Prefabricated roof panel

Abstract

2021254542 19 Oct 2021 20 21 25 45 42 1 9 O ct 2 02 12021254542 2021 19 Oct 110 104 L2 130 120 W FIGURE 1 100 134 130 132 FIGURE 2

Description

TECHNICAL FIELD

[001] The present invention relates to a prefabricated roof panel. BACKGROUND

[002] Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge.

[003] Insulated metal panels are typically used on wall and roof building applications to form part or all of the building envelope. A panel typically has opposing inside and outside steel surfaces with an insulating foam core adhered between the surfaces. The panel can then be mounted onto support structures to form the wall or roof application in a building. The combination of steel and foam provides for a relatively lightweight insulating panel that can span significant distances between support structures.

[004] One difficulty of roofing applications particularly when such prefabricated panels are used for building a roof over an outdoor area such as a patio or driveway is that it is desirable for these roof structures to extend as close to the boundary of a property. However, building regulations require any building material within close proximity of the boundary to have enhanced properties such as non-combustibility. Presently available prefabricated insulated roof panels use core materials that often don’t meet such non-combustibility criteria. It is therefore desirable to provide prefabricated insulated roof panels that can meet such criteria. It is also desirable 2021254542  19 Oct 2021 that such roof panels possess structural strength in order to be used over long spans. SUMMARY OF INVENTION

[005] In an aspect, the invention provides a prefabricated structural roof panel having a length (I) extending between two ends and a width (w) extending between two lateral sides (s1 and s2), the panel comprising: an outer external sheet configured to provide a roof for a building a structure; an inner internal sheet configured to provide a ceiling for a building structure; an insulating core assembly positioned between the outer external sheet and the inner sheet; the core comprising: a first core comprising a first solid material, the first core portion extending across the width of the panel and having a length (11) extending along a first section of the length (I) of the panel, and a second core comprising a second solid material, the second core portion extending across the width of the panel and having a length (I2) and extending along a second section of the length (I) of the panel.

[006] In an embodiment, the sum of the length (11) of the first core and the length (I2) of the second core is substantially equal to the length of the panel.

[007] In an embodiment, at least a portion of the first core extends comprises a complementary configuration to be received into a cavity provided in the second core. 2021254542  19 Oct 2021

[008] In an embodiment, length (11) of the first core is in the range of 500 millimetres to 1500 millimetres and more preferably in the range of 700 millimetres to 1200 millimetres.

[009] In an embodiment, the length of the first core is less than 1000 millimetres and at least 900 millimetres.

[0010] In an embodiment, combustibility of the first core is less than combustibility of the second core.

[0011] In an embodiment, the first core substantially comprises fibrous material such as but not limited to mineral wool.

[0012] In an embodiment, the first core comprises a plurality of blocks of fibrous material such that for each block the fibres substantially extend in one direction, the blocks being arranged to form the first core such that adjacently located blocks are arranged in a configuration so that the fibres of any two adjacently located blocks substantially extend in the direction of the length of the panel.

[0013] In an embodiment, the second core substantially comprises one or more of the following: Expanded Polystyrene (EPS), Polyisocyanurate (PIR), Thermosetting Phenolic Composite (TPC), Extruded Polystyrene (XPS) and Polyurethane (PUR).

[0014] In an embodiment, the first core comprises a first substantially homogenous solid material and wherein the second core comprises a second substantially homogenous solid material. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 2021254542  19 Oct 2021

[0015] Figures 1 to 4 illustrate several embodiments of a prefabricated roof panel in accordance with the invention. Referring to Figure 1, an exploded view of a prefabricated panel 100 is shown. The panel 100 comprises a length L that extends between ends 102 and 104 of the panel 100. The panel 100 also comprises a width W extending between lateral sides S1 and S2 of the panel 100. Each panel 100 comprises an outer profiled metal sheet 110 that is configured to be exposed as a roof sheet. The panel 100 also comprises an inner internal sheet 120 with its outer face being exposed as a ceiling during use. An insulating core assembly 130 is provided between the outer sheet 110 and the inner sheet 120. The core assembly 130 comprises a first core 132 comprising a first type of solid material and a second core 134 comprising a second type of solid material. The first core 132 extends across the entire width W of the panel 100 and has a length (L1) extending along a first section of the length (L) of the panel 100. The second core 134 also extends across the width (W) of the panel 100 and has a length (L2) extending along the length (L) of the panel 100.

[0016] The sum of the lengths (L1+L2) for each core 132 and 134 is substantially equal to the total length L of the panel 100. The first core 132 made from mineral wool typically also has a higher bulk density relative to the second core 134. As a result, the length L1 of the first core 132 should preferably be less than length L2 of the second core 134 so that the second core 134 can provide sufficient structural strength to the prefabricated panel 100. Preferably, the length L1 of the first core 132 should be at least 900mm so that the prefabricated panel 100 can be positioned such that the first end 102 of the prefabricated panel 100 is positioned at the 2021254542  19 Oct 2021 boundary and any structure of the prefabricated panel that is within a distance of 900mm from the boundary is substantially non-combustible.

[0017] Importantly, the first core 132 is formed from a solid material that has less combustibility when compared with the second core 134. In a preferred embodiment, the first core 132 is formed from mineral wool (having a bulk density of around 100kg / m3) that is substantially non-combustible. In contrast, the second core 134 is formed from expanded polystyrene (EPS) (with a lower bulk density in the range of 10 to 20kg / m3) that is flammable and possesses greater combustibility when compared with mineral wool. It is important to appreciate that the materials forming the first and second cores 132 and 134 are not limiting. However, it is desirable for the first core portion 132 to be non-combustible to address at least some of the deficiencies of the prior art.

[0018] The applicants have also found that it is desirable to fabricate the first core 132 from a plurality of blocks wherein each block 1320 comprises fibrous material (such as mineral wool). The manufacturing process may involve procuring large blocks of mineral wool (that for example may have a length of 1200mm and a thickness of 1200mm. Such large blocks may be cut into lamellas (or small blocks) to have a thickness that is substantially equal to the desired thickness of the prefabricated panel 100 whilst still maintaining the length of 1200mm. Each small block or lamella 1320 comprises fibres oriented in one direction., During prefabrication of the panel 100, particularly the first core 132, the lamellas or fibrous sub-blocks 1320 are turned and stacked side by side to orient the fibres in a lengthwise configuration so that the fibres of any two adjacently located sub-blocks 2021254542  19 Oct 2021 or lamellas 1320 substantially extend in a lengthwise direction along the length of the prefabricated panel 100.

[0019] Referring to Figure 4, an exploded view of a panel 200 in accordance with a second embodiment has been illustrated. The panel 200 comprises a length L that extends between ends 202 and 204 of the panel 200. The panel 200 also comprises a width W extending between lateral sides S1 and S2 of the panel 200. Each panel 200 comprises an outer profiled metal sheet 210 that is configured to be exposed as a roof sheet. The panel 200 also comprises an inner internal sheet 220 with its outer face being exposed as a ceiling during use. An insulating core assembly 230 is provided between the outer sheet 210 and the inner sheet 220. The core assembly 230 comprises a first core 232 comprising a first type of solid material and a second core 234 comprising a second type of solid material. The first core 232 extends across the entire width W of the panel 200 and interfaces with the second core 234 along a stepped interface whereby a portion of the first core 232 extends into a cavity formed in the second core 234. Similarly, the second core 234 extends across the entire width (W) of the panel 200 and a portion of the second core 234 also extends into a cavity of the first core 232. In effect, the first core 232 comprises a first section with a length S1 across a first width WS1 and a second section with a length S2 across a second width WS2 whereby S1 is greater than S2 and whereby the sum of WS1 and WS2 equals the width of the panel 200. Similarly, the second core 234 comprises a first section with a length R1 across a first width WR1 and a second section with a length R2 across a second width WR2 whereby R1 is greater than R2 and whereby the sum of WR1 and WR2 equals the width of the panel 200. The interconnection between the first and second cores 232 and 234 improves strength 2021254542  19 Oct 2021 characteristics along the length and width of the panel 200. Across any longitudinal section, the sum of the instant lengths of the first core 232 and the second core 234 equal the total length of the panel 200.

[0020] Referring to Figure 5, an exploded view of a panel 300 in accordance with yet another embodiment has been illustrated. The panel 300 comprises a length L that extends between ends 302 and 304 of the panel 300. The panel 300 also comprises a width W extending between lateral sides S1 and S2 of the panel 300. Each panel 300 comprises an outer profiled metal sheet 310 that is configured to be exposed as a roof sheet. The panel 300 also comprises an inner internal sheet 320 with its outer face being exposed as a ceiling during use. An insulating core assembly 330 is provided between the outer sheet 310 and the inner sheet 320. The core assembly 330 comprises a first core 332 comprising a first type of solid material and a second core 334 comprising a second type of solid material. The first core 332 extends across the entire width W of the panel 300 and has a length (L1) extending along a first section of the length (L) of the panel 300. The second core 334 also extends across the width (W) of the panel 300 and has a length (L2) extending along the length (L) of the panel 300.

[0021] The sum of the lengths (L1+L2) for each core 332 and 334 is substantially equal to the total length L of the panel 300. The first core 332 made from mineral wool typically also has a higher bulk density relative to the second core 334. As a result, the length L1 of the first core 332 should preferably be less than length L2 of the second core 334 so that the second core 334 can provide sufficient structural strength to the prefabricated panel 300. Once again, the length L1 of the first core 2021254542  19 Oct 2021 332 should be at least 900mm so that the prefabricated panel 300 can be positioned such that the first end 302 of the prefabricated panel 300 is positioned at the boundary and any structure of the prefabricated panel that is within a distance of 900mm from the boundary is substantially non-combustible.

[0022] As previously discussed, the first core 332 is formed from a solid material that has less combustibility when compared with the second core 334. In a preferred embodiment, the first core 332 is formed from mineral wool that is substantially noncombustible. In contrast, the second core 334 is formed from expanded polystyrene (EPS) that is flammable and possesses greater combustibility when compared with mineral wool. It is important to appreciate that the materials forming the first and second cores 332 and 334 are not limiting. However, it is desirable for the first core portion 332 to be non-combustible to address at least some of the deficiencies of the prior art.

[0023] It will be understood that the panels 100, 200 or 300 may be prefabricated by using conventional methods involving the use of adhesives to bond the outer external sheet and the inner internal sheet with the first and second insulating cores. In addition, as shown in Figure 5, strengthening members 350 may be provided in some embodiments to provide bridging strength between the first and second cores 332 and 334. The strengthening members 350 may extend across the width of the panel to connect the first core 332 with the second core 334 via the sheets 310 and 320.

[0024] 2021254542  19 Oct 2021

[0025] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term “comprises” and its variations, such as “comprising” and “comprised of’ is used throughout in an inclusive sense and not to the exclusion of any additional features.

[0026] It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect.

[0027] The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

Claims

1. A prefabricated structural roof panel having a length (I) extending between two ends and a width (w) extending between two lateral sides (s1 and s2), the panel comprising:an outer external sheet configured to provide a roof for a building a structure;an inner internal sheet configured to provide a ceiling for a building structure;an insulating core assembly positioned between the outer external sheet and the inner sheet; the core comprising:a first core comprising a first solid material, the first core portion extending across the width of the panel and having a length (11) extending along a first section of the length (I) of the panel, anda second core comprising a second solid material, the second core portion extending across the width of the panel and having a length (I2) and extending along a second section of the length (I) of the panel.

2. A panel in accordance with claim 1 wherein the sum of the length (11) of the first core and the length (I2) of the second core is substantially equal to the length of the panel.2021254542  19 Oct 20213. A panel in accordance any one of claims 1 or 2 wherein at least a portion of the first core extends comprises a complementary configuration to be received into a cavity provided in the second core.

4. A panel in accordance with any one of the preceding claims wherein length (11) of the first core is in the range of 500 millimetres to 1500 millimetres and more preferably in the range of 700 millimetres to 1000 millimetres.

5. A panel in accordance with any one of the preceding claims wherein the length of the first core is less than 1000 millimetres and at least 900 millimetres.

6. A panel in accordance with any one of the preceding claims wherein combustibility of the first core is less than combustibility of the second core.

7. A panel in accordance with any one of the preceding claims wherein the first core substantially comprises fibrous material such as but not limited to mineral wool.

8. A panel in accordance with claim 7 wherein the first core comprises a plurality of blocks of fibrous material such that for each block the fibres substantially extend in one direction, the blocks being arranged to form the first core such that adjacently located blocks are arranged in a configuration so that the fibres of any two adjacently located blocks substantially extend in the direction of the length of the panel.

9. A panel in accordance with any one of the preceding claims wherein the second core substantially comprises one or more of the following: Expanded2021254542  19 Oct 2021Polystyrene (EPS), Polyisocyanurate (PIR), Thermosetting Phenolic Composite (TPC), Extruded Polystyrene (XPS) and Polyurethane (PUR).10.A panel in accordance with any one of the preceding claims wherein the first core comprises a first substantially homogenous solid material and wherein the second core comprises a second substantially homogenous solid material.

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