U.S. patent application number 10/995678 was filed with the patent office on 2005-07-21 for building elements.
Invention is credited to Kroie, Robert.
Application Number | 20050155322 10/995678 |
Document ID | / |
Family ID | 34750723 |
Filed Date | 2005-07-21 |
United States Patent
Application |
20050155322 |
Kind Code |
A1 |
Kroie, Robert |
July 21, 2005 |
Building elements
Abstract
A building panel 20 is disclosed which is of sandwich
construction having metal sheet structures 21, 22 interconnected by
a core 23. The panel 20 includes profiled edge regions 24, 25
enabling the panel to interlock with a like panel. In one form a
paper covering 27 is bonded to the metal sheet structure so that
panel has a surface characteristic similar to that of plasterboard.
A reinforcing element 40 is also disclosed which is arranged to be
connected at the join between abutting panels to improve the load
bearing capability of the panel 20.
Inventors: |
Kroie, Robert; (Lindfield,
AU) |
Correspondence
Address: |
Michael L. Goldman
Nixon Peabody LLP
Clinton Square
P.O. Box 31051
Rochester
NY
14603-1051
US
|
Family ID: |
34750723 |
Appl. No.: |
10/995678 |
Filed: |
November 23, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10995678 |
Nov 23, 2004 |
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09673001 |
Oct 6, 2000 |
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6834468 |
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09673001 |
Oct 6, 2000 |
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PCT/AU99/00264 |
Apr 9, 1999 |
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Current U.S.
Class: |
52/782.1 |
Current CPC
Class: |
B32B 2607/00 20130101;
B32B 2307/50 20130101; E04B 2/825 20130101; E04C 2/08 20130101;
E04C 2/292 20130101; B32B 15/12 20130101; B32B 7/12 20130101; E04B
1/6141 20130101 |
Class at
Publication: |
052/782.1 |
International
Class: |
E04B 002/00 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 9, 1998 |
AU |
PP2898 |
Claims
1. A composite building panel for use as exterior cladding, the
panel being of sandwich construction comprising a core, an exterior
facing sheet and an interior facing sheet, the facing sheets being
fixed to respective ones of the opposite major surfaces of the
core, wherein the interior facing sheet has a metal substrate and a
paper coating bonded to the substrate.
2. A building panel according to claim 1, wherein the exterior
facing sheet comprises a steel sheet substrate having a corrosion
resistant metal coating applied thereto.
3. A building panel according to claim 1, wherein the exterior
facing sheet has a cross-sectional profile displaying crests and
troughs which are displaced from a centre plane of the sheet.
4. A building panel according to claim 1, wherein at least one of
the facing sheets includes opposite edges which are shaped to form
at least part of the edge regions of the panel, each edge region
being formed to include a connecting element which extends along
that edge region and which allows for interconnection of the panel
with another panel.
5. A building panel according to claim 4, wherein one of the edge
regions of the exterior facing sheet projects beyond the edge
region of the panel to form a tail portion, and wherein when the
panel is interconnected with another panel at that edge region, the
tail portion overlaps the exterior facing sheet of the other
panel.
6. A building panel according to claim 4, wherein the edge regions
are formed so that when the panel is interconnected with another
panel, the exterior and interior facing sheets of interconnected
panels are aligned and in substantially abutting relationship to
enable a continuous surface to be obtained on both the exterior and
the interior of the panel on the application of conventional
finishing techniques to the facing sheets of the interconnected
panels.
7. A building panel according to claim 6, wherein the conventional
finishing technique for the exterior facing sheet includes
rendering, painting, or spraying a surface coating to that facing
sheet.
8. A roofing panel of sandwich construction comprising a core, an
exterior facing sheet, and an interior facing sheet, the facing
sheets being fixed to respective ones of the opposite major
surfaces of the core, wherein the interior facing sheet has a sheet
metal substrate and a paper coating bonded to the substrate, and
wherein the exterior facing sheet, comprises a sheet steel
substrate that incorporates a corrosion resistant metal
coating.
9. A roofing panel according to claim 8, wherein the exterior
facing sheet has an outer surface that is pre-painted.
10. A roofing panel according to claim 8, wherein the exterior
facing sheet has a cross-sectional profile that displays crests and
troughs displaced from a centre plane of the sheet.
11. An elongate building element formed as a hollow section and
having spaced apart first and second ends, opposite side surfaces
and opposite end surfaces extending between the ends, the element
being formed from first and second parts, the parts extending
between the first and second ends and interfitting in a manner that
allows the size of the hollow section to be varied.
12. An elongate building element according to claim 11, wherein
each part is channel shaped having a web and opposing flanges,
wherein on interfitting of the parts, the flanges of one part is
lapped with the flanges of the other part so as to form the
opposite side surfaces, and the webs of the parts form the opposite
end surfaces.
13. An elongate building element according to claim 11, wherein at
least one of the webs is profiled so as to form a connecting
element which extends along that web.
14. An elongate building element according to claim 11, wherein at
least one of the parts is formed from a metal sheet substrate and a
paper covering bonded to the substrate.
15. A method of constructing a partition having an exterior and
interior surface, the method comprising the steps of: providing a
plurality of panels, each panel being of sandwich construction and
comprising a core, an exterior facing sheet, and an interior facing
sheet, the facing sheets being fixed to respective ones of opposite
major surfaces of the core, the interior facing sheet having a
metal sheet substrate and a paper covering bonded to the substrate:
interconnecting the panels so that the exterior and interior major
surfaces of the interconnected panels are aligned and in
substantially abutting relationship; and applying finishing
techniques to both the interior and exterior major surfaces of the
interconnected panels to form continuous interior and exterior
surfaces across the interconnected panels.
Description
CROSS REFERENCE
[0001] This is a continuation-in-part of U.S. application Ser. No.
09/673,001 filed 6 Oct. 2000, the contents in which are herein
incorporated by a cross reference.
TECHNICAL FIELD
[0002] The present invention relates to building elements and
methods of building construction.
BACKGROUND
[0003] In the building industry, panels are widely used in interior
walls, partitions and ceilings. Building panels are also used on
external cladding, partition wall cladding and roof cladding. One
of the most common type of internal paneling used is plasterboard,
which traditionally is formed from a core of gypsum or anhydrite
plaster, faced with two sheets of heavy paper. Plasterboard has
gained widespread acceptance because it is inexpensive, relatively
light weight, can be easily cut and provides a good surface
finish.
[0004] However, there are significant problems with plasterboard.
Traditional plasterboard panels are not self supporting and need to
be fixed to a supporting frame such as a stud wall or the like.
This substantially increases the cost of installation. Furthermore,
plasterboard has relatively poor thermal and acoustic insulation
properties as compared to block walls, and is relatively inflexible
thereby making it difficult to form into complex shapes.
[0005] Various proposals have been made to address these problems.
These include the development of hollow core reinforced plaster
panels or prefabricated sandwich panels made form two sheets of
plasterboard bonded to a paper honeycomb core. Whilst such designs
are self supporting, they have limited applications and have not
gained widespread acceptance.
SUMMARY OF THE INVENTION
[0006] According to one aspect, there is disclosed a building panel
which includes a metal sheet substrate and a paper covering bonded
to the substrate.
[0007] Throughout the specification the term "paper" includes sheet
material formed from any fibrous material produced from either
naturally occurring or synthetic fibres. The sheet material may be
of unitary or composite construction. It also includes other types
of sheet material which have characteristics, in particular surface
texture, which are similar to paper.
[0008] A cladding or partition formed using the panels, can be
finished to appear continuous using standard techniques used on
plasterboard walls. Such techniques include plaster rendering and
the use of plaster tape.
[0009] In one form, the panel is formed in continuous lengths using
a laminating process to adhere the paper covering to the metal
substrate. The production of panels in this way provides
significant cost benefit and also has the advantage of enabling
panels of indefinite length to be produced.
[0010] In one form, the panel includes longitudinal edges which are
profiled. These profiles may be incorporated to allow the panel to
be interconnected with like panels, or associated componentry such
as fixing rails, edge trim or the like. The profiled edges may also
be designed to allow the panel to interconnect with a traditional
plasterboard panel so that the panel can easily be used in
conjunction with these traditional plasterboard panels. In
addition, the panel may be profiled to enhance it's load bearing
characteristics. These strengthening profiles may be included at
the longitudinal edges, or could be incorporated mid span in the
form or ribs or corrugations or similar structure. The profiles may
be formed in the panel using any known technique such as roll
forming, folding or the like. However in a particular form, the
panels are roll formed to the desired profile. In this way this
forming step can be easily include as an extension to the
laminating process.
[0011] Any appropriate sheet metal may be used as the substrate,
such as steel, aluminium, tin or the like. In general construction,
galvanised steel has wide application as the metal substrate as it
is relatively inexpensive, has good structural properties and is
corrosive resistant. The gauge of the metal substrate may be chosen
depending on the required structural properties of the panel.
However it is envisaged that the gauge will be between 0.3 to 1 mm
in the most applications. Metal falling within this range of
thicknesses can easily be cut thereby enabling services to be
easily installed in the panel on the site.
[0012] In one form, the panel is bonded directly to the metal
surface. In one form, a reactive hot melt adhesive is used to bond
the paper to the metal substrate. An advantage of using a reactive
hot melt adhesive is that it provides high bond strength including
high initial adhesive and cohesive strength which makes it ideal
for laminating the paper directly onto the bare metal substrate.
The ability to bond the paper directly onto a metal substrate again
provides significant cost benefit in that it avoids the need for
pre-treatment of the metal such as the application of a primer coat
to the metal surface. However, it is to be appreciated that the
intermediate layers such as paint or waterproof coatings may be
included between the metal substrate and the paper covering if
required.
[0013] In one form, the adhesive is applied by a roller to the
metal surface, as this gives good even coverage of the adhesive
across the substrate surface which is important for providing an
even surface finish on the panel.
[0014] The building panel has widespread application and can be
used instead of, or in conjunction with, traditional paneling such
as plasterboard. For example, the paneling of the invention may be
used as a fascia, a ceiling panel or the like. In addition it may
be used in conjunction with a traditional plasterboard partition
(such as a wall). For example, the panel may be included in a
section of a plasterboard wall where a complex surface, such as a
curved wall, is required which could not be formed using
conventional plasterboard.
[0015] The building panel may also incorporate additional layers to
improve its structural properties. For example, the panel may
include additional insulating or thermal layers bonded to the metal
substrate on the opposite surface to the paper covering. Again
these additional layers may be bonded using any known technique but
are preferably applied using a laminating process so as to be
easily incorporated in the overall forming process of the
panel.
[0016] In a particular form, the building panel is incorporated as
part of an integrated structural or composite panel. In this
arrangement, the composite panel includes spaced facing sheets
which are interconnected by a core and wherein at least one of the
sheets includes a building panel as described above with the paper
covering forming an outer surface of the composite panel.
[0017] A composite panel according to this form has widespread
application for use as interior walls or partitions or as
combination external/internal wall. The composite panel is self
supporting, is able to be configured to be load bearing and can
incorporate profiled edge regions to enable the panel to be
interlocked with adjacent panels.
[0018] In one form, both the filing sheets of the panel are formed
at least partially from a metal sheet. If only one side of the
panel is to be an exposed interior wall, then only the exposed face
need include the covering; the other face may remain bare metal. If
both sides are to be viewed then both faces can include the paper
covering. Alternatively, if required, different surface finishes
may be used. For example, one surface may include a plastic or
similar water impermeable covering for use in a bathroom or the
like while the other face may include the paper covering. If
required, one face may include a decorative surface such as a
timber veneer or the like. Alternatively one face may form an
external surface and may be profiled or designed to be coated with
an appropriate top coat such as a render or the like.
[0019] In a further aspect, a composite panel is disclosed for use
as exterior cladding, the panel being of sandwich construction
comprising a core, an exterior facing sheet and an interior facing
sheet, the facing sheets being fixed to respective ones of the
opposite major surfaces of the core wherein the interior facing
sheet has a metal substrate and a paper coating bonded to the
substrate.
[0020] In one form, the exterior facing sheet comprises a steel
sheet substrate having a corrosion resistant metal coating applied
thereto.
[0021] In one form, the exterior facing sheet has a cross-sectional
profile displaying crests and troughs which are displaced from a
centre plane of the sheet. The profiled exterior facing sheet may
be in the form the corrugations, ribs, pleats or the like. Further,
the crests and troughs may be smoothly curved throughout or the
profile may comprise straight portions meeting at relatively abrupt
angles, or a combination of both these possibilities.
[0022] An advantage of using metal sheet as part of the composite
panel is that the longitudinal edges can be formed so as to enable
the panel to connect with adjacent panels thereby facilitating the
construction of a partition, using the structural panels. The
profile of the longitudinal edges of the composite panel may be
such that no additional fasteners are required. Alternatively, the
edge profiles may be designed solely to align the adjacent panels
and mechanical fasteners such as rivets, screws or inserts are used
to fasten the panels together.
[0023] In one form, the panels are installed using top and bottom
rails. The rails may have a simple C-shaped cross section. In this
arrangement, the depth of the rails, the distance they are spaced
apart, and the height of the panel is related so that the panels
may be easily installed by merely locating the upper end of the
panel into the top rail and then swinging the bottom end of the
panel into alignment with the bottom rail and then dropping the
panel down into the bottom rail. The panel is then captured between
the top and bottom rails and may be secured in place by fasteners,
such as rivets or self tapping screws or the like. It is to be
appreciated that other fastening arrangements may be used. For
example the rails may be specially formed so that they interlock
with the panels without the need for separate fasteners.
[0024] In an alternate form, the panel is mounted to a frame, such
as a portal frame.
[0025] In one form, one of the edge regions of the exterior facing
sheet projects beyond the edge region of the panel to form a tail
portion, and wherein when the panel is interconnected with another
panel at that edge region, the tail portion overlaps the exterior
facing sheet of the other panel.
[0026] In another aspect, there is disclosed a roofing panel of
sandwich construction comprising a core, an exterior facing sheet,
and an interior facing sheet, the exterior facing sheets being
fixed to respective ones of opposite major surfaces of the core,
wherein the interior facing sheet has a sheet metal substrate and a
paper coating bonded to the substrate, and wherein the exterior
facing sheet comprises a sheet steel substrate that incorporates a
corrosion resistant metal coating.
[0027] In one form, the exterior facing sheet of the roofing panel
has an outer surface that is pre-painted. Further, in one form, the
exterior facing sheet has a cross-sectional profile that displays
crests and troughs displaced from a centre plane of the sheet.
[0028] The core of the composite panel may be of any suitable form
depending on its application or requirements. In particular, the
core may be of solid construction of may be of open form including
interconnecting webs to thereby form cavities within the core.
These cavities may be used to reduce the weight of the integrated
panel or to provide passage for services such as wiring and the
like. The core may be formed of a polymeric composition such as
polystyrene or polyurethane, or may be formed of other settable
material such as cementitious based materials. In one form, the
core is chosen to have fire retardant properties.
[0029] In one form, the edge profiles are shaped to form a slip
joint at the interlock between the adjacent panels. In this
arrangement, one edge profile forms the male component of the slip
joint where as the edge profile of the other panel forms a
complimentary female component of the joint. In one form, the
panels are arranged to interlock in a manner where one panel is
drawn into engagement with another panel so as to facilitate proper
engagement of the panels and to resist inadvertent separation.
[0030] In another form, the edge profiles are specifically designed
to form a load bearing member at the interlock between adjacent
panels. In one form, the interlock is still by virtue of a
male/female coupling but the edge profiles are shaped to form a
part box section. This section has inherent strength and also is
convenient for use in the passage of cabling or other services.
Moreover, the male coupling may be arranged to be drawn into tight
engagement with the female couple so that the overlapping structure
of the male and female connection acts in unison thereby increasing
the load bearing capability of the panels.
[0031] In one form, the composite panel is designed to be able to
receive a structural member between its facing sheets. The
structural member improves the load bearing capability of the panel
and preferably comprises a metal beam.
[0032] In one form, the edge profiles are designed to be able to
receive the structural member so that the member is contained
within the connection between the adjacent panels and is fully
concealed. In this way, a wall formed from the panels may be
continuous across the join which contains the reinforcing
member.
[0033] In a further arrangement, the edge profiles are formed
separate to the panel and are arranged to be located over, and
secured to, the edge margins of the panels which are typically
unformed. This arrangement enables use of a composite panel with
straight edges. Alternatively, the separate edge profiles may be
used as an accessory to the building system incorporating the
composite panels with the profiled edges. For example, the edge
profiles may be used when it is required to cut the composite panel
or when the composite panel is required to interfit with
conventional panels or other building members.
[0034] In a further aspect, there is disclosed an elongate building
element formed as a hollow section and having spaced apart first
and second ends, opposite side surfaces and opposite end surfaces
extending between the ends, the element being formed from first and
second parts, the parts extending between the first and second ends
and interfitting in a manner that allows the size of the hollow
section to be varied.
[0035] In one form, each part is channel shaped having a web and
opposing flanges, wherein on interfitting of the parts, the flanges
of one part is lapped with the flanges of the other part so as to
form the opposite side surfaces, and the webs of the parts form the
opposite end surfaces.
[0036] In one form, at least one of the webs is profiled so as to
form a connecting element which extends along that web.
[0037] In one form, the elongate building element is used as an
internal stud and may be used in conjunction with the composite
building panel as disclosed above. In one form, at least one of the
parts is formed from a metal sheet substrate and a paper covering
bonded to the substrate. In one form, both parts are so formed.
[0038] In a further aspect, a building system which has enhanced
load bearing capabilities is disclosed.
[0039] According to this aspect, a building system comprises a
building panel and a reinforcing element, the building panel having
spaced sheet structures interconnected by a core, said sheet
structures defining opposite major surfaces of said panel and
wherein the element is locatable between the planes of said major
surfaces so as to form in use, a concealed reinforcing member which
is operative to improve the load bearing characteristics of said
panel.
[0040] In one form, the sheet structures are formed of metal and at
least one of the sheet structures may incorporate a paper covering
as previous disclosed. Alternatively, the metal sheet structures
may be fully exposed such as if a stainless steel surface is
required, or other finishes or composite materials may be used.
[0041] The advantage of this system is that it provides a building
panel with enhanced load bearing properties as compared to simple
sandwich panels. Further, fully concealing the reinforcing member
enables continuous smooth surfaces on both sides of the panels to
be obtained.
[0042] A panel in accordance with this aspect of the invention is
suitable for use both as wall panels, ceiling floor paneling or
exterior wall or roof cladding.
[0043] In one form, the sheet structure includes longitudinal edge
regions which are profiled to enable the panels to be connected in
abutting relationship with a like panel in edge to edge
relationship and the reinforcing member is locatable within the
join formed at the abutting panels.
[0044] In one form, the panel is arranged to connect with a like
panel at the longitudinal edge regions. The longitudinal edge
regions may interlock with the reinforcing element. This
arrangement has the advantage that it further increases the load
bearing capability of the panel as the reinforcing member and the
profiled longitudinal edge regions can work together.
[0045] A method of constructing a partition is also disclosed
having an exterior and interior surface, the method comprising the
steps of:
[0046] providing a plurality of panels, each panel being of
sandwich construction and comprising a core, an exterior facing
sheet, and an interior facing sheet, the facing sheets being fixed
to respective ones of opposite major surfaces of the core, the
interior facing sheet having a metal sheet substrate and a paper
covering bonded to the substrate;
[0047] interconnecting the panels so that the exterior and interior
major surfaces of the interconnected panels are aligned and in
substantially abutting relationship; and
[0048] applying finishing techniques to both the interior and
exterior major surfaces of the interconnected panels to form
continuous interior and exterior surfaces across the interconnected
panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] It is convenient to hereinafter describe embodiments of the
present invention with reference to the accompanying drawings. It
is to be appreciated however that the particularity of the drawings
and the related description is to be understood as not limited the
preceding broad description of the invention.
[0050] In the drawings:
[0051] FIG. 1 is a perspective view of a panel;
[0052] FIG. 1A is a detailed view to an enlarged scale illustrating
the construction of the panel of FIG. 1;
[0053] FIG. 2 is a perspective view illustrating the panel in FIG.
1 used as a ceiling panel when in position;
[0054] FIG. 3 is a perspective view of a composite panel
[0055] FIG. 3A is a detailed view to an enlarged scale illustrating
the construction of the panel of FIG. 3;
[0056] FIG. 4 is an exploded perspective view illustrating the
connection of the panel of FIG. 3 with another panel;
[0057] FIG. 5 is a cross sectional view of the connection of the
panel of FIG. 3 with another panel;
[0058] FIG. 6 is a perspective view illustrating the connection of
a variation of the panel of FIG. 3 with another panel and including
an intermediate reinforcing member;
[0059] FIG. 7 illustrates a variation of the panel of FIG. 3 and
its connection with another panel;
[0060] FIG. 8 is a partial perspective view illustrating the
connection of an end trim component to the panel of FIG. 7;
[0061] FIGS. 9A and 9B are schematic side views showing
installation of the panel into top and bottom rails;
[0062] FIG. 10 is a perspective view illustrating the connection of
a variation of the panel of FIG. 3 with another panel and including
an intermediate reinforcing member;
[0063] FIG. 11 illustrates a variation of the panel of FIG. 3
incorporating separately formed longitudinal edge profiles;
[0064] FIG. 12 is a partial perspective view illustrating the panel
of FIG. 10 when used as a flooring system;
[0065] FIG. 13 is a line diagram of a laminating process for use in
the production of a building panel;
[0066] FIG. 14 is a schematic perspective view of the parts of a
stud member;
[0067] FIG. 15 shows the stud member of FIG. 14 when in an
assembled form;
[0068] FIG. 16 is a partial perspective view of a roofing
panel;
[0069] FIG. 17 is a schematic view of the roofing panel of FIG. 16
being installed on a frame; and
[0070] FIG. 18 is a schematic view of a house constructed using
various panel elements.
[0071] The panel 10 is of composite material and formed from a
laminating process which forms the panel in continuous lengths. The
panel may be of any desired width, although if made from one sheet,
the width will be limited by the width of the feed stock. In one
form, the panel is formed in standard widths of 120 mm, 900 mm, 600
mm and 300 mm.
DETAILED DESCRIPTION OF THE INVENTION
[0072] FIG. 1 illustrates a building panel 10 which is generally
planar and includes opposite major surfaces 11 and 12
interconnected by edge regions 13 and 14.
[0073] The panel includes a metal substrate 15 and a paper covering
16 which is bonded to the substrate 15 by a reactive hot melt
adhesive 17. The covering 16 constitutes a heavy plasterboard paper
so that the outer face 11 of the panel has the same general
appearance and surface characteristics of a plasterboard panel. In
the illustrated form, the substrate 15 is formed of galvanised
steel thereby enabling the inner surface 12, which in use is
concealed, to remain exposed due to its corrosive resistant
properties.
[0074] The edge portions 13 and 14 of the panel are profiled so as
to enable the panel 10 to be connected at these edge regions to
another panel. In the illustrated form, the profiles on the edge
regions 13 and 14 are formed by roll forming the metal substrate
13. The edge regions 13 and 14 are formed with one edge portion 13
forming a female coupling which is adapted to receive and contain
the other edge region 14 which is formed as a male coupling. With
this arrangement, the male edge region 14 located in and is
retained within a seat 18 formed within the female edge region 13
of a like panel so that the adjacent panels can be interconnected
along their edge regions.
[0075] It is to be appreciated that the profiles formed in the edge
regions 13 and 14 may take different forms as will be appreciated
to those skilled in the art of roll forming techniques.
Specifically, the profiles can be matched to suit the particular
requirements of the panel and the mode of connection required
between adjacent panels. For instance, the profiles may be designed
such as those illustrated, to not require the addition of any
mechanical fasteners to interconnect like panels together.
Alternatively the edge regions could be formed so as to provide
formations to receive specific mechanical fasteners such as rivets
or screws or the like.
[0076] FIG. 2 illustrates the panel 10 in place as part of a
ceiling with the panel 10 aligned, and fixed to, the underside of
parallel roof battens 60. In the illustrated form, the battens
incorporate clips which are adapted to engage and hold the edge
regions 13 and 14 of the panels. In this arrangement, the ceiling
panels are installed progressively across the batten. A first panel
10.sup.i is installed and fastened to the clips 61. A second panel
10.sup.ii is then installed by locating the male edge region 14ii
within the female edge region 13.sup.i of the affixed panel
10.sup.i whilst the panel 10.sup.ii is inclined relative to the
fixed panel 10.sup.i. Once located in place, the panel 10.sup.ii is
then swung up into alignment with the panel 10.sup.i wherein its
female edge region 13.sup.i engages with associated clips 61
attached to the battens. The process then continues until all the
panels are in place.
[0077] With this arrangement, the fixed panels 10 have respective
outer faces which incorporate the plasterboard paper covering and
thereby have a general appearance of plasterboard. If required,
edge trim (not shown) can be inserted between the adjacent panels.
Typically the panels would include a bead or similar protrusion
which locates within an associated groove (not shown) formed in the
edge regions 13 and 14 of the respective panels. Alternatively, the
join between the panels could be concealed so that the ceiling
surface is continuous using standard finishing techniques such as
plaster rendering or the like.
[0078] FIG. 3 illustrates a composite building panel 20. The panel
20 is of sandwich construction incorporating first and second
facing sheets 21 and 22 respectively, which are interconnected by a
core 23. The panel 20 further includes edge regions 24 and 25 which
are profiled to enable the panel 20 to be interconnected to another
panel.
[0079] As best illustrated in FIG. 3A, each of the facing sheets 21
and 22 incorporate a structure which is similar to the panel 10
illustrated above. Specifically the sheets 21 and 22 incorporate a
metal sheet substrate 26 which includes a covering 27 formed from
heavy plasterboard paper which is bonded to an outer surface 28 of
the metal substrate 26 by a reactive hot melt adhesive 29.
Similarly, an inner face 30 of the metal substrate 26 is bonded to
the core 23 by a similar adhesive 31. The longitudinal edge regions
24 and 25 are profiled by roll forming the respective edge regions
of the metal substrates 26 of the respective sheets 22 and 21.
[0080] The core 23 of the panel is illustrated as a foam block.
Typically the foam is a polymer foam such as polystyrene or
polyurethane. However it is to be appreciated that the core may be
formed of any suitable structure depending on the application of
the panel 20. For example, the core may be formed from a composite
construction and/or may include cavities or channels if
desired.
[0081] In a similar manner to the earlier described embodiment, the
panel 20 is formed from a laminating process. Typically the sheets
21 and 22 are formed in a first laminating process. The sheets then
form part of a second laminating process where they are bonded to
the core. If desired, additional layers can be bonded to the panels
to further improve the structural properties of the panel 20. For
example additional layers may be incorporated to further increase
the thermal or acoustic insulation properties of the panel. By
virtue of the laminating process, the panels 20 are formed in
continuous lengths and are typically formed in a range of standard
widths such as 120 mm, 900 mm, 600 mm and 300 mm.
[0082] The panel 20 has the general appearance and surface
characteristics of plasterboard by virtue of the heavy paper
covering 27. However because of its sandwich construction and sheet
metal substrate, the panel 20 is lightweight, yet is self
supporting and capable of acting as a load bearing member.
[0083] The edge regions 24 and 25 of the panel 20 are roll formed
to include a longitudinally extending projection 32 and recess 33
which are located intermediate the opposite outer surfaces 38 and
39 of the panel 20. In the illustrated form, at edge region 24, the
projection 32 is formed from roll forming the edge of the structure
21 whereas the recess is formed from roll forming the edge region
of the structure 22. An abutment face 34 is located between the
face 38 and projection 32 and a similar abutment face 35 is formed
between the recess 33 and the face 39.
[0084] Both the projection 32 and the recess 33 are shaped to be
complementary such that the projection 32 is able to be received
within the recess 33 of another panel. To facilitate
interconnection of adjacent panels, both the projections and the
recesses include tapered surfaces to provide adequate lead in.
[0085] The other longitudinal edge region 25 of the panel 20
includes a similar edge profile and includes both a recess 32 and a
projection 33, with the exception that the projection is formed
from roll forming the edge of the sheet structure 22 whereas the
recess 33 is formed from roll forming the edge region 21.
[0086] The panel 20 is arranged to be self supporting and typically
arranged to be installed between top and bottom rails (62 and 63)
which are formed as C-shaped channels or the like. FIGS. 9A and 9B
illustrate the installation of the panel 20 between the rails 62
and 63. The panels are easily installed by merely locating the
upper end 51 of the panel into the top rail 62 and then swinging
the bottom end 52 into alignment with the bottom rail 63 and then
dropping the bottom panel 20 into the bottom rail. The relationship
of the distance between the panels to the height of the panel is
such that the panel remains captured between the top and bottom
rails as best illustrated in FIG. 9B. Once in this position, the
panels can then be interlocked with a like panel as will be
described in more details below. Once fully in position the panels
are then secured in place to the rails merely by the use of
fasteners, such as rivets or self tapping screws or the like.
[0087] FIGS. 4 and 5 illustrate the connection of the panel with
another panel. For ease of identification, one panel is designated
20.sup.i whereas the other panel is designated 20.sup.ii. Other
features of the panels are distinguished in a similar manner.
[0088] As best illustrated in FIG. 5, the edge regions 24.sup.i and
25.sup.ii enable two panels 20.sup.i and 20.sup.ii to be connected
in edge to edge relationship with the respective projections and
recesses of the edge region 24.sup.i engaging with the respective
projections and recesses of the edge region 25.sup.ii of the
adjacent panel 20.sup.ii. Furthermore, the abutment surfaces
34.sup.i and 35.sup.ii engage so as to form a simple linear join 36
between the abutting panels 20.sup.i and 20.sup.ii.
[0089] In the illustrated form, both the longitudinal edge regions
24 and 25 of the panel is slightly waisted to form a recessed
portion 37 in the outer surface of both the facing sheets 21 and
22. This recess is designed to enable the join 36 between adjacent
panels to be easily covered over by plaster tape or plaster
rendering which will be applied within this recess and create a
flush surface across the join.
[0090] The profile of the edge regions 24 and 25 also enables the
panel 20 to be easily used in conjunction with standard
plasterboard panels. Specifically, the abutment surfaces 34 and 35
provide a space to enable a plasterboard panel to be located in
abutting relationship with the panel 20. The abutment surfaces 34
and 35 are dimensioned to be slightly larger than a standard
plasterboard panel which is typically 10 mm or 13 mm, so as to
provide adequate clearance for the plasterboard panel to be located
outside the projection 21 and the recess 33 so that the
plasterboard surface can be flush with the respective faces 38 and
39 of the panel 20.
[0091] The coupling arrangement to join adjacent panels using the
interfitting projections and recesses 32 and 33 provide an area of
load bearing strength at the engaged edge regions. This improves
the load bearing characteristics of the wall formed by the adjacent
panels. In most applications, the interconnection of the panels
gives the wall sufficient load bearing characteristics. If,
however, additional load bearing strength is required in the
constructed wall using the panels 20, a metal reinforcing member 40
may be incorporated at the connection. Once such example is
illustrated in FIG. 6 where the reinforcing member is formed from
roll formed metal sheet 41 and incorporates oppositely disposed
channels 42 and 43 which are arranged to interfit between the
engaging projections and recesses (32 and 34) of the adjacent
panels 20.sup.i and 20.sup.ii. The member 40 substantially improves
the load bearing characteristics of the wall as, by virtue of its
configuration and its engagement with the adjacent panels, it is
able to accommodate substantial compressive loading.
[0092] FIG. 7 illustrates a variation of the coupling arranging
between adjacent panels 20.sup.i and 20.sup.ii. In this arrangement
both the longitudinal edge regions 24 and 25 incorporate a pair of
recesses 33. As illustrated in FIG. 7 in connecting the panel
20.sup.i to the like panel 20.sup.ii, the recesses 33.sup.i,
33.sup.ii of the respective panels are arranged to be aligned and
inserts 44 are located within the cavity formed between the aligned
recesses to couple the panels together.
[0093] The inserts may be of any suitable form and may include a
continuous strip 45 which extends over the majority of the length
of the connected panels, or may be in the form of smaller wedges 46
which extends over only a portion of the length of the panels.
[0094] FIG. 8 illustrates a specially formed edge strip 50 which is
arranged to be coupled to the longitudinal edge region 24 or 25 of
the panel 20. The edge strip 50 may be solely as a decorative end
strip or may have a functional purpose such as to form part of a
door frame assembly as in the illustrated embodiment where the
strip 50 is configured to form a doorjamb.
[0095] FIGS. 14 and 15 illustrates a building element 70 that is
engagable with the longitudinal edge region 24 or 25 of the panel
in a similar manner to the edge strip 50. The element 70 is formed
from a first and second part each of which are typically formed
from profiling sheet metal that incorporates a paper covering. Each
part 71 and 72 is formed generally as a channel section having a
web 73, 74 and respective flanges 75, 76, 78 and 79. As best
illustrated in FIG. 14, the parts 71 and 72 are designed to be
brought together so that the flanges of the parts overlap so that
the element 70 forms a hollow section. Typically, the overlapping
flanges can be secured in place through the use of fasteners 78
which are typically rivets or screws. In this way, the overlapping
flanges form first and second sides 79 and 80 with the webs 73, 74
forming the opposite end edges of the element which interconnect
the sides 79, 80.
[0096] The element 70 is designed as a stud member and locates
between adjacent panels 20. To facilitate the connection of the
element 70 to the panels 70, the end surfaces 73, 74 of the element
70 include connecting elements in the form of recesses 81 and
projections 82 that are designed to interconnect with the
connecting element 32, 33 of the panel 20.
[0097] By having the parts 71, 72 of the element 70 being formed
with a paper covering and using a connection system which
complements the connection system used on the panel 20 it is
possible to interfit the element 70 between adjacent panels whilst
maintaining a continuous surface. The element 70 can be used as a
structural member and/or to handle services in a partition formed
by interconnection of the panels 20.
[0098] A further feature of the element 70 is that as it is formed
in separate parts, it is possible to change the amount of overlap
between the flanges thereby varying the size of the hollow section.
This arrangement can have particular advantage when installing a
partition with the element 70 providing some adjustment in the
width of the partition.
[0099] FIG. 10 illustrates a further variation of the panel 20.
This panel includes many similar features to the earlier
embodiments and accordingly like reference numerals have been given
to like features. In a similar arrangement to the previous
embodiments, the panel 20 includes longitudinal edge regions 24, 25
which are profiled to enable the panel 20 to interlock with a like
panel. A reinforcing member 40 is also arranged to interfit at the
join between adjacent panels.
[0100] In the illustrated form, the longitudinal edge region 24
provides a pair of recesses or female couplings 33 whereas the edge
regions 25 provide a pair of male couplings or projections 32. It
is to be appreciated that if desired, each edge region could
include both a male and female coupling similar to that illustrated
in FIG. 3.
[0101] In the embodiment of FIG. 10, the profiles have been
specifically designed to give the panel enhanced load bearing
characteristics at it join with an adjacent panel. The male and
female couplings are shaped to provide generally a part box section
which interlocks through resistant action of the couplings. In
particular the male coupling is drawn into engagement with the
female coupling by this resilient action. This arrangement has the
advantage that the box section provides good load bearing
characteristics and the interlocking action draws the interlocking
members together. This inhibits inadvertent separation of the
members and also enables the interlocking panels to act as a single
unit thereby enhancing the panels overall load bearing capabilities
at this connection.
[0102] The male coupling 32 includes opposite walls 53 and 54 which
are interconnected by a base portion 55. To provide the resilient
action, the walls 53 and 54 are not linear but rather include
outwardly extending crests 56 intermediate the ends of the
respective walls 53, 54. The female coupling 33 incorporates a
complementary shaped recess. Specifically, the female coupling 33
incorporates opposite walls 57, 58 which are interconnected by base
portion 59 and which incorporate re-entrant portions 64 on their
inner surface. In use, on interconnecting the panels together the
male and female couplings are caused to flex through engagement of
the male coupling walls 53, 54 with the female coupling walls 57,
58. The flexing continues until the crests 56 begin to align with
the re-entrant surfaces 64 whereafter the couplings begin to return
to their natural state as the crests move into alignment with the
re-entrant surfaces 64. Once in alignment, the resilience of the
couplings inhibits the release of the two interconnected
members.
[0103] The positive or resilient fit between the male and female
coupling occurs whether or not the reinforcing member 40 is
incorporated. The profile of the reinforcing member 40 has inner
surfaces 65 which matches that of the female couplings 33 and an
outer surface 66 which matches that of the male coupling 32. As a
result, the reinforcing member 40 is able to fit into connection
with the female couplings 33.sup.i of a first panel 20.sup.i. Once
in place, the male couplings 32.sup.ii of the like panel 20.sup.ii
is then able to locate into engagement with the inner surface 65 of
the connected reinforcing member 40.
[0104] FIG. 1 illustrates a similar view to that illustrated in
FIG. 10 except that the edge profiles 24,25 are formed separately
to the panel 20. In this arrangement, the edge profiles 67, 68 are
similar to the edge strip 50 are formed from a folded metal sheet
and are secured to the edge margins of the panels using any
suitable fastening arrangements such as by screw, adhesive or the
like. These edge profiles 67, 68 enable the system to be used with
a panel 20 having a straight edge and may be used when it is
required to cut the structural panel or when the structural panel
is required to interfit with conventional panels or other building
materials.
[0105] The composite panel 20 incorporating the profiled edges and
the internal reinforcing member 40 may be advantageously used in
many aspects of building constructions including in interior as
well as exterior wall structures, or in flooring or ceiling
systems. Further, the choice of the surface materials used to form
the outer faces 38, 39 of the panel will depend on the application
of the panel. For example, if the panel is to be used as an
internal partition wall, then the paper covering may be laminated
to the metal substrate as described earlier so that the panel has a
surface characteristic which is similar to that of plasterboard.
Alternatively, the outer face of the panel may be exposed metal,
such as stainless steel, which is suitable for use in operating
theatres or the like. In this example, to reduce material cost, the
stainless steel may be applied as a laminate to the metal substrate
of the panel 20 or alternatively the substrate may be formed from
solid stainless steel. It is to be appreciated that other surface
configurations could be used as will be appreciated by those
skilled in the art.
[0106] FIG. 12 illustrates a further variation of the panel when
used as part of a flooring system. In this arrangement the
reinforcing member 40 acts as an internal bearer thereby providing
the required loading characteristics for the flooring system. In
this arrangement the upper face 38 incorporates a timber veneer so
as to give the impression of a timber floor.
[0107] FIG. 16 shows a further variation of the panel when used for
roofing. This arrangement of the roofing panel 85 includes an
exterior facing sheet 86 and an interior facing sheet 87. The
facing sheets 86, 87 are bonded to a core 88. The interior facing
sheet 87 is formed from the sheet metal substrate having the paper
covering as disclosed in the earlier panel arrangements. In
contrast, the outer panel 86 is made from metal and typically from
a galvanised sheet steel that includes a pre-painted coating.
Furthermore, whilst the exterior panel 86 can be substantially
flat, in the embodiment shown, it is profiled as is typical in roof
cladding. In the illustrated form, the profile is the roofing panel
86 is corrugated.
[0108] In the illustration shown in FIG. 16, two roofing panels 85,
85.sup.i are shown. These panels are interconnected along edge
margins 89 and 90.sup.i. Further edge regions 89, 90 are profiled
so as to provide a connection detail which in the illustrated form,
comprise an interfitting projection and recess (91 and 92.sup.i).
In addition, the roofing panel 85 is arranged so that an edge
portion 93 of the exterior facing sheet projects beyond the edge
region 89. In this way, this edge region 93 forms a tail portion
which is designed to overlap with the exterior sheet 86.sup.i of
the other panel 85.sup.i.
[0109] An advantage of the roofing panel 85 is that once installed,
the interior facing sheet 87 is caused to move into abutment with
the interior facing sheet 87.sup.i of its adjacent connected panel
85.sup.i. As the material facing sheets 87.sup.i are paper coated,
a finished interior surface can be easily formed by using standard
finishing techniques in a similar manner as described above in
conjunction with the panel 20.
[0110] FIG. 17 illustrates the installation of the roofing panel 85
on a portal frame 150. In this arrangement, the portal frame 150
includes top and bottom members 151, 152 and rafters 153. Purlins
may also be provided with extend between adjacent rafters 153. The
roofing panels are located onto the portal frame 150 in a manner
which is similar to existing roofing cladding. Individually they
are fixed to the frame by mechanical fasteners. The construction is
particularly suited for raked ceilings where the interior surface
87 of the roofing will be exposed.
[0111] FIG. 13 illustrates a line diagram of a laminating process
used to bond the paper covering to the metal substrate for use in
the building panel of the invention.
[0112] In this process, the metal feed stock 26 which is typically
galvanised steel but may be any other sheet metal, is fed from an
uncoiler 101 into the process line 100. The sheet metal is then
correctly positioned by running through an edge guide 102 and then
subsequently through a straightener 103. The sheet metal then
passes through a cleaning and heating unit to remove any debris on
the metal surface and to bring the temperature up to a
predetermined level. The exact temperature range used is dependent
on the characteristics of the adhesive being applied but is
typically in the range of 20 to 50.degree. C. The sheet metal then
passes through to an adhesive coater 105 which incorporates a
roller 106 which comes into contact with the upper surface 28 of
metal substrate 26 so as to apply a thin film to the metal sheet.
The adhesive is a reactive hot melt polyurethane and is typically
applied at a temperature in the range of typically 110 to
140.degree. C. with a coating being applied to the metal surface in
the order of 10-20 mircons in thickness.
[0113] After the adhesive has been applied, the metal sheet 26 then
passes through a humidifier 107 which further conditions the
adhesive coating on the metal surface 28. The sheet then passes to
a laminator 108 where the paper 27 which is stored in a coil 109 is
applied under tension to the surface 28 of the metal 26. The
laminated product is then fed to a recoiler wherein it is stored in
rolls ready for transporting (as illustrated) or to a further
production station. The station further processes the metal panel
and may include a roll forming station to form the edge profiles, a
sheering station to form the panel into sheet form or to slit the
metal panel so as to alter the panel so as to alter the panel
width. To make the integrated composite building panel 20, the
laminated metal sheet is fed to a separate laminating process to
form the panel 20 with its sandwich construction.
[0114] FIG. 18 shows a schematic view of a house construction
incorporating the above panels. Specifically, the construction
(generally designated 500) includes the use of the panels 20 as
external cladding. In this arrangement, one of the facing sheets 21
is designed for exterior use. This exterior facing sheet may be
sheet metal (such as galvanised steel) or could be formed from
other material that can cater for external use such as cement fibre
or the like. The interior face 22 of the panel 20 include the paper
coated metal substrate as described above.
[0115] In the illustrated form, the panels 20 are installed onto a
portal frame 150. In an alternative arrangement however the frame
could be formed at least partially within the cladding by the use
of the reinforcing member 40 described above, or the stud member
70. Further, both the internal and external surfaces of the
cladding 20 can be finished to form continuous surfaces using
conventional finishing techniques. For example, the internal
surfaces could be formed through the use of plaster rendering and
plaster tape whilst the external surface may be coated with a
render.
[0116] In addition, roofing panels 85 are installed to form the
roof cladding and also to form the basis of an interior lining for
the roof void 501. In addition ceiling panels 10 can be used to
create ceilings between the various levels of the construction.
Finally, flooring panel 90 can also be used. The flooring panel
again take the basic structure of the panels 20 being a sandwich
construction with the metal facing sheets. In an alternative
arrangement where the flooring panels are used in intermediate
levels of the building, a lower surface of the flooring panel may
be paper coated so that it can be used in place of the ceiling
panels 10.
[0117] Finally it is to be understood that modifications and or
additions may be made to the parts as previously described without
departing from the spirit or ambit of the invention.
* * * * *