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(11) | EP 0 164 952 A2 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | Composite panel, manufacture thereof and use thereof in cladding a roof or wall of a building |
| (57) The invention relates to a composite panel for cladding a roof or wall of a building,
comprising a block of insulating material (1) one or more, rigid shaped plates (3)
abutting the surface of the black and collectively covering at least the periphery
of the underside thereof and extending beyond the block to form a flange (4), and
a layer of laminated plastics material (2) covering and adhering to the upper surface
of the block and extending to cover and adhere to the adjacent surface of the flange. The invention also relates to a method of manufacturing such a composite panel, and a cladding for a roof or wall of a building comprising an array of such panels. |
[0001] This invention relates to a composite panel, the manufacture thereof and the use thereof in cladding a roof or wall of a building.
[0002] GB-A-2115346 describes a preformed composite panel for use in the construction of a roof, comprising a layer of glass reinforced plastic (GRP) which has been laminated onto a layer of insulating material, such as a block of polyurethane foam. Such panels may be arranged on the roof and secured thereon by fixing means passing through edge portions of GRP, the joints between adjacent panels being protected by laminating GRP thereon in situ.
[0003] The lamination of GRP in situ requires a considerable degree of skill and experience on the part of the workman performing the task. It is also dependent on suitable weather conditions. In cold weather more hardener is needed, and the resin may then set prematurely. Also, the resin does not set satisfactorily if it gets wet.
[0004] An object of. the present invention is to eliminate the necessity for laminating. GRP in situ and to provide alternative means for sealing the joints between adjacent composite panels and fixing the panels to the building structure. Another object of the invention is to provide the panels with edges of different shapes using rigid shaped plates (referred to as forming pieces), whilst still enabling the panels to be made to varying shapes and sizes on a flat table without the need for a mould.
[0005] The present invention thus provides a composite panel for cladding a roof or wall of a building, comprising a block of insulating material, one or more rigid shaped plates abutting the surface of the block and collectively covering at least the periphery of the underside thereof and extending beyond the block to form a flange, and a layer of laminated plastics material covering and adhering to the upper surface of the block and extending to cover and adhere to the adjacent surface of the flange.
[0006] The invention also provides a method of manufacturing a composite panel, which comprises placing one or more rigid shaped plates around the periphery of a block of insulating material on a flat surface, the plates collectively abutting at least the periphery of the underside of the block and extending beyond the block to form a flange; preventing relative movement of the block, shaped plates and flat surface; and laminating plastics material over the exposed upper surface and any exposed side surface of the block and over the adjacent surface of the flange, whereby the plastics material adheres on setting to the block and to the flange.
[0007] The invention further provides a cladding for a roof or wall of a building, comprising an array of preformed composite panels as defined above, wherein adjacent panels in the array are slightly spaced apart and respective adjacent edges have upwardly extending flanges; a capping piece of substantially inverted U-section positioned to overlap and shroud the flanges and abut the upper surfaces of the respective panels; and fixing means to fix the capping piece to the roof or wall in the space between the panels.
[0008] The insulating material in each panel is preferably a closed cell plastic foam, in particular a block of rigid polyurethane foam. The forming pieces and the capping piece are preferably made of GRP. The laminated plastics material is also preferably GRP. Insulating material is preferably disposed in the space between adjacent panels, and preferably comprises a flexible plastics foam.
[0009] Reference is now made to the accompanying drawings, in which:
Figure 1 is a transverse section (relative to the line of fall of the roof). showing the joints between adjacent-panels in a roof cladding according to a preferred embodiment of the invention;
Figure 2 is a longitudinal section showing the use of the panels in a roof construction;
Figure 3 illustrates an adjustable joint between the end of a panel forming part of a roof cladding and an adjacent wall;
Figure 4 is a longitudinal section showing two panels overlapping lengthwise;
Figure 5 shows an alternative method of overlapping panels lengthwise; and
Figure 6 shows how a forming piece can be used to provide a different shape of the end or side of a panel.
[0010] Panels according to the invention are made as follows. A generally rectangular block of rigid polyurethane foam 1 is cut to the desired size for the panel. Forming pieces 3 of GRP of generally L-shaped cross-section are arranged around the sides of the block so that they press against the side edges of the block and extend under the peripheral part of the underside of the block. The forming pieces are clamped to a flat surface, such as a table, and the block is pressed down between them, so that the whole is held rigidly. A layer 2 of GRP is then laminated over the upper surface of the block and the adjoining exposed surface of the forming pieces, in the following manner. A layer of resin containing hardener is first painted on the surface. While the resin is still liquid a layer of glass fibre matting is laid over it and rolled in, then further resin is added until the glass fibre is saturated. As the resin sets it-adheres to the block and to the forming pieces, so that the block becomes permanently sandwiched between the laminated GRP and the forming.-pieces. After at least partial hardening, a top coat of resin is painted on to give a smooth final finish.
[0011] Where a forming piece has a depending flange instead of an upstanding flange, then of course the GRP layer 2 is laminated over the adjoining side of the block in addition to the top surface of the block and the surface of the flange, so as to form a continuous layer.
[0012] It will be appreciated that a mould is not required for the formation of a composite panel as described above, with consequent savings in cost. All that is required is a flat working surface. The resin does not spread onto this surface because it is prevented from doing so by the forming pieces. There is therefore no need to use wax or a mould release agent as in GB-A-2115346.
[0013] The panels can be made to any size up to the maximum suitable for handling on a roof. Forming pieces and strengthening pieces (shown at 14 in Figure 2) are premade in standard moulds and can be kept in stock. They are cut to the required lengths and placed on the flat working surface. Bars of wood or metal are clamped to the flat surface to support the forming pieces, and the rigid foam 1 cut to pieces of the required size is pressed down between the forming pieces. More than one block can be used in a single panel and strengthening pieces can then be placed between the blocks of foam to give additional rigidity. The forming pieces are prevented from moving by the foam and bars clamped to the flat surface to prevent outward movement. An alternative method of holding the forming pieces in place is to use adhesive tape. The GRP layer 2 is then laminated over the-foam and the forming and strengthening pieces, to produce a panel of the required size and configuration. The forming pieces and strengthening pieces also prevent the liquid resin penetrating to the flat surface and causing adhesion of the foam to the surface.
[0014] As shown in Figure 1, each panel thus comprises a block of rigid polyurethane foam 1 onto which has been laminated a layer of GRP 2. The forming piece 3 of GRP covers the sides of the panels and a peripheral portion of the underside. A raised rim 4 is formed from an upstanding flange of the forming piece 3 and additionally has GRP laminated- thereon. When the panels are used in roof construction, the upstanding flanges 4 are approximately parallel with the line of fall on the roof. The upper end of each panel (in the longitudinal direction) also has a raised rim, and at the lower end the layer 2 is continued over the side of the panel and joins with the corresponding forming piece to form a dependent flange, as described below with reference to Figure 2.
[0015] Adjacent panels are laid, for example on a roof, with a small gap between them as shown in Figure 1. A capping piece 5 of GRP, having an inverted channel shape, is placed over the-raised rims 4 so that it overlaps and shrouds the rims and a peripheral portion of the'panels. The capping piece is fixed, for example by screws or nails 6, to the timbers of the roof 7. The edges of the capping piece thus hold the panels firmly against the roof. The capping piece has dimensions suitable for the panels. The top edge (in the longitudinal direction) is raised and laps the raised edges of the panels, and the bottom edge also laps the panels and descends over the fascia, as described below with reference to Figure 2. Before the capping piece is fixed in position, a liquid foam 8 is injected into the space between the adjacent panels and bonds at the bottom of the roof structure and at the top to the capping piece, and also to the edges of the panels. When this foam has set it forms continuous insulation so that condensation caused by uninsulated areas of the roof covering is eliminated. The foam is preferably flexible and has good adhesive properties so that a secondary seal is formed against the entry of water.
[0016] Figure 2 is a longitudinal section of a roof cladding showing the shaped upper and lower ends of the panels and the capping pieces. This embodiment applies to a flat roofed house extension. The raised rim at the upper end of the panel is extended as shown at 9 and the capping piece has a corresponding raised end 10. The latter abuts against a side wall 11 of the house and is covered by a flashing'12. The space between the upper end of the panel and the wall 11 is filled with flex- ib-le foam 15 in situ in the same way as the foam 8 in Figure 1.
[0017] At the lower end of the panel, the forming piece 3 is continued downwardly as a dependent flange, together with a downward extension of the laminated layer 2, to overlap the fascia 13. The lower end of the capping piece 5.is similarly shaped downwardly.
[0018] The arrangement described above eliminates the necessity for laminating GRP in situ. Any experienced bui.lder will be able to apply the panels either to a new roof or to recover and old roof. Since only the capping pieces are fixed to the roof structure, the panels are free to expand and contract with heat or cold without exerting any strain on the joints or panels. The capping piece is made of relatively thick GRP to withstand any strain and since the fixing passes through the capping piece 5 cm or more above the roof there is some flexibility in the fixing. This flexibility is enhanced by the flexible foam 8 which is applied in situ. It is not desirable for the capping pieces to be longer than 2 or 3 metres, to keep the strain on the fixings low. Capping pieces can be made to overlap one another.
[0019] If it is considered desirable to manufacture and stock a range of standard size panels, the system can be adapted to give flexibility enabling the panels to be used on roofs which are not exactly of standard size. The capping pieces can be made wider so that the gap between panels can be varied.
[0020] Figure 3, showing the joint between the upper end of a panel and a side wall corresponding to that shown in Figure 2, illustrates a method of varying the distance between the upper end of the panel and the wall. A shaped fixing piece 16 is bolted to the raised edge of the panel and capping piece. It can span several panels. A special skirting 17 is then bolted to the fixing piece so that the gap between the end of the panel and the wall is spanned.
[0021] If it is desired to cover a roof requiring longer panels than are suitable for handling, two or more panels can be used by raising the height of the top panel and forming a step in the roof. This is shown in Figure 4, where the roof has a slight s'lope from left to right. Again, the overlap of the top panel can be varied to comply with the roof dimensions. The capping pieces are also made to overlap, the top one having to fit over the bottom one and at its lower end descent to the top of the lower panel. It is made to a length to comply with the top panel.
[0022] Figure 5 is a longitudinal section showing an alternative method of joining panels lengthwise and is analogous to Figure.4, except that-the roof slopes slightly from right to left. The forming piece of the upper panel has a shaped flange 18 which extends to overlap and abut the upper surface of the other panel.
[0023] The flanges of the forming pieces can assume a variety of shapes, according to the design of the roof and the relative positions of the panels in the array. Figure 6 is a section showing a flange, with its affixed laminated GRP layer, which is used for an end of a flat roof which has a raised rim.
1. A composite panel for cladding a roof or wall of a building, comprising a block
of insulating material, one or more rigid shaped plates abutting the surface of the
block and collectively covering at least the periphery of the underside thereof and
extending beyond the block to form a flange, and a layer of laminated plastics material
covering and adhering to the upper surface of the block and extending to cover and
adhere to the adjacent surface of the flange.
2. A panel according to claim 1, wherein the insulating-material is a closed cell
plastics foam.
3. A panel according to claim 1, wherein the insulating material is rigid polyurethane
foam.
4. A panel according to claim 1, wherein the rigid shaped plates are of glass-reinforced
plastic -(GRP).
5. A panel according to claim 1, wherein the block is generally rectangular and has
rigid shaped plates along at least two opposing sides which cover the periphery of
the underside and the adjacent edges of the block and extend upwardly to form flanges
in the form of raised rims.
6. A panel according to claim 5, wherein a rigid shaped plate along one side of the
block covers the periphery of the underside and extends downwardly to form a depending
flange, the layer of plastics material covering the side surface of the block adjacent
the depending flange as well as the surface of the flange itself.
7. A panel according to claim 1, wherein the laminated plastics material is GRP.
8. A method of manufacturing a composite panel, which comprises placing one or more
rigid shaped plates around the periphery of a block of insulating material on a flat
surface, the plates collectively abutting at least the periphery of the underside
of the block and extending beyond the bl.ock to form a flange; preventing relative
movement of the block, shaped plates and flat surface; and laminating plastics material
over the exposed upper surface and any exposed side surface of the block and over
the adjacent surface of the flange, whereby the plastics material adheres on setting
to the block and to the flange.
9. A cladding for a roof or wall of a building, comprising an array of preformed composite
panels according to claim 1, wherein adjacent panels in the array are slightly spaced
apart and respective adjacent edges have upwardly extending flanges; a capping piece
of substantially inverted U-section positioned to overlap and shroud the flanges and
abut the upper surfaces of the respective panels; and fixing means to fix the capping
piece to the roof or wall in the space between the panels.
10. A cladding according to claim 9, wherein insulating material comprising a flexible
plastics foam is disposed in the space between adjdcent panels.
11. A cladding according to claim 9, wherein spaces between panels transverse to the
spaces covered by a capping piece are covered by a shaped flange of one of two adjacent
panels extending to overlap and abut the upper surface of the other panel.
12. A cladding according to claim 11 for a roof, wherein spaces between panels parallel
to the line of fall of the roof are covered by capping pieces, and spaces transverse
to the line of fall of the roof are covered by overlapping flanges of the upper panels
adjacent each such space.