SECCOMBE, Campbell, John (141 Pentecost Avenue, Turramurra, New South Wales 2074, AU)
THE CLAIMS :
1. A cladding panel comprising a panel body having opposite major surfaces and a peripheral edge extending between said surfaces, and an edge strip located along at least a portion of the peripheral edge, the edge strip incorporating a recess to allow for edge mounting of the panel and forming a sealing surface that provides a barrier to inhibit the ingress of moisture along that edge.
2. A cladding panel according to claim 1, wherein the panel body incorporates at least one sheet formed from metal incorporating a corrosion resistant coating.
3. A cladding panel according to claim 2, wherein the edge strip extends entirely over the edge of the or each metal sheet so as to seal that sheet edge .
4. A cladding panel according to any preceding claim, wherein the panel body incorporates at least two sheets that are spaced apart along the at least one edge, and wherein the at least one recess extends between the sheets.
5. A cladding panel according to claims 4 , wherein edge margins of the edge strip are bonded to the sheets.
6. A cladding panel according to claim 4 or 5, wherein the panel body is of sandwich construction having a core extending between the two sheets.
7. A cladding panel according to any preceding claim, wherein the edge strip is formed separately from the panel body and is adhered to the peripheral edge of the panel body.
8. A cladding panel according to any one of claims 1 to 6, wherein the edge strip is formed on the peripheral edge of the panel body.
9. A cladding panel according to claim 8, wherein the panel body incorporates a thermoplastic core and the core is partially melted and caused to flow across the peripheral edge of the panel body so as to form the edge strip thereon.
10. A cladding panel according to any preceding claim wherein the cladding panel is arranged to be used in conjunction with a mechanical fixing arrangement that incorporates a flange that locates in said recess.
11. A method of forming a cladding panel comprising the steps : forming a panel blank from strip material; cutting the panel blank into discrete lengths to form a panel body; and applying an edge strip to the or each cut edge of the panel body, the edge strip incorporating at least one recess to allow for edge mounting of the panel and the edge strip forming a sealing surface that provides a barrier to inhibit the ingress of moisture along that cut edge.
12. A method according to claim 11 further comprising the step of forming panel blank as a composite structure having a core and facing sheets applied to opposite sides of the core, each of the facing sheets being formed from strip material .
13. A method according to claim 12 , wherein the strip material is sheet metal incorporating a corrosion resistant coating.
14. A method according to either claim 12 or claim 13, wherein the panel blank incorporates a thermoplastic core, and wherein the edge strip is applied to the cut edges by partially melting the core and causing it to flow across the edge of the panel body to form the sealing surface.
15. A method according to claim 14, wherein the thermoplastic core is partially melted by applying a heated tool to the cut edge of the panel body.
16. A method of forming a cladding panel comprising the steps of: forming a panel body having a composite structure having a thermoplastic core and opposite facing sheets; and applying an edge strip to at least one of the edges of the panel body by partially melting the core and causing it to flow across the edge of the panel body to form the edge strip .
17. A method according to claim 16, wherein the edge strip incorporates at least one recess to allow for edge mounting of the panel and the edge strip forms a sealing surface that provides a barrier to inhibit the ingress of moisture along that edge. |
WALL CLADDING
Technical Field
The present invention relates to a cladding panel and has been developed especially, but not exclusively, to wall panels that use fixing clips to mount the panels to the underlying structure. The invention is herein described in this context, however it is to be appreciated that the invention has broader application and is not limited to that use.
Background of the Invention
In recent times, systems have been developed that use mechanical fixing assemblies to mount cladding panels onto walls. These assemblies have the advantage over traditional adhesive techniques in that they allow quick installation of the panels as the fixing assemblies both guide and secure the panels in place. An example of these fixing assemblies is disclosed in International application WO 02/27109 which discloses a fixing clip that engages an edge of the panel to secure the panel in place .
Summary of the Invention
In a first aspect the invention provides a cladding panel comprising a panel body having opposite major surfaces and a peripheral edge extending between said major surfaces, and an edge strip located along at least a portion of the peripheral edge, the at least one edge strip incorporating a recess to allow for edge mounting of the panel and forming a sealing surface that provides a barrier to inhibit the ingress of moisture along that edge .
In a particular embodiment, the panel body incorporates at least two sheets and the recess is
disposed between those sheets. In use the panel is arranged to be secured in place by a fixing arrangement that locates in the recess . An advantage of this arrangement is that by disposing the recess between the sheets, the structure of the sheets can be utilised to prevent inadvertent release of the panel from the fixing arrangement .
In one form, at least one of the sheets is formed from metal that incorporates a corrosion resistant coating. In a particular embodiment, the edge strip is operative to extend entirely over the edge of the metal sheet so as to provide a seal across that edge surface. This arrangement has particular advantage where the metal sheet had been cut to form the panel body. In that instance, the cut edge has the metal exposed and is thereby susceptible to corrosion and the edge strip may be arranged to provide a corrosion resistant barrier to that cut edge .
In a particular embodiment, edge margins of the edge strip are bonded to the metal sheet .
In a particular embodiment, the panel body is of sandwich construction having spaced apart sheets and a core extending between the sheets. In a particular embodiment, the sheets are formed from metal, and more particularly from steel sheet that incorporates a corrosion resistant coating such as a metal or metal alloy coating. Whilst the core may be made from any suitable material, in one form it is made from a settable material such as polymeric foam, cemetitious composition, polymeric resin or natural rubber. Alternatively, the core may be formed from a composite construction.
In one form, the edge strip is formed separately from the panel body and applied to the panel body. In one
form, the edge strip is bonded to the panel body by a suitable adhesive.
In an alternative form, the edge strip is formed on the edge of the panel body. In one embodiment, the edge strip is formed at least primarily from the material of the panel body. In a particular embodiment of that arrangement, the panel body incorporates a thermoplastic core and the core is partially melted and caused to flow across the edge of the panel body to form the sealing surface. This process can also form the recess in the panel edge to allow for edge mounting of the cladding panel .
In another form, a coating is applied to the panel body edge to form the edge seal . Suitable forms of coatings include butyl, acrylic, silicone and the like.
In one form, the cladding panel is polygonal having a peripheral edge formed from a plurality of mutually inclined straight edges. Preferably edge strips are included and on at least two straight edges, and more particularly on each straight edge of the panel.
The invention also relates to a method of forming a cladding panel .
In one aspect, the invention provides a method of forming a cladding panel comprising the steps of: forming a panel blank from strip material; cutting the panel blank into discrete lengths to form a panel body; and applying an edge strip to the or each cut edge of the panel body, the edge strip incorporating at least one recess to allow for edge mounting of the panel and forming a sealing surface that provides a barrier to inhibit the ingress of moisture along that cut edge.
In one form, the method further comprises the step of forming the panel blank as a composite structure having a core and facing sheets applied to opposite sides of the core, each of the facing sheets being formed from strip material .
In one form, the strip material is sheet metal and more specifically is sheet steel having a corrosion resistant metal coating.
In one form, the edge strip is formed on the cut edge of the panel body. In that arrangement, the edge strip is applied to the panel cut edges of the panel body in the form of a coating. In another embodiment, where the panel blank incorporates a thermoplastic core, the edge strip is applied to the cut edges by partially melting the core and causing it to flow across the edge of the panel body to form the sealing surface. In one form, the edge strip is formed on the application of a heated tool to the cut edge of the panel body.
In yet a further aspect, the invention provides a method of forming a cladding panel comprising the step of: forming a panel body from a composite structure having a thermoplastic core and opposite facing sheets; and applying an edge strip to at least one of the edges of the panel body by partially melting the core and causing it to flow across the edge of the panel body to form the edge strip.
In one form, in this aspect of the invention, the edge strip incorporates at least one recess to allow for edge mounting of the panel and the edge strip forms a sealing surface that provides a barrier to inhibit the ingress moisture along that edge.
Brief Description of the Drawings
It is convenient to hereinafter describe the embodiments of the present invention with reference to the accompanying drawings. The particularity of the drawings and their related description is to be understood as not superseding the generality of the preceding broad description of the invention.
In the drawings:
Fig. 1 is a perspective view of a cladding panel; Fig. 2 is a detailed sectional view of an edge region of the panel of Fig. 1 shown in proximity to a fixing clip; Fig. 3 shows an alternative edge arrangement of the panel of Fig. 1;
Fig. 4 is a schematic view of a panel line for forming the panel of Fig. 1; and
Fig. 5 is a schematic view of tooling for formation of the edge margin of the panel as illustrated in Fig. 3.
Detailed Description
Turning firstly to Figs. 1 and 2, a cladding panel 10 incorporates a body 11 formed as a sandwich panel having a core 12 disposed between two facing sheets 13. The core 12 is typically formed from a polymeric foam such as polystyrene or polyurethane . Other foams may be used, including phenolic foams or phenolic composite foams such as polyphen. Alternatively, the core could be made from other settable material such as cemetitious compositions or from polymeric resins or natural rubbers .
The facing sheets 13 are bonded to the foam core and in the illustrated form, are formed from sheet metal strip which incorporates a corrosion resistant coating.
Suitable sheet material is provided by the applicant under the trademark COLORBOND® INSULATION PANEL. Other types of
facing sheets may be provided as will be appreciated by those skilled in the art. In particular, the metal sheet strips may incorporate other layers such as a paint coating or protective film layer. Alternatively, the facing sheets may be formed from other materials such as fibre cement, or plastic material.
In the illustrated form, the panel 10 is rectangular and also includes an edge strip 14 that extends around each of the opposite sides 15, 16 and end 17 and 18 edges of the panel body 11. The edge strip which is best illustrated in Fig. 2 is formed from plastic and includes a recess 19 that allows for edge mounting of the panel onto flange 101 of a fixing clip 100. In the illustrated form, the edge strip 14 incorporates tangs 20 which project inwardly into the recess 19 so as to provide a firm engagement with the flange 101 of the fixing clip 100.
The edge strip 14 also incorporates distal portions
21 and 22 that project over edges 23 and 24 of the respective facing sheets 13. These distal portions 21 and
22 are bonded onto the edges 23 and 24 so that the edge strip 14 forms a seal across the respective edge 15, 16, 17 and 18 of the cladding panel 10 thereby preventing the ingress of moisture into the panel. Furthermore, the distal portions 21 and 22 provide a barrier over the edges
23 and 24 of the sheets 13 which can assist in prevention of corrosion of those edges .
Fig. 3 illustrates a variation of the edge strip used in the panel 10.
In the illustrated form, the edge strip 30 is formed on the edge of the panel body 11. In the illustrated form, the core 12 is formed from a thermoplastic polymer such as polystyrene and the edge 30 is formed from the application of a heated tool 200 (see Fig. 5) which is
forced into the edge of the panel body 11. On application of the tool 200, the core 12 is caused to melt with the molten material caused to flow out and over the edges 23 and 24. As a result, a skin 31 is formed along the edge margin of the panel body 11 that extends over and is bonded to the edge margins 23 and 24. This skin also defines a recess 32 which again is operative to receive the flange 102 of the fixing assembly 100. Accordingly, with the arrangement of Fig. 3, the edge strip 30 provides both a seal across the respective edge 15, 16, 17 and 18 of the panel body 11 and also provides the recess 32 which is operative to receive the flange 101 of the fixing clip 100.
Fig. 4 illustrates diagrammatically a panel line 50 for formation of the panels 10.
In an initial stage 51, the sheet metal strip 52 and 53 is laminated onto a central core 54 to produce a composite structure 55 in continuous lengths. The sheet coils 52 and 53 are adhered to the core 54 with an adhesive being applied between the sheet 52 and 53 and the core 54. Nib rollers 55, 56 are provided in the laminating stage 51 to provide sufficient pressure to ensure adequate adhesion between the sheets 52 and 53 and the core 54. The line 50 includes a second shearing stage 57 where the composite structure 55 is cut into discrete lengths to form the individual panel bodies 58. In a third stage 59, the edge strip is applied to the edges of the panel. The edge strip may be applied by bonding the plastic edge strip 14 as illustrated in Fig. 2 or by the application of a tooling element 200 to form the sealing skin 31 as illustrated in Fig. 3. The complete panel 10 is then discharged from the stage 59.
In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary
implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention. Modification and/or additions may be made to the parts previously described without departing from the sprit or ambit of the present invention.
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