Roofing panel interlock system

[0001] The present application is related to and takes priority from U.S. Provisional Patent Application Ser. No. 60/643,795, filed Jan. 12, 2005, entitled Roofing Panel Interlock System, the entire contents of which are expressly incorporated herein by reference.

[0002] This invention relates to modular panel structures for constructing side and overhead portions of structures and more particularly to modular panel structures provided with improved interlocking edges.

[0003] Insulated building panels are well known in the present art and are commonly used for modular construction of walls and ceilings. These types of panels are generally formed of two outer thin layers of aluminum or sheet steel, which cover an interior core layer of an insulating material, such as plastic, foam, or the like.

[0004] Many different shapes and sizes of such building panels have been known and used over the years and various means of coupling two panels together have been discussed. Typically, one edge of the panel will be formed into a male-type connection member, while the other edge is formed into a corresponding mating female-type connector.

[0005] While effective in allowing coupling of adjacent panels together, the prior-art systems are configured in such a manner that they allow moisture, in the form of rain and condensation, to introduce itself into the interior of the panel, thereby wetting the insulating core and threatening the integrity of the panels. Prior art systems are capable of locking two panels together, but do not have the capability of self-guttering rain and other moisture away from the panel joint.

[0006] Accordingly, what is required in the art is a building panel interlock joint that is formed in such a manner as to direct rain or other moisture away from the panel seam, while promoting an interlock fit and maintaining the advantageous features and qualities of interlocking building panels.

[0007] An insulated building panel, according to the present invention, includes a male connector configuration as well as a female connector configuration that are both formed of generally bent surfaces. The male connector as well as the female connector extends outwardly from the side faces of an insulating foam core so that the foam is protected from damage. The male connector, is formed by bending the metal edge into a generally U shaped configuration with the outer edge of the U bent downwardly towards the interior of the panel. The female connector is bent back almost towards itself and terminates in a curvilinear gutter portion. The female portion includes a detent edge which defines a shallow receptacle into which a male detent edge is inserted so as to lock the male and female connectors in a nested position, thereby securing two panels together.

[0013] A modular building panel includes an interlock mechanism for connecting building panels in series to one another. A panel includes two metal sheets, each overlaying a major surface of the panel, and separated by an insulating foam core, or other similar structural material. The insulating core material is bonded to the inside surfaces of the metal sheets. Each panel includes a first interlocking member on one side and a second interlocking member on the other side, as indicated in FIG. 1, with the interlocking members adapted to be inserted into one another in a male-female manner. The interlocking members secure their respective panels together by a “detent fit”.

[0014] The male connector configuration as well as the female connector configuration, in the context of the invention, are both formed of generally bent surfaces, with multiple compound bends defining each connector. The male connector as well as the female connector is formed from steel (or aluminum) sheet end portions that extend outwardly from the side faces of the foam so that the foam core is protected from damage.

[0015] The male connector, 10 is formed by bending the metal edge into a generally flat bottomed, U shaped configuration 11 with the outer edge 12 of the U (the edge farthest from the foam core) bent downwardly towards the interior of the panel at an acute angle. The apex of the acute angle 20 defines a male “detent” portion devised to mate with a corresponding female detent portion on the other connector. The female connector 14 is bent back almost towards itself and terminates in a curvilinear gutter portion (indicated at 16). The female portion includes a detent edge (indicated at 18) which defines a shallow receptacle into which the male detent edge (indicated at 20) may be inserted so as to lock the male and female connectors in a nested position.

[0016] As shown in FIG. 2, the connector portions are urged together such that angled surfaces of the male 22 and female 24 connectors engage one another, allowing the connectors to slide together and mate with a “spring detent” action.

[0017] As seen in FIG. 3, when the panels are mated together, the male and female detent edges are juxtaposed so as to lock the respective panels together. The locked together connectors provide a double gutter system to prevent leakage and condensation. The male connector U section 11 defines one of the gutters, while the curvilinear gutter section 16 of the female connector defines another. Characteristically, both connectors have gutter portions provided such that condensation on any one surface, or both surfaces, will be directed away from the core insulation material.

[0018] The remaining illustrations of FIG. 4 give an indication of how the connector portions are formed in a metal bending machine. Since the bends are made with several hard radii, the bending operation is carried out in a series of sequential bending operations, each providing a portion of the final “bend” until the completed connector is formed.

[0019] It will be obvious to those skilled in the art that many modifications and variations may be made to the structures set forth above without departing from the spirit of the present invention. Accordingly it will be understood that the scope of the present invention is defined solely in terms of the appended claims and their functional equivalents.