Variable section interlocking structural panel

Abstract

An interlockable structural panel with a channel cross-section including a base and first and second side wall forming the sides of the channel, wherein 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 and an end of the second side wall is curved as a second arc directed towards the central portion of the channel and wherein a straight section extends from the end of the second arc distal the base. Also methods for forming interlockable structural panels and for forming curved interlockable structural panels for constructions including roofs.

1 . An interlockable structural panel for forming roofs with a channel cross-section including:
 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 a 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 and a section adjoining an end of the second side wall is curved as a second arc directed towards the central portion of the channel;   wherein a straight section extends from a distal end of the second arc;   wherein the end of the first arc comprises a projection, a distal tip of the projection extending towards the first side wall;   wherein the second side wall comprises at least first and second intermediate arcs extending from a generally horizontal section of the second sidewall and through a generally vertical section of the second side wall intermediate the first and second intermediate arcs; and   wherein the structural panel includes mateable portions arranged to engage with identical first and second arcs of an adjacent identical structural panel in a locking manner without deforming the first or second arcs or the straight section.   
     
     
         2 . The interlockable structural panel as claimed in  claim 1 , wherein the straight section is approximately parallel to the second side wall. 
     
     
         3 . The interlockable structural panel as claimed in either  claim 1  or  claim 2 , wherein the entire length of the first arc and the entire length of the second arc with the straight section may define the mateable portions. 
     
     
         4 . The interlockable structural panel as claimed in any one of  claims 1  to  3 , wherein the second side wall extending distally from the second intermediate arc is approximately parallel to the extension of the second sidewall at its proximal end. 
     
     
         5 . The interlockable structural panel as claimed in  claim 1 , wherein the second arc is arranged to nest within the first arc on an adjacent interlockable structural panel so that the two are locked together. 
     
     
         6 . The interlockable structural panel as claimed in  claim 1 , wherein the first and second side walls extend at an angle of approximately 45° to 60° with respect to the horizontal and to the base. 
     
     
         7 . The interlockable structural panel as claimed in  claim 1 , wherein the second side wall extending distally from the second intermediate arc is approximately parallel to tangents apexes of the first and second intermediate arcs. 
     
     
         8 . The interlockable structural panel as claimed in  claim 1 , wherein the first arc is an arc of between 180° to 330°. 
     
     
         9 . The interlockable structural panel as claimed in  claim 1 , wherein the second arc is an arc of between 90° to 180°. 
     
     
         10 . The interlockable structural panel as claimed in any one of the preceding claims, wherein the first arc terminates in a hook section. 
     
     
         11 . The interlockable structural panel as claimed in  claim 10 , wherein the straight section extending from the second arc in one interlockable structural panel is arranged to engage the projection of the first side wall on a second interlockable structural panel that the second arc is nested with. 
     
     
         12 . The interlockable structural panel as claimed in  claim 1 , wherein the channel has longitudinal depressions. 
     
     
         13 . The interlockable structural panel as claimed in  claim 1 , wherein base of the channel has a longitudinal corrugated or fluted profile. 
     
     
         14 . The interlockable structural panel as claimed in  claim 1 , wherein reinforcing flutes are located on the side walls. 
     
     
         15 . The interlockable structural panel as claimed in  claim 14 , wherein the reinforcing flutes run the length of the panels. 
     
     
         16 . The interlockable structural panel as claimed in  claim 10 , wherein the straight section terminates in an end that is configured to abut and be restrained from rotating by the hook section when the second arc is nested into the first arc of an adjacent panel. 
     
     
         17 . The interlockable structural panel as claimed in  claim 1 , wherein the length of the straight section is configured to be received within and extend across the first arc of the adjacent panel. 
     
     
         18 . An interlockable structural panel for forming roofs with a channel cross-section including:
 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 a 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 and a section adjoining an end of the second side wall is curved as a second arc directed towards the central portion of the channel;   wherein a straight section extends from a distal end of the second arc, the straight section being approximately parallel to the second side wall; and   wherein the second side wall comprises at least first and second intermediate arcs extending from a generally horizontal section of the second sidewall and through a generally vertical section of the second side wall intermediate the first and second intermediate arcs, the second side wall extending distally from the second intermediate arc is approximately parallel to the extension of the second sidewall at its proximal end.   
     
     
         19 . The interlockable structural panel as claimed in  claim 18 , wherein the entire length of the first arc and the entire length of the second arc with the straight section define mateable portions arranged to engage with identical first and second arcs of an adjacent identical structural panel in a locking manner without deforming the first or second arcs or the straight section. 
     
     
         20 . The interlockable structural panel as claimed in  claim 18 , wherein the first arc terminates in a hook and the straight section terminates in an end that is configured to abut and be restrained from rotating by the hook when the second arc is nested into the first arc of an adjacent panel. 
     
     
         21 . The interlockable structural panel as claimed in  claim 18 , wherein the length of the straight section is configured to be received within and extend across the first arc of an adjacent panel. 
     
     
         22 . The interlockable panel of any one of the preceding claims, wherein the base comprises a transverse crimp zone. 
     
     
         23 . The interlockable panel of any one of the preceding claims, wherein the first and second side walls comprise a respective sidewall crimp zone. 
     
     
         24 . The interlockable panel of any one of the preceding claims, wherein the sidewall crimp zones are tapered. 
     
     
         25 . The interlockable panel of any one of the preceding claims, wherein either or both the first and second sidewalls include a stiffening means comprising a stiffening flute. 
     
     
         26 . The interlockable panel of  claim 25 , wherein each sidewall comprises a plurality of stiffening flutes. 
     
     
         27 . The interlockable panel of any one of the preceding claims, wherein the second side wall extending distally from the second intermediate arc is approximately parallel to the extension of the second sidewall at its proximal end. 
     
     
         28 . The interlockable panel of any one of the preceding claims, wherein the second arc is arranged to nest within the first arc on an adjacent interlockable structural panel so that the two are locked together. 
     
     
         29 . The interlockable panel of any one of the preceding claims, wherein the first and second side walls extend at an angle of approximately 45° to 60° with respect to the horizontal and to the base. 
     
     
         30 . The interlockable panel of any one of the preceding claims, wherein the second side wall extending distally from the second intermediate arc is approximately parallel to the tangents and of the apex of the first and second intermediate arcs. 
     
     
         31 . The interlockable panel of any one of the preceding claims, wherein the first arc is an arc of between 180° to 330°. 
     
     
         32 . The interlockable panel of any one of the preceding claims, wherein the second arc is an arc of between 90° to 180°. 
     
     
         33 . The interlockable panel of any one of the preceding claims, wherein the first arc terminates in a hook section. 
     
     
         34 . The interlockable panel of any one of the preceding claims, wherein the straight section extending from the second arc in one interlockable structural panel is arranged to engage the ridge of the first side wall on a second interlockable structural panel that the second arc is nested with. 
     
     
         35 . The interlockable panel of any one of the preceding claims, wherein the channel has longitudinal depressions. 
     
     
         36 . The interlockable panel of any one of the preceding claims wherein the base of the channel has a longitudinal corrugated or fluted profile. 
     
     
         37 . The interlockable panel of any one of the preceding claims, wherein reinforcing flutes are located on the side walls. 
     
     
         38 . The interlockable panel of  claim 37  wherein the reinforcing flutes run the length of the panels. 
     
     
         39 . The interlockable panel of any one of the preceding claims, further comprising a plurality of crimp zones adapted to receive and be formed into transverse corrugations. 
     
     
         40 . A roofing section comprising a plurality of the interlockable structural panel of any one of  claims 1  to  39 , wherein the second arc of a first panel of the plurality of panels is nested into the first arc of an adjacent panel of the plurality of panels to lock the panels together. 
     
     
         41 . A construction comprising a plurality of the interlockable structural panels of any one of  claims 1  to  39 . 
     
     
         42 . A method of forming an interlockable structural panel for forming roofs with a channel cross-section comprising:
 providing a panel profiling configuration comprising a plurality of formations adapted to receive a sheet material; and   rolling the sheet material through the panel profiling configuration to form a profiled structural panel;   wherein panel profiling configuration comprises a plurality of rollers adapted to form the sheet material to a profiled interlockable structural panel as claimed in any one of  claims 1  to  39 .   
     
     
         43 . The method of  claim 42 , wherein panel profiling configuration is configured to form one or more longitudinal stiffening flutes in sidewalls of the profiled interlockable structural panel. 
     
     
         44 . The method of  claim 42 , further comprising:
 providing a pair of complementary curvature rollers, each curvature roller comprising a plurality of corrugating rods and adapted to receive a profiled interlockable structural panel and pass the profiled interlockable structural panel between the complementary curvature rollers to form a plurality of transverse corrugations in a portion of the profiled interlockable structural panel, thereby to form a curved profiled interlockable structural panel.   
     
     
         45 . The method of  claim 44 , wherein the transverse corrugations are formed in the base of the profiled interlockable structural panel. 
     
     
         46 . The method of either  claim 44  or  claim 45 , comprising providing a plurality of complementary curvature rollers pairs configured to form a plurality of transverse corrugations in a plurality of portions of the profiled interlockable structural panel. 
     
     
         47 . The method of  claim 45 , wherein the plurality of complementary curvature rollers pairs are configured to form the transverse corrugations in the base and in one or more portions of the sidewalls of the profiled interlockable structural panel. 
     
     
         48 . The method of  claim 47 , wherein the depth of the transverse corrugations in the sidewalls of the profiled interlockable structural panel decreases with distance from the base of the profiled interlockable structural panel. 
     
     
         49 . The method of either  claim 47  or  claim 48 , wherein the depth of the transverse corrugations in the sidewalls of the profiled interlockable structural panel are tapered. 
     
     
         50 . The method of any one of  claims 46  to  49 , wherein the profiled interlockable structural panel comprises a plurality of crimp zones adapted to receive and be formed into transverse corrugations by the plurality of complementary curvature rollers.