AU2002309202B2 - An insulated panel - Google Patents

Description

"An insulated panel"

Introduction

The invention relates to an insulated panel of the type comprising a profiled external sheet, an internal liner sheet, and an insulating core between the external sheet and the liner sheet.

Various panels of this type are known. There is, however, a need for an improved construction of panel which will facilitate a highly sealed joint between adjacent panels for improved insulation and fire performance which will be economic to manufacture and readily easily assembled to similar panels. In particular, there is a need for a panel of this type which will be substantially air-tight for use particularly for cold-stores and the like.

Statements of Invention

According to the invention there is provided an insulated panel comprising:-

an external sheet;

an internal sheet;

an insulating core between the external sheet and the internal sheet;

the external sheet and internal sheet having profiled joint forming portions for connecting adjacent panels;

the external sheet being turned back to define a male projecting part on one side and a female recess part on an opposite side; the internal sheet being turned back to define a male projecting part on one side and a female recess part on an opposite side;

the insulating core extending between the internal and external recess and projecting parts;

the male projecting parts engaging in the corresponding recess parts on assembly of adjacent panels, and the insulating cores of adjacent panels between the internal and external parts engaging to provide an insulated substantially air tight joint on assembly of adjacent panels.

In one embodiment of the invention the insulating core at the joint between adjacent panels is of generally trapezoidal shape. Preferably the web of the trapezoidal section of the insulating core extends at an angle of from 100° to 120° to the base or top of the trapezoidal section. Ideally the angle is approximately 110°.

In another case the or each male projecting part comprises an outwardly extending leg and an inwardly extending leg which define a region therebetween which is filled with the insulating core material. Preferably the outwardly extending leg extends at an angle of from 15° to 25° to the horizontal. The inwardly extending leg preferably extends at an angle of from 2° to 8° to the horizontal. Ideally the outwardly extending leg extends at an angle of approximately 19°. Most preferably the inwardly extending leg extends at an angle of approximately 5° to the horizontal.

In a preferred embodiment the corresponding female recess part is of substantially the same profile as that of the male projecting part.

Desirably the internal and external sheets include clip defining end sections which are embedded in the insulating core. Preferably adjacent panels, on assembly, define an outer gap therebetween of from 2 mm to 5 mm. Most preferably the gap is approximately 3 mm.

In a preferred embodiment a male projecting part defines together with a female recess part of an adjacent panel, on assembly, a recess for receiving a seal.

In a particularly preferred embodiment the external and/or internal sheets define, on assembly of adjacent panels, a trap for holding a seal in the joint between the panels. Preferably the male part of the external and/or internal sheet has an outwardly extending leg and the trap is defined by a seal receiving recess in the outwardly extending leg. Preferably the female part of the external and/or internal sheet has an outwardly extending leg and the trap is defined by an angled lead-in portion of the outwardly extending leg.

The invention also provides an insulated panel assembly including a plurality of the panels of the invention.

Brief Description of the Drawings

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

Fig. 1 is a cross sectional view of a panel according to the invention;

Fig. 2 is a side cross sectional view of portion of two adjacent panels according to the invention separated;

Fig. 3 is a side cross sectional view of the panels jointed together; Fig. 4 is a cross-sectional view similar to Fig. 3 with seals in place; and

Fig. 5 is a side cross-sectional view of alternative panels jointed together.

Detailed Description of the Drawings

Referring to the drawings and initially to Figs 1 to 4, there is illustrated an insulated panel 1 according to the invention and comprising an external sheet 2, an internal sheet 3 and an insulating core 4 between the external sheet 2 and internal sheet 3. The sheets 2 and 3 are typically of steel material and the core 4 is of polyurethane or polyisocyanurate foam material which fills the space between the sheets 2, 3. The panel 1 is in this case typically used for cold-stores.

The external sheet 2 and internal sheet 3 have profiled joint-forming portions for connecting adjacent panels, on assembly as illustrated.

The external sheet 2 has an external male projecting part 10 and an internal male projecting part 11 on one side for engagement, on assembly, with a corresponding external recess or female part 12 and internal recess or female part 13 respectively on the opposite side of the panel. A seal 52, 53 may be placed in one or both of the recesses 12, 13 for sealing engagement, on assembly, with the male projecting parts 10, 11 of an adjacent panel. The seals are typically of silicone and are site-applied.

Both the external sheet 2 and the internal sheet 3 are turned back to define a male projecting part 10, 11 on one side and a female recess part 12, 13 on an opposite side of a panel. Each male part 10,11 comprises an outwardly extending leg 20 and an inwardly extending leg 21 which terminates in a clip portion 22 which is embedded in the insulating core 4. The corresponding recesses 12, 13 are formed by similarly shaping the ends of the external and internal sheets 2, 3. The recesses 12, 13 are defined by an outwardly extending leg 24 and an inwardly extending leg. Again, the sheets 2, 3 terminate in clip portions 23 which are embedded in the insulating core 4.

The outwardly extending leg 20 extends at an angle θ of from 15° to 25°, ideally about 19° to the horizontal. The inwardly extending leg 21 extends at an angle β of from 2° to 8°, ideally about 5° to the horizontal. This facilitates ease of engagement of a male projecting part in a corresponding recess whilst ensuring adequate insulation at the joint and facilitating filling of the area defined by the male projecting part with foam on manufacture of a panel.

The insulating core at the edges of the panel between the joint forming portions engage on assembly as illustrated in Fig. 3 to provide an insulated substantially airtight joint. In this case the exposed section of the insulating core is of generally trapezoidal shape with a male part 30 defined at one edge and a female recess part 31 defined at an opposite edge. The webs of the trapezoidal sections of the insulating core extend at an angle of from 100° to 120°, ideally about 110° to the base or top of the trapezoidal section. Thus, the angle α is about 20°. This facilitates effective jointing whilst facilitating economic manufacture of the panel.

On assembly, the exposed gap g is about 3 mm to facilitate expansion and contraction, in use.

A seal trap is also provided at the joint between the panels at least on one of the inside and outside, in this case on both the inside and outside. The seal trap is defined by a recess 40 provided in the outwardly extending leg 20 of the male projections 10, 11 and an angled lead-in portion 41 of the sheets 2, 3. After on-site assembly of the panels, a waterproof sealant 50 such as a gun applied silicone may be injected into the region defined by the recess 40 and lead-in portion 41 through the outer and/or inner gap. The sealant 50 becomes trapped between 40 and 41 and is firmly retained in situ, on setting. This is important in ensuring that the integrity of the seal 50 is maintained when the exposed walls of the panels are washed for cleaning, in use, even when cleaning is carried out using pressure jet washing.

In use, the panels may be overlapped either vertically or horizontally. Typically an end bearer is used to start a panel assembly, the end bearer having a head part for engagement in a female recess 12 of the external sheet 2 of a first panel. The other side of the first panel is then fixed in place by a fastener. This side of the first panel is then engaged with the mating side of a second panel. Construction is continued in this way. After on-site construction, fixing pins may be inserted, and a seal may be applied to ensure the integrity of the joint especially in environments in which the inner wall requires washing, for example in food applications.

Example

Panels of the type Figs 1 to 3 with a thickness of 150 mm were tested for fire resistance using the test method described in BS476 part 22 (1987), clauses 5 (wall test) and 9 (ceiling test). The test results are described using the terms insulation and integrity. Both are in units of minutes:-

a) Wall Test (Clause 5)

Insulation : 47 minutes

Integrity : 48 minutes b) Ceiling Test (Clause 9)

Insulation : 52 minutes

Integrity : 132 minutes

Referring to Fig. 5 there is illustrated a joint between adjacent alternative panels according to the invention. The panels are of similar construction to those of Figs 1 to 4 and like parts are assigned the same reference numerals. In this case, the panels are thinner and the joint between the insulation foam body is smaller.

The invention provides an insulated panel with side edges which are arranged for highly efficient insulation and sealing.

It will be appreciated that the panels may be provided with opposite side edges or two different panels with a similar profile on both side edges may be provided.

The invention is not limited to the embodiments hereinbefore described which may be varied in construction and detail.

Claims (19)

Claims

1. An insulated panel comprising:-

an external sheet;

an internal sheet;

an insulating core between the external sheet and the internal sheet;

the external sheet and internal sheet having profiled joint forming portions for connecting adjacent panels;

the external sheet being turned back to define a male projecting part on one side and a female recess part on an opposite side;

the internal sheet being turned back to define a male projecting part on one side and a female recess part on an opposite side;

the insulating core extending between the internal and external recess and projecting parts;

the male projecting parts engaging in- the corresponding recess parts on assembly of adjacent panels, and the insulating cores of adjacent panels between the internal and external parts engaging to provide an insulated substantially air tight joint on assembly of adjacent panels.

2. An insulated panel as claimed in claim 1 wherein the insulating core at the joint between adjacent panels is of generally trapezoidal shape.

3. An insulated panel as claimed in claim 2 wherein the web of the trapezoidal section of the insulating core extends at an angle of from 100° to 120° to the base or top of the trapezoidal section.

4. An insulated panel as claimed in claim 3 wherein the angle is approximately

110°.

5. An insulated panel as claimed in any preceding claim wherein the or each male projecting part comprises an outwardly extending leg and an inwardly extending leg which define a region therebetween which is filled with the insulating core material.

6. An insulated panel as claimed in claim 5 wherein the outwardly extending leg extends at an angle of from 15° to 25° to the horizontal.

7. An insulated panel as claimed in claim 5 or 6 wherein the inwardly extending leg extends at an angle of from 2° to 8° to the horizontal.

8. An insulated panel as claimed in claim 6 or 7 wherein the outwardly extending leg extends at an angle of approximately 19°.

9. An insulated panel as claimed in claim 7 or 8 wherein the inwardly extending leg extends at an angle of approximately 5° to the horizontal.

10. An insulated panel as claimed in any of claims 5 to 9 wherein the corresponding female recess part is of substantially the same profile as that of the male projecting part.

11. An insulated panel as claimed in any preceding claim wherein the internal and external sheets include clip defining end sections which are embedded in the insulating core.

12. An insulated panel as claimed in any preceding claim wherein adjacent panels, on assembly, define an outer gap therebetween of from 2 mm to 5 mm.

13. An insulated panel as claimed in claim 12 wherein the gap is approximately 3 mm.

14. An insulated panel as claimed in any preceding claim wherein a male projecting part defines together with a female recess part of an adjacent panel, on assembly, a recess for receiving a seal.

15. An insulated panel as claimed in any preceding claim wherein the external and/or internal sheets define, on assembly of adjacent panels, a trap for holding a seal in the joint between the panels.

16. An insulated panel as claimed in claim 15 wherein the male part of the external and/or internal sheet has an outwardly extending leg and the trap is defined by a seal receiving recess in the outwardly extending leg.

17. An insulated panel as claimed in claim 15 or 16 wherein the female part of the external and/or internal sheet has an outwardly extending leg and the trap is defined by an angled lead-in portion of the outwardly extending leg.

18. An insulated panel substantially as hereinbefore described with reference to accompanying drawings.

19. An assembly comprising a plurality of panels as claimed in any preceding claim.