.
[0015] The channel may include longitudinal depressions.
[0016] The base of the channel may have a longitudinal corrugated or fluted
profile.
[0017] Reinforcing flutes may be located on the side walls. The reinforcing
flutes may run the
length of the panels.
[0018] The straight section may terminate in an end that is configured to abut
and may be
restrained from rotating by the hook section when the second arc is nested
into the first arc of an
adjacent panel.
[0019] The length of the straight section may be configured to be received
within and extend
across the first arc of the adjacent panel.
[0020] According to a second aspect of the invention, there is provided an
interlockable
structural panel for forming roofs with a channel cross-section including:
a base and first and second side walls forming the sides of the channel;
wherein the first and second side walls mirror each other's extension from the
base and
provide a generally straight extension from the base;
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wherein a region adjoining an end of the first side wall distal the base is
curved as a first
arc directed away from a central portion of the channel and a section
adjoining an end of the
second side wall is curved as a second arc directed towards the central
portion of the channel;
wherein a straight section extends from a distal end of the second arc, the
straight
section being approximately parallel to the second side wall; and
wherein the second side wall comprises at least first and second intermediate
arcs
extending from a generally horizontal section of the second sidewall and
through a generally
vertical section of the second side wall intermediate the first and second
intermediate arcs, the
second side wall extending distally from the second intermediate arc is
approximately parallel to
the extension of the second sidewall at its proximal end.
[0021] The entire length of the first arc and the entire length of the second
arc with the straight
section may define mateable portions arranged to engage with identical first
and second arcs of
an adjacent identical structural panel in a locking manner without deforming
the first or second
arcs or the straight section.
[0022] The first arc may terminate in a hook and the straight section may
terminate in an end
that may be configured to abut and be restrained from rotating by the hook
when the second arc
is nested into the first arc of an adjacent panel.
[0023] The length of the straight section may be configured to be received
within and extend
across the first arc of an adjacent panel.
[0024] The base may comprise a transverse crimp zone. The first and second
side walls
comprise respective sidewall crimp zones. The sidewall crimp zones may be
tapered.
[0025] Either or both the first and second sidewalls may include a stiffening
means comprising
a stiffening flute. Each sidewall may comprise a plurality of stiffening
flutes.
[0026] The second side wall extending distally from the second intermediate
arc may be
approximately parallel to the extension of the second sidewall at its proximal
end.
[0027] The second arc may be arranged to nest within the first arc on an
adjacent interlockable
structural panel so that the two are locked together.
[0028] The first and second side walls may extend at an angle of approximately
450 to 60 with
respect to the horizontal and to the base.
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[0029] The second side wall extending distally from the second intermediate
arc may be
approximately parallel to the tangents and of the apex of the first and second
intermediate arcs.
[0030] The first arc may be an arc of between 180 to 330 .
[0031] The second arc may be an arc of between 90 to 1800
.
[0032] The first arc may terminate in a hook section.
[0033] The straight section extending from the second arc in one interlockable
structural panel
may he arranged to engage the ridge of the first side wall on a second
interlockable structural
panel that the second arc is nested with.
[0034] The channel may have longitudinal depressions. The base of the channel
may have a
longitudinal corrugated or fluted profile.
[0035] Reinforcing flutes may be located on the side walls. The reinforcing
flutes may run the
length of the panels.
[0036] The profiled interlockable structural panel of either the first or
second aspects may
comprise a plurality of crimp zones adapted to receive and be formed into
transverse
corrugations by complementary curvature rollers.
[0037] According to a third aspect of the invention, there is provided a
roofing section
comprising a plurality of the interlockable structural panels of the first or
second aspects wherein
the second arc of a first panel is nested into the first arc of an adjacent
panel to lock the panels
together.
[0038] According to a fourth aspect of the invention, there is provided a
construction
comprising a plurality of the interlockable structural panels of the first or
second aspects.
[0039] According to a fifth aspect of the invention, there is provided a
method of forming an
interlockable structural panel for forming roofs with a channel cross-section
comprising:
providing a panel profiling configuration comprising a plurality of formations
adapted
to receive a sheet material;
rolling the sheet material through the panel profiling configuration to form a
profiled
structural panel;
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wherein panel profiling configuration comprises a plurality of rollers adapted
to form
the sheet material to a profiled interlockable structural panel as recited in
the first or second
aspects.
[0040] The panel profiling configuration may be configured to form one or more
longitudinal
stiffening flutes in sidewalls of the profiled interlockable structural panel.
[0041] The method may further comprise:
providing a pair of complementary curvature rollers, each curvature roller
comprising a
plurality of corrugating rods and adapted to receive a profiled interlockable
structural panel and
pass the profiled interlockable structural panel between the complementary
curvature rollers to
form a plurality of transverse corrugations in a portion of the profiled
interlockable structural
panel, thereby to form a curved profiled interlockable structural panel.
[0042] The transverse corrugations may be formed in the base of the profiled
interlockable
structural panel.
[0043] The method may further comprise providing a plurality of complementary
curvature
rollers pairs configured to form a plurality of transverse corrugations in a
plurality of portions of
the profiled interlockable structural panel.
[0044] The plurality of complementary curvature rollers pairs may be
configured to form the
transverse corrugations in the base and in one or more portions of the
sidewalls of the profiled
interlockable structural panel.
[0045] The depth of the transverse corrugations in the sidewalls of the
profiled interlockable
structural panel may decrease with distance from the base of the profiled
interlockable structural
panel.
[0046] The depth of the transverse corrugations in the sidewalls of the
profiled interlockable
structural panel may be tapered.
[0047] The profiled interlockable structural panel may comprise a plurality of
crimp zones
adapted to receive and be formed into transverse corrugations by the plurality
of complementary
curvature rollers.
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Brief Description of the Drawings
[0048] Further features of the present invention are more fully described in
the following
description of several non-limiting embodiments thereof. This description is
included solely for
the purposes of exemplifying the present invention. It should not be
understood as a restriction
on the broad summary, disclosure or description of the invention as set out
above. The
description will be made with reference to the accompanying drawings in which:
Figure 1 is a cross section of a prior art panel;
Figure 2 is a perspective of a single panel with normal cross-section of
interlocking
building panels according to a first embodiment of the present invention;
Figure 3 is a sectional cross-section of the joining of the interlocking
building panels of
Figure 2;
Figure 3A is a sectional cross-section of the joining of a further embodiment
of
interlocking building panels with increased sidewall stiffness;
Figure 3B is a perspective view of a plurality of interlocking building panels
shown in
use;
Figure 3C is a further perspective view of a plurality of flattened
interlocking building
panels shown in use with edge restraint;
Figure 4 is a perspective of the flattened interlocking building panels of
Figure 2;
Figure 5 is a cross-section of the joining of adjacent panels flattened as in
Figure 3A;
Figure 6 is a perspective view of a single panel with normal cross-section of
interlocking building panels according to a second embodiment of the present
invention;
Figure 7A shows a sectional cross-section of a further embodiment of
interlocking
building panels;
Figure 7B shows a detail view of the joining between adjacent panels of Figure
7A;
Figure HA shows a sectional cross-section of a further embodiment of
interlocking
building panels comprising a plurality of stiffening means in the panel
sidewalls;
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Figure 8B shows a shows a detail view of the interlocking joining of adjacent
panels of
Figure 8A;
Figure 8C shows a shows a shows a detail view of the corrugated/fluted base of
the
panel of Figure 8A;
Figure 9A shows a schematic depiction of a curvature roller configuration for
forming
curved panels;
Figure 9B shows a detail view of a curved panel comprising a plurality of
transverse
corrugations in the base and sidewalls of the panel;
Figure 10A shows a schematic depiction of a curvature roller configuration
comprising
a plurality of curvature roller pairs for forming curved panels;
Figure 10B shows an alternate configuration of a profiled panel with a flat
base; and
Figures 11A and 11B show examples of an arched roof construction formed from a
plurality of longitudinally-curved interlocking panels of the previous panel
embodiments.
Detailed Description of the Invention
[0049] With reference to Figure 1 of the figures, a prior art interlockable
building panel 33 is
shown. The interlockable building panel 33 includes male rib 36 and female rib
34. The
interlockable building panel also includes a first projection 37 proximate the
male rib 36 and a
second projection 35 proximate the female rib 34. Where adjacent panels 33 are
interlocked, the
male rib 36 in one panel 33 engages into the female rib 34 in the adjacent
panel 33.
Additionally, the first projection 37 in one panel 33 nests with the second
projection 35 in
another panel 33 that the one panel is interlocked with. Due to the U-shaped
profiles of the male
and female ribs 36, 34, when the two are interlocked there is minimal give for
deformation.
Therefore, when the panels 33 are flattened the male rib 36 has a tendency to
spring out of the
female rib 34. The common solution to this has been to fasten the female rib
to the male rib with
screws which defeats the self interlockable of adjoining panels and adds to
the cost of
construction.
[0050] With reference to Figures 2 to 5, interlockable structural panels 4
according to a first
embodiment of the present invention are shown. The panels 4 are arranged as
channels with a
base 3, a first side wall 55 and a second side wall 53 extending from the base
3, both with a
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component of vertical extension to form the channel. The first and second side
walls 55, 53,
mirror each other in their generally straight extension from the base. The end
of the first side
wall 55 is arranged as a first arc 13 that curves away from the centre of the
channel and the end
of the second wall 53 is arranged as a second arc 23 that curves towards the
centre of the
channel. Two or more interlockable panels 4 are connected together by nesting
the second arc
23 of one interlockable panel 4 into a first arc 13 of an adjacent
interlockable panel 4.
[0051] The first side wall 55 includes a base extension 1 that extends from
the base 3. A first
section 11 extends from the base extension 1 at an angle closer to the
horizontal than the base
extension 1. In one embodiment the first section is at an angle between 0 and
45 to the
horizontal. A second section 12 extends from the first section 11 and is at an
angle closer to the
vertical than the first section 11. In one embodiment the second section is at
an angle of between
30' and 90' to the horizontal. The first side wall 55 extends generally
straight from the base 3 as
illustrated in the Figures.
[0052] Extending from the second section 12 is a first arc 13 that is curved
away from the
centre of the channel of panel 4. The end of the arc 13 is arranged as a hook
that includes a
projection at its distal tip that extends towards the first side wall 55.
[0053] In an alternative embodiment the end of the arc 13 includes an
alternative arrangement
hook 14 that still projects towards the first side wall 55. This can be a
folded or straight section
or otherwise as understood by the skilled addressee.
[0054] The second side wall 53 extends from the base 3 opposite first wall 55.
The second side
wall 53 includes a second base extension 2. A third section 21 extends from
the second base
extension 2. In one embodiment the third section is angled from the horizontal
between 135
and 180 . A fourth section 22 extends from the third section 21 and is at an
angle closer to the
vertical than the third section 21. In one embodiment the fourth section is at
an angle of between
90 and 150 to the horizontal. The second side wall 53 extends generally
straight from the base
3 as illustrated in the Figures.
[0055] Extending from the fourth section 22 is a second arc 23 that is curved
towards the centre
of the channel of panel 4. The end of the arc 23 is arranged as a straight
section 24 running
approximately parallel to the fourth section 22. The straight section 24 is of
a length to be
received within the first arc 13. The end of the straight section 24 is
arranged to abut and be
restrained by the projection 15 of hook 14 at the end of arc 13 when the
second arc 23 is nested
into a first arc 13 of an adjacent panel 4.
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[0056] Figure 3 illustrates the joining of one interlockable panel 4 with
another. Arc 23 of
second side wall 53 nests inside arc 13 of the first side wall 55. The
straight section 24 extends
and its end is restrained from rotating by hook 114. Arc 13 acts as a female
mating section to
receive arc 23. As detailed in Figures 3 and 5, first side wall 55 is formed
with first section 11
extending form the base extension, the first section 11 is angled at 15 to
the horizontal
connecting to a further section 12 angled at 60' to the horizontal and
connecting to a section 13
curving in an arc of 270 . Section 13 terminates in a hook section 14.
[0057] Also as detailed in Figure 3, second side wall 53 is formed with third
section 21 angled
at 165 to the horizontal connecting to fourth section 22 angled at 120 to
the horizontal and
connecting to a section 23 curving in an arc of 130'. Section 23 connects to a
straight section 24
such that sections 23 and 24 nest inside section 13 of base extension 1.
[0058] In a further embodiment, Figure 3A shows the joining of one
interlockable panel 5 with
another, where panel 5 is an improved panel 5 of panel 4 having increased
panel strength. First
and second side walls 55 and 53 extend generally straight from base 3 at an
angle of
approximately 45 to the horizontal.
[0059] Section 21 in second side wall 53 of panel 4, as shown in Figure 3, is
replaced with a
horizontal section 60 in second side wall 53 of panel 5 in the further
embodiment of Figure 3A.
Horizontal section 60 leads into new additional intermediate arc sections 61
and 62 in second
side wall 53 interspaced with a substantially vertical section 63.
Intermediate arc sections 61 and
62 may have the same or approximately equal radii of curvature. Intermediate
arc sections 61
and 62 form a longitudinal flute (similar to flute portions 100 of Figures 7B,
8A or flutes 57, 58
of Figure 10A) along the length of panel 5 to provide additional strength to
sidcwall 53 to realise
a stiffened sidewall 53.
[0060] Further straight section 22 extending to the distal end of second side
wall 53 is also
aligned at approximately 60 degrees to horizontal section 60 and to base 3,
before leading into
male arc section 23 of second side wall 53. Section 22 in most embodiments
will be aligned at
approximately 60 to horizontal section 60 and to base 3. Section 22 extends
away from
intermediate arc sections 61 and 62 approximately parallel to the second side
wall 53 such that
straight section 2 of panel 5 also extends away from the base 3 of panel 5 at
approximately 45
degrees to the horizontal depending on the cover width of the panel 4 as
desired. In some
embodiments, sections 11 and 60 are aligned at about 15 to base 3 which would
provide a cover
width of about 650 mm. In alternate embodiments, for the same precursor sheet
material coil,
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sections 11 and 60 are aligned approximately horizontal to base 3 which would
provide a cover
width of about 800 mm. Straight section 22 also is approximately parallel to
the tangents 64 and
65 of the apex of intermediate arcs 61 and 62 respectively.
[0061] As before, first side wall 55 of panel 5 is formed with first section 1
extending form the
base extension, and includes a generally horizontal section 11 which connects
to further section
12. However, in panel 5, first and second side walls 55 and 53 are each
disposed at an angle of
either about 45 or about 60 from the horizontal with respect to base 3.
Section 12, as before
connects to a female arc section 13 curving in an arc of 270 . Section 13
terminates in a hook
section 14.
[0062] When engaged with an adjacent panel 5, arc 23 nests inside arc 13 of
first sidewall 55.
Similarly, arc 13 acts as a female mating section to receive arc 23 and
straight section 24 extends
and its end is restrained from rotating by hook 14 as before with panel 4.
[0063] As can be seen in Figure 3A, the stiffening of the side walls by
intermediate arc
sections 61 and 62 is only necessary in second side wall 53 which includes
male arc section 23.
The advantage of the stiffened male sidewall 53 is realised in increased
strength in panel 5,
especially at the edge of the roof where male arc section 23 defines the roof
extremity of a
collection of many panels 5.
[0064] The stiffened sidewall 53 provides increased strength to the end panel
when a pipe
section 71 is inserted into arc section 23 along the length of panel 5 and
secured to adjacent
panel with edge restraints 70 as seen in Figure 3B and Figure 3C. Edge
restraints 70 are
secured by a bolt or screw fastener through arc section 23 of stiffened
sidewall 53 to the pipe
section inserted through arc section 23.
[0065] In use in a particular arrangement, panel 5 may be used in conjunction
with a plurality
of panels 4 to form a roof, whereby the finished roof comprises a plurality of
interlocked panels
4 and a single panel 5 at the extreme edge of the roof interlocked with an
adjacent one of panels
4 such that the roof edge has increased strength arising from stiffened
sidewall 53 of the edge
panel 5 when tied to adjacent interlocked panel 4 with edge restraints 70.
[0066] Figure 5 shows a panel in which the channel profile of panel 4 has been
flattened to
provide greater horizontal coverage. This is particularly advantageous for
roofs where the span
admits of self-supporting panels where a lesser second moment of bending is
adequate. The
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second moment of bending is proportional to the square of the depth of the
channel. The latter
may be strengthened by pressing longitudinal depressions into the sheet
material.
[0067] Figure 4 shows how the joint geometry of first and second side walls
55, 53 of panel 4
accommodates the flattening of first and second side walls 55, 53 with the
integral nesting of
sections 23 and 24 inside section 13 being maintained. Similarly, as shown in
FIG 3C, the joint
geometry of first and second side walls 55, 53 of panel 5 accommodates the
flattening of first
and second side walls 55, 53 with the integral nesting of sections 23 and 24
inside section 13
being maintained. Accordingly, the integrity of the joint minimizes the need
for fasteners which
are required in prior art panels. As the second side wall 53 flexes and arc 23
attempts to rotate,
the straight section hits the projection 15 of hook 14 and is restrained from
rotating and slipping
out of arc 113.
[0068] Figures 2 and 4 show the interlockable panels 4 interlocked to form a
single roof
section.
[0069] With reference to Figure 6 a second embodiment of the present invention
is shown.
For convenience features of the interlockable panel 44 that are similar or
correspond to features
of the interlockable panel 4 of the first embodiment have been referenced with
the same
reference numerals.
[0070] Interlockable panel 44 includes a base 43 in place of base 4 for panel
4. The base 43 is
of a waved profile to strengthen the base 43.
[0071] In an alternative embodiment, ridges or fluting are formed along the
length of the first
and second side walls for reinforcement. The ridges or fluting can be located
along the first or
second base extensions 1, 2, or the second or fourth sections 12, 22.
[0072] Figure 7A shows a further embodiment of interlockable panel 80. The
panels 80 are
arranged as channels with a base 81, a first side wall 82 and a second side
wall 83 extending
from the base 81, both with a component of vertical extension to form the
channel, extending
generally straight from base 81 at an angle of approximately either about 45
or about 60 to the
horizontal. In particular arrangements, the angle of sidewalls 82 and 83 may
be about 50 to
about 60 to the horizontal. In alternate arrangements, the angle of sidewalls
82 and 83 may be
about 30 to about 45 to the horizontal. It will be appreciated that a
shallower angle of the
sidewalls to the horizontal provides for a wider panel 80 such that a larger
roof span can be
achieved with a smaller total number of interconnected panels 80 compared with
panels having a
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greater sidewall angle. However, shallower panels are not as strong as deeper
panels, hence for
larger total roof spans, panels 80 having a deeper profile are preferred at
the expense of requiring
more individual panels to form the total roof area per specifications. The
first and second side
walls 82, 83, mirror each other in their generally straight extension from the
base. First and
second side walls 82, 83 include horizontal sections 84 and 85 respectively.
Similarly to panel 5
of Figure 3A, sidewall 82 of improved pane 80 includes intermediate arc
sections 86 and 87
interspaced with generally vertical section 88. Intermediate arc sections 86
and 87 may have the
same or approximately equal radii of curvature Intermediate arc sections 86
and 87 provide
additional strength to sidewall 82 to realise a stiffened sidewall 82. Further
straight section 89
extending to the distal end of second side wall 82 is aligned at approximately
60 degrees to
horizontal section 84 and to base 81. before leading into male arc section 90
of second side wall
82. Intermediate arc 87 in conjunction with generally straight sections 88 and
89 either side of
arc 87 form a stiffening flute 100 formed in the panel profile and extending
longitudinally along
the length of panel 80 (i.e. into the page in Figure 7A).
[0073] The end of the first side wall 82 is arranged as a male arc section 90
that curves toward
the centre of the channel. The end of the second wall 83 is arranged as a
female arc section arc
91 that curves away from the centre of the channel. Female arc section 91
terminates in a hook
section 94. Two or more interlockable panels 80 are connected together by
nesting the male arc
section 90 of one interlockable panel 80 into a female arc section 91 of an
adjacent interlockable
panel 80. The end of the male arc section 90 is arranged as a straight section
92 which is of a
length to be received within the female arc section 91 of an adjacent panel
80. Section 92 is, at
the distal end, bent away from the centre of arc 90 to form a barb 93. The
barb 92 is arranged to
abut and be restrained by hook section 94 at the end of female arc section 91
when the male arc
section 90 is nested into a female arc 91 of an adjacent panel 80.
[0074] Panel 80 includes a plurality of crimp zones to enable the panel to be
formed into
curved panels where a curve to panels 80 is applied longitudinally (i.e. into
the page with respect
to Figure 7A).
[0075] Embodiments of the building panels as described herein are formed,
typically on site, by
passing a sheet of metal material (e.g. aluminium) of a desired width through
a series of profiling
rollers configured to bend the sheet in the direction perpendicular to the
longitudinal length of
the coiled sheet metal into the desired panel profile (e.g. as shown in the
Figures). Sheet
material typically is delivered to the constructions site as a large coil of
sheet material of the
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14
desired width for formation of the panels which are rolled through the series
of profiling rollers
to the desired length.
[0076] As can be seen in Figure 7A, base 81 of panel 80 includes a crimp zone
95, and first
and second side walls 82 and 83 respectively include sidewall crimp zones 96
and 97. Sidewall
crimp zones 96 and 97 are tapered such that the proximal end (nearest to base
81) is deeper than
at the distal ends (farthest from base 81) of sidewall crimp zones 96 and 97.
[0077] Referring to Figure 7B, first sidewall 82 also includes a stiffening
means, shown in
Figure 7B as a stiffening flute 98. Stiffening flute 98 is shown located about
intermediate arc 87
extending into generally straight sections 88 and 89 and acts to further
increase the strength of
sidewall 82. Stiffening flutes are formed in the same manner as the
predetermined profile of
finished panels, e.g. 4, 5, 80, by profiling rolls that are integral to the
machine which forms the
panel profiles as shown in the attached figures, e.g. Figure 4 and Figure 6.
Stiffening flutes
comprise a shallow groove running along a surface in the longitudinal
direction of the formed &
profiled panels. For example, in Figure 3A the combination of intermediate arc
sections 61 and
62 and straight sections 60 and 63 either side of arc 61 form one
strengthening flute of profiled
panel 5. In alternate arrangements, the second sidewall 83 may include a
stiffening means as
shown in Figure 8A, or both first and second sidewalls 82 an 83 may comprise
respective
stiffening means comprising a respective stiffening flute. Sidcwalls 82 and/or
83 may
additionally each comprise more than one stiffening means including stiffening
flutes 100 as
shown in Figures 8A and 8B. Stiffening flutes 100 run longitudinally along the
sidewalls for the
length of the panel 80.
[0078] Panel 80 may also include corrugated or fluted sections 101 in base 81
as shown in
Figures 8A and 8C which also run longitudinally along the base for the length
of the panel 80.
[0079] Once profiled in the profiling rollers and cut to length,
longitudinally curved panels are
formed by passing the profiled panels through a separate series of curvature
rollers 101 and 102
which exert a pressure to both the top and bottom sides of the profiled panel
as shown in
curvature roller configuration 900 of Figure 9A. Figure 9A shows a cross
section of a
previously profiled panel 80, shown along central axis of the base 81 (seen as
axis A-A of
Figure 3C). Complementary curvature rollers 101 and 102 each comprise a
plurality of
corrugating rods 103 disposed regularly about the circumference of curvature
rollers 101 and
102. Curvature rollers 102 and rods 103 are aligned such that as the rollers
turn, drawing panel
80 through and between curvature rollers 101 and 102, respective corrugating
rods 103 engage
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the panel 80 intermediate to two adjacent corrugating rolls of the
complementary curvature
roller. Profiled panel 80 is drawn through the curvature rollers which apply a
small transverse
corrugation HO to panel 80 in the longitudinal direction to form a curved
panel 80A (transverse
corrugations 110 shown exaggerated) emerging from curvature roller pair 102
and 103.
Figure 9B depicts a partial perspective view of curved profiled panel 80A
having a flat base 81
and a plurality of transverse corrugations 110a formed in base 81 (i.e. by
curvature roller pair
102 and 103 of Figure 9A) and further transverse corrugations 100b in
sidewalls 82 and 83
(formed by additional curvature roller pairs arranged to engage sidewalls 82
and 83 respectively
as shown, for example, in Figure 10A). Curved panel 80A emerges from curvature
roller pair
102, 102 with a predetermined curvature 105 which, when interlocked with like
curved panels
80A, form a curved roof structure 1100, for example, as seen in Figures 11A
and 11B. In
further arrangements, a plurality of curved panels formed by the methods
described herein may
be used for constructions including roofs, walls, and the like.
[0080] In a typical arrangement, the transverse corrugations 110 have a
corrugation pitch 111
of the order of about 30 ¨ 60 mm, typically about 40mm, and a corrugation
depth 113 of the
order of about 4 ¨ 6 mm, typically about 5 mm. Curvature rollers 101, 102 have
the effect of
shortening the bottom edge of profiled panel 80 by about 10 mm per metre with
respect to the
top edge of panel 80. However, it will be appreciated that corrugations of
different pitch and/or
depth may be applied to panel 80 to achieve a curved panel 80A having a
desired panel
curvature.
[0081] Figure 10A shows a depiction of a curvature profiling configuration
1000 to accept a
profiled panel 50 (i.e. similar to previously described panels 4, 5, 80 etc.
above) and to apply a
transverse corrugation along the length of the panel to form a curved,
profiled panel. As per
panel 80 shown in Figure 7A, profiled panel 50A is formed with a plurality of
crimp zones 52,
54, and 56, respectively in the base 51, and first and second sidewalls 55 and
53. Panel 50A is
depicted comprising a plurality of flute formations 57 and 58 respectively in
sidewalls 53 and 55
as additional strengthening features of panel 50A. A plurality of curvature
roller pairs 220 ¨ 230
are configured to apply transverse corrugations to profiled panel 50A.
Plurality of curvature
rollers 220 ¨ 230 are positioned with respect to panel 50A to preserve flute
formations 57 and 98
as panel 50A is being curved. Each curvature roller pairs 220 ¨ 230 comprises
a pair of
complementary curvature rollers 101 and 102 as shown in Figure 9A,
respectively engaging the
top and bottom surfaces of panel 50A (Note that, as depicted in Figure 10A,
curvature roller pair
220 is located behind curvature roller pairs 228 and 229). Crimp zones 52, 54,
and 56 enable the
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16
panel 50A to be formed into a curved panel by curvature roller pairs 220 ¨
230. In particular
arrangements, the pitch of the transverse corrugations formed in base 51 of
panel 50A by
curvature configuration 200 is about 40mm with a depth of about 5 mm as
described above.
Transverse corrugations formed in sidewalls 53 and 55 may decrease in depth
along the
sidewalls where the sidewall corrugations nearest to base 51, for example
provided by curvature
roller pairs 228 and 230, may have a similar depth to the transverse
corrugations formed in base
51 (i.e. about 5 mm depth), and decreasing in depth along the sidewalls 53 and
55 further from
the base 51. For example, the depth of the transverse corrugations formed by
curvature rollers
226 and 227 farthest from base 51 may be significantly less than the depth of
the transverse
corrugations formed in base 51 and may taper to zero depth at the extremities
of sidewalls 53 and
55. The reduction in transverse corrugation depth along the sidewalls may be
smoothly
decreasing with distance from base 51. To facilitate such a smooth tapering of
the transverse
corrugation depth along the sidewalls, crimp zones 54, and 56 may be tapered
similar to tapered
crimp zones 96, and 97 depicted in Figure 7A.
[0082] Panel 50A of Figure 10A is shown in a first optional embodiment
comprising
additional optional complementary strengthening flutes 59 in sidewalls 53 and
55. In an
alternate embodiment, shown in Figure 10B, panel 50B comprises a wider and
flat base 51B
compared with base 51 where flat base 51B does not include optional
strengthening flutes 59. It
will be appreciated that, when forming a curved longitudinal profile of a
panel 59B, an alternate
configuration of curvature rollers 220 to 230 would be used. For instance, in
this particular
example of panel 50B, shown in Figure 10B to scale with panel 50A above,
curvature roller
pairs 228 and 230 are not required and curvature roller pair 220 may be
substituted for wider
roller pair 220A to engage a wider base 51B of panel 50B.
Variations and Modifications
[0083] It will be realized that the foregoing has been given by way of
illustrative example only
and that all other modifications and variations as would be apparent to
persons skilled in the art
are deemed to fall within the broad scope and ambit of the invention as herein
set forth.
[0084] In this specification, adjectives such as first and second, left and
right, top and bottom,
and the like may be used solely to distinguish one element or action from
another element or
action without necessarily requiring or implying any actual such relationship
or order. Where
the context permits, reference to an integer or a component or step (or the
like) is not to be
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17
interpreted as being limited to only one of that integer, component, or step,
but rather could be
one or more of that integer, component, or step etc.
[0085] The above description of various embodiments of the present invention
is provided for
purposes of description to one of ordinary skill in the related art. It is not
intended to be
exhaustive or to limit the invention to a single disclosed embodiment. As
mentioned above,
numerous alternatives and variations to the present invention will be apparent
to those skilled in
the art of the above teaching. Accordingly, while some alternative embodiments
have been
discussed specifically, other embodiments will be apparent or relatively
easily developed by
those of ordinary skill in the art. The invention is intended to embrace all
alternatives.
modifications, and variations of the present invention that have been
discussed herein, and other
embodiments that fall within the scope of the above-described invention.
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