Field of the Invention

The present invention relates to a construction panel system and to methods for assembling a construction panel system. The invention relates particularly, although not exclusively, to construction panels such as decking and cladding, intended for use at the exterior of buildings.

Background

It is known to provide a balcony for a building in the form of a balcony cassette. The building is first constructed, typically leaving balcony attachment points at positions on the exterior of the building at which it is intended to affix balconies. Subsequently, balcony cassettes, assembled off site, are lifted into position and attached to the building at the balcony attachment points. The balcony cassettes typically have an arrangement of beams (also referred to as joists or rafters) which provide support for a balustrade, decking and soffits. It is the balustrade, decking and soffits which provide the balcony with its external appearance.

The decking of the balcony provides support to a user standing and walking on the balcony. It is necessary for the decking to be weather resistant and to provide a substantially continuous underfoot surface without substantial gaps and yet providing suitable grip and drainage. Previously, suitable decking for balconies has used plastics or engineered wood. Such materials are useful because they can be manufactured at low cost and can provide the benefits mentioned above. However, in the light of increased scrutiny of fire safety performance, it is necessary to consider the combustibility of such materials.

Existing decking products can be affixed to the rafters of the balcony using screws through the decking panel and into the rafters. More elegant solutions use clips which attach to the rafters at gaps between adjacent decking panels and which thereby fasten the decking panels with respect to the rafters, and yet which are substantially hidden from sight when the decking is assembled and ready for use. However, such approaches result in relatively slow installation.

Fig. 1 shows a schematic partial cutaway view of a known balcony construction attached to a building. Note that the balcony would in reality have a balustrade (not shown). Floor slab 10 provides anchor points (not shown) for attachment of balcony beams 12, 14. Rafters 16 extend between the balcony beams, in this arrangement extending perpendicularly away from the building. The rafters support an arrangement of decking panels 18 extending substantially perpendicularly to the rafters. The decking panels are arranged in parallel and adjacent relation in order to provide a substantially continuous underfoot surface for a user to walk on. Panel clips 20 are provided on the rafters 16, the panel clips 20 being operable to hold the decking panels 18 with respect to the rafters 16. Fig. 2 shows a partial schematic cross sectional view of two adjacent decking panels for use in the construction of Fig. 1 . Panel clip 20 is attached to the upper surface of the rafter 16 and has a shank portion 22 and a head portion 24. Head portion 24 has a shape such that it can be inserted in one orientation into a gap between adjacent panels. Panels 18 have a side surface groove 26 to receive the head portion 24 when the clip is rotated from an insertion orientation to a fixing orientation. In this way, the clip 20 holds the panels 18 with respect to rafter 16 but remains out of sight in use, except on close inspection of the gap between adjacent panels. Fig. 2 includes some dimensional information, for context. Note that the decking panels 18 in Fig. 2 have an engineered wood construction. The upper surface has grooves formed in it, to provide drainage and grip. The lower surface has a rebate formed in it, to suppress warping of the panel in use.

As mentioned above, however, it is necessary to revisit the format of such decking in the light of the need for improved fire safety performance. The present invention has been devised in light of the above considerations.

Summary of the Invention

In view of the potential fire safety implications of plastics or engineered wood, the present inventors have devised an approach that allows the use of extruded metal panels in place of known plastics or engineered wood panels. The use of metal, such as aluminium, addresses the fire safety implications of plastics or engineered wood. The ease of extrusion forming of metals such as aluminium permits the manufacture of panels having a precise and uniform cross sectional shape.

The present inventors have realised that the general concepts of the present invention apply not only to decking panels but also to other constructional panels such as cladding panels. Accordingly, the general expression“constructional panels” is used sometimes in the disclosure below.

Accordingly, in a first aspect, the present invention provides a constructional panel system including at least one panel and at least one support member, the system being adapted to fix the panel with respect to the support member, wherein the panel is an extruded metal panel having an upper region and a lower region covered by the upper region, wherein the panel has a longitudinal extrusion direction and a lateral direction perpendicular to the longitudinal extrusion direction, wherein the lower region is provided with at least two legs formed integrally with the panel, each leg extending longitudinally along the lower region of the panel and being laterally elastically displaceable with respect to the upper region of the panel, wherein the support member is provided with a clip to retain the panel in use, the clip having an upper cam surface and a recess formed beneath the upper cam surface respectively for each leg, so that during installation of the panel onto the clip, the respective upper cam surface of the clip laterally elastically displaces the legs with respect to each other as the panel is pressed towards the support member and subsequently the recess of the clip allows the legs at least partially to spring back elastically, the legs thereby being retained respectively by the recess of the clip. The panel may be a cladding panel, in which case the upper region of the panel may have an upper surface adapted to provide an externally-visible surface for a building. However, in preferred

embodiments, the panel may be decking panel. Of particular interest are decking panels for balconies. The upper region of the panel may therefore have an upper surface adapted to be walked upon.

There may be two or more support members, extending non-parallel with respect to the longitudinal extrusion direction of the panel. The support members may each be provided with respective clips to retain the panel with respect to the support members.

In the constructional panel system there may be provided at least two panels adapted to be installed adjacent and parallel to each other on the support member. There may be a gap of not more than 1 cm between the panels. More preferably, such a gap may be of width 4-7 mm.

In the case where there are at least two panels, the support member may be provided with a plurality of clips, spaced apart on the support member to retain the respective panels in use.

With respect to the shape of the panel, the legs may comprise web portions and foot portions. The foot portions may have a lateral extent greater than that of the web portions, allowing the foot portions to be retained by the recess of the clip.

In a second aspect, the present invention provides a method of installation of constructional panels using a constructional panel system according to the first aspect. In this second aspect, each constructional panel is pressed towards the support member to retain the constructional panel with respect to the clips.

In a third aspect, the present invention provides a constructional panel system including at least two panels and at least one support member, the system being adapted to fix the panels with respect to the support member, wherein each panel is an extruded metal panel having an upper region and a lower region covered by the upper region, wherein the panel has a longitudinal extrusion direction and a lateral direction perpendicular to the longitudinal extrusion direction, wherein the lower region is provided with at least two legs formed integrally with the panel, each leg extending longitudinally along the lower region of the panel, wherein the support member is provided with a clip module, the clip module providing at least two clips to retain the panels in use by interaction with the legs of the panel, the clips being spaced apart on the clip module to provide a corresponding spacing between the panels when installed.

Preferably, there are two or more support members, each support member being provided with a respective clip module. The panels may therefore be fixed with respect to each support member by clips on the respective clip modules.

The clip module may have a base member extending in a direction corresponding to the lateral direction of the panels, the base member having a shape adapted to fit a profile of the support member. The clips may be formed integrally with the base member. For example, the base member may be in the form of a plate. The clips may be defined in the base member at required locations by partial cutting of the base member to form clip precursor members. The base member may then be subjected to bending to form the clips to be upstanding from the base member.

In some embodiments, the legs of the panels are laterally elastically displaceable with respect to the upper region of the panel. The clips may each have an upper cam surface and a recess formed beneath the upper cam surface respectively for each leg. In this manner, during installation of the panel onto the clip, the respective upper cam surface of the clip may laterally elastically displace the legs with respect to each other as the panel is pressed towards the support member. Subsequently the recess of the clip may allow the legs at least partially to spring back elastically, the legs thereby being retained respectively by the recess of the clip.

In some embodiments, the clip module may be formed separately from the support member. For example, the clip module may be adapted to be located with one or more adjacent clip modules, the clip module having at least one of a male joint portion and a female joint portion at one end, adapted to tessellate with corresponding elements of the adjacent clip modules.

In other embodiments, the clip module may be formed integrally with the support member. In this case, the support member may be formed from a flat support member plate. The plate may be subjected to partial cutting to form clip precursor members. The clip precursor members may then be formed into clips which are upstanding from the support member by bending. For example, the operation of bending to form the clips may be carried out at the same time as bending of the support member plate into the support member.

In a fourth aspect, the present invention provides a method of installation of constructional panels using a constructional panel system according to the third aspect. In this fourth aspect, each constructional panel is pressed towards the support member to retain the constructional panel with respect to the clips.

The invention includes any combination of the aspects and/or preferred features described except where such a combination is clearly impermissible or expressly avoided.

Summary of the Figures

Embodiments and experiments illustrating the principles of the invention will now be discussed with reference to the accompanying figures in which:

Fig. 1 shows a schematic partial cutaway view of a known balcony construction.

Fig. 2 shows a partial schematic cross sectional view of two adjacent decking panels for use in the construction of Fig. 1 . Fig. 3 shows a schematic partial perspective view of a decking panel for use in an embodiment of the invention.

Fig. 4 shows a schematic cross sectional view of the decking panel of Fig. 3.

Fig. 5 shows a schematic perspective view of a system according to an embodiment of the invention.

Fig. 6 shows a schematic perspective view of an alternative clip for use with an embodiment of the invention.

Fig. 7 shows a clip module for use with an embodiment of the invention.

Fig. 8 shows an enlarged view of the part A of Fig. 7.

Fig. 9 shows a schematic partial plan view of a support member plate for use with an embodiment of the invention.

Fig. 10 shows a schematic partial perspective view of a support member for use with an embodiment of the invention.

Fig. 1 1 shows an enlarged view of a portion of the support member of Fig. 10.

Detailed Description of Embodiments of the Invention

Aspects and embodiments of the present invention will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art.

The preferred embodiments of the present invention provide improvements to existing decking panel systems. However, it will be apparent that the present invention may be embodied in other constructional panel systems, such as those used for attaching cladding panels to buildings. Such cladding panels are typically attached to be upright rather than horizontal.

Fig. 3 shows a schematic partial perspective view of a decking panel for use in an embodiment of the invention. Fig. 4 shows a schematic cross sectional view of the decking panel of Fig. 3. The decking panel 18a is an extruded aluminium product. Extrusion of metals such as aluminium is a well known process in which a feedstock metal is pushed through a die of a specified shape corresponding to the cross section of the extruded product.

As shown in Fig. 4, decking panel 18a has upper region 30. Upper region 30 provides an upper surface (intended to be walked on by users) with an arrangement of longitudinal grooves 34 to provide grip and to assist with drainage. Decking panel 18a also has lower region 32. Lower region 32 is covered by upper region 30 and so when the decking panel is installed, the lower region is typically out of sight.

The decking panel has a principal axis P, corresponding to a longitudinal extrusion direction, evident from Fig. 3. The decking panel has a lateral direction L, perpendicular to principal axis P.

Lower region 32 is provided with an arrangement of legs formed integrally with the panel. Each leg extends longitudinally along the lower region of the panel. In Figs. 3 and 4, there are central legs 36 and side legs 38. These each comprise a foot portion 42, for contact with a support member (e.g. rafter - not shown) and a web portion 40 linking the foot portion to the upper region 30.

The legs 36, 38 are laterally (i.e. in direction L) elastically displaceable with respect to the upper region of the panel. This is possible primarily due to the construction of the web portions 40 as relatively thin. It is the elastic displacement of the legs that permits the panel to be affixed with respect to the support member using a clip (or clips) as now described.

Fig. 5 shows a schematic perspective view of a system according to an embodiment of the invention and Fig. 6 shows a schematic perspective view of an alternative clip for use with an embodiment of the invention.

Considering Fig. 5 first, decking panel 18a has a similar format to the decking panel shown in Fig. 3, but with certain features simplified for ease of drawing. The panel has an extruded form with principal axis P corresponding to the longitudinal extrusion direction and lateral direction L. Only part of the panel is shown, for simplicity. Rafter 80 corresponds to the“support member” discussed above and extends in direction L. Options for the rafter 80 are discussed in more detail below, but a typical balcony rafter can be formed from steel or aluminium plate, bent into a suitable cross sectional shape to provide adequate structural support for the decking panels and users of the balcony. At the upper surface of the rafter 80 are located clips 82. These are fixed to the rafter. As discussed above, the decking panel 18a has legs 36, 38. The clips 82 are located in register with gaps between the legs of the decking panel. During installation, the decking panel is pressed down onto the clips in order to secure the decking panel in position with respect to the rafter 80.

A clip for use in this embodiment has an upper cam surface and a recess formed beneath the upper cam surface. During installation of the panel onto the clip, the upper cam surface of the clip laterally elastically displaces adjacent legs 36, 38 as the panel is pressed towards the support member. On subsequent further pressing of the panel towards the support member the recess of the clip allows the legs at least partially to spring back elastically, the legs thereby being retained by the recess of the clip. The foot portions 42 of the legs, as seen in Fig. 4, have a lateral extent greater than that of the web portions 40, allowing the foot portions to be retained by the recess of the clip. As shown in Fig. 5, it is possible for individual clips to be attached to the support member (e.g. rafter) in order subsequently to secure the decking panels. In that case, individual clips are located at precise intervals on the support member, in order to match the positions of the legs of the decking panels. This in turn ensures that the spacing between adjacent panels is consistent, uniform and set at a desired value.

In the case where individual clips are separately attached to the support member, these may be provided as having a substantially circular form in plan view. This is the format indication in Fig. 5. They can be considered to have a flattened mushroom shape in general. The upper cam surface 84 may have a linear or curved profile, shaped for engagement with the foot portions 42 and to guide the lateral elastic displacement of the legs. The upper cam surface ends at an outer rim 86 of the clip. Below the outer rim is provided the recess. The recess may also have a cam surface, designated as a lower cam surface.

The shape of the lower cam surface is designed so that when the decking panel is lifted away from the support member, the lower cam surface elastically displaces the legs apart. However, it is intended that this is more difficult to achieve than during the corresponding installation of the decking panel.

Accordingly, the decking panel is intended to be relatively easy to install (e.g. by simply pushing the decking onto the clips) and possible, but more difficult, to remove. Removal may be achieved by lifting the decking relative to the support member using a special tool (not shown) for example.

The individual clips in this embodiment have a central aperture 88 to allow fixing of the clips to the support member, e.g. using a screw, bolt, rivet or other fixing means. The circular format of the clip shown in Fig. 5 means that the rotational orientation of the clip in plan view does not affect its

performance in securing the decking panel.

In an alternative embodiment, the clips may have a non-circular form in plan view, as shown in Fig. 6.

This has advantages in that it allows the clips to be formed by extrusion and subsequent cutting. With such a format, it is necessary to take care to orient the clips carefully so that the upper cam surface is oriented correctly to receive the legs of the decking panel. In Fig. 6, the upper cam surface 84a is shaped for engagement with the foot portions 42 and to guide the lateral elastic displacement of the legs. The upper cam surface 84a ends at an outer rim 86a of the clip 82a. Below the outer rim is provided the recess 87a. Central aperture 88a to allow fixing of the clips to the support member, e.g. using a screw, bolt, rivet or other fixing means, as described above.

Preferably, as in the example of decking for a balcony, there are provided two or more support members. The support members typically extend non-parallel to the longitudinal direction P of the decking panels. For example, the support members may extend perpendicular to the longitudinal direction P of the decking panels.

In an alternative to the embodiment described above in which there are individual clips secured individually to the support member, it is possible for the clips to be provided on a clip module. The clip module may be provided to attach to a support member (e.g. rafter) for example. There may be one or more clip modules per support member. Each clip module is provided with two or more clips. A first clip is intended to secure a first decking panel and a second clip on the same module is intended to secure a second decking panel, adjacent the first decking panel. As will be understood, it is possible for a single decking panel to interact with more than one clip on the clip module. Furthermore, where there are two or more support members (as indicated above), each support member may be provided with one or more clip modules, so that the decking panels are fixed with respect to each of the support members by clips on the respective clip modules.

The clip modules may have three or more clips, more preferably four or more, five or more, or six or more clips.

An advantage of the use of clip modules is that the spacing of the clips on the clip modules can be precisely set during manufacture of the clip modules. Therefore the clip modules can be manufactured to match the spacing of the legs on the decking panels. Furthermore, the clip modules can be attached to the support members relatively easily, by screwing, bolting, etc. In this way, the clip modules can be attached to the support members (e.g. after installation of a balcony), with the construction of the clip modules precisely setting the spacing of the clips, and the decking panels may then be fixed using the clips. Furthermore, by taking this approach, it is possible for the clip module to be secured to the support member using fewer fixing points than would be necessary where the clips were fixed individually.

The clip module typically has a base member. The base member may extend in a direction

corresponding to the lateral direction L used in Fig. 3. The clips may therefore be arranged in series along direction L. The base member may take the form of a strip or plate for example. In one embodiment, the base member may have an L-shaped cross section, to fit to a profile of the support member.

The clips may be formed separately from the base member, and affixed to the base member in a fixing operation. In this case, each clip member may for example have the construction described above for the individual clips.

Alternatively, it is possible for the clips to be formed integrally with the base member. This is now explained, with reference to Figs. 7 and 8. Fig. 7 shows a clip module 50 for use with an embodiment of the invention. Fig. 8 shows an enlarged view of the part A of Fig. 7.

The base member may be in the form of a metal plate (e.g. steel or aluminium). Integral clips 52 may be defined in the base member at required locations. For example, this definition by be done by partial cutting of the base member to form clip precursor members. Such partial cutting may be carried out using any convenient process, such as laser cutting. The clip precursor members are then formed into clips which are upstanding from the base member by bending. Bending of the individual clip precursor members may be carried out, so that the resultant clips are upstanding from the base member.

Additionally or alternatively, the base member itself may be bent (this is what is shown in the embodiment of Figs. 7 and 8). In this case, it is possible to consider a first portion 54 of the base member and a second portion 56 of the base member. The first and second portion meet at a border line B. The base member is bent along the border line B. The clip precursor members are arranged along the border line so that as the bending proceeds, the clip precursor members remain coplanar with the first portion 54 (for example) as the second portion 56 is bent out of plane. After bending, the result is an arrangement of clips 52 which are upstanding with respect to the second portion 56. The clip module 50 may then be fixed to a support member so that the second portion 56 lies flat along an upper surface of the support member and the first portion 54 lies flat along a side surface of the base member, with the clips 52 upstanding from the base member and available to receive the decking panels.

As shown in Fig. 7, male joint portion 58 and female joint portion 60 are provided at respective ends of the clip module. These elements tessellate with corresponding elements of adjoining clip modules (not shown). This allows the clip modules to be attached to a support member with the required continuous spacing between the clips on adjoining clip modules in order to ensure uniform installation of the decking panels.

In this embodiment, the shape of the clip members provides the upper cam surface 62 and the recess 64 as described above to enable fixing of the decking panels by elastic displacement of the legs of the decking panels.

As shown in Figs. 7 and 8, the clip module 50 has apertures 66 for fixing of the clip module with respect to the support member.

In a further embodiment, the clip module may be integrated with the support member. In this way, the support member (e.g. a joist or rafter 100) is formed from a flat plate, designated here as a support member plate 100a. The plate 100a is subjected to partial cutting to form clip precursor members 102a. Such partial cutting may be carried out using any convenient process, such as laser cutting. The clip precursor members 102a are then formed into clips which are upstanding from the support member by bending. Bending of the individual clip precursor members may be carried out, so that the resultant clips are upstanding from the support member. Additionally or alternatively, the support member plate itself may be bent (this is what is shown in the embodiment of Figs. 9, 10 and 1 1). In this case, it is possible to consider a first portion 104a of the support member plate and a second portion 106a of the support member plate. The first and second portions meet at a fold line F. The support member plate 100a is bent along the fold line F to form first portion 104 and second portion 106 of the support member 100.

The clip precursor members 102a are arranged along the fold line so that as the bending proceeds, the clip precursor members remain coplanar with the first portion 104a (for example) as the second portion 106a is bent out of plane. After bending, the result is an arrangement of clips 102 which are upstanding with respect to the second portion 106 after folding.

In a further step, a third portion 108 adjacent the first portion may be bent out of the plane of the first portion 104 in order to form the support member 100 into a C-shaped cross section, to better support a load. In this way, the support member 100 itself is provided with integral upstanding clips 102 at spacings defined by the laser cutting process. The decking panels may then be attached to the clips in the manner described above in relation to the other embodiments.

As will be understood, in the embodiments of Figs. 7-1 1 , the clips take the form of shaped tabs. In Fig.

1 1 , which is an enlarged view of part of Fig. 10, the shape of clip 102 is generally similar to the shape of clip 62 shown in Figs. 7 and 8 and so further description is omitted here.

A typical gap between adjacent decking panels in the lateral direction L is 6 mm. More generally this can be expressed as preferably being the range 4-7 mm.

The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.

For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.

Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

Throughout this specification, including the claims which follow, unless the context requires otherwise, the word“comprise” and“include”, and variations such as“comprises”,“comprising”, and“including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

It must be noted that, as used in the specification and the appended claims, the singular forms“a,”“an,” and“the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from“about” one particular value, and/or to“about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent“about,” it will be understood that the particular value forms another embodiment. The term“about” in relation to a numerical value is optional and means for example +/- 10%.

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