U.S. patent application number 10/496831 was filed with the patent office on 2005-01-27 for wall panel.
Invention is credited to Seccombe, Campbell John.
Application Number | 20050016104 10/496831 |
Document ID | / |
Family ID | 27424542 |
Filed Date | 2005-01-27 |
United States Patent
Application |
20050016104 |
Kind Code |
A1 |
Seccombe, Campbell John |
January 27, 2005 |
Wall panel
Abstract
A modular wall panel 1 includes two containment sheets 15 and
spacer means (7, 8, 9, 30, 31, 32, 50, 52) disposed between the
containment sheets. The containment sheets are formed from sheet
metal and are designed to receive a poured in settable material
such as concrete. The containment sheets have linear stiffening
formations extending in a first direction to resist outward bowing
of the containment sheets in planes extending in the first
direction when the wall panel is filled with the settable
material.
Inventors: |
Seccombe, Campbell John;
(Turramurra, AU) |
Correspondence
Address: |
MILES & STOCKBRIDGE PC
1751 PINNACLE DRIVE
SUITE 500
MCLEAN
VA
22102-3833
US
|
Family ID: |
27424542 |
Appl. No.: |
10/496831 |
Filed: |
May 27, 2004 |
PCT Filed: |
November 27, 2002 |
PCT NO: |
PCT/AU02/01605 |
Current U.S.
Class: |
52/506.01 |
Current CPC
Class: |
E04B 2/8647 20130101;
E04B 2/8635 20130101 |
Class at
Publication: |
052/506.01 |
International
Class: |
E04B 002/00 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 27, 2001 |
AU |
PR 9143 |
Feb 19, 2002 |
AU |
PS 0622 |
Jul 9, 2002 |
AU |
2002950065 |
Jul 11, 2002 |
AU |
2002950214 |
Claims
1-38. (canceled)
39. A modular wall panel comprising two containment sheets formed
from sheet metal, and spacer means disposed between the containment
sheets and fixed thereto so as to prevent separation of the
containment sheets, the wall panel being arranged to be filled with
a settable material and wherein, to resist hydrostatic pressure
induced on filling the panel with the settable material, the
containment sheets are profiled to have linear stiffening
formations extending along the sheets in a first direction to
resist outward bowing of the containment sheets in planes extending
in the first direction, and the spacer means extend along the
containment sheets in a direction transverse to the first direction
so as to resist bowing of the containment sheets in planes
extending in a second direction perpendicular to the first
direction.
40. A modular panel according to claim 39, wherein the spacer means
are disposed at or near respective opposite edges of the panel, and
one of the spacer means is inboard of the edges of the containment
sheets adjacent to it and the other spacer means outboard of the
edges of the containment sheets adjacent to it.
41. A modular panel according to claim 40, wherein the distance the
spacer means are disposed either inboard or outboard of the
respective opposite edges of the panel is substantially the
same.
42. A modular wall panel according to claim 39, wherein the
stiffening formations are profiled to include elongated zones which
are displaced longitudinally from a midplane of the respective
sheet.
43. A modular wall panel according to claim 39, wherein the
stiffening formations are profiled to include corrugations
extending from one edge of the sheet to the other.
44. A modular wall panel according to claim 39, further comprising
at least one rigid batten secured to an outer surface of one or
both of the containment sheets, and extending transverse to the
linear stiffening formations.
45. A modular wall panel according to claim 44, wherein the panel
includes at least one pair of the rigid battens, each batten in the
pair being disposed opposite one another on respective containment
sheets and being tied together by tensile means to form one of the
spacer means.
46. A modular wall panel according to claim 39, wherein the spacer
means are in the form of a sheet metal studs, the studs being
channel shaped and includes a web and a pair of flanges which
extend laterally from the web, and fastener means affixing the
sheets to respective flange elements.
47. A modular wall panel comprising two containment sheets formed
from sheet metal and spacer means disposed between the containment
sheets, the containment sheets being profiled to have linear
stiffening formations extending in a first direction to resist
outward bowing of the containment sheets in planes extending in the
first direction, and wherein the spacer means are in the form of
sheet metal studs, the studs being channel shaped and including a
web and a pair of flanges which extend laterally from the web, and
fasteners fixing the sheets to respective flange elements.
48. A modular wall panel according to claim 47, wherein the spacer
means extend along the sheets in a direction transverse to the
first direction so as to resist bowing of the containment sheets in
planes extending in a second direction perpendicular to the first
direction.
49. A modular panel according to claim 47, wherein the fasteners
affix the containment sheets to the flanges of the studs adjacent
said web so as to inhibit torsional strain at the junction of the
flanges and the web.
50. A modular panel according to claim 47, wherein the flanges are
formed as hollow flanges elements.
51. A modular wall panel according to claim 50, wherein the hollow
flange elements project substantially from one face of the web.
52. A modular wall panel according to claim 50, wherein each stud
is generally in the form of a hollow flanged I-beam, wherein the
hollow flange element projects from both faces of the web.
53. A modular wall panel according to claim 50, wherein the hollow
flange elements are generally triangular in cross section.
54. A modular wall panel according to claim 50, wherein the hollow
flange elements include openings along their length to enable, in
use, filler material to enter and at least partially fill the
hollow within the flange elements.
55. A modular wall panel according to claim 50, wherein the
fastening means extends through opposite walls of the respective
flange elements.
56. A modular wall panel according to claim 39, wherein the spacer
means include a plurality of spaced apart anchorage devices affixed
to opposing faces of the containment sheets, wherein each anchorage
device on one sheet is in register with a corresponding anchorage
device on the other sheet, and a plurality of connector elements
wherein the anchorage devices and the connector elements have
cooperating coupling formations such that each connector element
may be coupled to an anchorage device on one containment sheet and
the corresponding anchorage device on the other containment sheet
by being moved endwisely of itself and of those corresponding
anchorage devices to effect mutual engagement of their respective
coupling formations.
57. A modular wall panel according to claim 53, wherein each
anchorage device and each connector element is an elongated
component extending substantially from one edge of a containment
sheet to an opposite edge of the sheet.
58. A modular wall panel comprising two containment sheets, and a
plurality of spacer means disposed between the sheets, the spacer
means including a plurality of anchorage devices fixed to opposing
faces of the containment sheets and a plurality of connector
elements, each anchorage device on one sheet being in register with
a corresponding anchorage device on the other sheet, and the
anchorage devices and the connector elements having cooperating
coupling formations such that each connector element may be coupled
to an anchorage device on one containment sheet and the
corresponding anchorage device on the other containment sheet so as
to interconnect the anchorage devices, the panel being operative to
adopt an assembled form where a cavity is formed between the sheets
arranged to be filled with a settable material and the spacer means
prevent separation of the containment sheets on filling of the
cavity.
59. A modular panel according to claim 58, wherein each connector
element may be coupled to an anchorage device on one containment
sheet and the corresponding anchorage device on the other
containment sheet by moving endwisely of itself and of those
corresponding anchorage devices to effect mutual engagement of
their respective coupling formations.
60. A modular panel according to claim 58, wherein each anchorage
device and each connector element is an elongated component
extending substantially from one edge of a containment sheet to an
opposite edge of the sheet.
61. A modular panel according to claim 58, wherein the containment
sheets are formed from sheet metal.
62. A modular panel according to claim 61, wherein the containment
sheets are profiled to have linear stiffening formations extending
in a first direction to resist outward bowing of the containment
sheets in planes extending in the first direction, and the spacer
means are mounted to the containment sheets so as to resist bowing
of the containment sheets in planes extending in a second direction
perpendicular to the first direction.
63. A modular panel according to claim 61, wherein the anchorage
devices are formed from metal brackets that include flanges that
abut the containment sheets and are retained in engagement by
clinches formed between the flanges and the containment sheets.
64. A modular panel according to claim 58, wherein the panel is
movable from a collapsed form where the containment sheets are in
close proximity, to the assembled form and wherein the spacer means
are movable from a first to a second position to allow the panel to
move from its collapsed to its assembled form.
65. A modular panel according to claim 64, wherein the spacer means
are operative to move between their first and second positions by
relative rotation of the connector elements relative to the
anchorage devices to which they are coupled.
66. A modular panel according to claim 39, wherein the spacers
means extend in the second direction.
67. A modular wall panel according to claim 39, further comprising
a planar grid of reinforcing, the reinforcing being aligned
generally parallel with, and disposed between, the containment
sheets and being supported by the spacer means.
68. A modular wall panel according to claim 67, wherein the
reinforcing includes horizontal rods which locate on seats disposed
in the spacer means.
69. A modular wall panel according to claim 39, including starter
elements which extend from at least one of the upper or lower edges
of the panel.
70. A building wall including a plurality of modular wall panels
according to claim 39, the panels being assembled edge to edge so
that the containment sheets of the panels align to form a pair of
containment walls of the building wall, wherein the cavity formed
between the containment walls are filled with a settable
material.
71. A building wall according to claim 70, wherein a plurality of
rigid battens are secured to an outer surface of at least one of
the containment walls.
72. A building wall according to claim 71, further including at
least one facing panel which is secured to the battens of the at
least one containment wall.
73. A building wall according to claim 70, further comprising at
least one acoustic panel which is disposed generally parallel to at
least one of the containment walls, the acoustic panel being spaced
from said containment wall so as to form an air gap
therebetween.
74. A building wall according to claim 73, wherein the acoustic
panel is formed from a profiled metal sheet and incorporates
longitudinal extending ribs.
75. A building wall according to claim 73, further including at
least one facing panel which is secured to the ribs of the acoustic
panel.
76. A method of making a building wall including the steps of: (i)
rigidising two metal sheets by roll-forming or press-forming linear
stiffening formations therein, (ii) affixing a plurality of spaced
apart anchorage devices to one face of each of the rigidised sheets
such that the anchorage devices extend along the sheets
transversely of the stiffening formations, (iii) joining the sheets
together by securing a connector element to each anchorage device
on one sheet to a corresponding anchorage device on the other
sheet, and (iv) substantially filling the cavity between the sheets
with a settable filling material.
Description
TECHNICAL FIELD
[0001] The invention relates to modular, prefabricated wall panels
adapted to be assembled edge to edge for the construction of
building walls. More particularly, the invention relates to such
wall panels which include two containment sheets which are spaced
apart and which are designed for the receipt of a poured in filling
of concrete or like settable material.
BACKGROUND ART
[0002] Composite building walls which are formed on site by pouring
a settable material (such as concrete) between two spaced
containment sheets are known. The filling is necessarily dense to
give substance to the finished wall and is necessarily fluid when
being put in place. Thus the containment sheets are required to
resist considerable hydrostatic pressure until such time as the
filling material sets. As a result, some bulging of the containment
sheets is inevitable and in prior art panels various approaches
have been adopted in efforts to limit that bulging. These prior art
approaches have met with limited success and have been
objectionable for other reasons.
[0003] A previous modular wall panel comprises three, equal spaced
apart, channel sectioned sheet-steel studs, with the channel webs
lying in vertical planes extending transversely of the panel, and
two fibre-cement sheets secured flatly against the channel flanges.
Those fibre-cement sheets may function as wall cladding sheets and
as the containment sheets for the concrete filling. Notwithstanding
the additional support from the intermediate stud, the fibre-cement
containment sheets have had to be thick and heavy to function
satisfactorily. This adds to the weight of the panel and thus
increases the difficulty of site assembly of the panels and of
course the additional intermediate stud increases the cost of the
panel.
[0004] It is also known to provide a modular panel with only two
studs, one at or near each vertical edge of the panel and two
sheet-steel containment sheets. In this instance, the containment
sheets have been provided with two dove tail shaped, vertically
extending stiffening ribs, intermediate vertical edges of the
panel. The ribs in one containment sheet are in register with the
ribs in the other, and tensile ties extend transversely of the
panel from each rib in one sheet to the corresponding rib in the
other. This reduces the weight of the unfilled panel by comparison
with the panel mentioned above, but permits objectionable bowing of
the containment sheets in horizontal planes. Usually, an external
cladding sheet, for example plaster board, is applied to the ribs
of at least one of the containment sheets, and is itself
undesirably bowed. Further, it is difficult to fix the plaster
boards to the filled ribs.
[0005] An aim of at least a preferred form of the invention is to
provide a modular wall panel which is light weight when unfilled,
relatively inexpensive to fabricate, is resistant to bowing of the
containment sheets and may be handled and installed without having
to be overly protected from minor surface damage likely to occur
during those operations.
SUMMARY OF THE INVENTION
[0006] A modular wall panel comprising two containment sheets
formed from sheet metal, and spacer means disposed between the
containment sheets and fixed thereto so as to prevent separation of
the containment sheets, the wall panel being arranged to be filled
with a settable material and wherein, to resist hydrostatic
pressure induced on filling the panel with the settable material,
the containment sheets are profiled to have linear stiffening
formations extending along the sheets in a first direction to
resist outward bowing of the containment sheets in planes extending
in the first direction, and the spacer means extend along the
containment sheets in a direction transverse to the first direction
so as to resist bowing of the containment sheets in planes
extending in a second direction perpendicular to the first
direction.
[0007] The linear stiffening formations may be corrugations, ribs
or pleats or the like, such that a cross sectional profile of the
containment sheet displays a regular wave form with crests and
troughs displaced from the centre plane of the sheet. The wave form
may be smoothly curved throughout or it may comprise straight
portions meeting at relatively abrupt angles, or a combination of
both these possibilities.
[0008] For descriptive convenience, further description of the
panels according to the invention is made hereinafter as if the
panels were in place in a conventional vertical wall extending
upwardly from a horizontal floor, and the terms "horizontal" and
"vertical" as applied to the panels and the panel components are
used accordingly.
[0009] The construction of the spacer means may take various forms.
In one embodiment, the spacer means are in the form of sheet metal
studs, the studs are channel shaped and include a web and a pair of
flanges. In one form, these flanges are generally linear. In that
embodiment, fastener means fix the containment sheet to the flanges
of the studs preferably adjacent the web so as to inhibit torsional
strain at the junction of the flanges and the web.
[0010] In a second form, the studs include hollow flange elements
which are integral with and spaced apart by the web. Preferably the
flanges are positioned and shaped to reduce torsional strain at the
junctions between the flange elements and the web.
[0011] In yet a further aspect, the invention provides a modular
wall panel comprising two containment sheets formed from sheet
metal and spacer means disposed between the containment sheets, the
containment sheets being profiled to have linear stiffening
formations extending in a first direction to resist outward bowing
of the containment sheets in planes extending in the first
direction, and wherein the spacer means are in the form of sheet
metal studs, the studs being channel shaped and including a web and
a pair of flanges which extend laterally from the web, and
fasteners fixing the sheets to respective flange elements.
[0012] There are two classes of embodiments of the invention which
incorporate the hollow flange elements. In the first, each stud may
be a generally channel sectioned member wherein the hollow flange
elements project from one face of the web, in which the width of
the junction renders it very resistant to torsional strain. In a
second of those classes, each stud may be in the nature of a hollow
flanged I-beam of "dumbell" cross section, wherein the hollow
flange elements are preferably circular or triangular in cross
section and are symmetrical about the centre plane of the web, in
which class the line of action of fastening means may be in
substantial register with the centre plane of the web, so as to
substantially eliminate torsional stress on the junction and
therefore torsional strain of the junction.
[0013] Preferably the fastening means penetrates opposing walls of
the respective hollow flange elements. This provides a firm
affixture of the containment sheets to the studs and is one reason
why studs of this particular cross sectional shape are
preferred.
[0014] For preference, the hollow flange elements may be provided
with openings along their length to enable, in use, filler material
to enter and at least partially fill the hollow within the flange
elements thereby to enhance soundproofing and fireproofing the wall
panel.
[0015] In another form, the spacer means includes a plurality of
spaced apart anchorage devices affixed to opposing faces of the
containment sheets. Preferably each anchorage device on one sheet
is in register with a corresponding anchorage device on the other
sheet and a plurality of connector elements, wherein the anchorage
device and the connector elements have cooperating coupling
formations such that each connector elements may be coupled to an
anchorage device on one containment sheet and the corresponding
anchorage device on the other containment sheet. Preferably this is
achieved by the connector element being moved endwisely of itself
and of those corresponding anchorage devices to effect mutual
engagement of their respective coupling formations.
[0016] In yet a further aspect, the invention provides a modular
wall panel comprising two containment sheets, and a plurality of
spacer means disposed between the sheets, the spacer means
including a plurality of anchorage devices fixed to opposing faces
of the containment sheets and a plurality of connector elements,
each anchorage device on one sheet being in register with a
corresponding anchorage device on the other sheet, and the
anchorage devices and the connector elements having cooperating
coupling formations such that each connector element may be coupled
to an anchorage device on one containment sheet and the
corresponding anchorage device on the other containment sheet so as
to interconnect the anchorage devices, the panel being operative to
adopt an assembled form where a cavity is formed between the sheets
arranged to be filled with a settable material and the spacer means
prevent separation of the containment sheets on filling of the
cavity.
[0017] Preferably each anchorage device and each connector element
is an elongated component extending substantially from one edge of
a containment sheet to an opposite edge of the sheet. However, each
such elongated anchorage device may be replaced in less preferred
embodiments, by a row of spaced apart, short lengths of the
elongated device. Thus, the term "anchorage device" as herein is to
be construed not only a single elongated item but also a
functionally equivalent row of spaced apart, shorter sections of
such an item.
[0018] Preferably the linear stiffening formations extend
horizontally in the finished panel, that is to say the first
direction is horizontal. In that event, the second direction is
vertical and the spacer means lie in vertical planes. That
orientation is preferred as it facilitates the placement of the
filling, in that the spacer means than present a minimum of
obstruction to the flowing of filling material from the top to the
bottom of the cavity between the containment sheets.
[0019] Preferably the wall panel further includes at least one
rigid batten which is secured to an outer surface of one or both of
the containment sheets. Preferably each rigid batten extends in the
second direction perpendicular to the first direction.
[0020] In yet another form, the panel includes at least one pair of
rigid battens. Each batten in the pair is disposed opposite one
another on respective containment sheets and is tied together by
tensile means to prevent separation of the battens to thereby
resist bowing of the containment sheets in planes extending in the
second direction.
[0021] In a further aspect, the invention relates to a building
wall formed using the modular panels and to a method of making a
building wall.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] It is convenient to hereinafter describe an embodiment of
the present invention with reference to the accompanying drawings.
It is to be appreciated that the particularity of the drawings is
to be understood as not superseding the generality of the preceding
broad description of the invention.
[0023] In the drawings:
[0024] FIG. 1 is a side elevation of a wall panel according to a
first embodiment of the invention;
[0025] FIG. 2 is a plan view of the panel of FIG. 1;
[0026] FIG. 3 is an inverted plan view of the panel of FIG. 1;
[0027] FIG. 4 is a cross sectional view of a stud, being a
component of the panel of FIG. 1;
[0028] FIG. 5 is a side elevation of the top portion of the panel
of FIG. 1 including detailed views of an associated concrete
reinforcing component;
[0029] FIG. 6 is a view similar to FIG. 5 showing a bottom portion
of the panel of FIG. 1 including a detailed view of a further
concrete reinforcing component;
[0030] FIG. 7 is a plan view of a wall panel according to a second
embodiment of the invention;
[0031] FIG. 8 is a side elevation of the top portion of the panel
of FIG. 7;
[0032] FIG. 9 is a plan view of a wall panel according to a third
embodiment of the invention;
[0033] FIG. 10 is a detailed view of a spacer, being a component of
the panel of FIG. 9;
[0034] FIG. 11 is a plan view of a modular wall panel according to
a fourth embodiment of the invention;
[0035] FIG. 12 is a detailed view of the material within the
enclosure marked (xii) within FIG. 11, drawn to a larger scale and
omitting the containment sheet appearing in the enclosure;
[0036] FIG. 13 is a perspective sketch of a portion of the modular
wall panel according to FIG. 11;
[0037] FIG. 14 is a side elevation sketch of the subject matter of
FIG. 12, showing the containment sheet;
[0038] FIG. 15 is a diagrammatic end elevation of the essential
components of a continuous clinch forming apparatus showing a
containment sheet and an anchorage device being clinched
together;
[0039] FIG. 16 is a sectional elevation view of a wall system;
[0040] FIG. 17 is a plan view of the wall system according to claim
16; and
[0041] FIG. 18 is a diagrammatic perspective view of an acoustic
barrier used in the wall system of FIG. 16.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] The panel 1 illustrated in FIGS. 1 to 6 includes five
upright, substantially parallel, equally spaced apart, sheet-steel
studs, namely end studs 7 and 8 and intermediate studs 9.
[0043] Each of the studs is a length of a known structural channel
member that may be roll-formed from a sheet-metal strip, for
example a strip of steel coated with a protective coating of an
alloy of aluminium and zinc. As may best be seen from FIG. 3 each
stud comprises a web 10 and hollow flanges 11 formed from edge
margins of the original strip. The flanges 11 display outer walls
12 extending integrally from the web 10 and inner walls 13
terminating in edge margins 14 lying flatly against the web 10. The
edge margins 14 may be secured to the web 10 by, for example, spot
welds, clinches or other conventional localised fastening means
spaced apart regularly along the length of the stud. Alternatively,
conventional continuous fastening means may be used, for example,
seam welding, crimping or adhesives.
[0044] The panel also includes two sheet-steel containment sheets
15 secured to the studs 7, 8 and 9 by, for example, closely spaced
self-tapping screws, pop rivets, or other conventional fastening
means. The presently preferred option is self-drilling,
self-tapping screws 16, positioned, as shown by their centre-lines
in FIG. 4, so as to penetrate both of the walls 12 and 13 of the
flanges 11. That last mentioned feature provides for a firm
affixture of the containment sheets to the studs and is one reason
why studs of this particular cross-sectional shape are preferred.
Also, as shown in FIG. 1, the spacing between the screws 16 may be
closer at the lower end of the panel 1 as compared to its upper end
so as to accommodate the larger hydrostatic forces that occur at
the lower end on filling the panel with a settable material as
described in more detail below.
[0045] Each containment sheet 15 is corrugated with the
corrugations extending horizontally from one vertical edge of the
sheet to the other, as indicated diagrammatically by the horizontal
parallel lines appearing in FIG. 1. Such a profile rigidifies the
sheet in respect of bowing in horizontal planes. Other ridigifying
profiles characterised by elongated zones of the sheet being
displaced horizontally from its mid-plane may also be used if
desired.
[0046] It will be noted that the stud 7 projects outboard of the
adjacent vertical edges of the sheets 15 by a distance
approximating one half of the width of the flanges of that
stud.
[0047] It will also be noted that the stud is disposed inboard of
the vertical edges of the sheets 15 adjacent to it to the same
extent. This is a preferred, but not essential feature of the
invention. It facilitates the location and alignment of adjacent
panels during their assembly into a finished wall.
[0048] For preference battens, for example hat-sectioned,
sheet-steel battens 17, are applied to the containment sheets 15 to
facilitate the affixture of wall cladding sheets, for example,
plaster board sheets, to the panels once they have been assembled
into a wall.
[0049] Once two or more of the above-described panels have been
assembled edge-to-edge in a building wall, concrete or the like may
be poured into the cavity between the panels, to add substance to
the wall, and render it more sound proof and more fire proof.
[0050] In some embodiments, to enhance the sound proofing and fire
proofing of the panel, the hollow flange elements may be provided
with openings along their length to enable concrete to enter and at
least partially fill the hollow within the flange elements.
[0051] For preference the concrete filling is reinforced. To that
end, a planar grid 18 of reinforcing rods may be provided, in the
pre-fabricated panel. That grid may comprise horizontal rods 19
extending through clearance holes in the webs of the studs and held
in place by down turned ends, as shown in FIGS. 5 and 6, and a
plurality of horizontal rods 20 tied to the rods 19.
[0052] In those instances where the panel is to be incorporated in
a multi-storey building and is called upon to support a concrete
floor, and may be a superimposed similar panel, the reinforcement
provided in the pre-fabricated panel may also comprise "starter"
elements 21 intended to be embedded in the concrete of two pours
and bridge the gap between them. In this instance those starter
elements may be tubes affixed to an appropriate number of studs by
saddles 22 and a fastener extending through a fastened end 23 into
and through the web of the relevant stud.
[0053] FIGS. 7 and 8 illustrate a second embodiment of the panel.
As the panel of the second embodiment includes many of the features
of the first embodiment illustrated in FIGS. 1 to 6, like features
have been given like reference numerals.
[0054] The second embodiment differs in the construction of the
sheet-steel stud, namely end studs 30 and 31 and intermediate studs
32.
[0055] The studs 30, 31 and 32 are formed as a simple channel
section which comprise a web 33 and sheet flanges 34 which extend
from edge margins of the web 33. Typically the studs 30, 31 and 32
are pressed or roll formed from sheet metal strip, for example a
strip of steel coated with a protective coating of an alloy of
aluminium and zinc.
[0056] The purpose of the studs 30, 31 and 32 is the same as studs
7, 8 and 9 as disclosed in the first embodiment and as such they
are disposed in a similar manner relative to the containment sheets
15. The containment sheets 15 are secured to the studs 30, 31 and
32 via, for example closely spaced self-tapping screws, pop rivets
or other conventional fastening means. As in the first embodiment,
the preferred option is self-drilling, self-tapping screws 16.
Preferably these screws are positioned to extend through the
flanges 34 at a location which is immediately adjacent the web 33
of the respective stud. The advantage of this position is that the
line of action of the fasteners 16 is close to the centre plane of
the web 33 so as to substantially reduce torsional stress induced
in the studs.
[0057] Similar to the first embodiment, the studs 30, 31 and 32 may
include clearance holes in their webs to locate the planar grid 18
of reinforcing rods in the pre-fabricated panel. That grid may
comprise horizontal rods 19 which extend through the clearance
holes 35 and are held in place by downturned ends as shown in FIG.
8. In the embodiment of FIG. 2, the clearance holes 35 include
constricted seats 36 at their opposite upper and lower ends which
are arranged to receive the rods 19.
[0058] FIGS. 9 and 10 illustrate a third embodiment of the panel 1.
Again the third embodiment includes many of the features of the
previous two embodiment and like features have been given like
reference numerals.
[0059] In the third embodiment of FIGS. 9 and 10, the containment
sheets 15 are maintained in at least one location at a
predetermined spacing by a spacer assembly 40 and are sandwiched
between two of the battens 17. In the illustrated form, the battens
are formed from sheet metal but it is to be appreciated that they
could also be made from timber if desired.
[0060] In the illustrated form, the two battens 17 are fixed
together by tensile ties 41 and/or spacers 42 separating the
containment sheets 15. Each tie may be an elongated bolt and nut
combination, a threaded rod in combination with two nuts or other
tensile elements. Each spacer may be a sheet-steel, angle section
member or the like element able to withstand axial compression, and
may be staked through the containment sheets into the battens.
Preferably the spacer ends 43, apart from the self-nailing or
staking formations, are profiled to correspond to the profile of
the containment sheet so as to make substantially full line contact
therewith.
[0061] Thus, in all instances, the containment sheets 15 and the
battens 17 are held fixably together at a predetermined spacing and
the battens serve to resist bowing of the containment sheets in
vertical planes.
[0062] The end battens 17 register with the stud 31 and are applied
to the containment sheets to facilitate the affixture of wall
cladding sheets, for example, plaster board sheets, to the panels
once they have been assembled into a wall.
[0063] In an alternative arrangement, not shown, the ties may also
function as spacers. For example, they may comprise rods with
intermediate abutments in contact with the inner surface of the
containment sheets and end abutments, for example, rivet heads or
push-on fixes, in contact with the outer surface of the battens.
Conveniently those rods may be externally threaded and the abutment
may be conventionally internally threaded nut engaged
therewith.
[0064] Yet a further embodiment of the invention is disclosed with
reference to FIGS. 11 to 15. Again the fourth embodiment of the
invention includes many of the features of the earlier embodiments
and like features have been given like reference numerals.
[0065] As illustrated in FIGS. 11 to 13, the panel comprises two
containment sheets 15, each furnished with five anchorage devices
50 and five connector elements 51. All those components are
preferable made of coated, sheet-steel.
[0066] As in the earlier embodiments, each containment sheet 15 is
corrugated with the corrugations extending horizontally from one
vertical edge of the sheet to the other. Each anchorage device 50
is generally angle-sectioned strip comprising an affixture flanges
52, whereby it may be fixed to a containment sheet 15 so that it
extends substantially vertically from the bottom to the top of the
containment sheet, and a hook sectioned coupling flange 53. The
affixture flange 52 may be planar.
[0067] Alternatively it may be at least partly profiled to enable
it to make area contact with the inner surface of the adjacent
containment sheet 15. It will be noted that the rightmost anchorage
devices 50 (as seen in FIG. 11) are disposed inboard of the
adjacent vertical edges of the sheets 15 by a distance
approximating one half of the width of the flanges 52. It will also
be noted that the flanges 52 of the leftmost anchorage devices 50
project outboard of the vertical edges of the sheets 15 to a
similar extent. This is a preferred, but not essential, feature of
the invention. It facilitates the location and alignment of
adjacent panels during their assembly into a finished wall.
[0068] The anchorage devices 50 may be secured to the respective
containment sheets 15 by any suitable fastening means. However for
preference they are clinched to the sheets by row of clinches 54.
That preference arises because of the speed with which multiple
clinches may be applied by a continuous clinching apparatus.
[0069] Such an apparatus is described in some detail in the
complete specification of Australian Patent No. 675590 (BHP Steel
(JLA) Pty Ltd). Briefly stated such apparatus comprises a rotary
die assembly 100 and a co-acting rotary punch 101, between which
two workpiece sheets to be clinched together, in this instance a
containment sheet 15 a affixture flange 52, are passed. The
apparatus acts to cut two parallel slits in the sheets, depresses a
centre part of the material between the slits until it is clear of
the sheets, and then compresses the centre part to cause it to
expand laterally so that it cannot thereafter return between the
slits. Thus, continuous clinching lends itself to automatic
operation, produces an effective affixture between the workpiece
sheets and avoids the need for additional fastening devices.
[0070] Preferably, clinching apparatus used in the manufacture of
panels according to the invention is a gang apparatus, able to
clinch all of the anchorage devices to each containment sheet in a
single pass.
[0071] Each connector element 51 comprises body strap 55 with
hooked coupling flanges 56 extending along its vertical edges. It
will be apparent that each connector element 51 may be moved
endwisely of itself and of the corresponding anchorage devices 50
to cause their respective coupling flanges 56 and 53 to mutually
engage, as may best be seen in FIG. 12, to couple those components
together. Following which the containment sheets are held in the
required spaced apart configuration and the connector elements are
effective to resist bowing of those sheets transversely of the
vertical direction.
[0072] As in the earlier embodiments, once two or more of the
above-described panels have been assembled edge-to-edge in a
building wall and secured together by fasteners extending through
overlapping portions of mating containment sheets and anchorage
device affixture flanges, concrete or a like filler material may be
poured into the cavity between the panels, to add substance to the
wall, and render it more sound proof and more fire proof.
[0073] Preferably the body straps 55 of the connector elements 51
are pierced by one or more openings 57 to enable filling material
to flow from one side of each connector element to the other.
[0074] The couplings between the anchorage devices 50 and the
connector elements 51 preferably provide for some play to
facilitate the insertion of the connector elements. For this reason
the rectangular shape of the panel as seen in FIG. 11 may relax
into a near rectangular parallelogram during transport and handling
of an assembled panel before the filling is put in place and
allowed to set. To obviate this effect a U-shaped clip or
anti-racking strap 58 may be tightly applied to an edge of the
panel. That clip becomes redundant once the filling has set and may
then be removed or left in place at the option of the person
building the wall.
[0075] FIGS. 16 and 17 illustrate a wall system 70 installed
between two adjacent floors (103, 104) of a multistorey building.
The wall system 70 incorporates the panel 1 which spans the
adjacent floors and which is filled with concrete 71. For ease of
illustration, the steel reinforcement which locates within the
concrete 71 is omitted.
[0076] The wall system 70 is designed to have good acoustic
characteristics. This is achieved in part by the fact that the
panel 1 is filled with concrete. However, to render the wall system
70 more soundproof, an additional metal cladding panel 72 is
incorporated within wall system 70. The wall panel 72 is made from
sheet metal and profiled to include a plurality of ribs 73 which
extend vertically along the entire length of the panel 72.
[0077] The ribbed panel 72 is mounted parallel to the panel 1 but
is spaced from the containment sheet 15 so as to provide an air gap
79 between the panel 72 and the containment sheet 15. As best
illustrated in FIG. 16, the panel 72 is secured to fixing angles
76, 77 which are secured to the floors 103, 104.
[0078] The wall system 70 includes facing sheets 74, 75 which are
typically formed from plaster board. On one side of the wall the
facing sheet 75 is mounted directly to battens 17 which are mounted
to the containment sheet 15 of the panel 1 as described earlier. On
the other opposite side of the wall 70, the facing panel 74 is
mounted directly on the ribs 73 of the metal panel 72.
[0079] The panel 72 also includes service holes 78 which extend
through the opposing side walls of the individual ribs 73. In this
way electrical and plumbing services can run horizontally through
the service holes 78 or vertically within the cavity formed on the
inner side of the ribs 73. In addition, whilst not shown, the panel
72 may incorporate insulation bonded to the inner side of the steel
sheet.
[0080] An advantage of the wall system 70 is that it provides a
high resistance to sound penetration in a relatively thin section
wall. Typically the thickness of the wall system would be in the
order of 200 mm, although it is to be appreciated that the
dimensions could vary depending on the design requirements.
[0081] It is to be appreciated that variations and/or modifications
may be made to the parts previously described without departing
from the spirit or ambit of the invention.
* * * * *