Structural panels

Claim 2

A structural panel forming member comprising a continuous sheet of material of substantially uniform thickness formed to provide a central web having spaced thereon on opposite sides a first side edge and a second side edge, an outer face on said central web adapted to form an exposed wall surface and an inner opposite surface, opposite first and second end edges, said first side edge being bent downwardly forming a face transverse to the outer face, then inwardly parallel to said outer face, downwardly transverse to the outer face and outwardly parallel to said outer face forming a groove like recess spaced from both the outer face and inner face and extending the length of the panel, the second side edge being bent downwardly forming a face transverse to the outer face and parallel to the first side edge face, out-wardly parallel to the outer face, downwardly transverse to the outer face and then inwardly parallel to the outer face forming a tongue spaced from the outer face and adapted to fit with the groove like recess of the first edge.

Claim 3

A structural panel forming member as claimed in claim 1 wherein the first and second side edge faces are bent downwardly from the outer face at about 90°.

Claim 4

A structural panel member as claimed in claim 1 wherein the tongue is provided with a sealant slot.

Claim 5

A structural panel member as claimed in claim 3 wherein the slot is filled with a resilient member.

Claim 6

A structural panel forming member comprising a continuous sheet of material of substantially uniform thickness formed to provide a central web having spaced thereon on opposite sides a first side edge and a second side edge, an outer face on said central web adapted to form an exposed wall surface and an inner opposite surface, opposite first and second end edges, a first side wall extending along the first side edge generally transverse to the central web, a second side wall extending along the second side edge generally transverse to the central web and extending in the same direction as the first side edge, each wall being generally transverse to said central web, a first flange generally transverse to the said first side wall beneath and generally parallel to said central web, a second flange extending generally transversely outwardly from said second side wall generally parallel to said central web, complementary mating elements includ-ing said flange on said first and second side walls disposed lengthwise of each of said side walls, said first and second edges being bent upwardly above the outer surface, and said first edge being provided with an upstanding lip beyond the complementary mating elements and the second edge being provided with an upstand-ing lip beyond the complementary mating elements, said lip of adjacent panels being adapted to lie side-by-side and be crimped together to form a sealed joint.

Claim 7

A structural panel forming member comprising a continuous sheet of material of substantially uniform thickness formed to provide a central web having spaced thereon on opposite sides a first side edge and a second side edge, an outer face on said central web adapted to form an exposed wall surface and an inner opposite surface, opposite first and second end edges, a first side wall extending along the first side edge generally transverse to the central web, a second side wall extending along the second side edge generally transverse to the central web and extending in the same direction as the first side edge, each wall being generally transverse to said central web, a first flange generally transverse to the said first side wall beneath and generally parallel to said central web, a second flange extending generally transversely outwardly from said second side wall generally parallel to said central web, complementary mating elements includ-ing said flange on said first and second side walls disposed lengthwise of each of said side walls, said first and second edges being bent upwardly above the outer surface, and said first edge being provided with an upstanding lip beyond the complementary mating elements and the second edge being provided with an upstand-ing lip beyond the complementary mating elements, said lip of adjacent panels being adapted to lie side-by-side and be crimped together to form a sealed joint.

Claim 8

A structural panel comprising a pair of spaced apart panel forming members as claimed in claim 1 having their inner faces toward one another and the first side edge of one adjacent the second side edge of the other to form a box-like configuration into which an insulant is formed in situ between and adhering to the inner faces of the two panel forming members, at least one of said panel forming members having said first and second side edges turned upwardly above the outer surface thereof, a lip on the flange of said first side edge extending beyond the complementary mating element, a lip on said second side edge flange extending beyond the complementary mating element, said lips of adjacent panels being adapted to lie side-by-side and be crimped together to form a sealed joint.

Claim 9

A structural panel comprising a pair of spaced apart panel members, each of said panel members being in the form of a continuous sheet of material of substantially uniform thickness formed providing an outer face adapted to form an exposed wall surface and an inner opposite surface, opposite first and second side edges and opposite first and second end edges, said first side edge being bent downwardly forming a face transverse to the outer face, then inwardly parallel to said outer face, downwardly transverse to the outer face and outwardly parallel to said outer face forming a groove-like recess spaced from both the outer face and inner surface and extending the length of the panel, the second side edge being bent downwardly forming a face transverse to the outer face and parallel to the first side edge face, out-wardly parallel to the outer face, downwardly transverse to the outer face and then inwardly parallel to the outer face forming a tongue spaced from the outer face and adapted to fit within the groove-like recess of the first edge and said end edges being adapted for abutting relationship, said panel members having their inner surfaces toward one another and the first side edge of one adjacent the said second side edge of the other forming a box-like configuration containing an insulant between and adhering securely to the inner faces of the two panel forming members.

Claim 10

A structural panel comprising a pair of spaced apart panel members, each of said panel members being in the form of a continuous sheet of material of substantially uniform thickness formed providing an outer face adapted to form an exposed wall surface and an inner opposite surface, opposite first and second side edges and opposite first and second end edges, said first side edge being bent downwardly forming a face transverse to the outer face, then inwardly parallel to said outer face, downwardly transverse to the outer face and outwardly parallel to said outer face forming a groove-like recess spaced from both the outer face and inner surface and extending the length of the panel, the second side edge being bent downwardly forming a face transverse to the outer face and parallel to the first side edge face, out-wardly parallel to the outer face, downwardly transverse to the outer face and then inwardly parallel to the outer face forming a tongue spaced from the outer face and adapted to fit within the groove-like recess of the first edge and said end edges being adapted for abutting relationship, said panel members having their inner surfaces toward one another and the first side edge of one adjacent the said second side edge of the other forming a box-like configuration containing an insulant between and adhering securely to the inner faces of the two panel forming members.

Claim 11

A structural panel as claimed in claim 7 wherein the insulant is a foamed insulant.

Claim 12

A structural panel as claimed in claim 7 wherein the tongue is provided with a sealant slot.

Claim 13

A structural panel as claimed in claim 9 wherein the slot is filled with a resilient member.

Claim 14

A structural panel as claimed in claim 7 wherein the tongue of one panel member is spaced from the groove of the other panel member forming an offset portion and fastening means are inserted between the spaced first and second side edges passing through said offset portion.

Claim 15

A building construction panel comprising an outer facing sheet, an inner facing sheet and a foamed-in-place core disposed between the said outer facing sheet and the said inner facing sheet; each said facing sheet having a central web and a first side edge and a second side edge, a first side wall extending along the said first side edge, a second side wall extending along the said second side edge in the same direction as the first side wall, a first flange extending inwardly generally trans-verse to the said first side wall beneath and generally parallel to the said central web, and a second flange extending generally transversely outwardly from the said second side wall generally parallel to the said central web; said outer facing sheet and said inner facing sheet being arranged with said second flange of each facing sheet con-fronting the opposing central web of the other facing sheet, and with the second flange of each facing sheet laterally spaced apart from the said first flange of the other facing sheet whereby the said outer facing sheet is entirely spaced apart from the said inner facing sheet; and complementary mating elements formed in said outer facing sheet, one disposed lengthwise of one said side wall and one disposed lengthwise of the other said side wall, said complementary mating elements including said first flange and said second flange of said outer facing sheet; the said outer facing sheet including: a channel-like configuration defined by the said first flange, the first side wall and an adjoining portion of the said central web; said foamed-in-place core filling the channel-like configuration whereby a positive mechanical connection is provided between the said outer facing sheet and the said foamed-in-place core; said panel adapted to be engaged side-by-side with others of said panel, with one of said mating elements of each panel engaged with the complementary mating element of an abutting panel whereby the outer facing sheets are mechanically engaged with one another.

Claim 16

A building construction panel comprising an outer facing sheet, an inner facing sheet and a foamed-in-place core disposed between the said outer facing sheet and the said inner facing sheet; each said facing sheet having a central web and a first side edge and a second side edge, a first side wall extending along the said first side edge, a second side wall extending along the said second side edge in the same direction as the first side wall, a first flange extending inwardly generally trans-verse to the said first side wall beneath and generally parallel to the said central web, and a second flange extending generally transversely outwardly from the said second side wall generally parallel to the said central web; said outer facing sheet and said inner facing sheet being arranged with said second flange of each facing sheet con-fronting the opposing central web of the other facing sheet, and with the second flange of each facing sheet laterally spaced apart from the said first flange of the other facing sheet whereby the said outer facing sheet is entirely spaced apart from the said inner facing sheet; and complementary mating elements formed in said outer facing sheet, one disposed lengthwise of one said side wall and one disposed lengthwise of the other said side wall, said complementary mating elements including said first flange and said second flange of said outer facing sheet; the said outer facing sheet including: a channel-like configuration defined by the said first flange, the first side wall and an adjoining portion of the said central web; said foamed-in-place core filling the channel-like configuration whereby a positive mechanical connection is provided between the said outer facing sheet and the said foamed-in-place core; said panel adapted to be engaged side-by-side with others of said panel, with one of said mating elements of each panel engaged with the complementary mating element of an abutting panel whereby the outer facing sheets are mechanically engaged with one another.

Claim 17

A building construction panel comprising an outer facing sheet, an inner facing sheet and a foamed-in-place core disposed between the said outer facing sheet and the said inner facing sheet; each said facing sheet having a central web and a first side edge and a second side edge, a first side wall extending along the said first side edge, a second side wall extending along the said second side edge in the same direction as the first side wall, a first flange extending inwardly generally transverse to the said first side wall generally parallel to the said central web, and a second flange extending generally transversely outwardly from the said second side wall generally parallel to the said central web; the said outer facing sheet and the said inner facing sheet being laterally offset from one another such that the said second flange of each facing sheet (a) confronts the opposing central web of the other facing sheet and (b) is lat-erally spaced spart from the said first flange of the other facing sheet; the said first flange and the said second flange of the said inner facing sheet being positioned at a leavel be-tween (c) the said central web of the said outer facing sheet and (d) a plane extending between the said first flange and the said second flange of the said outer facing sheet.

Claim 18

A building construction panel comprising an outer facing sheet, an inner facing sheet and a foamed-in-place core disposed between the said outer facing sheet and the said inner facing sheet; each said facing sheet having a central web and a first side edge and a second side edge, a first side wall extending along the said first side edge, a second side wall extending along the said second side edge in the same direction as the first side wall, a first flange extending inwardly generally transverse to the said first side wall generally parallel to the said central web, and a second flange extending generally transversely outwardly from the said second side wall generally parallel to the said central web; the said outer facing sheet and the said inner facing sheet being laterally offset from one another such that the said second flange of each facing sheet (a) confronts the opposing central web of the other facing sheet and (b) is lat-erally spaced spart from the said first flange of the other facing sheet; the said first flange and the said second flange of the said inner facing sheet being positioned at a leavel be-tween (c) the said central web of the said outer facing sheet and (d) a plane extending between the said first flange and the said second flange of the said outer facing sheet.

Claim 19

The building construction panel defined in claim 12 wherein said complementary mating elements comprise a bead extending along the length of one of said first and second side walls and a complementary groove extending along the other said first and second side walls.

Claim 20

The building construction panel defined in claim 14 wherein the said outer facing sheet includes a channel-like configuration defined by the said first flange, the said first side wall and an adjoining portion of the said central web, and an arcuate side wall portion projecting inwardly of said second side wall and defining the said complementary groove, the said foamed-in-place core filling the said channel-like configuration and embracing said arcuate side wall portion to provide positive mechanical connections between the said outer facing sheet and the said foamed-in-place core.

Claim 21

The building construction panel defined in claim 12 including complementary mating elements formed in said inner facing sheet, one disposed lengthwise along one said side wall and one disposed lengthwise along the other said side wall, and wherein the complementary mating elements in said outer facing sheet and the complementary mating elements in said inner facing sheet include a bead extending along the length of one said side wall and a complementary groove extending along the length of the other said side wall.

Claim 22

The building construction panel defined in claim 16 wherein the said first flange and the said second flange of the said inner facing sheet are positioned at a level between (a) the said central web of the said outer facing sheet and (b) a plane extending between the said first flange and the said second flange of the said outer facing sheet.

Claim 23

The building construction panel defined in claim 12 including complementary mating elements formed in said inner facing sheet, one disposed lengthwise along one said side wall and one disposed lengthwise along the other said side wall, said complementary mating elements including said first flange and said second flange of said inner facing sheet, and wherein said complementary mating elements of said inner facing sheet include a bead extending along the length of said one said side wall and a complementary groove extending along the said other said side wall.

Claim 24

The building construction panel defined in claim 12 including complementary mating elements formed in said inner facing sheet, one disposed lengthwise along one said side wall and one disposed lengthwise along the other said side wall, said complementary mating elements including said first flange and said second flange of said inner facing sheet, and wherein the said complementary mating elements of one said facing sheet include a bead extending along the length of one said side wall and a complementary groove extending along the other said side wall, and wherein the said com-plementary mating elements of the other said facing sheet include the said first side wall sloping away from the adjoining said first side edge and outwardly of the said central web, and the said second side wall sloping away from the adjoining said second side edge and inwardly over the said central web, the said first side wall and the said second side wall being generally parallel.

Claim 25

The building construction panel defined in claim 14 wherein the said first flange terminates at an edge spaced from the said first side wall.

Claim 26

The building construction panel defined in claim 14 wherein the said complementary mating elements provide the sole positive mechanical connection between the said outer facing sheet and the outer facing sheets of adjacent ones of said panel.