AU2015101935A4

AU2015101935A4 - Improved composite panel

Info

Publication number: AU2015101935A4
Application number: AU2015101935A
Authority: AU
Inventors: Marc Herman Stampke
Original assignee: Stratco Australia Pty Ltd
Current assignee: Stratco Australia Pty Ltd
Priority date: 2014-03-07
Filing date: 2015-03-06
Publication date: 2019-05-16
Anticipated expiration: 2023-03-06
Also published as: AU2015226838A1; WO2015131241A1

Abstract

The present invention relates to an improved composite panel which may be used to form an item such as a door. The composite panel includes at least one corrugated panel located within a space defined by a second member. The second member includes a back panel, a peripheral edge and a front edge. The space is bounded, at least in part, by the back panel, the peripheral edge, and the front edge. The composite panel has particular, but not exclusive, application in the building and construction industry.

Description

Improved Composite Panel

Related Application [0001] This application claims convention priority from Australian provisional patent application 2014900777, filed 7 March 2014, the contents of which are incorporated herein by reference.

Technical Field [0002] The invention relates to an improved composite panel. The invention has particular, but not exclusive, application in the building and construction industry.

Background of Invention [0003] Metal panels are widely used in the building and construction industry. Typically, such metal panels are corrugated and a variety of different profiles are in common use. Roofing, walls, doors and fencing are constructed with such panels. Garages and garden sheds are also commonly constructed from such corrugated panels.

[0004] Composite panels are also widely used in the building and construction industry. For example, roofing and walling panels are available including a metal corrugated upper layer with, for example, a polyurethane foam applied to the underside thereof. The foam providing improved insulation properties to the panels. Another form of insulated roofing and walling panel includes a core sandwiched between an upper corrugated metal panel and a lower metal panel. The core may be solid or honeycombed. A feature common to these panels is that a first elongated edge of the upper corrugated layer is configured so that it can be overlapped onto a second elongated edge of an adjacent one of such panels. In this way, adjacent panels can be used to form a larger continuous corrugated insulated panel.

[0005] Although such composite panels are suitable for roofing and walling applications, they are not generally suitable for use in constructing components that require strength along the face of the first and second elongated edges. Such

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2015101935 06 Mar 2015 composite panels are also relatively expensive and are thus not cost effective for use in many applications. Most composite panels are also difficult to recycle due to the combinations of different materials used and the difficulty of separating those different materials.

[0006] The present invention seeks to provide a composite panel that offers advantages over prior composite panels. These advantages may include, for example, one or more of improved strength, improved rigidity, unique appearance, easy installation and cost effective manufacture.

[0007] The discussion of the background to the invention herein is included to explain the context of the invention. This is not to be taken as an admission that any of the material referred to was published, known or part of the common general knowledge as at the priority date of this application.

Summary of Invention [0008] According to the present invention there is provide a composite panel including at least one corrugated panel located within a space defined by a second member.

[0009] The second member preferably includes a back panel, a peripheral edge and a front edge. The space is preferably bounded, at least in part, by the back panel, the peripheral edge and the front edge.

[0010] In accordance with a preferred embodiment, the second member is formed from a single flat metal panel that has cut-outs at each corner. The cut-outs are preferably square. The metal panel is preferably folded at about 90° along respective fold lines to form an open box configuration. The peripheral edge is made from four panels, two length panels and two width panels. The front edge is made from four panels, two length panels and two width panels. The peripheral edge extends at about 90° to the back panel and the front edge extends generally parallel to the back panel. The front edge acts as a flashing and when a single corrugated panel is located within the space, the front edge extends over the width and length edges of the corrugated panel. When more than one corrugated panel is located within the space, the corrugated panels are preferably overlapped along one length edge to

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2015101935 06 Mar 2015 form a larger panel. The width and length edges of the larger corrugated panel are covered by the front edge of the second member.

[0011] The second member establishes both a backing for the composite panel and flashing of the composite panel.

[0012] The at least one corrugated panel is preferably connected and/or adhered to the second member. Screws or rivets may be used to connect the at least one corrugated panel to the second member. Adhesive may also be used to connect the at least one corrugated panel to the second member.

[0013] The invention further provides a door including a composite panel, the composite panel including at least one corrugated panel located within a space defined by a second member.

[0014] In accordance with an embodiment of the invention, at least one hinge is connected to a length edge of the composite panel.

[0015] Preferably, a handle mounting bracket and/or handle is arranged to be connected to the door.

Brief Description of Drawings [0016] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0017] Figure 1 is an isometric view of a door made from a composite panel according to a first embodiment of the invention;

[0018] Figure 2 is an assembly view of the door shown in Figure 1;

[0019] Figure 3A is an isometric view of the backing flashing of the door shown in Figure 1;

[0020] Figure 3B is a plan view of the flat panel that is folded to form the backing flashing shown in Figure 3A;

[0021] Figure 4 depicts Step 1 in the construction of the door as shown in Figure 1;

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2015101935 06 Mar 2015 [0022] Figure 5 depicts Step 2 in the construction of the door shown in Figure1;

[0023] Figure 6 depicts Step 3 in the construction of the door shown in Figure1;

[0024] Figure 7 depicts Step 4 in the construction of the door shown in Figure1;

and [0025] Figures 8A and 8B illustrate two arrangements for connection of a hinge or other member to a composite panel in accordance with an embodiment of the invention.

Detailed Description [0026] Figure 1 illustrates a door 10 made from a composite panel in accordance with an embodiment of the invention. As depicted and as will be explained in more detail below, the composite panel includes at least one corrugated panel located within a space defined by a second member. The composite panel of the illustrated embodiment includes a half sheet corrugated panel 12A and a full sheet corrugated panel 12B that together establish the outer face 14 of the composite panel. The composite panel further includes a second member in the form of backing flashing 16. However, it should be appreciated that the outer face 14 of a composite panel in accordance with an embodiment of the invention may include only a single corrugated panel or may include more than two such corrugated panels. When multiple corrugated panels are included they may be of different or identical width. Preferably, they have identical corrugations so that when assembled together to form the outer face of the composite panel, the appearance is one of a continuous outer corrugated panel. The corrugated panels 12A, 12B are overlapped in use as per conventional corrugated fencing, walling or roofing panels.

[0027] Backing flashing 16 is made from a single flat metal panel that has square cut-outs at each corner. When the metal panel is folded at 90° along respective fold lines (see dashed lines in Figure 3B) an open box configuration is formed. The box configuration includes a back panel 16A, a peripheral edge 16B (made from four panels, two length panels and two width panels) and a front edge 16C (made from four panels, two length panels and two width panels). The peripheral edge 16B extends at 90° to the back panel 16A and the front edge 16c extends parallel to the

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2015101935 06 Mar 2015 back panel 16A. The back panel 16A, peripheral edge 16B and front edge 16C define a space for receiving the corrugated panels 12A, 12B. The positioning of the corrugated panels 12A, 12B within that space will be described in more detail below.

[0028] The door 10 shown in Figure 1 further includes a handle mounting bracket 18 and upper and lower hinges 20. Numerous rivets 22 are used to secure the corrugated panels 12A, 12B to the backing flashing 16. The included components of the door 10 are best shown in Figure 2.

[0029] Handle mounting bracket 18 may adopt different forms but as illustrated includes an edge face 18A and a front face 18B (Figure 4).

[0030] Door 10 is assembled using the components shown in Figure 2 in a series of simple assembly steps.

[0031] As shown in Figure 4, Step 1 of the assembly process is to trim a first longitudinal elongated edge of the half sheet corrugated panel 12A and to fold the trimmed edge at 90° to form edge 12A’ (see Details A and B of Figure 4). A part of the edge 12A’ is then located substantially flush with the inner side of the edge face 18A of the handle mounting bracket 18. Handle mounting bracket 18 is preferably positioned substantially mid-way along the length of the half sheet corrugated panel 12A.

[0032] Adhesive is applied to the outer peaks 12A” of the half sheet corrugated panel 12A and to the edge 12A’ of the half sheet corrugated panel 12A. The adhesive is preferably applied to the trimmed edge 12A’ before it is located flush with the inner side face 18A of the handle mounting bracket 18. In this way, adhesive will be located between the part of the edge 12A’ that makes contact with the inner side face 18A of the handle mounting bracket 18. Adhesive is further preferably applied to the width edges of the half corrugated panel 12A.

[0033] The half sheet corrugated panel 12A and handle mounting bracket 18 are then adhered to the backing flashing 16. This is Step 2 of the assembly process and is illustrated in Figure 5. As shown, half sheet corrugated panel 12A with handle mounted bracket 18 located thereon is positioned within the space of the backing flashing 16. Handle mounting bracket 18 is positioned so that that the edge face 18A

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2015101935 06 Mar 2015 of the mounting bracket 18 is located between the edge 12A’ and the first length part of the peripheral edge 16B of the backing flashing 16. A part of the front face 18B of the handle mounting bracket 18 adjacent most to the edge face 18A is positioned in contact with or closely adjacent to an underside part of the adjacent length panel of the front edge 16C of the backing flashing 16. Accordingly that part of the front face 18B of the handle mounting bracket 18 is hidden from view by the length panel of the front edge 16C of the backing flashing 16.

[0034] The upper and lower width edges of the half sheet panel 12A are positioned in contact with or closely adjacent to an underside of the associated width panel of the front edge 16C of the backing flashing 16.

[0035] The adhesive applied to the half sheet corrugated panel 12A helps to secure the half sheet corrugated panel 12A to the backing flashing 16.

[0036] Step 3 of the assembly process is shown in Figure 6. The full sheet corrugated panel 12B is firstly trimmed to remove the underlap of the corrugated panel 12B. The trimmed edge is then folded at 90° to form edge 12B’ (See detail D of Figure 6).

[0037] Adhesive is applied to the outer peaks 12B” of the full sheet corrugated panel 12B and to the edge 12B’ of the full sheet corrugated panel 12B. Adhesive is further preferably applied to the width edges of the full sheet corrugated panel 12B.

[0038] The full sheet corrugated panel 12B is then adhered to the backing flashing 16 after properly positioning the full sheet panel 12B with respect to half sheet panel 12A and the backing flashing 16. More particularly, the full sheet panel 12B is located so that the untrimmed longitudinal edge of the full sheet panel 12B is positioned on top of the untrimmed longitudinal edge of the half sheet panel 12A, and edge 12B’ is located in contact with or closely adjacent to the second length panel of the peripheral edge 16B of the backing flashing 16. The upper and lower width edges of the full sheet panel 12B are positioned in contact with or closely adjacent to an underside of the associated width panel of the front edge 16C of the backing flashing 16. The full sheet corrugated panel 12B is located within the space of the backing flashing 16.

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2015101935 06 Mar 2015 [0039] Step 4 is the final assembly step for the door 10. As part of Step 4, rivets 22 are applied to join the components of the composite panel. Rivets are applied at each of the corners of the backing flashing 16 joining the overlapping length and width panels of the front edge 16c to the adjacent half or full corrugated panel 12A, 12B. Rivets 22 are also applied along the overlap of the half and full corrugated panels 12A, 12B. Further, rivets 22 are applied to join the peaks 12A’, 12B” to the width panels of the front edge 16C of the backing flashing 16.

[0040] Hinges 20 are then mounted to the completed composite panel (shown fitted with the handle mounting bracket 18) to complete the door 10. Figure 8A and 8B illustrate two arrangements for connection of a hinge 20 or other connector to a complete composite panel in accordance with an embodiment of the invention.

Figure 8A illustrates the hinge 20 connected to a composite panel as described and illustrated with reference to Figures 1 to 7. The composite panel shown in Figure 8B is different to that shown in Figure 8A as it additionally includes a reinforcing channel 100 located between the length of the panel 12B and the length panel of the peripheral edge 16B of the backing flashing 16. Reinforcing channel 100 is configured to fit over the length edge of the panel 12B and provided additional strength and rigidity, particularly in relation to any connection made through the length panel of the peripheral edge 16B of the backing flashing 16.

[0041] It is envisaged that the backing flashing 16 would be held in a jig during assembly of a composite panel and that it may be necessary to hold one or more of the panels that form the peripheral edge 16B and/or front edge 16C away from the back panel 16a so as to enable proper positioning of the half and full corrugated panels 12A, 12B within the space of the backing flashing 16. The panel(s) of the peripheral edge 16B may be held in the required position during assembly by clamps, those clamps being released once the half and full corrugated panels 12A, 12B are properly positioned within the space of the backing flashing 16. When the clamps are released the panels of the front edge 16C tend to squash the corrugated panel 12A, 12B located within the space of the backing flashing 16 providing a connection therebetween.

[0042] A composite panel made in accordance with an embodiment of the invention is advantageous because it provides a composite panel which is cost

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2015101935 06 Mar 2015 effective to manufacture, is relatively light weight and offers improved strength as compared to a single corrugated sheet panel. The composite panel is simple to manufacture, without the need to handle foams or other like materials typically used to form the core or another layer of a composite panel that bonds to the corrugated layer.

[0043] The composite panel has a unique appearance in that the outer face is corrugated and the inner face (i.e. the outer side of the back panel 16A) is flat. The inner face may be painted and may also be used as a planar display surface (e.g. for displaying advertising information) or planar attachment surface.

[0044] It is envisaged that in accordance with another embodiment of the invention (not illustrated) a flat panel could be located on top of or over the corrugated panel so that the resultant composite panel includes at least the corrugated panel, the second member and the flat panel. Such a composite panel would then have a flat inner face and a flat outer face. The flat panel may be located within the space of the second member or may be secured externally to the second member.

[0045] There are several features of the described embodiments of the invention that provide the described panel with improved strength and rigidity. These features include:

• The use of the corrugated panel 12A, 12B to support the flat back panel 16a of the backing flashing 16. Prior art composite panels provide support to a flat panel using plastic, foam, wood or honeycomb structures. Such materials and structures are more difficult to work with and/or manufacture.

• Rigidly connecting the corrugated panel 12A, 12B to the backing flashing 16 preferably along the peaks 12A”, 12B” of the corrugated panel 12A, 12B creates tubular structures within the composite panel and this establishes a composite panel with high longitudinal bending strength and rigidity.

• Enclosing all side edges of the composite panel and rigidly connecting the corrugated panel 12A, 12B and the second members provides improved torsional and shearing strength and improved rigidity. Adhesive, rivets and/or squash folds are used to provide this connection in accordance with the

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2015101935 06 Mar 2015 described embodiment. However, any number or combinations of different mechanical connections could be provided to establish the required connection.

[0046] Composite panels made in accordance with an embodiment of the invention may offer other advantages. Such advantages may include:

• Improved recyclability where the components of the composite panel are made from the same material.

• An ability to use different materials for the components of the composite panel. For example, for building facades it may be desirable for the composite panel to have either an inner or outer face made form a decorative material, for example copper.

• Ease of manufacture by virtue of the composite panel being made on a roll former.

[0047] The embodiments have been described by way of example only and modifications within the spirit and scope of the invention are envisaged.

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Claims

Claims

1. A composite panel including at least one corrugated panel located within a space defined by a second member.
2. A composite panel according to claim 1 wherein the second member includes a back panel, a peripheral edge and a front edge and the space is bounded, at least in part, by the back panel, the peripheral edge and the front edge.
3. A composite panel according to claim 2 wherein the back panel is substantially flat.
4. A composite panel according to any one of claims 1 to 3 wherein the second member is formed from a single panel.
5. A composite panel according to claim 4 wherein the panel has cut-outs at each corner.
6. A composite panel according to claim 5 wherein the cut-outs are square.
7. A composite panel according to claim 5 or claim6 wherein the panel is folded at about 90° along respective fold lines to form an open box configuration.
8. A composite panel according to claim 2 wherein the peripheral edge is made from four panels, two length panels and two width panels and the front edge is made from four panels, two length panels and two width panels.
9. A composite panel according to claim 8 wherein the front edge acts as a flashing.
10. A composite panel according to any one of the preceding claims where the second member establishes both a backing for the composite panel and flashing of the composite panel.
11. A composite panel according to any one of the preceding claims wherein the at least one corrugated panel is connected and/or adhered to the second member.

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12. A composite panel according to claim 11 wherein the at least one corrugated panel is connected to the second member by at least one screws or rivet.
13. A composite panel according to claim 11 or claim 12 wherein the connection establishes tubular structures.
14. A composite panel according to any one of the preceding claims wherein the second member is a flat metal panel.
15. A composite panel according to any one ofthe preceding claims further including a flat panel located on top of or over the corrugated panel.
16. A composite panel according to claim 15 wherein the flat panel is located within the space ofthe second member.
17. A door including a composite panel, the composite panel in accordance with any one of claims 1 to 16.
18. A door according to claim 17 further including at least one hinge connected to the second member.
19. A door according to claim 17 or claim 18 further including at least one hinge connected to a length edge ofthe composite panel.
20. A door according to any one of claims 17 to 19 further including a handle mounting bracket and /or handle.

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