"A panel assembly"

Introduction

This invention relates to a building panel assembly. In particular this invention relates to a building panel assembly which is suitable, in one embodiment, for use as a translucent roof panel assembly, also known as a rooflight.

The invention also relates to a building panel system of the type comprising a plurality of opaque insulated panels and translucent panels. Insulated panels used in such systems are described for example in our GB-A-2257086 and comprise an outer sheet, an inner or backing sheet and an insulating foam body between the sheets. The sheets are generally of metal such as coated steel and the foam may be a polyisocyanurate, phenolic or other suitable insulating material. Translucent panels (also referred to as roofiights) used in such systems are described for example in our GB-A-2413808.

Such translucent panels may comprise an outer skin, an inner skin and a multiwall support between the inner and outer skins. The inner and outer skins and the multiwall may be all of a polycarbonate material.

Generally, roofs using such panel systems are supported on building elements such as purlins. The panels are side and end lapped to cover the structure and form a roof Translucent rooflight panels are interspersed with the opaque insulated panels to allow light into the building. To achieve optimum light distribution the roofiights may be laid somewhat in the manner of a chequerboard although other configurations are also used such as ridge to eaves, ridge, and mid slope. In all cases however, there is a problem in assembling the pre-formed panels on site because the translucent panels and opaque panels are of different thickness. In general, the translucent panels are thinner in cross section than the opaque panels. This leads to difficulties in supporting the panels on structural elements (such as purlins).

This invention is directed towards providing an improved building panel system which will address these problems.

Statements of Invention

According to the invention there is provided a building panel assembly comprising: -

a panel element; and

spacer means to space the panel element at a desired distance from a building frame element;

the spacing means being provided detached from the panel element for coupling to a building frame element on-site.

In one embodiment the spacing means is configured to be coupled to a building frame element prior to attachment of the spacing means to the panel element.

Preferably the spacing means is configured to be releasably coupled to a building frame element.

In a preferred embodiment the spacing means is configured to be magnetically coupled to a building frame element.

The spacing means and/or the building frame element may comprise a magnetic material.

In one embodiment the spacing means is magnetic, at least in a region of contact with a building frame element.

The spacing means may be rendered magnetic by incorporation of a magnetic material. The spacer means may comprise a magnetic material applied to the spacer means. The magnetic material may be applied to the spacer means in the form of at least one magnetic strip.

In one embodiment the spacing means comprises a beam. The spacing means may have a longitudinal axis which extends, on assembly substantially at right angles to the longitudinal axis of the panel element.

In one case the spacing means defines a substantially hollow internal space. The spacing means may comprise a double box section.

The assembly may also comprise a fixing means to fix the spacing means to a building frame element. The fixing means may be configured to extend through the spacing means into a building frame element.

In one embodiment the spacing means is configured to be attached to the panel element on-site. The assembly may comprise means to attach the spacing means to the panel element on-site. The attachment means may be configured to extend through the panel element into the spacing means.

In one embodiment the panel element is configured to be attached to a building frame element. The panel element may be configured to be attached to a building frame element on-site. The assembly may comprise means to attach the panel element to a building frame element. The attachment means may be configured to extend through the panel element into a building frame element.

In one embodiment the attachment means comprises a fixing pin. The fixing pin may comprise a drill point for drilling through the panel element, the spacing means, and into a building frame element.

In one embodiment the panel element comprises a translucent panel comprising a single body of translucent material. The panel element may comprise an outer weather skin, an inner liner skin and a multiwall support between the outer weather skin and the inner liner skin, the inner liner skin, the outer weather kin and the multiwall support all being of translucent material. The panel element may comprise an integral overlap portion at at least one end and/or side thereof, the overlap portion having a thickness close to the thickness of the outer weather skin.

The translucent material may comprise a translucent thermosetting material. The translucent material may comprise a polycarbonate material.

In one embodiment the assembly comprises a plurality of opaque panels and a plurality of translucent panels, the thickness of the opaque panels being greater than the thickness of the translucent panels and the spacer means compensating for the difference in thickness between the opaque panels and the translucent panels.

In one embodiment the assembly comprises a building frame element such as a purlin.

The invention also provides a building panel assembly comprising: -

a panel element; and

means to space the panel element at a desired distance from a building frame element;

the spacing means being configured to be releasably coupled to the building frame element.

In one embodiment the spacing means is configured to be magnetically coupled to a building frame element.

The building frame element and/or the spacing means may be of a metallic material.

The spacing means and/or the building frame element may be of a magnetic material.

The spacing means may be configured to be attached to a building frame element. The spacing means may be configured to be attached to a building frame element on- site.

In one case the panel element comprises a profiled form. The panel element may comprise one or more raised formations. The attachment means may be configured to extend through the panel element at at least one of the raised formations.

In one case the panel element comprises one or more first raised formations and one or more second raised formations, the one or more first raised formations being raised a greater distance than the one or more second raised formations. The attachment means may be configured to extend through the panel element at at least one of the first raised formations.

According to another aspect the invention provides a building panel assembly comprising: -

a panel element comprising one or more first raised formations and one or more second raised formations;

the one or more first raised formations being raised a greater distance than the one or more second raised formations;

means to attach the panel element to a building frame element;

the attachment means being configured to extend through the panel element at at least one of the one or more first raised formations into the building frame element.

Because the spacing means is provided detached from the panel element, this arrangement enables the position of the spacing means to be adjusted on-site to a desired position relative to the panel element and relative to the building frame element. The building panel assembly of the invention may therefore be assembled more easily and more quickly than conventional systems.

In one embodiment, the invention provides a polycarbonate rooflight with an optimised fixing arrangement. The invention uses a site applied magnetic spacer in one embodiment. The extruded rooflight may be 20 mm thick (core). Adjacent roof panels may have a 30 mm to 100 mm core, so the invention uses the spacers to take this space up.

Conventional rooflights in some cases use factory applied fillers. These have to be exactly located in the correct position to suit supporting purlins. Mistakes can be made during production which require remanufacture of the panels with the spacers in the correct positions.

Also purlins can twist, or bend, or buckle meaning fillers may not be over corresponding purlins and fasteners intended to go through fillers may miss corresponding purlins.

In the invention the spacers have magnetic strips and are supplied loose for placement on purlins.

Brief Description of the Drawings

The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which: -

Fig. 1 is a side view of a building panel assembly according to the invention;

Fig. 2 is a side view of another building panel assembly according to the invention;

Fig. 3 is a side view of a further building panel assembly according to the invention;

Fig. 4 is a side view of a further building panel assembly according to the invention;

Fig. 5 is a perspective view of the assembly of Fig. 4; and

Figs. 6 and 7 are end views of another building panel assembly according to the invention.

Detailed Description

Referring to the drawings and initially to Fig. 1 thereof, there is illustrated a building panel assembly 1 according to the invention. The assembly 1 comprises a panel element 2, a building frame element 3, and a spacer 4 to space the panel element 2 at a desired distance from the building frame element 3. In this case the building frame element is a purlin 3 of a metallic material.

The panel element 2 comprises a translucent panel or rooflight of the type described in our GA-A-2413808, the entire contents of which are incorporated herein by reference.

The panel 2 comprises a single body of translucent polycarbonate material, the single body comprising a profiled outer weather skin, an inner liner skin, and a multiwall support between the inner liner skin and the outer weather skin. The inner liner skin, the outer weather skin, and the multiwall support are all of translucent polycarbonate material. The rooflight may be of Lexan Thermoclear multiwall polycarbonate sheet from GE Structural Products. This material is highly resistant to sheet covering discoloration, loss of light and loss of strength due to weathering.

The panel element 2 has an integral overlap portion at one end of the panel element 2. This is used for overlapping with other panels such as composite insulating roof panels or wall panels of similar profile. The overlap portion has a substantially reduced thickness with respect to the overall thickness of the panel element 2 and in this case the thickness is reduced to close to the thickness of the outer weather skin. This is achieved by collapsing and/or forcing the inner liner skin and the multiwall support in the region of the overlap towards the outer weather skin. In a first step the inner liner skin is notched with a cutting tool. A heated pressing tool of complementary profile to that of the outer weather skin is then pressed against the inner liner skin and the multiwall support which are melded to the inner surface of the outer weather skin. We have found that this is a very efficient method for manufacture on a large factory scale.

The panel element 2 further comprises a border extending between the main panel portion and the overlap portion. The border has a depth comprising the overall depth of the multiwall support and the inner liner skin, and extends substantially at right angles to the outer weather skin and the inner liner skin. Formation of the notch prior to pressing provides for the border on pressing. In a preferred embodiment, the notch

extends across the width of the panel element 2, however, it will be appreciated that the depth and/or extent of the notch may be varied as required.

In use, the border and the overlap portion together define a connection means for connection of the panel element 2 with adjacent panels having a similar profile. The adjacent panels may be rooflight panels 2 or insulated building panels 22 having the same profile as the outer weather skin. The adjacent panels may be of a similar or greater thickness than the panel element 2. The panel element 2 is configured so that in use the overlap portion overlaps an adjacent panel of a similar profile and the border lies side by side in close abutment with the side edge of the adjacent panel. A sealing member for example, a tape covering may be applied to the border. The overlap portion and the border provide for an improved connection between the panel element 2 and adjacent roof panels and also for improved sealing and insulation of the roofing system.

As noted above, the pressing tool has the profile of the outer weather skin so that the inner liner skin and the multiwall support are compressed against the outer weather skin, but the overall profile of the outer weather skin is maintained. The overlap portion extends laterally across the width of the panel element 2. In an embodiment, the outer weather skin is profiled and the overlap portion is formed in such a way as to maintain the profile of the outer weather skin at the overlap portion. This provides a good aesthetic finish to the roof and ensures that an improved seal and connection is achieved between the panel element 2 and adjacent panels.

In addition to the overlap portion which in one embodiment extends laterally, the panel element 2 further comprises a side lap which extends longitudinally along one side of the panel element 2. The side lap in this case comprises only the outer weather skin and provides a means for connection with adjacent profiled building panels or adjacent like panel elements 2. If necessary the side lap may be formed in a process similar to that for forming the overlap portion.

The spacer 4 extends between the outer surface of the inner liner skin of the translucent panel 2 and the roof purlin 3. The spacer 4 is magnetic. A ferro-magnetic material may be incorporated into the material of the spacer or the spacer may be rendered magnetic by, for example, a magnetic strip. The spacer 4 is provided in this case in the form of a beam, and may for example be of hollow PVC double box- section. The spacer 4 is used to bridge the gap in thickness between the relatively shallow rooflight 2 and the purlin 3. The location of the purlins 3 is set to accommodate the opaque insulated panels which are thicker than the translucent panels. The rooflight 2 is thinner than the opaque panels 22 because of the high thermal insulation efficiency of the translucent panel element 2.

A fixing pin 5 is used for attaching the translucent panel element 2 to the spacer 4, and attaching the spacer 4 to the roof purlin 3. The fixing pin 5 has a shaft 6 with a drill point 7 for drilling through the panel element 2, the spacer 4, and into the purlin 3.

The spacer 4 and the panel element 2 are formed separately, and are not attached to each other during production. The spacer 4 and the panel element 2 are provided to the intended site of use detached from one another.

The spacer 4 is magnetically coupled to the purlin 3 on-site, due to the spacer 4 being magnetic and the purlin 3 being of a metallic material. The translucent panel element 2 is then placed resting on top of the spacer 4 with the longitudinal axis of the panel element 2 substantially perpendicular to the longitudinal axis of the spacer 4.

On-site, the fixing pin 5 is then extended through the panel element 2 into the spacer 4, and through the spacer 4 into the purlin 3 by means of drilling. In this manner the panel element 2 is attached to the spacer 4 on-site, and the spacer 4 is attached to the purlin 3 on-site. Overall the panel element 2 is effectively attached to the purlin 3 on- site via the spacer 4 by means of the fixing pin 5.

Because the spacer 4 is not attached to the panel element 2 during production, this enables the user to adjust the position of the spacer 4 relative to the panel element 2 on-site, and to adjust the position of the spacer 4 relative to the purlin 3 on-site to ensure that all of the components: the panel element 2, the spacer 4 and the purlin 3 are in the desired position.

The magnetic coupling of the spacer 4 to the purlin 3 provides a convenient means of temporarily retaining the spacer 4 in place while the steps of positioning the panel element 2 and drilling of the fixing pin 5 take place.

Fig. 1 illustrates the polycarbonate rooflight panel 2 and the site applied magnetic spacer 4. The width W of the spacer 4 may be 30 mm in one embodiment.

Four fixing pins 5 with a storm washer in each crown location are employed for each rooflight 2, for each purlin 3.

In Fig. 2 there is illustrated another building panel assembly 10 according to the invention, which is similar to the building panel assembly 1 of Fig. 1 , and similar elements in Fig. 2 are assigned the same reference numerals.

In this case the assembly 10 comprises a first panel element 2 adjacent to a second panel element 2 ¹ . The overlap portion 11 of the first panel element 2 overlaps the second panel element 2 ¹ . The length B of the overlap portion 11 may in one embodiment be 150 mm. In this case both of the panel elements 2, 21 are rooflight panels.

Two spacers 4, 4 ¹ are provided between the panel elements 2, 2 ¹ and the purlin 3. The first spacer 4 is provided between the first panel element 2 and the purlin 3 adjacent to the junction 13 between the first panel element 2 and the second panel element 2 ¹ . The second spacer 4 ¹ is provided between the second panel element 2 ¹ and the purlin 3

adjacent to the junction 13 between the first panel element 2 and the second panel element 2 ¹ . The width A of each spacer 4, 4 ¹ may in one embodiment by 25 mm.

The fixing pin 5 is extended through the overlap portion 11 of the first panel element 2 into the second panel element 2 ¹ , through the second panel element 2 ¹ into the second spacer 4 ¹ , through the second spacer 4 ¹ into the purlin 3.

A smaller fixing pin 12 is provided extending through the overlap portion 11 of the first panel element 2 into the second panel element 2 ¹ . In this manner the first panel element 2 is attached to the second panel element 2 ¹ , the second panel element 2 ¹ is attached to the second spacer 4 ¹ , and the second spacer 4 ¹ is attached to the purlin 3. The distance C of the center-line of the smaller fixing pin 12 from the end of the overlap portion 11 may in one embodiment be about 50 mm.

The end-laps 11 are crown stitched twice with mega-stitcher screws 12, for example

6.3 mm diameter, 25 mm long, with 19 mm diameter washers.

Three runs of, for example, 6 x 5 mm butyl rubber sealant 14 may be applied in continuous unbroken lengths at the end-lap 11.

Four fixing pins 5 with a storm washer in each crown location are used for each rooflight 2, 2 ¹ , for each purlin 3.

The site applied magnetic spacer 4 may be held in place with adhesive.

Fig. 3 illustrates a further building panel assembly 20 according to the invention, which is similar to the building panel assembly 10 of Fig. 2, and similar elements in Fig. 3 are assigned the same reference numerals.

In this case the assembly 20 comprises a translucent panel element 2 adjacent to an opaque insulated roof panel 22. The overlap portion 11 of the roof panel 22 overlaps the panel element 2. The length B of the overlap portion 1 1 may in one embodiment be about 150 mm.

The spacer 4 is provided between the panel element 2 and the purlin 3 adjacent to the junction 23 between the panel element 2 and the roof panel 22. The width A of the spacer 4 may in one embodiment be 25 mm.

The fixing pin 5 is extended through the overlap portion 11 of the roof panel 22 into the panel element 2, through the panel element 2 into the spacer 4, through the spacer 4 into the purlin 3. A smaller fixing 12 extends through the overlap portion 11 of the roof panel 22 into the panel element 2. In this manner the roof panel 22 is attached to the panel element 2, the panel element 2 is attached to the spacer 4, and the spacer 4 is attached to the purlin 3. The distance C of the center-line of the smaller fixing pin 12 from the end of the overlap portion 11 may in one embodiment be about 50 mm.

The roof panel 22 rests directly on the purlin 3. The length D of the roof panel 22 resting on the purlin 3 may in one embodiment be about 30 mm.

Referring to Figs. 4 and 5 there is illustrated another building panel assembly 30 according to the invention, which is similar to the building panel assembly 20 of Fig. 3, and similar elements in Figs. 4 and 5 are assigned the same reference numerals.

In this case the overlap portion 11 of a translucent panel element 2 overlaps an opaque insulated roof panel 22.

The fixing pin 5 is extended through the overlap portion 11 of the panel element 2 into the roof panel 22, through the roof panel 22 into the purlin 3. A smaller fixing pin 12 extends through the overlap portion 11 of the panel element 2 into the roof panel 22.

In this manner the panel element 2 is attached to the roof panel 22, and the roof panel 22 is attached to the purlin 3.

The site applied magnetic spacer 4 may be held in place with adhesive.

In Figs. 6 and 7 there is illustrated another building panel assembly 40 according to the invention, which is similar to the building panel assembly 10 of Fig. 2, and similar elements in Figs. 6 and 7 are assigned the same reference numerals.

In this case the upper surface of the outer weather skin of the panel element 2 has a profiled form. In particular the panel element 2 comprises a plurality of first raised formations 41 and a plurality of second raised formations 42. As illustrated in Fig. 6, the first raised formations 41 are raised a greater distance from the upper surface of the outer weather skin of the panel element 2 than the second raised formations 42. A fixing pin 5 is extended through the panel element 2 at each first raised formation 41 to attach the panel element 2 to the purlin 3 (Fig. 6).

A smaller fixing pin 12 is extended through the panel element 2 at each first raised formation 41 to attach adjacent panel elements 2, 2 ¹ together.

In one embodiment the side-laps may be stitched at 300 mm with mega-stitcher screws, for example, 6.3 mm diameter, 25 mm long, with 19 mm diameter washers.

In one case a 6 x 5 mm butyl rubber sealant may be applied in a continuous unbroken length at the side-lap to the weather side of the stitching screw.

The end lap stitchers may be inserted where the rooflight end laps over a roof panel.

The rooflight of the invention has an excellent U- value rating, does not suffer from the effects of thermal expansion and provides excellent light transmission properties.

In the embodiments described above, the panel element is comprised of a translucent polycarbonate material. It will however, be appreciated that the panel element may alternatively be comprised of any suitable translucent thermosetting material.

The process of forming the panel element as described above has advantages including efficiency and cost effectiveness. It will however be appreciated that the panel element may be formed by other suitable means.

The panel element of the invention has a number of advantages including the following. The provision of the overlap portion enables the panel element to be securely connected to adjacent profiled structural roof panels. The profiled form of the overlap portion provides a good aesthetic finish, and provides a positive connection between panels for an improved weatherproof sealed finish.

The panel element of the invention comprises connection means to enable secure connection with adjacent similar rooflight panels and/or insulated building panels which may have a thickness greater than the thickness of the panel element. The panel element is configured to provide for a side by side connection of the panel element with adjacent panels by virtue of the overlap portion and border features. This arrangement provides improved sealing and insulation between the panel element and adjacent roof panels.

The spacer and fixing features of the building panel assembly provide further advantages. The spacer provides for an improved structural connection between the panel element and the building frame element which provides an assembly having improved insulation properties.

The invention is not limited to the embodiments hereinbefore described, with reference to the accompanying drawings, which may be varied in construction and detail.