INSULATED PANEL AND INTERLOCK MECHANISM THEREOF
FIELD OF THE INVENTION
The present invention relates to insulated building panel according to the preamble of claim 1 , and particularly to an insulated building panel hav- ing first and second side edges connectable to second and first side edges of a like adjacently positioned second panel respectively, the panel comprising: oppositely positioned first and second relatively thin metal sheets forming first and second side faces of the panel respectively, at least one of the said metal sheets further forming longitudinally extending first and second male side edge connectors on the first side edge of the panel and longitudinally extending first and second female side edge connectors on the second side edge of the panel, the male side edge connectors and female side edge connectors being arranged to be respectively joined with female and male side edge connectors of a like adjacently positioned second panel for interlocking the panel to a sec- ond panel; and central core insulating material arranged between the first and second metal sheet. The present invention relates also to a interlock mechanism for an insulated building panel according to the preamble of claim 24, and particularly to an interlock mechanism for insulated building panels, the interlock mechanism comprising one or more longitudinally extending tongue pro- vided on a first side edge of a first panel, one or more longitudinally extending generally U-shaped or V-shaped or at least partially tapering shaped groove provided on a second side edge of the first panel, the tongues and grooves being arranged to be respectively joined with grooves and tongues of a like adjacently positioned second panel for interlocking the first panel to a second panel.
BACKGROUND OF THE INVENTION
Insulated building panels having two oppositely positioned thin metal sheets forming the side faces of the panel and a central core insulating material provided between the metal sheets. This kind of insulated panels are joined together from side edges with interlock, tongue-and-groove or butment joints. These joints have usually one, two or possibly more respectively interlocking female and male connector elements. Accordingly the male connector elements extend along the first side edge of the panel, preferably along the entire length of the first side edge, and female side edge connector elements
extend along the second side edge of panel, preferably along the entire length of the second side edge. Each panel is therefore configured to be joined with a like adjacent second panel such that the male connector elements on the first side edge of a panel interlock with the female connector elements on the sec- ond side edge of a like adjacent second panel.
One of the problems with the prior art joints between two adjacent panels is that the female and male connectors do not provide a tight joint that would prevent moisture, gases and heat from passing through the joint from one side of the panel to the other side of the panel or inside the panel. Another disadvantage of the prior art is that in a case of fire the prior art joints tend to open damaging the panels and therefore structures consisting of several panels and the fire may spread to bearing structures and other parts of a building. This endangers safety of the building such that fire gases may pass through the joints of the panels and the fire may spread and hazardous gases will con- vey to possible other parts of a building.
Furthermore, for providing tight joints between two adjacent panels the female connector are in many cases provide with a sealing element that is mounted on the bottom of the female connector such that the sealing element is compressed between the bottom of the female connector and front end of the male connector. This sealing element seals the joint preventing moisture, heat and gases from passing through the joint from one side of the panel to the other side of the panel.
One of the problems associated with these joints is that the sealing element usually tends to escape, move or slip away from the bottom of the fe- male connector when building panels are mounted and joined together and further removed from each other and from the abutment to each other. This escaping of the sealing element may also happen due to thermal deformations of the panels or the metal sheets of the panels. Typically the sealing element tends to move away from the joint causing the sealing of the joint to weaken. This is especially the case when adjacent together joined panels has to be disengaged from each other, the sealing element tends to drop or move away from the bottom of the female connector. Therefore the sealing element may be absent when the building panels are mounted together again. This weakening of the sealing of the joint endangers safety of the building such that fire gases may pass through the joints of the panels and the fire may spread and hazardous gases will convey to possible other parts of a building. Also mois-
ture may pass through the joints to other part of the building and inside the building panel.
BRIEF DESCRIPTION OF THE INVENTION An object of the present invention is to provide an insulated building panel and an interlock mechanism thereof so as to overcome the above disadvantages. The objects of the invention are achieved by an insulated building panel that is characterized in that the at first and/or second of the female side edge connectors are formed to have a substantially uniform width or at least partially tapering profile towards the bottom of the female side edge connector, and that the first and/or second male side edge connectors, respectively, are formed to deform resiliently when received in the respective female side edge connector for generating a biasing force against the female side edge connector. The objects of the invention are further achieved by an interlock mecha- nism that is characterized in that the at least one tongue is provided with a resilient spring element deforming when received in the respective groove and generating a biasing force against the inner sidewalls of the groove through the deformation.
The preferred embodiments of the invention are disclosed in the de- pendent claims.
The invention is based on the idea of providing a insulated panel having two oppositely arranged thin metal sheets and a central core insulating material between the metal sheets with an interlock mechanism having male and female, or groove and tongue, connectors provided on the side edges of the building panel. The male connectors or some of the male connectors extend longitudinally preferably and generally along the whole length of the side edge of a panel, and they are formed such that they compress or deform resiliently as they are installed into the respective female connectors. The male and female connectors are formed such that the male connector biases and/or provides a force against the sidewalls on the generally groove shaped female connector. The female connectors are formed such that they have a uniform or tapering width from the open upper part of the groove towards the bottom of the groove. Therefore the male connectors are formed such that they compress or deform biasing against the sidewalls of the female connector trans- verse to the longitudinal direction of the female connector. This biasing force is
applied to the female connector preferably along the whole length of the female connector and along the entire length of the side edge of the panel.
An advantage present invention is that it produces a force that seals tightly the joints between two adjacent panels and prevents or the joint from opening in a case of fire as well provides an easy interlocking of two adjacent panels. The panel and interlock mechanism of the panel therefore provides a strong seal between the adjacent panels without any additional gaskets, sealing materials or locking members. Thus the invention enhances the structural characteristics as well as the sealing properties of an insulated building panel.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following the invention will be described in greater detail by means of preferred embodiments with reference to the attached drawing, in which
Figure 1 is schematic view building panels and the interlock mecha- nism thereof according to the present invention;
Figures 2A and 2B show partial cross section of a building panel according to one embodiment of the present invention; and
Figure 3 shows an interlock mechanism for a building panel according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Figure 1 shows a section of two adjacent interlocked building panels 2, 3. The building panels 2, 3 comprise a first and second oppositely positioned first and second relatively thin metal sheets 8, 10 forming first and second side faces of the panels 2, 3 respectively. Between the metal sheets 8, 10 is provided a central core insulating material 12 that may be attached to the metal sheets 8, 10 for example by gluing or some other way. The insulating material 12 may be any possible material that provides sufficient insulation and structural rigidity for the panel 2, 3. Each panel 2, 3 have also first and second side edges 5, 7, which are provided with male and female side edge connectors, respectively. In use these the side edges 5 and 7 extend generally horizontally. It should be noted that the panels comprise also third and fourth side edges, which in use extend generally vertically. Also the third and fourth side edges may be provided with male and female side edge connectors of the same type as the first and second side edges, if desired.
According to the state of the art male and female side edge connectors are provided by forming, bending or the like the metal sheets 8 and 10. This forming may be accomplished by making the metal sheets 8, 10 extend over the insulating material 12 in the edge region of the panel 2, 3 and roll forming the edge regions of the metal sheets 8, 10 such that the metal sheets 8, 10 at the first side edge 5 of the panel 2, 3 generate one or more male side edge connectors 14, 16 projecting first side edge 5 of the panel 2, 3, and that the metal sheets 8, 10 at the second side edge 7 of the panel 2, 3 generate one or more female side edge connectors 18 , 20 configured to receive the respective male side edge connectors 14, 16, as shown in figure 1. The male side edge connectors 14, 16 and female side edge connectors 18, 20 are arranged to extend preferably along the entire side edges 5, 7 of the panel 2, 3, respectively, to provide a joint between to adjacently positioned like panels 2, 3. However, it should be noted that the panel 2, 3 may also be provided such that the metal sheets 8, 10 form one, two, three or even more respective male and female side edge connectors on the respective side edges 5, 7 a panel 2, 3. Furthermore, it should be noted that also separate means may be installed or attached to the panels 2, 3 for providing an interlock mechanism to the side edges of the panels 2, 3. In the embodiment shown in figure 1 , interlock mechanism, and therefore the male and female side edge connectors 14, 16, 18, 20 are provided by forming the metal sheets 8, 10.
As shown in figure 1 , the female side edge connectors 18, 20 are formed as grooves that extend longitudinally along the second side edge 7 of the panel 3. The grooves 18, 20 tapering cross section or profile towards the bottom of the groove transversely to the longitudinal direction of the groove 18, 20, The cross section of the grooves 18, 20 may be also be generally U- shaped such that the width of the groove 18, 20 remains generally constant towards the bottom of the groove 18, 20. The grooves 18, 20 may also have partially tapering cross section such that the only on part of the cross section has a tapering profile whilst the other parts of the groove have generally constant width. In figure 1 the female side edge connectors 18, 20 are formed by bending the metal sheets 8, 10 first towards the centre of the panel 3 and then back towards the second side edge 7 of the panel 7. Thus the metal sheets 8, 10 form the sidewalls 22, 24 and 26, 28 of the grooves 18 and 20, respectively, as well as the bottom of the grooves 18, 20. The grooves that receive male
side edge connectors and/or tongues are formed to have a tapering, U- shaped, V-shaped or the like profile without any narrow necks or waists such that the installation of two panels together is easy and that joined panel may also be easily released from each other. As shown in figure 1 that sidewalls 22, 24 and 26, 28 of the grooves
18 and 20 respectively do not have be formed symmetrically, but the sidewalls of a groove may have a different tapering, bending and forming characteristics in the cross section profile.
According to the invention and figure 1 , the first side edge 5 of a panel 2, 3 is provided with male side edge connectors 14, 16 configured to be received in the female side edge connectors 18, 20. The male side edge connectors are formed as tongues extending longitudinally along the first side edge 5 of the panel 2. The tongues 14, 16 are arranged to project form the first side edge 5 such that they may be inserted into the respective grooves 18, 20 on the second side edge 7 of a like adjacently positioned panel 3. The tongues 14, 16 are formed to have curved, hook like, J-shaped, S-shaped, Z-shaped, zigzag shaped, reversed U-shaped or the like cross section transversely to the longitudinal direction of the grooves 18, 20. The tongue 14, 16 is formed such that it may compress or deform resiliently when installed in the respective groove 18, 20. The resilient compression or deformation biases the tongue 14, 16 against the sidewalls 22, 24 and/or 26, 28 of the respective grooves and then the tongue 14, 16 applies a force against the sidewalls of the groove.
To achieve the deformation or compression and biasing of the tongue 14, 16, the tongue should have a width transversely to the longitudinal direction of the grooves 18, 20 greater than the corresponding width of the grooves 18, 20. Then the sidewalls 22, 24 and/or 26, 28 of the groove compress the tongue 14, 16 as it is inserted into the groove 18, 20. In other words at least a part of the groove 18, 20 has a width that is smaller than a width of at least a part of a tongue 14, 16 that is inserted into the groove 18, 20. This may be accomplished by forming the groove 18, 20 to have a tapering profile towards the bottom of the groove 18, 20 and/or by forming the tongue 14, 16 to have a tapering profile towards the tip of the tongue 14, 16. In this way the biasing force of the tongue 14, 16 increases continuously as the tongue 14, 16 moves deeper into the groove 18, 20 and the biasing force against the inner sidewalls 22, 24, and/or 26, 28 of the groove remains when the tongue 14, 16 is its position in the grooves 18, 20. It is enough that a part of the groove 18,
20 has a smaller width than a part of the tongue 14, 16 in the transverse direction to the groove. It should be noted that the grooves 18, 20 and the tongues have preferably a uniform shape in the longitudinal direction of the groove 18, 20 and the tongue 14, 16. The tongue 14, 16 may be arranged to deform or compress such that it generates a biasing force in the transverse direction of the first and second side faces of the panel 2, 3 and/or against the inner sidewails 22, 24, 26, 28 of the respective groove 18, 20. The tongue 14, 16 is also shaped such that it biases against the both inner sidewails 22, 24 and/or 26, 28 of the groove 18, 20, respectively, in at least one contact point and/or area in a sidewall 22, 24, 26, 28. The tongue 14, 16 and groove 18, 20 may also be formed such that at least one sidewall 30, 32 of the tongue 14, 16 is pressed against a sidewall 22, 26 of the groove 18, 20 to form a longitudinally extending contact area when the tongue 14, 16 is received in the groove 18, 20. If the tongue 14, 16 has a S-shaped, Z-shaped, zigzag shaped or the like profile in the transverse direction to the longitudinally extending groove 18, 20, the tongue 14, 16 may biases against both inner sidewails 22, 24, 26, 28 of the groove (18, 20) in at least two or more contact points/areas.
The grooves 18, 20 and the tongues 14, 16 extend respectively along the entire length of first and second side edges 5, 7 of the panel 2, 3 such that the tongue 14, 16 or part of it biases against the sidewails 22, 24, 26, 28 of the groove 18, 20 along the entire length of the side edge 5, 7 of the panel 2, 3. This is advantageous since the biasing force seals the joint between two adjacent panels 2, 3 against moisture and heat. Additionally the bi- asing force prevents the grooves 18, 20 and tongues 14, 16 from deforming disadvantageously in a case of fire, when the metal sheets 8, 10 tend to bend due to the high temperature such that the joint between the panels 2, 3 opens. This way the opening of the joint may be prevented longer or delayed without additional equipment or parts and still conserve the easy installation of the panels 2, 3 together.
In use building panel 2, 3 normally is arranged such that the female groove 18, 20 of a second panel 3 opens downwards to receive the upwards extending tongue 14, 16 of the first panel 2 below the second panel 3.
Furthermore, the tongue 14, 16 may be provided with a resilient element deforming when received in the respective groove 18, 20 and generating a biasing force against the inner sidewails 22, 24, 26, 28 of the groove 18,
20 through the deformation. The resilient element may be a separate part attached or provided to the tongue 14, 16 or it may be part of the tongue 14, 16. The tongue 14, 16, part thereof or the resilient element forms a spring like element arranged to bias against inner sidewalls 22, 24, 26, 28 of the female side edge connector 18, 20. Further, the groove may be provided by separate groove means such that the groove is separate part attached or installed to the second side edge 7 of the panel 2, 3.
From the above it is evident that in the present invention the panels 2, 3 or the interlock mechanism according to the invention may comprise one or more tongue-groove, male-female or abutment joints as described. Additionally, the shape, dimensions and other configurations of the tongues and grooves may differ from what is described without departing from the scope of the present invention.
Figure 2A is shows a section of a building panel 2 comprise a first and second oppositely positioned first and second relatively thin metal sheets 8, 10 forming first and second side faces of the panel 2. Between the metal sheets 8, 10 is provided a central core insulating material 12 that may be attached to the metal sheets 8, 10 for example by gluing or some other way. The insulating material 12 may be any possible material that provides sufficient in- sulation and structural rigidity for the panel 2. The panel 2 has also first and second side edges 5, 7 (figure 2B), which are provided with male and female side edge connectors 14, 18, 20, respectively. In use these the side edges 5 and 7 extend generally horizontally. It should be noted that the panels comprise also third and fourth side edges, which in use extend generally vertically. Also the third and fourth side edges may be provided with male and female side edge connectors of the same type as the first and second side edges, if desired.
According to the state of the art male and female side edge connectors 14, 18, 20 are provided by forming, bending or the like the metal sheets 8 and 10. This forming may be accomplished by making the metal sheets 8, 10 extend over the insulating material 12 in the edge region of the panel 2, 3 and roll forming the edge regions of the metal sheets 8, 10 such that the metal sheets 8, 10 at the first side edge 5 of the panel 2 generate one or more male side edge connectors 14 projecting from first side edge 5 of the panel 2, and that the metal sheets 8, 10 at the second side edge 7 of the panel 2, 3 generate one or more female side edge connectors 18 , 20 configured to receive the
respective male side edge connectors 14, as shown in figure 2B. The male side edge connectors 14 and female side edge connectors 18, 20 are arranged to extend preferably along the entire side edges 5, 7 of the panel 2, respectively, to provide a joint between two adjacently positioned like panels 2, 3.
However, it should be noted that the panel 2 may also be provided such that the metal sheets 8, 10 form one, two, three or even more respective male and female side edge connectors 14, 18, 20 on the respective side edges 5, 7 a panel 2. Furthermore, it should be noted that also separate means may be installed or attached to the panel 2 for providing an interlock mechanism to the side edges of the panel 2. In the embodiment shown in figure 2A and 2B1 interlock mechanism, and therefore the male and female side edge connectors 14, 18, 20 are provided by forming the metal sheets 8, 10.
As shown in figure 2A, the female side edge connectors 18, 20 are formed as grooves that extend longitudinally along the second side edge 7 of the panel 2. According to prior art the grooves 18, 20 have tapering cross section or profile towards the bottom of the groove transversely to the longitudinal direction of the groove 18, 20. Other possibilities for the cross section of the grooves 18, 20 have been generally U-shaped such that the width of the groove 18, 20 remains generally constant towards the bottom of the groove 18, 20. In figure 3 the female side edge connectors 18, 20 are formed by bending the metal sheets 8, 10 first towards the centre of the panel 2 and then back towards the second side edge 7 of the panel 2. The grooves that receive male side edge connectors and/or tongues may be formed to have a tapering, U- shaped, V-shaped or the like profile such that the installation of two panels together is easy and that joined panel may also be easily released from each other.
As shown in figures 2A and 2B, the bottom 40 of a groove or female side edge connector 18, 20 may be in some cases provided with a sealing element 50. The sealing element 50 may be a sealing strip, extrudable sealing mass, adhesive mass or the like that may be attached to the bottom 40 of the groove 18, 20. Such as polyurethane may be used as material for the sealing element 30. When two adjacent panels 2 and 3 are joined together the sealing element 30 is compressed between or is in contact with the bottom of the groove 18, 20 and the upper end of the tongue 14, as shown in figure 2B. This way the joint between the tongue 14 and the groove 18, 20 may be sealed
such that heat, moisture, gases or fire cannot pass through the joint from one side of the panels 2, 3 to the other. During the installation of two adjacent panels 2, 3 together and after the installation as well as when the joint between the panels 2, 3 has to be opened temporarily or for later reinstallation of the panel or panels 2, 3, the sealing element 50 tends to move away from the bottom of the groove 18, 20. Thus the seal between tongue 14 and grooves 18, 20 is endangered or weakened as the sealing element 50 is not in correct place.
According to the present invention, the female side edge connector or groove 18, 20 receiving the sealing element 50 is provided with at the bot- torn or close to the bottom with an expansion 52 for increasing the width of the groove 18, 20 locally at the bottom or in vicinity of the bottom of the groove 18, 20. One embodiment of this expansion or expansion chamber 52 is shown in all figures 2A, 2B and 3.
The result is accordingly achieved, when biasing force and the ex- tension for the sealing element are used in a same insulated panel and specifically in the same interlock mechanism.
It will be obvious to a person skilled in the art that, as the technology advances, the inventive concept can be implemented in various ways. The invention and its embodiments are not limited to the examples described above but may vary within the scope of the claims.