Hollow structural panel of extruded plastics material and a composite panel structure formed thereof

Claim 1

A composite panel structure including a number of hollow structural panels of extruded plastics material, each panel comprising mutually spaced interparallel end walls, at least two intermediate I-beams spaced from the end walls and extending along the end walls in parallel therewith, each I-beam having a web and flanges on each end and integral therewith, which flanges extend along the web and project on both sides of the web generally perpendicular thereto to form substantially planar outer surfaces of the beams, portions on the inner surface of each flange forming channels extending along the web one on each side of the web, the channels formed by opposite flanges of an Ibeam opposing each other on the respective sides of the web to receive a stiffening member extending along the web, opposite side walls extending between and joined to the I-beam flanges and the end walls and spanning the spaces therebetween, the side walls having a concave outer surface and a convex inner surface and bounding, together with the end walls and the I-beams, a number of individual cavities, and connecting means on the end walls for interconnecting panels adjoining each other and comprising first and second flanges formed at first and second ends of each of said end walls, of which said first flanges on the opposite end walls of adjoining panels are formed as hookshaped portions and are diagonally opposed to each other and are joined to said first end of each said end wall by a reverse curve connecting web, said side wall being joined to said reverse curve connecting web portion of said end wall, said second flanges on the opposite end walls of adjoining panels are diagonally opposing each other and have a planar surface generally parallel to said I-beam flanges and are formed each on an extension of the second End of each said end wall extending beyond the adjoining side wall, said hook-shaped first flanges on adjacent end walls of adjoining panels receiving each one of the second flanges on such end walls, each said first flanges including a substantially planar surface extending generally parallel to said planar I-beam flanges and being of substantially the same width and at the same level as said I-beam flanges, an outwardly projecting slanting lip extending from the free end of said planar surface of said first flange and terminating in a ledge projecting inwardly substantially in parallel with said planar surface of said first flange, said planar surface of each said first flanges together with the associated lip and ledge forms said hook-shaped portions, outer planar strip surface portions on said side walls and connected to said extensions, each said strip surface portion extending along an associated extension, each said outer planar strip surface portions abutting said ledge portion of an adjacent panel when said panels are joined, and forming, together with said ledge portion and said extension, a labyrinth seal between said panels, and at least one wedge insertable between adjacent end walls of adjoined panels for forming a spacer between said panels, said wedge having edge surfaces which extend along the first and second flanges formed at the end walls of each of said adjoined panels, pressing each said first flange into firm engagement with each said adjacent second flange.