Tapered interlocking structural panel

Abstract

An interlockable longitudinally extending tapered structural panel with a channel cross-section for construction of a structure, the tapered structural panel comprising: a base and first and second side walls forming the sides of the channel, wherein the first and second side walls mirror each other's extension from the base and provide a generally straight extension from the base, wherein the base describes a horizontal projection; a first locking-region adjoining an end of the first side wall distal the base is curved as a first arc directed away from a central portion of the channel, wherein the first locking-region is oriented at a first locking-region angle with respect to the horizontal projection; and a second locking-region adjoining an end of the second side wall is curved as a second arc directed towards the central portion of the channel, wherein the second locking-region is oriented at a second locking-region angle with respect to the horizontal projection; wherein a straight section extends from a distal end of the second arc; wherein the end of the first arc comprises a projection; wherein the first and second sidewalls at a proximal end of the longitudinally extending structural panel meet the base at a first wall angle with respect to the horizontal projection and the first and second sidewalls at a distal end of the longitudinally extending structural panel meet the base at a second wall angle with respect to the horizontal projection; wherein the second wall angle is greater than the first wall angle such that the longitudinally extending panel provides a wide coverage at the proximal end; and wherein the coverage smoothly tapers to a narrower coverage at the distal end, forming the tapered structural panel.

Description

TAPERED INTERLOCKING STRUCTURAL PANELField of the Invention

[0001] This invention relates to panels which interlock to form long-span roofs of buildings, in particular, roofs with a curved outer edge, as well as irregular shaped or undulating building roofs and walls.Background

[0002] Any discussion of the background art throughout the specification should in no way be considered as an admission that such background art is prior art, nor that such background art is widely known or forms part of the common general knowledge in the field in Australia or worldwide as at the priority date of the present application.

[0003] All references, including any patents or patent applications, cited in this specification are hereby incorporated by reference, which means that it should be read and considered by the reader as part of this text. That the document, reference, patent application or patent cited in this text is not repeated in this text is merely for reasons of conciseness.

[0004] No admission is made that any reference or documentation cited in the present specification constitutes prior art. The discussion of the references states what their authors assert, and the applicants reserve the right to challenge the accuracy and pertinence of the cited documents. It will be clearly understood that, although a number of prior art publications may be referred to herein, such reference does not constitute an admission that any of these documents forms part of the common general knowledge in the art, in Australia or in any other country, at the priority date of the application.

[0005] Interlocking panels for large span roofs have been in use for some time. One of the most successful such panels is disclosed in US 4,759,159 as having a pair of upstanding flanges 15, 16 at opposite longitudinal sides as reproduced in cross section in Figure 1A. A male rib 21 supported by one flange 15 and a female rib 22 supported by the other flange 16, both the male and female ribs extending wholly to one side of their supporting flanges, the male rib 21 engageable with the female rib 22 of an adjacent panel to form a contiguous wide-span roof section for a building.

[0006] The female rib is defined as being of generally inverted II shape form in transverse cross section having a first leg comprising an extension of said supporting flange and a second leg spaced from said first leg, said second leg having a at its free end, an inwardly directed first deformation and there being provided a second deformation in the region of the junction between said first leg and said supporting flange.

[0007] The male rib is defined as being generally of an inverted II shape form in transverse cross section having a first leg comprising an extension of said supporting flange and a second leg spaced from said first leg and inclined outwardly away from said first leg, and there being an inwardly directed projection defining a recess in the region of the junction between said first leg and said supporting flange being complementary to said second deformation such that when interlocked said male rib is located within said female rib, said first legs of said male and female ribs are juxtaposed, said second leg of said male rib resiliently engages said second leg of said female rib rearward of said first deformation and said second deformation engages within said recess.

[0008] Improvements to panel 10 are described in US 2024 / 0011295 A1 and reproduced in cross-section as prior art panel 80 in Figure 1B, showing two such interlocking panels 80 in an engaged configuration when in use. First and second side walls 82, 83, mirror each other in their generally straight extension from base 81. The end of the first side wall 82 is arranged as a male arc section 90 that curves toward the centre of the channel. The end of the second wall 83 is arranged as a female arc section arc 91 that curves away from the centre of the channel. Female arc section 91 terminates in a hook section 94. Two or more interlockable panels 80 are connected together by engaged the male arc section 90 of one interlockable panel 80 with a female arc section 91 of an adjacent interlockable panel 80 as depicted in detail Figure 1C.

[0009] Prior art panels 10 and 80 are generally provided in lengths of about 30 to 40 metres (however, panels 10 and 80 may be between about 5 and about 150 m in length) and multiple, like panels are interlocked together longitudinally to form a rectilinear roof.

[0010] However, architects often would prefer to design structures outside the confines of rectilinear limitation imposed by the building materials. Therefore, there is a need for improvements to interlocking roof and / or wall panels which are adaptable for alternate roof geometries, for example a curved roof / wall profile when viewed from above (i.e. , in plan view), or a combination of curved or undulating structures with rectilinear structuresto construct, for example, circular buildings, fan-shaped buildings, undulating or wave shape roof lines, and / or irregular shaped buildings and walls.Summary

[0011] It is an object of the present invention to overcome or ameliorate at least one or more of the disadvantages of the prior art, or to provide a useful alternative.

[0012] Throughout this specification, unless the context requires otherwise, the words “comprise”, “comprises” and “comprising” will be understood to imply the inclusion of a stated step or element or group of steps or elements but not the exclusion of any other step or element or group of steps or elements.

[0013] Any one of the terms “including” or “which includes” or “that includes” as used herein is also an open term that also means including at least the elements / features that follow the term, but not excluding others. Thus, “including” is synonymous with and means “comprising”.

[0014] In the claims, as well as in the summary above and the description below, all transitional phrases such as “comprising”, “including”, “carrying”, “having”, “containing”, “involving”, “holding”, “composed of”, and the like are to be understood to be open-ended, i.e., to mean “including but not limited to”. Only the transitional phrases “consisting of” and “consisting essentially of” alone shall be closed or semi-closed transitional phrases, respectively.

[0015] Even though particular combinations of features are recited in the claims and / or disclosed in the specification, these combinations are not intended to limit the disclosure of possible implementations. In fact, many of these features may be combined in ways not specifically recited in the claims and / or disclosed in the specification. Although each dependent claim listed below may directly depend on only one claim, the disclosure of possible implementations includes each dependent claim in combination with every other claim in the claim set.

[0016] According to a first aspect of the invention, there is provided an interlockable longitudinally extending tapered structural panel with a channel cross-section for forming roofs and walls. The panel may comprise a base and first and second side walls forming the sides of the channel. The first and second side walls may mirror each other’sextension from the base and may provide a generally straight extension from the base. The base may describe as a horizontal projection. The panel may further comprise a first locking-region adjoining an end of the first side wall distal the base which may be curved as a first arc directed away from a central portion of the channel. The first locking-region may be oriented at a first locking-region angle with respect to the horizontal projection. The panel may further comprise a second locking-region adjoining an end of the second side wall which may be curved as a second arc directed towards the central portion of the channel. The second locking-region may be oriented at a second locking-region angle with respect to the horizontal projection. The circular shape of the interlocking ribs may act as a hinge to accommodate slight discrepancies in the 60-degree rib angle. This is not possible with the interlocking ribs 21 and 22 of prior art panel 10 shown in Figure 1A.

[0017] A straight section may extend from a distal end of the second arc. The end of the first arc may comprises a projection. The first and second sidewalls at a proximal end of the longitudinally extending structural panel may meet the base at a first wall angle with respect to the horizontal projection and the first and second sidewalls at a distal end of the longitudinally extending structural panel may meet the base at a second angle with respect to the horizontal projection. The second wall angle may be greater than the first angle such that the longitudinally extending panel provides a wide coverage at the proximal end, and the coverage smoothly tapers to a narrower coverage at the distal end, forming the tapered structural panel.

[0018] According to a particular arrangement of the first aspect, there is provided an interlockable longitudinally extending tapered structural panel with a channel crosssection for forming roofs comprising: a base and first and second side walls forming the sides of the channel, wherein the first and second side walls mirror each other’s extension from the base and provide a generally straight extension from the base, wherein the base describes a horizontal projection; a first locking-region adjoining an end of the first side wall distal the base is curved as a first arc directed away from a central portion of the channel, wherein the first locking-region is oriented at a first locking-region angle with respect to the horizontal projection; and a second locking-region adjoining an end of the second side wall is curved as a second arc directed towards the central portion of the channel, wherein the secondlocking-region is oriented at a second locking-region angle with respect to the horizontal projection; wherein a straight section extends from a distal end of the second arc; wherein the end of the first arc comprises a projection; wherein the first and second sidewalls at a proximal end of the longitudinally extending structural panel meet the base at a first wall angle with respect to the horizontal projection and the first and second sidewalls at a distal end of the longitudinally extending structural panel meet the base at a second angle with respect to the horizontal projection; wherein the second wall angle is greater than the first angle such that the longitudinally extending panel provides a wide coverage at the proximal end; and wherein the coverage smoothly tapers to a narrower coverage at the distal end, forming the tapered structural panel.

[0019] The first locking-region angle at the proximal end of the structural panel may be the same as the first locking-region angle at the distal end of the structural panel. The second locking-region angle at the proximal end of the structural panel may be the same as the second locking-region angle at the distal end of the structural panel.

[0020] The first and second locking-regions may be configured in use to engage with respective second and first locking-regions of adjacent identical along the entire length of the structural panels in use to form an interlocked roof structure. Additionally, an interlockable longitudinally extending tapered structural panels, may have a greater or lesser amount of tapering (tapering strength) than adjacent panels to which it is engaged with. A tapered panel may also be engaged with an adjacent un-tapered panel. Since the angle of the locking regions remains relatively constant (typically about 60 ± 5 degrees from horizontal), then adjacent panels will engage securely with each other to form a roof or wall structure.

[0021] The first wall angle may be between 20 and 50 degrees with respect to the horizontal projection and the second wall angle may be greater than about 70 degrees with respect to the horizontal projection.

[0022] The first locking-region angle and the second locking-region angle may be between about 50 and 70 degrees i.e. , may be about 60 ± 10 degrees with respect to the horizontal projection. The first locking-region angle and the second locking-region angle may be about 60 ± 5 degrees with respect to the horizontal projection.

[0023] According to a second aspect of the invention, there is provided a method of forming a tapered structural panel for forming roofs with a channel cross-section. The method may comprise the step of providing a panel tapering configuration comprising a plurality of roller formations adapted to receive a profiled structural panel. The roller formations may be arranged in a plurality of formation sections including: first profiling configuration zone configured to receive a base of the profiled structural panel; a second profiling configuration zone configured to receive a first wall of the profiled structural panel; and a third profiling configuration zone configured to receive a second wall of the profiled structural panel.

[0024] The second and the third profiling configuration zones may be initially aligned at a first wall angle with respect to the horizontal. The roller formations may further include: a fourth profiling configuration zone configured to receive a first locking section of the profiled structural panel; and a fifth profiling configuration zone configured to receive a second locking section of the profiled structural panel.

[0025] The fourth and the fifth profiling configuration zones may be aligned at a locking section angle with respect to the horizontal. The method may comprise the further step of rolling the profiled panel through the panel tapering configuration to form a tapered structural panel. As the profiled panel is rolled through the panel tapering configuration. The method may comprise the further step of smoothly increasing the angle of the second and third profiling configuration zones with respect to the horizontal from a first wall angle at a proximal end of the tapered structural panel to a second wall angle at a distal end of the tapered structural panel. The locking section angle of the fourth and fifth profiling configuration zones may remain constant with respect to the horizontal for the entire length of the tapered structural panel as it is rolled through the panel profiling configuration, thereby to form the sheet material to a tapered interlockable structural panel as claimed in the first aspect.

[0026] According to a particular arrangement of the second aspect of the invention, there is provided a method of forming a tapered structural panel for forming roofs with a channel cross-section comprising:providing a panel tapering configuration comprising a plurality of roller formations adapted to receive a profiled structural panel, the roller formations arranged in a plurality of formation sections including: a first profiling configuration zone configured to receive a base of the profiled structural panel; a second profiling configuration zone configured to receive a first wall of the profiled structural panel; a third profiling configuration zone configured to receive a second wall of the profiled structural panel; wherein the second and the third profiling configuration zones are initially aligned at a first wall angle with respect to the horizontal; a fourth profiling configuration zone configured to receive a first locking section of the profiled structural panel; a fifth profiling configuration zone configured to receive a second locking section of the profiled structural panel; wherein the fourth and the fifth profiling configuration zones are aligned at a locking section angle with respect to the horizontal; rolling the profiled panel through the panel tapering configuration to form a tapered structural panel; wherein as the profiled panel is rolled through the panel tapering configuration, the angle of the second and third profiling configuration zones is smoothly increased with respect to the horizontal from a first wall angle at a proximal end of the tapered structural panel to a second wall angle at a distal end of the tapered structural panel; and wherein the locking section angle of the fourth and fifth profiling configuration zones remains constant with respect to the horizontal for the entire length of the tapered structural panel as it is rolled through the panel profiling configuration, thereby to form the sheet material to a tapered interlockable structural panel as claimed in the first aspect.

[0027] According to a third aspect of the invention, there is provided a curved or undulating construction comprising a plurality of the tapered structural panel of the first aspect. The first locking-region of a first panel of the plurality of panels may be engaged with the second locking-region of an adjacent panel of the plurality of panels to lock the panels together along the full length of each of the tapered structural panels.

[0028] According to a particular arrangement of the third aspect, there is provided a curved or undulating construction comprising a plurality of the tapered structural panel of the first aspect, wherein the first locking region of a first panel of the plurality of panels is engaged with the second locking region of an adjacent panel of the plurality of panels to lock the panels together along the full length of each of the tapered structural panels.

[0029] The curved or undulating construction may comprise either a roofing section or a wall section of a structure.

[0030] According to a fourth aspect of the invention, there is provided a circular or undulating construction comprising a plurality of the tapered structural panel of the first aspect, wherein the first locking-region of a first panel of the plurality of panels may be engaged with the second locking-region of an adjacent panel of the plurality of panels to lock the panels together along the full length of each of the tapered structural panels.

[0031] According to a particular arrangement of the fourth aspect, there is provided a circular roofing section comprising a plurality of the tapered structural panel of the first aspect, wherein the first locking-region of a first panel of the plurality of panels is engaged with the second locking-region of an adjacent panel of the plurality of panels to lock the panels together along the full length of each of the tapered structural panels.

[0032] According to a fifth aspect of the invention, there is provided a method of forming a tapered structural panel for forming roofs with a channel cross -section. The method may comprise the step of providing a panel profiling configuration comprising a plurality of roller formations adapted to receive a sheet material. The roller formations may be arranged in a plurality of formation sections. A first profiling configuration zone may be configured to form the base of the tapered structural panel in the sheet material. A second profiling configuration zone may be configured to form the first wall of the tapered structural panel in the sheet material. A third profiling configuration zone may be configured to form the second wall of the tapered structural panel in the sheet material. The second and the third profiling configuration zones may be initially aligned at a first wall angle with respect to the horizontal. A fourth profiling configuration zone may be configured to form the first locking section of the tapered structural panel in the sheet material. A fifth profiling configuration zone may be configured to form the second locking section of the tapered structural panel in the sheet material. The fourth and the fifth profiling configuration zones may be aligned at a locking section angle with respect to thehorizontal. The method may further comprise the step of rolling the sheet material through the panel profiling configuration to form a profiled structural panel. As the sheet material is rolled through the panel profiling configuration, the wall angle of the second and third profiling configuration zones may be smoothly increased with respect to the horizontal from a first wall angle at a proximal end of the tapered structural panel to a second wall angle at a distal end of the tapered structural panel. The locking section angle of the fourth and fifth profiling configuration zones may remain constant with respect to the horizontal for the entire length of the tapered structural panel as it is rolled through the panel profiling configuration, thereby to form the sheet material to a tapered interlockable structural panel according to the first aspect.

[0033] According to a particular arrangement of the fifth aspect, there is provided a method of forming a tapered structural panel for forming roofs with a channel crosssection comprising: providing a panel profiling configuration comprising a plurality of roller formations adapted to receive a sheet material, the roller formations arranged in a plurality of formation sections including: a first profiling configuration zone configured to form the base of the tapered structural panel in the sheet material; a second profiling configuration zone configured to form the first wall of the tapered structural panel in the sheet material; and a third profiling configuration zone configured to form the second wall of the tapered structural panel in the sheet material; wherein the second and the third profiling configuration zones are initially aligned at a first wall angle with respect to the horizontal; a fourth profiling configuration zone configured to form the first locking section of the tapered structural panel in the sheet material; a fifth profiling configuration zone configured to form the second locking section of the tapered structural panel in the sheet material; wherein the fourth and the fifth profiling configuration zones are aligned at a locking section angle with respect to the horizontal; rolling the sheet material through the panel profiling configuration to form a profiled structural panel; wherein as the sheet material is rolled through the panel profiling configuration, the wall angle of the second and third profiling configuration zones is smoothly increasedwith respect to the horizontal from a first wall angle at a proximal end of the tapered structural panel to a second wall angle at a distal end of the tapered structural panel; and wherein the locking section angle of the fourth and fifth profiling configuration zones remains constant with respect to the horizontal for the entire length of the tapered structural panel as it is rolled through the panel profiling configuration, thereby to form the sheet material to a tapered interlockable structural panel according to the first aspect.

[0034] Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. The invention includes all such variation and modifications. The invention also includes all of the steps, features, formulations, and compounds referred to or indicated in the specification, individually or collectively and any and all combinations of any two or more of the steps or features.Brief Description of the Drawings

[0035] Notwithstanding any other forms which may fall within the scope of the present invention, a preferred embodiment / preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:Figure 1A shows a prior art interlocking structural panel;Figure 1 B shows an improved prior art interlocking structural panel;Figure 1C shows a detail of interlocking structures of prior art structural panels of Figure 1B;Figure 2A shows a circular roof structure formed from tapered interlocking panels according to the tapered interlocking structural panels disclosed herein;Figure 2B shows a side profile of a tapered interlocking panel of the circular roof of Figure 2A according to the tapered interlocking structural panels disclosed herein;Figure 2C shows a top / plan view of a tapered interlocking panel of the circular roof of Figure 2A according to the tapered interlocking structural panels disclosed herein;Figure 2D shows a curved structure formed from untapered structural panels in combination with tapered interlocking panels of varying taper strength according to the tapered interlocking structural panels disclosed herein;Figure 2E shows a rectilinear wall structure formed from untapered structural panels in combination with tapered interlocking panels of varying taper strength according to the tapered interlocking structural panels disclosed herein;Figure 3 shows a perspective view of a tapered interlocking structural panel as disclosed herein;Figure 4 shows a cross-sectional profile of the tapered interlocking structural panel of Figure 3 at a proximal end.Figure 5 shows a cross-sectional profile of the tapered interlocking structural panel of Figure 3 at a distal end.Figure 6A shows a schematic depiction of a roller arrangement for forming tapered panels in a first configuration for forming the proximal end of the tapered interlocking structural panel of Figure 3; andFigure 6B shows a schematic depiction of the roller arrangement for forming tapered panels in a second configuration for forming the distal end of the tapered interlocking structural panel of Figure 3.Figure 7 shows an example commercial tapered structural panel 100 of Figure 3 in end view showing the increase in wall angle between the proximal and distal ends of the tapered panel 100.

[0036] In the drawings, like structures are referred to by like numerals throughout the several views. The drawings shown are not necessarily to scale, with emphasis instead generally being placed upon illustrating the principles of the present invention.Definitions

[0037] The following definitions are provided as general definitions and should in no way limit the scope of the present invention to those terms alone, but are put forth for a better understanding of the following description.

[0038] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the art to which the invention belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. For the purposes of the present invention, additional terms are defined below. Furthermore, all definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms unless there is doubt as to the meaning of a particular term, in which case the common dictionary definition and / or common usage of the term will prevail.

[0039] For the purposes of the present invention, the following terms are defined below.

[0040] The articles “a” and “an” are used herein to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article. By way of example, "an element" refers to one element or more than one element.

[0041] The term “about” is used herein to refer to quantities that vary by as much as 30%, preferably by as much as 20%, and more preferably by as much as 10% to a reference quantity. The use of the word ‘about’ to qualify a number is merely an express indication that the number is not to be construed as a precise value.

[0042] Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, preferred methods and materials are described. It will be appreciated that the methods, apparatus and systems described herein may be implemented in a variety of ways and for a variety of purposes. The description here is by way of example only.

[0043] Also, various inventive concepts may be embodied as one or more methods, of which an example has been provided. The acts performed as part of the method may be ordered in any suitable way. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments.

[0044] The phrase “and / or”, as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e. , elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and / or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and / or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and / or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.

[0045] As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and / or” as defined above. For example, when separating items in a list, “or” or “and / or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of”, or, when used in the claims, “consisting of” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e., “one or the other but not both”) when preceded by terms of exclusivity, such as “either”, “one of”, “only one of’, or “exactly one of’. “Consisting essentially of”, when used in the claims, shall have its ordinary meaning as used in the field of patent law.

[0046] As used herein in the specification and in the claims, the phrase “at least one”, in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B”, or, equivalently “at least one of A and / or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally includingelements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.

[0047] For the purpose of this specification, where method steps are described in sequence, the sequence does not necessarily mean that the steps are to be carried out in chronological order in that sequence, unless there is no other logical manner of interpreting the sequence.

[0048] In addition, where features or aspects of the invention are described in terms of Markush groups, those skilled in the art will recognise that the invention is also thereby described in terms of any individual member or subgroup of members of the Markush group.Detailed Description

[0049] Modifications and variations such as would be apparent to the skilled addressee are considered to fall within the scope of the present invention. The present invention is not to be limited in scope by any of the specific embodiments described herein. These embodiments are intended for the purpose of exemplification only. Functionally equivalent products, formulations and methods are clearly within the scope of the invention as described herein. It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.

[0050] Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0051] Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

[0052] The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[0053] Reference to positional descriptions and spatially relative terms), such as “inner”, “outer”, “beneath”, “below”, “lower”, “above”, “upper” and the like, are to be taken in context of the embodiments depicted in the figures, and are not to be taken as limiting the invention to the literal interpretation of the term but rather as would be understood by the skilled addressee.

[0054] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first”, “second”, and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0055] It will be understood that when an element is referred to as being “on”, “engaged”, "connected" or "coupled" to another element / layer, it may be directly on, engaged, connected or coupled to the other element / layer or intervening elements / layers may be present. Other words used to describe the relationship between elements / layers should be interpreted in a like fashion (e.g., “between”, “adjacent”). As used herein the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0056] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. The use of the singular includes the plural unless specifically stated otherwise. As used herein, the singular forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprise”, “comprises”, “comprising”, “including”, and “having”, or variations thereof are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0057] Figure 2A shows a top-down (plan) view of a structure 30 having a circular roof 31. Such a roof 31 having a circular, or a curved profile is not possible with prior art interlocking panels since the coverage of each panel must decrease at the inner circumference 33 compared with the coverage at the outer circumference 35. Roof 31 is constructed with a plurality of interlockable longitudinally extending tapered structural panels 100 as described in greater detail below. Panels 100 are formed from a sheet material having a constant material width along the entire length of the panel. However, as can be seen in the side view of tapered structural panel 100 in Figure 2B, the height 102 of panels 100 at distal end 103 is taller compared with the height 104 at the proximal end 101 of panel 100, thus forming a tapered width panel 100 as disclosed herein and seen in detail in Figure 2C. With respect to the circular roof structure of Figure 2A, the panels 100 are taller where they meet to form inner circumference 35 compared with the height of panel 100 at the proximal end 101 where adjacent panels 100 meet to form outer circumference 33 of roof 30 as the width of panel 100 increases for increased coverage at the outer circumference 33.

[0058] As can be seen in the top / plan view of tapered structural panel 100 in Figure 2C, tapered structural panels 100 have a proximal panel width 105 at proximal end 101 and a distal panel width 106 at distal end 103. As can be seen in Figure 2C, the proximal width 105 is wider than the distal width 106, thus providing greater panel coverage at the proximal end 105. However, it will be appreciated in further embodiments that the distal panel width 106 may be provided to be wider than proximal panel width 105 in accordance with requirements as these embodiments are equivalent.

[0059] It will also be appreciated that tapered panels 100 can be used to form further non-rectilinear structures including roofs and walls. For example, Figure 2D shows a non-rectilinear (curved) structure 40, for example a roof structure, which is formed by a combination of non-tapered panels, for example prior art panels 80, engaged with tapered panels 100 as described herein such that the curved edge profile 41 (when viewed from above) of structure 40 varies smoothly between straight and curved sections. Furthermore, the amount of taper applied to adjacent tapered panels 100 varies with adjacent panels such that the outer profile 41 of structure 40 changes smoothly betweenstraight and curved sections. It will be readily appreciated that the ability to form tapered panels 100 of variable taper strength (i.e. , the amount by which the width of panel 100 changes between the proximal and distal ends) provides architects with much greater flexibility in the shape of structures which can be realised and or the visual effect which can be achieved with structural panels of controllably variable widths at either end. Additionally, structures may also be realised with distinct visual qualities by combinations of tapered panels (potentially of varying taper strength) and non-tapered panels simply by engaging panels for example as in Figure 2C, and then trimming the outer edge 41 to a desired shape (e.g., a straight edge) to achieve a striking visual effect of a, for example a wall structure with varying panel widths at the top and bottom of the structure, see for example complex visually striking wall structure 45 of Figure 2E.Tapered Interlocking Structural Panel

[0060] With reference to Figure 3, interlockable longitudinally extending tapered structural panel 100 according to a first embodiment of the present invention is shown in perspective view along the longitudinal length of the panel from proximal end 10 to distal end 103. Panel 100 includes a base 107, first wall 110 and a second wall 120 forming a generally channel cross-sectional profile. Panel 100 further includes first locking-region 130 and second locking-region 140. First locking-region 130 comprises a first arc 131 that curves away from the centre of channel 150 formed by base 107 and side walls 110 and 120. The end of the first arc 131 comprises a projection 133. Second locking-region 140 comprises a second arc 141 that curves towards the centre of channel 150. A straight section 143 extends from a distal end of the second arc 141.

[0061] Two or more interlockable panels 100 are connected together by engaging the second arc 141 of one interlockable panel 100 with a first arc 131 of an adjacent interlockable panel 100 as shown in the inset detail 190 of Figures 4 and 5.

[0062] In the present arrangement of panel 100, base 107 is provided with an optional waved profile to strengthen base 107. It will be appreciated that the panel 100 could also have a flat base section 107.

[0063] Referring to Figure 4, the proximal end 101 of panel 100 is shown in end-view. First and second side walls 110, 120 mirror each other’s extension from the base 107 and provide a generally straight extension from base 107; wherein base 107 describes a horizontal reference projection 109. Side walls 110 and 120 meet base 107 at a first wallangle 111 with respect to the horizontal projection 109. First wall angle 111 is depicted as about 33 degrees (example only) from horizontal 109 in the present arrangement, however for the proximal end 101 of panel 100, the first wall angle 111 may be selected between about 30 degrees and about 55 degrees from horizontal 109, and typically about 43 ± 10 degrees from horizontal 109. The range of first wall angle 111 respectively provides a roof coverage at proximal end 101 of panel 100 of between about 900 mm to about 720 mmm, typically about 800 mm. Due to the shallow first wall angle 111 at proximal end 101, the panel 100 has a proximal panel height 102.

[0064] First and second locking-regions 130, 140 are each oriented with the horizontal 109 at a locking-region angle 113 with respect to horizontal projection 109. Locking-region angle 113 is depicted as about 60 degrees from horizontal 109 in the present arrangement, however the locking-region angle 113 may be selected between about 60 ± 10 degrees from horizontal 109, more typically between about 60 ± 5 degrees from horizontal 109, to maintain the locking engagement capability between adjacent panels 100.

[0065] Referring to Figure s, the distal end 103 of panel 100 is shown in end-view. Again, first and second side walls 110, 120 mirror each other’s extension from the base 107 and provide a generally straight extension from base 107; wherein base 107 describes a horizontal reference projection 109. Side walls 110 and 120 meet base 107 at a second wall angle 115 with respect to the horizontal projection 109. Second wall angle 115 is depicted as about 84 degrees (example only) from horizontal 109 in the present arrangement, however for the distal end 101 of panel 100, second wall angle 115 may be selected between about 55 degrees and 90 degrees from horizontal 109. The range of second wall angle 115 respectively provides a roof coverage at proximal end 101 of panel 100 of between about 358 mm to about 700mm. Due to the steep first wall angle 115 at distal end 103, the panel 100 has a distal panel height 104, which is larger than proximal height 102. The length of side walls 110 and 120 shortens through the tapering process between the wide (proximal) end 101 and narrow (distal) end 103 of tapered panel 100.

[0066] In the roll-forming machine 200 (described below - either embodied as a combined profiling and tapering roll-forming machine, or as an independent roll-forming tapering machine) adapted for forming panels 100, or for tapering preformed panels, such as prior art panels 80, there are 2 sets of scroll plate assemblies each side that bothcontrol the locking-region angle 113 (nominally 60 ± 5 degrees with respect to the horizontal at distal end 103 of panel 100, although may vary between about 45 and about 70 degrees at proximal end 101), whilst maintaining a nominal locking-region angle 113 of 60 ± 5 degrees at distal (narrow) end 103) and the shortening of the side walls, this results in material moving from the flat part of the side walls 110 and 120 into and increasing the arc lengths and / or radii of first and second arcs 131 and 141. Also, due to shallow first wall angle 111 at proximal end 101, the longitudinally extending panel provides a wide coverage at the proximal end, smoothly tapering to a narrower coverage at distal end 103 due to steep second wall angle 115 at distal end 103, thereby forming the tapered structural panel necessary to form curved or circular roof sections comprising a plurality of interlocked panels 100. In general, the locking-region angle 113 at the distal end 103 is configured to be a constant angle of about 60 ± 5 degrees to the horizontal. Locking-region angle 113 may be varied at proximal end 101 by manually pushing side walls 110 and 120 outward away from channel 150 if greater coverage is desired at the proximal end of panels 100. Importantly however, in use, the angle 111 which each of respective side walls 110 and 120 of panel 100 makes with the horizontal 109 at proximal end 101 should be at least approximately equal so that respective locking-region angle 113 of each of the locking regions 130 and 140 is approximately equal to ensure that a secure connection between locking regions 130 and 140 is made at proximal end 101 of panel 100 in use.

[0067] Similarly for the proximal end 101 of panel 100 (as seen in Figure 4B), first and second locking-regions 130, 140 at the distal end 103 of panel 100 (Figure 5) are each oriented with respect the horizontal 109 at the locking-region angle 113 with respect to horizontal projection 109, i.e., locking-region angle 113 is configured to be identical at both the proximal and distal ends 101, 103 of panel 100. In the example arrangement of Figures 4 and 5, the locking-region angle 113 is depicted as 60 degrees with respect to the horizontal 109. The intent of the roll-forming machine 200 (described below) is to maintain locking-region angle 113 at a nominal 60 degrees (with respect to horizontal 109) while rolling the side walls 110, 120 up. However, the initial rolling of this profile in the roll-forming machine 200 sets the profile of proximal (wide) end 101 of panel 100 to the typical values including wall angle 111 at about 43 degrees (example only) giving a panel coverage of about 800 mm; and locking-formation angle 113 at about 60 degrees. If it is required, that the panel 100 at the proximal (wide) end 101 to start with a wider cover than the typical roll-formed profile with about 800 mm coverage, then side walls110, and 120 may be physically pushed out to meet the coverage requirements. In this way, it is possible that the locking-region angle may vary slightly from the nominal value of about 60 degrees to the horizontal to between about 55 and about 65 degrees i.e., about 60 ± 5 degrees or about 6 ± 10 degrees.

[0068] Maintaining a generally constant locking-region angle 113 for both the first and second locking-regions 130, 140 along the entire length of panel 100 ensures that, when using a plurality of tapered panels 100 for a roof section with a curved or circular profile, complementary locking-regions of adjacent panels 100 maintain secure locking engagement along the entire length of the adjacent panels 100. Where the sidewalls 110 and 120 are pushed outward to provide greater coverage at proximal (wide) end 101, the sidewalls 110 and 120 are pushed out equally so that the locking-region angles 113 associated with each of the side walls 110 and 120 are substantially equal. In practice, to ensure the locking configuration of adjacent panels 100 for formation of a roof, it will be appreciated that the wall angle (and hence panel coverage) to the proximal (wide) end of each structural panel 100 is modified by the same amount such that locking regions 130 and 140 of adjacent panels respectively are substantially aligned.

[0069] To form circular roof 30 as shown in Figure 2A, a plurality of tapered panels 100 shaped at the respective proximal and distal ends 101, 103 per Figure 4 and Figure 5 respectively are adjacently interlocked by respective locking-regions 130 and 140. A first locking-region 130 of a first panel 100 of the plurality of panels is engaged with the second locking-region 140 of an adjacent identical panel 100 of the plurality of panels to lock the panels together along the full length of each of the tapered structural panels.Forming Method

[0070] Embodiments of the tapered panels 100 as described herein are formed, typically on site, by passing a sheet of metal material (e.g., aluminium) of a desired width through a roll forming machine 200 comprising a series of profiling rollers configured to bend the sheet in the direction perpendicular to the longitudinal length of the coiled sheet metal into the desired panel profile (e.g., as shown in Figures 4 and 5). Sheet material typically is delivered to the constructions site as a large coil of sheet material of the desired width for formation of the panels which are rolled through the series of profiling rollers to the desired length. The metal material to formed into panel 100 may either be an initially flat material which may be profiled and tapered in a single stage roll-forming machine.Alternatively, the flat material may be initially formed into a profiled panel (for example, prior art panel 50 of Figure 1 B) by a first roll-forming machine, and subsequently passed through a second independent roll forming machine to impart the taper to pre-profiled panel to form tapered panel 100.

[0071] To form the tapered panels 100 disclosed above from an initially flat sheet as provided in a roll of panel material, the roll forming machine 200 comprises a plurality of rollers adapted to forming the desired profile shape of panel 100. The plurality of profiling rollers of roll forming machine 200 are separated into a plurality of independent profiling configuration zones as depicted in Figure 6A.

[0072] Profiling configuration zone 201 is configured to form base 107 of panels 100. Base 107 remains at a constant width along the entire length of panel 100 in the present arrangement, thus complementary rollers, not shown but as would be appreciated by the skilled addressee, configured to form the profile of base 107 remain in a fixed position.

[0073] Second and Third Profiling Configuration Zones 203 and 205 are configured to form sidewalls 110 and 120 respectively. Finally, Fourth and Fifth Profiling Configuration Zones 207 and 209 are configured to form sidewalls 110 and 120 respectively.

[0074] At the start of profiling operation to form each of the tapered panels 100, the profiling configuration zones of the roll forming machine 200 are initially configured in the position as shown in Figure 6A particularly for forming the proximal end 101 of panel 100. In this configuration, the second and the third profiling configuration zones 203 and 205 are each initially aligned at the first wall angle 111 with respect to the horizontal 109 as shown in Figure 4. Furthermore, the fourth and the fifth profiling configuration zones 207 and 209 are each initially aligned at the locking-region angle 113 with respect to the horizontal 109 as shown in Figure 4 form the proximal end profile 101 of panel 100.

[0075] As the sheet metal is driven through roll forming machine 200 by drive rollers (not shown), second and third profiling configuration zones 203 and 205 are each smoothly rotated upwards until they are positioned in the final position of roll forming machine 200 as shown in Figure 6B particularly for forming the distal end 103 of panel 100. In this manner, the wall angle of the second and third profiling configuration zones 203 and 205 is smoothly increased about respective first pivot points 211 with respect to the horizontal from first wall angle 111 at a proximal end of the tapered structural panel to second wall angle 115 at a distal end of the tapered structural panel.

[0076] In the final position of Figure 6B, the second and third profiling configuration zones 203 and 205 are aligned at the second wall angle 115 respect to the horizontal 109 as shown in Figure 5 to form the distal end profile 103 of panel 100.

[0077] As can be seen in Figure 6B, the alignment of the fourth and fifth profile configuration zones 207 and 209 with respect to horizontal 109 remains constant at the locking-section angle 113 such that the orientation of the first and second locking-regions 130 and 140 remains unchanged such that formed first and second locking regions 130, 140, remain aligned at the locking-region angle 113 throughout the entire length of panel 100 as the sheet metal is fed through roll forming machine 200. To achieve this constant locking-section angle, the first and second locking regions 130 and 140 are smoothly rotated about second pivot points 213 as the wall angle of the second and third profiling configuration zones 203 and 205 is smoothly increased about respective first pivot points 211.

[0078] As can be appreciated by the skilled addressee from the proximal and distal configurations of Figures 6A and 6B respectively, as second and third profile configuration zones 203 and 205 rotate inwards, fourth and fifth profile configuration zones 207 and 209 must correspondingly move both inwards and upwards whist counter-rotating to maintain the same alignment angle 113 with horizontal 109 in order to maintain contact with the distal ends of side walls 110 and 120 respectively. For example, as configuration zone 203 rotates inwards (clockwise) to increase the wall angle 115 of side wall 110 about respective first pivot points 211 , configuration zone 207 moves upwards and inwards whilst counter-rotating (anticlockwise) about respective second pivot points 213 to maintain the locking-section angle 113 of first locking region 130. Simultaneously, and equivalently, configuration zone 205 rotates inwards (anti-clockwise) to increase the wall angle 115 of side wall 120, as configuration zone 209 moves upwards and inwards whilst counter-rotating (clockwise) to maintain the locking-section angle 113 of second locking region 140.

[0079] In a further embodiment, roll forming machine 200 may be configured to receive a pre-profiled, untapered panel, for example prior art panels 80 of Figure 1B. In this embodiment, a roll-forming tapering machine (including zones 201, 203, 205, 207, and 209 of Figure 6B) operates independently from a separate roll forming profiling machine. Therefore, pre-profiled, untapered, panels, such as prior art panels 80, may be delivered to a building site and may be tapered on demand according to the profiling requirementsof the particular building being constructed from the panels. Alternatively, profiled, untapered, panels may be prepared on-demand onsite by a roll forming profiling machine, and then, as required, the profiled, untapered panels may be tapered by an independent roll forming tapering machine to impart a taper lengthwise along the received panel as it is drawn through the roll forming tapering machine.

[0080] In this stand-alone roll forming tapering machine, configuration zones 201, 203, 205, 207, and 209 do not generally impart or change the profile of the panel as it is passed through the machine (but optionally they may do so), but may simply engage the wall panel to maintain the initial panel profile while drawing the panel through the roll-forming tapering machine as the wall angle is changed, (either increased or decreased according to requirements). Roll-forming tapering machine may be used both to increase the wall angle 113 of the panel, or optionally, may be used to decrease the wall angle 113.

[0081] In this stand-alone embodiment, to form the tapered panels 100 disclosed above, an initial roll forming machine (not shown) comprises a plurality of rollers adapted to forming the desired profile shape of panel 100. To form the tapered panel a further, independent roll forming machine 200 is provided which is configured to receive a profiled (untapered) panel and to form the panel into a tapered panel with varying coverage along the panel length. The plurality of profiling rollers of roll form tapering machine 200 are separated into a plurality of independent profiling configuration zones as depicted in Figure 6A, where each profiling configuration zone 201 , 203, 205, 207, 209, comprises roll-forming rollers positioned on either side of the panel (i.e. , top and bottom) to bend the initially profiled untapered panel into the profiled panel according to the tapered panel 100 of Figure 3. However, in contrast to a single roll-forming machine embodiment discussed above where each configuration zone 203, 205, 207, 209 comprises forming rollers which actively shape the panel profile, the rollers in each of zones 203, 205, 207, 209 of stand-alone roll-forming tapering machine are configured to merely maintain the pre-formed panel profile and the only active element of roll-forming tapering machine is in wherein each of second and third profiling configuration zones 203 and 205 are smoothly rotated upwards as the pre-profiled panel is drawn through the tapering machine until they are positioned in the final position as shown in Figure 6B for forming the distal end 103 of tapered panel 100. As before, , the wall angle of the second and third profiling configuration zones 203 and 205 is smoothly increased with respect to the horizontal from first wall angle 111 at a proximal end of the tapered structural panel to second wall angle115 at a distal end of the tapered structural panel such that the second and third profiling configuration zones 203 and 205 are aligned at the second wall angle 115 with respect to the horizontal 109 as shown in Figure 5 to form the distal end profile 103 of panel 100. As before, as configuration zones 203 and 205 are rotated inwards to form the steeper wall angle and create the panel taper, the fourth and fifth profile configuration zones 207 and 209, are counter-rotated so that their orientation with respect to horizontal 109 remains constant at the locking-section angle 113 such that the orientation of the first and second locking-regions 130 and 140 remains unchanged, thus ensuring that formed first and second locking regions 130, 140, remain aligned at the locking-region angle 113 throughout the entire length of panel 100 as the pre-profiled panel is fed through roll forming tapering machine.

[0082] Figure 7 shows an example commercial tapered structural panel 100 in end view showing the increase in wall angle between the proximal and distal ends of the panel 100 as the wall sections are angled inwards about respective pivot points 211 whilst maintaining the angle of male and female locking sections 130 and 140 respectively about respective second pivot points 213.

[0083] In particular arrangements, the tapered panel 100 can be configured to any width between about 400 mm to about 850 mm wide. In practice, the maximum amount of taper (taper strength) of tapered panel 100 is about 45 mm per lineal metre. Thus, a tapered panel with the maximum amount of taper will have a minimum length of about 10 m. Of course, tapered panels of shorter lengths can be provided with decreased taper strength from the maximum taper strength, and tapered panels 100 can be provided with much longer lengths (typically up to about 150m long) with any amount of taper strength up to the maximum lineal taper strength. However, exceptions to these panel characteristics are possible with suitable modifications to the roll-forming tapering machines described herein as would be appreciated by the skilled addressee.Embodiments

[0084] Reference throughout this specification to “one embodiment”, “an embodiment”, “one arrangement” or “an arrangement” means that a particular feature, structure or characteristic described in connection with the embodiment / arrangement is included in at least one embodiment / arrangement of the present invention. Thus, appearances of the phrases “in one embodiment / arrangement” or “in an embodiment / arrangement” in variousplaces throughout this specification are not necessarily all referring to the same embodiment / arrangement, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments / arrangements.

[0085] Similarly, it should be appreciated that in the above description of example embodiments / arrangements of the invention, various features of the invention are sometimes grouped together in a single embodiment / arrangement, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment / arrangement. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment / arrangement of this invention.

[0086] Furthermore, while some embodiments / arrangements described herein include some but not other features included in other embodiments / arrangements, combinations of features of different embodiments / arrangements are meant to be within the scope of the invention, and form different embodiments / arrangements, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments / arrangements can be used in any combination.Specific Details

[0087] In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.Terminology

[0088] In describing the preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in asimilar manner to accomplish a similar technical purpose. Terms such as "forward", "rearward", "radially", "peripherally", "upwardly", "downwardly", and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.Different Instances of Objects

[0089] As used herein, unless otherwise specified the use of the ordinal adjectives “first”, “second”, “third”, etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.Comprising and Including

[0090] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” are used in an inclusive sense, i.e. , to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

[0091] Any one of the terms “including” or “which includes” or “that includes” as used herein is also an open term that also means “including at least” the elements / features that follow the term, but not excluding others. Thus, “including” is synonymous with and means “comprising”.Scope of Invention

[0092] Thus, while there has been described what are believed to be the preferred arrangements of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as fall within the scope of the invention. Functionality may be added or deleted from the block diagrams and operations may be interchanged among functional blocks. Steps may be added or deleted to methods described within the scope of the present invention.

[0093] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.Industrial Applicability

[0094] It is apparent from the above, that the arrangements described are applicable to the profiled interlocking sheet metal roofing panels, specifically for tapered interlocking sheet metal roofing panels and methods for forming such tapered interlocking sheet metal roofing panels.

[0095] It will be appreciated that the roofing panels and methods for their formation described / illustrated above at least substantially provide a tapered interlocking sheet metal roofing panels and methods for their formation, the panels being particularly configured to provide a roof structure having a curved or circular profile whilst maintaining locked configuration between adjacent roof panels along the entire length of the plurality of roofing panels.

[0096] The tapered interlocking sheet metal roofing panels and methods described herein, and / or shown in the drawings, are presented by way of example only and are not limiting as to the scope of the invention. Unless otherwise specifically stated, individual aspects and components of the tapered interlocking sheet metal roofing panels and methods may be modified, or may have been substituted therefore known equivalents, or as yet unknown substitutes such as may be developed in the future, or such as may be found to be acceptable substitutes in the future. The tapered interlocking sheet metal roofing panels and methods may also be modified for a variety of applications while remaining within the scope and spirit of the claimed invention, since the range of potential applications is great, and since it is intended that the present tapered interlocking sheet metal roofing panels be adaptable to many such variations.Variations and Modifications

[0097] It will be realized that the foregoing has been given by way of illustrative example only and that all other modifications and variations as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as herein set forth.

[0098] In this specification, adjectives such as first and second, left and right, top and bottom, and the like may be used solely to distinguish one element or action from another element or action without necessarily requiring or implying any actual such relationship or order. Where the context permits, reference to an integer or a component or step (or the like) is not to be interpreted as being limited to only one of that integer, component, or step, but rather could be one or more of that integer, component, or step etc.

[0099] The above description of various embodiments of the present invention is provided for purposes of description to one of ordinary skill in the related art. It is not intended to be exhaustive or to limit the invention to a single disclosed embodiment. As mentioned above, numerous alternatives and variations to the present invention will be apparent to those skilled in the art of the above teaching. Accordingly, while some alternative embodiments have been discussed specifically, other embodiments will be apparent or relatively easily developed by those of ordinary skill in the art. The invention is intended to embrace all alternatives, modifications, and variations of the present invention that have been discussed herein, and other embodiments that fall within the scope of the above-described invention.

Claims

CLAIMS:

1. An interlockable longitudinally extending tapered structural panel with a channel cross-section for construction of a structure, the tapered structural panel comprising: a base and first and second side walls forming the sides of the channel, wherein the first and second side walls mirror each other’s extension from the base and provide a generally straight extension from the base, wherein the base describes a horizontal projection; a first locking-region adjoining an end of the first side wall distal the base is curved as a first arc directed away from a central portion of the channel, wherein the first locking-region is oriented at a first locking-region angle with respect to the horizontal projection; and a second locking-region adjoining an end of the second side wall is curved as a second arc directed towards the central portion of the channel, wherein the second locking-region is oriented at a second locking-region angle with respect to the horizontal projection; wherein a straight section extends from a distal end of the second arc; wherein the end of the first arc comprises a projection; wherein the first and second sidewalls at a proximal end of the longitudinally extending structural panel meet the base at a first wall angle with respect to the horizontal projection and the first and second sidewalls at a distal end of the longitudinally extending structural panel meet the base at a second wall angle with respect to the horizontal projection; wherein the second wall angle is greater than the first wall angle such that the longitudinally extending panel provides a wide coverage at the proximal end; and wherein the coverage smoothly tapers to a narrower coverage at the distal end, forming the tapered structural panel.

2. A tapered structural panel as claimed in Claim 1 , wherein: the first locking-region angle of the first side wall is the same as the second locking-region angle of the second side wall at the proximal end of the structural panel; and the first locking-region angle of the first side wall is the same as the second locking-region angle the second side wall at the distal end of the structural panel;wherein the first and second locking-regions are configured in use to engage with respective second and first locking-regions of adjacent identical interlockable longitudinally extending tapered structural panels along the entire length of the structural panels in use to form an interlocked roof structure.

3. A tapered structural panel as claimed in either Claim 1 or Claim 2, wherein: the first locking-region angle of the first side wall at the proximal end of the structural panel is the same as the first locking-region angle of the first side wall at the distal end of the structural panel; and the second locking-region angle of the second side wall at the proximal end of the structural panel is the same as the second locking-region angle of the second side wall at the distal end of the structural panel;4. A tapered structural panel as claimed in any one of the preceding claims: wherein the first wall angle of the first side wall varies smoothly between the proximal and distal ends of the panel; and wherein the second wall angle of the second side wall varies smoothly between the proximal and distal ends of the panel.

5. A tapered structural panel as claimed in any one of the preceding claims, wherein: the first locking-region angle at the proximal end of the structural panel is the same as the first locking-region angle at the distal end of the structural panel; and the second locking-region angle at the proximal end of the structural panel is the same as the second locking-region angle at the distal end of the structural panel; wherein the first and second locking regions are configured in use to engage with respective second and first locking regions of adjacent identical interlockable longitudinally extending tapered structural panels along the entire length of the structural panels in use to form an interlocked roof structure.

6. A tapered structural panel as claimed in any one of the preceding claims: wherein the first wall angle at the proximal end of the panel is between about 30 and about 55 degrees with respect to the horizontal projection; and wherein the second wall angle at the distal end of the panel is greater than about 70 degrees with respect to the horizontal projection.

7. A tapered structural panel as claimed in Claim 6, wherein the first wall angle is about 43 degrees with respect to the horizontal projection.

8. A tapered structural panel as claimed in either Claim 2 or Claim 5, wherein the first locking-region angle and the second locking-region angle is about 60 ± 10 degrees with respect to the horizontal projection.

9. A curved or undulating construction comprising a plurality of the tapered structural panel of any one of Claims 1 to 8, wherein the first locking-region of a first panel of the plurality of panels is engaged with the second locking-region of an adjacent panel of the plurality of panels to lock the panels together along the full length of each of the tapered structural panels.

10. A curved or undulating construction comprising a plurality of the tapered structural panel of any one of Claims 1 to 8, wherein the first locking-region of a first panel of the plurality of panels is engaged with the second locking-region of an adjacent panel of the plurality of panels to lock the panels together along the full length of each of the tapered structural panels.

11. A curved or undulating construction as claimed in either Claim 8 or Claim 9, wherein the curved or undulating constructions comprises either a roofing section or a wall section of a structure.

12. A method of forming a tapered structural panel for forming roofs with a channel cross-section comprising: providing a panel tapering configuration comprising a plurality of roller formations adapted to receive a profiled structural panel, the roller formations arranged in a plurality of formation sections including: a first profiling configuration zone configured to receive a base of the profiled structural panel; a second profiling configuration zone configured to receive a first wall of the profiled structural panel; a third profiling configuration zone configured to receive a second wall of the profiled structural panel; wherein the second and the third profiling configuration zones are initially aligned at a first wall angle with respect to the horizontal; a fourth profiling configuration zone configured to receive a first locking section of the profiled structural panel;a fifth profiling configuration zone configured to receive a second locking section of the profiled structural panel; wherein the fourth and the fifth profiling configuration zones are aligned at a locking section angle with respect to the horizontal; rolling the profiled panel through the panel tapering configuration to form a tapered structural panel; wherein as the profiled panel is rolled through the panel tapering configuration, the angle of the second and third profiling configuration zones is smoothly increased with respect to the horizontal from a first wall angle at a proximal end of the tapered structural panel to a second wall angle at a distal end of the tapered structural panel; and wherein the locking section angle of the fourth and fifth profiling configuration zones remains constant with respect to the horizontal for the entire length of the tapered structural panel as it is rolled through the panel profiling configuration, thereby to form the sheet material to a tapered interlockable structural panel as claimed in any one of Claims 1 to 8.

13. A method of forming a tapered structural panel for forming roofs with a channel cross-section comprising: providing a panel profiling configuration comprising a plurality of roller formations adapted to receive a sheet material, the roller formations arranged in a plurality of formation sections including: a first profiling configuration zone configured to form the base of the tapered structural panel in the sheet material; a second profiling configuration zone configured to form the first wall of the tapered structural panel in the sheet material; a third profiling configuration zone configured to form the second wall of the tapered structural panel in the sheet material; wherein the second and the third profiling configuration zones are initially aligned at a first wall angle with respect to the horizontal; a fourth profiling configuration zone configured to form the first locking section of the tapered structural panel in the sheet material; a fifth profiling configuration zone configured to form the second locking section of the tapered structural panel in the sheet material; wherein the fourth and the fifth profiling configuration zones are aligned at a locking section angle with respect to the horizontal;rolling the sheet material through the panel profiling configuration to form a profiled structural panel; wherein as the sheet material is rolled through the panel profiling configuration, the wall angle of the second and third profiling configuration zones is smoothly increased with respect to the horizontal from a first wall angle at a proximal end of the tapered structural panel to a second wall angle at a distal end of the tapered structural panel; and wherein the locking section angle of the fourth and fifth profiling configuration zones remains constant with respect to the horizontal for the entire length of the tapered structural panel as it is rolled through the panel profiling configuration, thereby to form the sheet material to a tapered interlockable structural panel as claimed in any one of Claims 1 to 8.

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