U.S. patent application number 12/223466 was filed with the patent office on 2009-01-29 for panel.
Invention is credited to James Carolan, Gregory Flynn.
Application Number | 20090025335 12/223466 |
Document ID | / |
Family ID | 37899131 |
Filed Date | 2009-01-29 |
United States Patent
Application |
20090025335 |
Kind Code |
A1 |
Flynn; Gregory ; et
al. |
January 29, 2009 |
Panel
Abstract
A composite cladding panel has an internal skin or backing tray
(2), and an external skin (3) with foam insulation (4) between the
tray (2) and skin (3). A pre-formed gasket (20) is bonded to the
external skin (3) and a coating (30) is applied to the external
skin (3) of the panel and to an outer face (21) of the gasket (20)
to provide a surface finish such as a textured finish. No joint is
visible between the coated skins (3) of adjacent panels.
Inventors: |
Flynn; Gregory; (County
Louth, IE) ; Carolan; James; (County Cavan,
IE) |
Correspondence
Address: |
JACOBSON HOLMAN PLLC
400 SEVENTH STREET N.W., SUITE 600
WASHINGTON
DC
20004
US
|
Family ID: |
37899131 |
Appl. No.: |
12/223466 |
Filed: |
February 12, 2007 |
PCT Filed: |
February 12, 2007 |
PCT NO: |
PCT/IE2007/000018 |
371 Date: |
July 31, 2008 |
Current U.S.
Class: |
52/792.11 ;
52/745.19; 52/794.1 |
Current CPC
Class: |
E04F 13/0889 20130101;
E04F 13/0876 20130101; E04F 2201/07 20130101; E04F 21/12 20130101;
E04F 13/042 20130101; E04D 3/355 20130101; E04C 2/292 20130101;
E04D 3/352 20130101 |
Class at
Publication: |
52/792.11 ;
52/794.1; 52/745.19 |
International
Class: |
E04F 13/08 20060101
E04F013/08; E04C 2/284 20060101 E04C002/284 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 10, 2006 |
IE |
2006/0095 |
Claims
1-27. (canceled)
28. A composite cladding panel comprising an internal skin and an
external skin with insulation material therebetween, one of the
skins having a gasket extending along one edge thereof, the gasket
having a decorative coating on an external face thereof.
29. The panel as claimed in claim 28 wherein the external skin
and/or the internal skin have profiled joint forming portions for
connecting adjacent panels.
30. The panel as claimed in claim 29 wherein the panel has a
projecting part on one side and a corresponding recess on the
opposite side of the panel.
31. The panel as claimed in claim 30 wherein the external skin has
a projecting part on one side and a corresponding recess on the
other side of the panel, the gasket being located in or on the
projecting part and/or recess.
32. The panel as claimed in claim 31 wherein the gasket is located
in the recess defined by the external skin.
33. The panel as claimed in claim 28 wherein the gasket is bonded
to the skin.
34. The panel as claimed in claim 33 wherein the gasket is
adhesively located to the skin.
35. The panel as claimed in claim 34 wherein the gasket has an
adhesive thereon for bonding to the skin.
36. The panel as claimed in claim 28 wherein the coating is applied
to the gasket after mounting the gasket to the panel.
37. The panel as claimed in claim 28 wherein the coating comprises
a screed-type finish.
38. The panel as claimed in claim 28 wherein the coating is applied
to the external face of the gasket and to the external skin of the
panel.
39. The panel is claimed in claim 38 wherein an edge coating is
applied to an overlap region adjacent the edge of the panel
opposite to the edge to which the gasket is applied.
40. The panel as claimed in claim 39 wherein the edge coating has a
different formulation to that of the coating applied to the
gasket.
41. The panel as claimed in claim 40 wherein the edge coating may
comprise a paint/pigment.
42. The panel as claimed in 41 wherein the edge coating is of the
same colour as that of the coating applied to the gasket.
43. A method for manufacturing a cladding panel of the type
comprising an internal skin and an external skin with insulation
material therebetween, the method comprising the steps, after
forming the panel, of applying a gasket to one side of the panel,
and applying a coating to the external skin of the panel and the
external face of the gasket.
44. The method as claimed in claim 43 wherein the coating is
applied after applying the gasket to the panel.
45. The method as claimed in claim 43 wherein the gasket is bonded
to the panel.
46. The method as claimed in claim 45 wherein the gasket is
adhesively bonded to the panel.
47. The method as claimed in claim 43 wherein the coating comprises
a screed-type finish.
48. The method as claimed in claim 43 wherein the coating is
applied to the external face of the gasket and to the external skin
of the panel.
49. The method as claimed in claim 48 wherein an edge coating is
applied to an overlap region adjacent the edge of the panel
opposite to the edge to which the gasket is applied.
50. The method as claimed in claim 49 wherein the edge coating has
a different formulation to that of the coating applied to the
gasket.
51. The method as claimed in claim 50 wherein the edge coating
comprises a paint/pigment.
52. The method as claimed in 51 wherein the edge coating is of the
same colour as that of the coating applied to the gasket.
Description
INTRODUCTION
[0001] The invention relates to a composite cladding panel of the
type comprising an inner skin and an external skin with insulation
foam material therebetween.
[0002] Buildings comprising a steel frame on which pre-formed
panels are mounted may be erected quickly and more cheaply than
buildings with brick or block facades.
[0003] One of the problems with buildings constructed from
pre-formed panels is that such panels can often be uninteresting
aesthetically. It is known to form such panels with various
profiles and in various colours, however, there is still a need to
provide an aesthetically different facade in some cases.
[0004] This invention is directed towards providing a panel system
which will address this need.
STATEMENTS OF INVENTION
[0005] According to the invention there is provided a composite
cladding panel comprising an internal skin and an external skin
with insulation material therebetween, one of the skins having a
gasket extending along one edge thereof, the gasket having a
decorative coating on an external face thereof.
[0006] In one embodiment the external skin and/or the internal skin
have profiled joint forming portions for connecting adjacent
panels. The panel may have a projecting part on one side and a
corresponding recess on the opposite side of the panel.
[0007] In one case the external skin has a projecting part on one
side and a corresponding recess on the other side of the panel, the
gasket being located in or an the projecting part and/or recess.
The gasket may be located in the recess defined by the external
skin.
[0008] In one embodiment wherein the gasket is bonded to the skin.
The gasket may be adhesively bonded to the skin. The gasket may
have an adhesive thereon for bonding to the skin.
[0009] In one embodiment the coating is applied to the gasket after
mounting the gasket to the panel.
[0010] The coating may be applied to the external skin and the
external face of the gasket.
[0011] The coating may comprise a screed-type finish.
[0012] The invention also provides a method for manufacturing a
cladding panel of the type comprising an internal skin and an
external skin with insulation material therebetween, the method
comprising the steps, after forming the panel, of applying a gasket
to one side of the panel, and applying a coating to the external
skin of the panel and the external face of the gasket.
[0013] The coating may be applied after applying the gasket to the
panel. The gasket may be bonded to the panel. In one case, the
gasket is adhesively bonded to the panel.
BRIEF DESCRIPTION OF DRAWINGS
[0014] The invention will be more clearly understood from the
following description thereof given by way of example only, in
which:--
[0015] FIG. 1 is a diagrammatic partially cross-sectional view of a
known composite insulating cladding panel;
[0016] FIG. 2 is a view of the composite panel of the invention
with a gasket being applied;
[0017] FIG. 3 is a view illustrating the gasket applied;
[0018] FIG. 4 is a view of a coating being applied to the gasket
and panel;
[0019] FIG. 5 is a cross-sectional view of two adjacent panels
prior to jointing;
[0020] FIG. 6 is a cross-sectional view of the panels of FIG. 5
jointed together;
[0021] FIG. 6(a) is a schematic cross-sectional view of a partially
open joint; and
[0022] FIGS. 7(a) to 7(h) are diagrams illustrating various steps
in the method of manufacturing and using the panels of the
invention.
DETAILED DESCRIPTION
[0023] Referring to the drawings and initially to FIG. 1 there is
illustrated a composite cladding panel 1. The panel 1 comprises a
skin or backing tray 2 which is usually of steel and an external
skin 3 which is also usually of steel with a layer of foam
insulation material 4 such as a phenolic or polyurethane based foam
material therebetween. The panel may be of any suitable type such
as that described in our UK 2325678A.
[0024] The panel has formations along both side edges. The
formations are profiled so that one side edge of a panel is
interengagable, on assembly, with the opposite side edge of an
adjacent panel. Thus, the external skin 3 is profiled to define a
male projecting part 6 along one side and a corresponding recess 7
along the opposite side. Similarly the internal skin 2 is profiled
to define a male projecting part 8 along one side and a
corresponding recess 9 along the opposite side. Various seals may
be provided at the joint.
[0025] In the invention, a pre-formed gasket 20 of a suitable
material such as a flexible material, for example a plastic or
rubber is bonded to the external skin 3, in this case to the
recess-forming portion 7 of the external skin 3. The gasket 20 has
a generally flat main part 21 and a depending leg 22 for bonding to
the external skin 3. The main part 21 has an external face 23 to
which a coating such as a screed 30 is applied. The gasket 20 is
bonded to the external skin in any suitable manner. For example the
leg 12 of the gasket may have an adhesive thereon for bonding to
the external skin 3. Alternatively or additionally, adhesive may be
applied to one or both of the gasket leg 22 or external skin 3. For
ease of use, generally the gasket 20 can be self-adhesively bonded
to the external skin 3. An adhesive layer 25 is shown schematically
in the drawings.
[0026] The coating 30 is in this case applied after the gasket 20
has been bonded to the external skin 3. The coating 30 is applied
not only to the outer face of the main part 21 of the gasket 20 but
also to the external skin 3 to the opposite side of the panel. In
the drawings, the depth of the coating has been exaggerated for
illustrative purposes. The coating 30 may be applied in any
suitable manner such as by using a spray head 40. Any suitable
material may be used as a coating to provide any desired surface
finish. It may provide a textured finish, for example.
[0027] The coating 30 may be applied fully to the external skin
from the gasket 20 to opposite side edge or it may be interrupted
or patterned to provide any desired effect. There may be more than
one layer/coat applied. For thicker coatings, the coating may be
stopped short of the opposite side edge or may be tapered towards
this edge so that an assembly of adjacent panels there is
continuity between the coatings of adjacent panels as illustrated
in FIG. 6. No joint is visible.
[0028] The coating 30 is applied to the external face of the gasket
20 and to the external skin 3 of the panel. An edge coating 50 may
be applied to an overlap region 52 adjacent the edge of the panel
opposite to the edge to which the gasket 20 is applied. Referring
to FIG. 5 the pigment/paint 50 may be applied to any bare surface
region 52 of the projecting part 6. The paint 50 may be applied in
any suitable manner, for example using a spray head 51. The paint
will generally be the same colour/pigment as that of the render
coating 20. It may be the same pigment as that of the render 20 but
without containing any aggregate so that a thin layer can be
applied. The paint 50 ensures that in extreme conditions if the
panels expand/contract slightly any gap between the render coatings
of adjacent panels at the joint is not readily visible. An extreme
exaggerated example is illustrated schematically in FIG. 6(a).
[0029] There are many advantages of the invention. Because the
coating can be applied off site from the location where the
cladding panels are to be used the installation is simplified.
There is no need for separate coatings to be applied on-site, thus
avoiding the use of so-called wet trades on site whilst still
providing an aesthetically desirable finish.
[0030] Very many variations on the invention are possible. For
example, a gasket and a coating may be applied alternatively or
additionally to the internal skin. The inner coating may be
different from the outer coating.
[0031] The invention is not limited to the embodiments hereinbefore
described which may be varied in detail.
* * * * *