Profiled panel for the cladding of walls, ceilings, roofs and the like

Abstract

This disclosure is directed to a panel of sheet material for the cladding of walls, ceilings, roofs or the like in which a generally planar main panel portion includes along transversely spaced longitudinally extending side portions first and second longitudinally extending ribs each of an inverted generally U-shaped configuration as viewed in transverse cross section and being defined by a pair of legs and a bight therebetween, each pair of legs has at least lower leg portions which diverge away from each other in a direction away from the main panel portion toward their respective bight with the height of the first longitudinally extending rib being greater than that of the height of the second longitudinally extending rib, and the divergent relationship of each rib being effected by at least one lower leg portion of each pair of legs being disposed at an angle other than normal to the main panel portion with preferably the last-mentioned lower leg portion of each pair of legs being transversely outermost and innermost leg portions of the respective first and second longitudinally extending ribs. Insulating means are provided between the first-mentioned and a second main panel portion with the second main panel portion including a longitudinally extending transversely projecting rib adjacent the first longitudinally extending rib with a longitudinally extending transversely undercut surface matching the contour of at least one surface of the projecting rib being disposed at an opposite edge of the second main panel portion.

Description

The present invention is directed to a panel of sheet material, preferably constructed of metal, for the cladding of walls, ceilings, roofs or the like which when collectively utilized are interlocked into relationship with each other in transverse and/or longitudinal directions.

Panels of the type to which the invention is directed are known wherein longitudinal sides or edges are bounded by longitudinally extending ribs of a profiled configuration as viewed in transverse cross section. Such ribs generally include legs or flanks which are undercut at their bases or adjacent to the main panel and more often than not between such "profile" ribs are disposed stiffening or reinforcing ribs which run transversely and/or longitudinally of the main panel. The transverse profile of the longitudinally extending ribs at the edge or sides of the panel are so constructed that they snap together one over another. In one particular type of such panels the panels are fixed to girders, beams, rafters or the like through the intermediary of a rail from which are integrally formed or into which are inserted caps with legs which spring biasly engage within the profile ribs such that the legs in effect biasingly engage the flanks or the legs of the profiled panel ribs. The caps in turn may be directly secured to the rails or can be connected directly to the understructure involved, i. e. the beam, rafter or the like, by screws, bolts or similar fasteners. Unfortunately, this mode of affixing a profiled panel to a supporting structure involves a considerable outlay in terms of material, labor, and of course expenditures of money. As an example, the caps need first to be affixed to their associated rail and thereafter the rails and caps are affixed to the understructure of the building to which the profiled paneling is to be attached. Moreover, such structure does not provide an area within which a continuous insulating layer may be provided at an underside between the paneling and the understructure.

In a further known conventional panel the edge ribs of two adjacent panels are fitted directly one over another with the transverse profile thereof being unsymmetrical as viewed in transverse cross section. Generally a single undercut maintains two interlock ribs in assembled condition and therefore conventional clips contoured to the profile of the ribs are found necessary to securely fix the panels to the understructure. At one edge of the panel which excludes the use of clips screws are generally employed to directly secure the panel at one of the profiled ribs to the particular understructure involved. However, since the wall thickness of the panel is relatively thin the head of the screw has only a weak holding force relative to the rib and therefore does not constitute a reliable connection.

Another common feature of known panels of this type is that the longitudinally extending ribs which are profiled in various manners and transverse cross-section are made of the same height as measured between the main planar body portion of the panel and the uppermost surfaces of the ribs resulting in difficulties not only as in regard to the overlapping of such ribs during interconnecting of the same, but also in securing the panels to the understructure requiring additional affixing, holding and like securing elements (clips).

In keeping with the foregoing, it is a primary object of this invention to avoid disadvantages of known profiled panels of the type heretofore described by providing a panel of sheet material for the cladding of walls, ceilings, roofs or the like which avoids the latter-noted disadvantages particularly by being affixed to any supporting structure in a simple and reliable manner in the absence of special clips or the like structure, yet provides for a continuous layer of insulating material between the padding and the understructure involved.

The latter-noted disadvantages of prior art structures are also overcome by providing one rib of a height greater than another rib such that interferences precluded, particularly when a fastening element is used to secure the rib of lesser height to an understructure.

A further object of this invention is to provide a novel panel of the type heretofore described wherein the interlocking of adjacent panels is achieved by providing at least the longitudinally extending profiled or edge ribs with one leg portion or wall which diverges relative to a main panel portion of the panel such that interlocking of the ribs of adjacent panels is efficiently assured, and the foregoing also permits the unification of adjoining or neighboring panels by a simple turning or rotary motion which makes assembly extremely simple and rapid.

A further object of this invention is to provide a novel panel of the type heretofore described wherein the rib of lesser height has a top wall or bight which is flat making it possible to use screws having heads which are relatively large and thick which therefore lie flat upon the flat top surface of the rib making manipulation required for tightening and fixing the screws much easier and utilizing but a single fastener for overall installations. Due to such structure there is no need for auxiliary element such as holding caps, clips or the like. However, such flattened top walls of the ribs provide greater stability and greater elastic properties such that the risk of the profile being crushed if walked upon by accident during assembly is avoided. Also, from a manufacturing standpoint such profile provides greater tolerances and the roll-forming of such profiled panels is thus facilitated.

Still another object of this invention is to provide a novel panel of the type heretofore described wherein the construction permits a layer of insulating material consisting for example of foam plastics or the like to be integrally united with the panel by being directly bonded thereto with the snap-engagement between the ribs of adjacent panels constructed as aforementioned avoiding the necessity of additional affixing means (clips) whereupon at least one of the ribs may be totally filled with the insulating material.

Preferably, though not necessarily, the panel included an addition to the first-mentioned main panel portion a second panel portion having the insulating material sandwiched therebetween with the panel being affixed through the use of fastening means (screws) passed through the longitudinally extending profiled rib of the lesser height.

Yet another object of this invention is to provide a novel sandwiched or composite panel of the type immediately aforesaid wherein the last-mentioned or second panel portion includes a transversely rejecting longitudinally extending rib along one of the profiled ribs whereas an opposite end edge of the same panel includes an angular surface contoured to the profile of at least one surface of the transversely projecting rib whereupon the latter-mentioned surface and ribs interengage during the assembly of adjoining or neighboring panels.

The foregoing objectives achieve a profiled and insulated panel which is relatively rigid thereby providing insulation which need not be separately applied thus saving considerable time, work and money. Additionally, such panels as heretofore described are advantageously maintained at a readily manually, manipulatable size not to exceed a width of approximately eighteen inches to two feet and a length commensurate with the particular installation desired. A profiled panel of such size not only makes handling easier but it also makes possible the affixation of the panels with as few as possible points of securement of the panel to a supporting or understructure.

With the above and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claims and the several views illustrated in the accompanying drawing.

IN THE DRAWINGS

FIG. 1 is a cross sectional view of a novel panel or profiled panel constructed in accordance with this invention, and illustrates two adjoining panels having ribs snap-engaging the same to each other.

FIG. 2 is a diagrammatic cross sectional view similar to FIG. 1, and illustrates a plurality of the panels each having applied thereto a layer of insulating material with the plurality of panels being interlockingly engaged to each other by the snap-engagement of adjoining ribs.

FIG. 3 is a fragmentary enlarged sectional view, and illustrates the manner in which two ribs of adjoining panels are snap-engaged to each other.

FIG. 4 is a sectional view of another pair of panels constructed in accordance with this invention, and illustrates the adjacent panels being interlockingly engaged to each other by the snap-engagement of adjoining ribs.

FIG. 5 is a transverse sectional view taken through another panel constructed in accordance with this invention, and illustrates the manner in which first and second main panel portions have sandwiched therebetween insulating material with the second panel portion having at opposite edges thereof a transversely projecting longitudinally extending ribs and a matching undercut, respectively.

FIG. 6 is an enlarged sectional view of a joint formed between adjoining panels of the type illustrated in FIG. 5, and specifically illustrates the manner in which snap-engagement is achieved between adjoining panel ribs.

A novel panel or profiled panel constructed in accordance with this invention is best illustrated in FIG. 1 of the drawing, and is generally designated by the reference numeral 1. The panel 1 is adapted for the cladding of walls, roofs, ceilings and the like and is preferably constructed from sheet metal to define a generally planar main panel portion 1a having a pair of transversely spaced longitudinally extending side portions 1b, 1c. First and second longitudinally extending ribs 2, 3, respectively, are disposed one along the first and second ones of the longitudinally extending side portions 1b, 1c, respectively.

Each of the first and second ribs 2, 3, respectively, as viewed in transverse cross section is of a generally inverted U-shaped configuration with each rib 2, 3, being defined by a pair of legs 1a, 3a, respectively, and a bight or bight portion 2b, 3b, respectively, therebetween. The pair of legs 2a include lower leg portions 2c, 2d which diverge away from the main panel portion 1a, and toward the bight 2b and upper leg portions 2e, 2f which converge toward each other in a direction away from the main panel portion 1a, and toward the bight 2b. Between the leg portions 2f, 2d is an undercut or shoulder 2g whereas the leg portion 2c terminates at a free terminal end or edge 2h forming a longitudinally extending hook.

The leg 3a of the rib 3 likewise includes a pair of lower leg portions 3c, 3d, the former of which immediately merges with a flat planar bight portion 3b and the latter of which is joined to an upper leg portion 3e by a shoulder 3f. The lower leg portion 3d has a terminal edge (unnumbered) which also serves to function as an interlock with respect to the rib 2 of an adjoining panel, as will be described more fully hereinafter.

The bight 3b of the rib 3 has a plurality of apertures (unnumbered) disposed along the length thereof and between the ribs 2, 3 may be formed one or more reinforcing ribs, such as the singular reinforcing rib 4 which is likewise of a generally inverted U-shaped configuration as viewed in transverse cross section. The apertures (unnumbered) of the bight 3b of the rib 3 is designed to receive fasteners 5, such as metal or wood screws, having relatively thick and large heads 5a.

Referring specifically to FIGS. 2 and 3 of the drawings, a plurality of the panels 1 are shown fixed by the screws 5 to an understructure 6 which may be, for example, one of a plurality of beams having webs 8. The screws 5 pass only through the apertures (unnumbered) of the ribs 3 which are, of course, of a shorter height than the ribs 2 as measured vertically from the main panel portion 1a of each panel 1. Thus as the ribs 2 are interlocked with the ribs 3 by a rotary motion, as indicated by the right-handmost rib 1 of FIG. 2 in the direction of the unnumbered headed arrow associated therewith, an interlock is achieved between the ribs 2, 3 with a gap being provided for receipt of the relatively large heads of the screws 5, as is best illustrated in FIG. 3 of the drawings.

Preferably though not necessarily the panels 1 are also provided with an insulating layer 7 of foam plastic or like material which with each panel 1 forms an integral composite panel thereby eliminating the separate application of insulation material in the assembly of the panels 1 with the support structure 6. Preferably the insulating material 7 has a planar bottom surface 7a to rest flush upon the upper surface (unnumbered) of the webs 7 of the beams, rafters or the like understructure 6.

Reference is specifically made to FIG. 3 which shows the rigid interlock achieved between the ribs 2, 3 upon the rotation of the adjoining panels to the finally snap-engaged position of the ribs. Due to the configuration of the portions 2c, 2d, 2f, 2g and 2h of the rib 2 and the complementary contoured portions 3c, 3d, 3e and 3f of the rib 3 an exceptionally rigid interlock engagement is obtained between the ribs 2, 3 assuring the absence of inadvertent and/or accidental disassembly therebetween. However, intentional disassembly is achieved with ease simply by reversing the direction of assembly heretofore described relative to the right-handmost panel 1 of FIG. 2.

Again referring to FIG. 3 of the drawing, the insulating material 7 of the panels 1 is preferably also provided with longitudinally extending steps 9, 10 adjacent the respective ribs 2, 3. The step 9 adjacent the rib 2 faces downwardly and away from the main panel portion 1a whereas the step 10 adjacent the rib 3 faces upwardly and toward the main panel portion 1a. The steps 9, 10 interlockingly engage each other due to the complementary contour thereof in the manner readily apparent in FIG. 3 upon, of course, the relative rotational interlocking action being imparted to one of the panels during the assembly thereof in the manner heretofore described relative to the right-handmost panel 1 of FIG. 2.

Preferably, though not necessarily, the underside of the insulation 7 as well as the faces and adjoining portion of the steps 9, 10 are provided with a covering of relatively impermeable material to assure that the insulation will not be adversely affected by the moisture, dirt and the like. Additionally, the panels of FIG. 2 may also be advantageously laid in offset relationship to one another in their longitudinal direction so that in each case there is a minimum of material overlap thickness at each of the overlap regions, namely, a maximum of three thicknesses of sheet material at adjoining longitudinal joints.

Another panel constructed in accordance with this invention is illustrated in FIGS. 4 through 6 of the drawings and once again is designed particularly for the cladding of walls, ceilings, roofs and the like. As in the case of the panel 1 the panel 11 is constructed from sheet material and includes longitudinally extending ribs 12, 13 having respective legs 12a, 12b and 13a, 13b. The legs 12a, 13a correspond identically in structure to the leg portions 2e, 2c and 2h of the panel 1 whereas the leg 13a corresponds identically to the leg portion 3c of the leg 3a of the panel 1.

The legs 12 and 13 also include bight portions 12c, 13c which receive fasteners 21. What was, one or more reinforcing ribs 13 may be disposed between the ribs 12, 13, as in the case of the reinforcing rib 4 of the panel 1. However, as opposed to the panel 1 the legs 12b, 13b of the ribs 12, 13 do not include a shoulder corresponding to the shoulder 3f of the ribs 3 but instead include generally normal or vertical leg portions 12d, 13b, the latter of which merges directly with the bight 13c whereas the former is joined by an upper leg portion 12e to the bight 12c. Thus the portions 12d, 13b are devoid of undercutting and are simply straight or very slightly curved. It should be particularly noted that the lower leg portion 12d is transversely innermost relative to the rib 12 whereas the leg or flank 13b is transversely outermost of the rib 13. Due to this construction inner engagement between the ribs 12, 13 of adjacent panels is readily effected by a turning or rotary movement about a centerpoint 15 (FIG. 4) of the portion 13a of the rib 13, as is most readily apparent by visualizing the right-handmost panel 11 of FIG. 4b in the position of the right-handmost panel 1 of FIG. 2 and then being rotated clockwise to the fully seated position illustrated in FIG. 4.

Preferably, though not necessarily, the panel 11 may also be provided as a composite structure to the underside of which may be secured a layer of insulating material 16. The lower surface of the insulating layer 16 may also be provided with another panel or panel portion of sheet metal 17 and in any event the insulating material 16 and/or the additional panel 17 is provided with a transversely directed longitudinally extending projection 18 adjacent the rib 12 having surfaces 18a, 18b converging in a direction transversely outboard of the overall panel 11. At an opposite longitudinal edge of the panel 11 adjacent the rib 13 the panel 17 has an longitudinally extending surface 20 contoured to the general configuration of the surface 18a of the transversely projecting longitudinally extending rib 18. Thus upon assembly of two of the components of panels 11 of FIG. 5 one to the other, in the manner illustrated in FIG. 6, smooth engagement is achieved between the surface 18a of the projection 18 and the undersurface 20 adjacent the rib 13. In order to achieve a vapor seal (where found necessary or desirable) between the panels sealing strips 22, 23 (FIG. 6) may be disposed along the longitudinal lengths of these innerconnections, although such is not a prerequisite for the operation of the invention.

While preferred forms and arrangements of parts have been shown in illustrating the invention, it is to be clearly understood that various changes in details and arrangement of parts may be made without departing from the spirit and scope of this invention.

Claims

What is claimed is:

1. A panelling combination for the cladding of walls, ceilings, roofs or the like comprising at least a pair of generally identical panels, each panel having a generally planar main panel portion having a pair of transversely spaced longitudinally extending side portions, first and second longitudinally extending ribs one along first and second ones of said longitudinally extending side portions of each panel, each of said first and second ribs as viewed in transverse cross section being of a generally inverted U-shaped configuration each defined by a pair of legs and a bight therebetween, each pair of legs having at least lower leg portions which diverge away from each other in a direction away from their associated main panel portion and toward their respective bight, each of said first and second longitudinally extending ribs of each panel being of a predetermined height as measured between their associated bight and their associated main panel portion, the height of each first longitudinally extending rib being greater than the height of each second longitudinally extending rib of each panel the divergent relationship of each rib of each panel is effected by at least one lower leg portion of each pair of legs being disposed at an angle other than normal to said main panel portion, the first longitudinally extending rib of a first of said pair of panels being in overlying snap engagement with the second longitudinally extending rib of the second of said pair of panels, the bights of said snap engaged ribs being substantially spaced from each other to define a gap therebetween, at least a single fastener having a head and a shank, said shank being passed through an aperture of said second panel second rib bight, and said head being housed in said gap.

2. The panelling combination as defined in claim 1 wherein in eacn panel the bight of the rib of lower height is generally flat.

3. The panelling combination as defined in claim 1 wherein said at least one lower leg portion of each pair of legs is a transversely outermost lower leg portion of said first longitudinally extending rib of each panel and a transversely innermost lower leg portion of said second longitudinally extending rib of each panel.

4. The panelling combination as defined in claim 3 wherein upper leg portions of said first longitudinally extending rib of each panel are in converging relationship to each other in a direction away from their associated main panel portion and toward the bight of their associated first longitudinally extending rib.

5. The panelling combination as defined in claim 3 wherein upper leg portions of said second longitudinally extending rib of each panel are in converging relationship to each other in a direction away from their associated main panel portion and toward the bight of their associated second longitudinally extending rib.

6. The panelling combination as defined in claim 3 wherein upper leg portions of said first longitudinally extending rib of each panel are in converging relationship to each other in a direction away from their associated main panel portion and toward the bight of their associated first longitudinally extending rib and the upper leg portions of said second longitudinally extending rib of each panel are in converging relationship to each other in a direction away from their associated main panel portion and toward the bight of their associated second longitudinally extending rib.

7. The panelling combination as defined in claim 3 wherein said at least one lower leg portion of each pair of legs is a transversely outermost free terminal lower leg portion of said first longitudinally extending rib of each panel and a transversely innermost nonterminal lower leg portion of said second longitudinally extending rib of each panel.

8. The panelling combination as defined in claim 1 wherein said at least one lower leg portion of each pair of legs is a transversely outermost lower leg portion of said first longitudinally extending rib of each panel and a transversely innermost lower leg portion of said second longitudinally extending rib of each panel, and the remaining lower leg portion of each pair of legs is generally normal to said planar main panel portion.

9. The panelling combination as defined in claim 1 wherein said at least one lower leg portion of each pair of legs is a transversely outermost free terminal lower leg portion of said first longitudinally extending rib of each panel, and a transversely innermost nonterminal lower leg portion of said second longitudinally extending rib of each panel.

10. The panelling combination as defined in claim 1 wherein said at least one lower leg portion of each pair of legs is a transversely outermost lower leg portion of said first longitudinally extending rib of each panel and a transversely innermost lower leg portion of said second longitudinally extending rib of each panel, and said second rib bight of each panel is immediately joined to a transversely outermost leg of said second longitudinally extending rib of each panel.

11. The panelling combination as defined in claim 1 including another generally planar main panel portion forming each panel, and insulating means between said two main panel portions of each panel.

12. The panelling combination as defined in claim 11 wherein said at least one lower leg portion of each pair of legs is a transversely outermost free terminal lower leg portion of said first longitudinally extending rib of each panel and a transversely innermost nonterminal lower leg portion of said second longitudinally extending rib of each panel.

13. The panelling combination as defined in claim 1 including another generally planar main panel portion forming each panel, and said another planar main panel portion of each panel includes a longitudinally extending transversely projecting rib adjacent said first longitudinally extending rib of each panel.

14. The panelling combination as defined in claim 13 wherein said at least one lower leg portion of each pair of legs is a transversely outermost free terminal lower leg portion of said first longitudinally extending rib of each panel and a transversely innermost nonterminal lower leg portion of said second longitudinally extending rib of each panel.

15. The panelling combination as defined in claim 1 including another generally planar main panel portion forming each panel, said another planar main panel portion of each panel includes a longitudinally extending transversely projecting rib adjacent said first longitudinally extending rib of each panel, and said another planar main panel portion of each panel includes a longitudinally extending transversely undercut surface matching the contour of at least one surface of said projecting rib of each panel.

16. The panelling combination as defined in claim 1 wherein said main panel portion of each panel includes insulating means upon an underside thereof including within said second rib of each panel but excluding said first rib of each panel.

17. The panelling combination as defined in claim 1 wherein said main panel portion of each panel includes insulating means upon an underside thereof including within said second rib of each panel but excluding said first rib of each panel, a portion of said insulating means transversely exteriorly of said second rib of each panel defines a step facing toward said main panel portion of each associated panel, and a portion of said insulating means adjacent said first rib defines a step facing away from said main panel portion of each associated panel.

18. The panelling combination as defined in claim 1 wherein the bight of the rib of lower height of each panel is generally flat, said at least one lower leg portion of each pair of legs is a transversely outermost lower leg portion of said first longitudinally extending rib of each panel and a transversely innermost lower leg portion of said second longitudinally extending rib of each panel, the remaining lower leg portion of each pair of legs is normal to or slightly inclined relative to their associated planar main panel portion, said at least one lower leg portion of said first longitudinally extending rib of each panel being a free terminal edge, said transversely innermost lower leg portion of said longitudinally extending rib of each panel being a nonterminal portion, said second rib bight is immediately joined to a transversely outermost leg of said second longitudinally extending rib of each panel, another generally planar main panel portions of each panel, said another planar main panel portion of each panel includes a longitudinally extending rransversely projecting rib adjacent said first longitudinally extending rib of its associated panel, said another planar main panel portion of each panel includes a longitudinally extending transversely undercut surface matching the contour of at least one surface of said projecting rib, said insulating means being excluded from within said first rib of each panel, a portion of said insulating means transversely exteriorly of said second rib of each panel defines a step facing toward its associated main panel portion, and a portion of said insulating means adjacent said first rib of each panel defines a step facing away from its associated main panel portion.

19. The panelling combination as defined in claim 1 wherein each pair of legs have upper leg portions which converge away from each other in a direction away from their associated main panel portion and toward their respective bight, a radius portion joining each lower leg portion to each upper leg portion, the radius portions of said first longitudinally extending rib being in overlying snap engagement with the radius portions of said second longitudinally extending rib, and the height of said gap being defined by the length of said upper leg portions of said first longitudinally extending rib projecting beyond and away from the bight of said second longitudinally extending rib.