U.S. patent application number 14/770703 was filed with the patent office on 2016-02-04 for building panels and building system using such panels.
This patent application is currently assigned to GLENTREVOR PTY LTD. The applicant listed for this patent is GLENTREVOR PTY LTD. Invention is credited to Michael John ELSEGOOD, Brian Robert HANSON, David John LOVELL.
Application Number | 20160032594 14/770703 |
Document ID | / |
Family ID | 51427578 |
Filed Date | 2016-02-04 |
United States Patent
Application |
20160032594 |
Kind Code |
A1 |
LOVELL; David John ; et
al. |
February 4, 2016 |
BUILDING PANELS AND BUILDING SYSTEM USING SUCH PANELS
Abstract
A wall panel system has at least one panel with face sheets of
compressed solid cement or gypsum based material bonded to a foam
core. The core has at least one channel extending through the core
on an axis along the length of the panel from a predetermined
position on a top edge to a bottom edge of the panel. A slot is
provided on opposed side/end edges of the core to allow for a
strengthening rod to be inserted between adjacent panels. An edge
recess extends along one or more edges of the panel between the
rear of the face sheet(s) and the core. The recess can receive and
discretely hide connecting panel/plate members connecting adjacent
panels.
Inventors: |
LOVELL; David John; (Halls
Head, AU) ; ELSEGOOD; Michael John; (Seville Grove,
AU) ; HANSON; Brian Robert; (Armadale, AU) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GLENTREVOR PTY LTD |
Western Australia |
|
AU |
|
|
Assignee: |
GLENTREVOR PTY LTD
Western Australia
AU
|
Family ID: |
51427578 |
Appl. No.: |
14/770703 |
Filed: |
February 28, 2014 |
PCT Filed: |
February 28, 2014 |
PCT NO: |
PCT/IB2014/059324 |
371 Date: |
August 26, 2015 |
Current U.S.
Class: |
52/105 ;
52/309.4; 52/588.1 |
Current CPC
Class: |
E04C 2/288 20130101;
E04F 13/0894 20130101; E04C 2/521 20130101; E04B 2001/6195
20130101; E04B 1/6145 20130101; E04B 1/14 20130101; E04F 13/0866
20130101; E04F 13/0875 20130101 |
International
Class: |
E04F 13/08 20060101
E04F013/08 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 1, 2013 |
AU |
2013900707 |
Claims
1. A wall panel comprising at least one material with dimensions of
a length, a width and a thickness defining the panel, the panel
having a first face and a second face forming opposed external
panel faces, the length and width being substantially greater than
the thickness, the width and thickness define two opposite end
faces, two opposite edges are located between the two opposite end
faces, the wall panel comprising at least one aperture extending
within the at least one material on an axis along the length of the
panel from a predetermined position on one end face of the panel
determined by said width and thickness.
2. The panel according to claim 1, wherein the at least one
aperture is a single aperture extending through the panel from one
end face to an the opposite end face defined by the width and
thickness.
3. The panel according to claim 1, wherein the axis extends
centrally from the end face(s).
4. The panel according to claim 1, the at least one aperture being
of regular cross sectional shape or having a cross section of
rectilinear shape.
5. (canceled)
6. The panel according to claim 1, comprising an indicator mark or
a plurality of indicator marks onto or into a surface of the
respective end face(s).
7. The panel according to claim 6, the indicator mark(s) being
scribed, written, printed or inscribed on the surface as a linear
indicator diagonally across the aperture.
8. The panel according to claim 1, wherein a first panel portion
and a second panel portion are formed once the panel is cut through
along its length following the at least one aperture.
9. The panel according to claim 8, wherein the cut made through the
at least one material along the axis is at an acute or obtuse angle
with respect to the first and second faces, each resulting panel
portion has a channel in an oblique edge face thereof formed by the
cutting along the length of the panel.
10. The panel according to claim 9, forming a corner panel with one
of the panel portions reversed, the oblique edge faces forming a
mitred corner with a corner central channel therethrough from one
end face to the other.
11. The panel according to claim 1, comprising an external channel
extending along the length of one or both edges of the panel
between the end faces.
12. The panel according to claim 11, each external channel being
half the cross section of said at least one aperture through the at
least one material.
13. The panel according to claim 1, the first and/or second face of
the panel comprising a respective recess adjacent a peripheral edge
thereof.
14. The panel according to claim 13, wherein the recess is between
20 and 50 mm wide and between 2 mm and 5 mm deep.
15. The panel according to claim 1, comprising one or multiple
apertures through a core material from one edge to the opposite
edge.
16. The panel according to claim 1, having a sandwich construction,
with a core of a thermal insulation material and the first and
second faces formed of sheet material.
17. The panel according to claim 16, the insulation material
comprising a foam material.
18. The panel according to claim 1, further comprising a core,
wherein the first and second faces are formed of a sheet material,
and are bonded to the core by adhesive.
19. The panel according to claim 1, further comprising sheets of a
core material, wherein the first and second faces are formed of a
sheet material extending over a peripheral recess around the edges
of the face of each sheet of the core material.
20. A building system comprising multiple panels according to claim
1, and connection means to retain adjacent panels together.
21. A building system according to claim 20, the connection means
connecting a top plate to a floor structure or a floor plate.
22. A building system according to claim 20, the comprising an
aperture channel extending vertically between adjacent panels and a
rod received therein, the rod connected to a top fixing and a lower
fixing.
23. A building system according to claim 20, the panels supported
by a floor, the floor comprises a metal surround around a concrete
base.
24. The building system according to claim 20, comprising a
connecting member inserted through a corner central channel to tie
a top plate and a floor plate of a building system together.
25. The building system according to claim 20, the connecting means
comprising a metal rod connected to a top plate member and a bottom
plate member by screw fastening, nut and bolt or welding.
26. The building system according to claim 20, comprising an
internal strengthener within the panel at an external corner.
27. The building system according to claim 26, comprising external
opposing facing sheets, wherein the strengthener comprises an
elongate angle member with an `L` in cross section between the
respective facing sheet(s) and a core material.
28. The building system according to claim 20, comprising multiple
said panels forming a doorway or a window opening.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to building panels and a
building system using such building panels, such as those used for
low cost housing and commercial properties.
BACKGROUND TO THE INVENTION
[0002] There is a need for low cost structures, such as residential
and employee housing as well as commercial and industrial
properties.
[0003] Traditional brick and concrete blocks are energy intensive
to manufacture. Constructing a building using bricks or blocks is
also time consuming and labour intensive, requiring brick layers to
lay the bricks/blocks using mortar.
[0004] Thermal panels are known and can be used as an alternative
form of building construction. Thermal panels are typically used
for cold stores because of their high thermal insulation
properties, but are also used to clad buildings for the same
reason.
[0005] Thermal panels typically have a sandwich construction of
outer sheets of timber, gypsum or anti-corrosion coated steel,
bonded either side of a sheet of material of low coefficient of
thermal conductivity, typically foam, such as expanded
polystyrene.
[0006] One benefit of using panels is that they can be packed flat
together and transported with minimal loss of space. Fast building
construction is achieved by mounting the panels to a metal or
wooden skeletal framework to erect the building. That is, the
panels are typically used to clad a framework.
[0007] Such thermal panels are generally supplied in set sizes.
Cutting panels to size on site is achievable if simple square ended
butt joints are acceptable. However, such butt joints, especially
at corners of walls lack strength and rigidity. An improved concept
is required whereby panels can be produced that form improved
corners, both for accuracy and rigidity.
[0008] Also, it would be beneficial to tie the top of the panels to
the floor for improved structural integrity of the building,
particularly in cyclone rated environments.
[0009] With this in mind, it has been found desirable to provide
wall panels with improved features to aid construction of a
building.
[0010] It is also desirable to provide a wall panel building system
with improved structural integrity.
[0011] It is further considered desirable to provide a wall panel
arrangement whereby corners of building or walls can be constructed
more accurately and with greater rigidity from flat building
panels.
SUMMARY OF THE INVENTION
[0012] With the aforementioned in view, an aspect of the present
invention provides a wall panel comprising at least one material
with dimensions of length, width and thickness defining the panel,
the panel having first and second opposed external panel faces, the
length and width being substantially greater than the thickness,
the wall panel including at least one aperture extending within the
material on an axis along the length of the panel from a
predetermined position on an end face of the panel determined by
said width and thickness.
[0013] Preferably the at least one aperture is a single aperture
extending through the panel from one end face to an opposite end
face defined by the width and thickness.
[0014] The axis preferably extends centrally from the end face(s)
i.e. halfway across the thickness and width.
[0015] The at least one aperture may be a rectilinear shape in
cross section, preferably square. However, circular or other shapes
are envisaged to fall within the scope of the present
invention.
[0016] The aperture extending into the material at the end face
provides a cutting marker. However, an additional linear or other
mark onto or into the surface of the end face(s) may be provided.
For example, a (ink) scribed, printed or inscribed mark on the
surface as a linear indicator diagonally across the aperture may be
provided. Such linear markers may, if imaginarily extended, extend
externally away from the opposed faces of the panel.
[0017] First and second panel portions are formed once the panel is
cut through along its length following the at least one aperture.
With the cut made through the material along the axis at an
acute/obtuse angle with respect to the first and second faces, each
resulting panel portion has a channel in an oblique edge face
thereof formed by the cutting along the length of the panel. With
one of the panel portions reversed, the oblique edge faces form a
mitred corner with a corner central channel therethrough from one
end face to the other.
[0018] A connecting member can be inserted through the corner
central channel to tie a top plate and a floor plate of a building
system. This connecting member ensures the roof is tied down to the
floor, which is particularly useful in high wind/cyclone regions.
The connecting member may be a metal rod connected to a top plate
and bottom plate member, such as by screw fastening, nut and bolt
or welding etc.
[0019] A structural member may alternatively or additionally be
inserted through the corner central channel to provide structural
integrity to the building. Preferably the structural member may
include an elongate steel member, preferably of steel (which may be
galvanised or stainless steel). The structural member may be
between 10 mm and 150 mm wide by 10 mm to 150 mm thick and
approximately between about 1200 mm long to about 3600 mm long.
[0020] An internal strengthener may be applied to the mitred
corner. Preferably the internal strengthener is positioned in the
recess at the respective exterior or interior angle of the corner
between the respective facing sheet and the core. The strengthener
may include an elongate angle member, such as `L` (uneven length
arms) or `V` (even length arms) in cross section to cover, protect
and strengthen the corner. The strengthener may be bonded to the
core and/or facing sheet by an adhesive and/or screw
fastener(s).
[0021] The panel may include an external channel extending along
the length of one or both edges of the panel between the end faces.
Each such external channel may be half the cross section of said at
least one aperture through the material. This, if one panel is cut
along its length through the at least one aperture and
perpendicular to the first and second panel faces, the resulting
panel portions will have channels with cross section corresponding
to the edge channels along the external edges of the panel.
[0022] The first and/or second face of the panel may include a
recess adjacent a peripheral edge thereof. For example, a recess of
a few millimetres depth into the panel face may be provided long a
peripheral edge portion of the respective first or second face such
that a corresponding adjacent panel with a similar recess creates a
recessed region for a connecting plate. The recess may preferably
be between 20 and 50 mm wide and between 2 mm and 5 mm depth.
Preferably the recess is between 35 and 40 mm wide and between 2.0
mm to 5 mm deep, and more preferably 37 mm wide and 2.0 mm
deep.
[0023] Thus, the connecting plate can cover the join between two
adjacent panels and, with the connecting plate a matching thickness
to the depth of the adjacent recesses, may create a continuous
facing surface across the two adjacent panels.
[0024] At corners, the external facing surfaces of two panels
meeting at an angle to one another may have the recesses adjoining
such that a corner connecting member creates a continuous exterior
surface at the corner.
[0025] The recess may be provided on a face of the panel(s) on an
interior of the room/building. Thus, a continuous surface can also
be created on the inside of the room/building.
[0026] Internal connecting plates (internal of the panel between
the core and facing sheet) may be joined though the thickness of
the core.
[0027] A said panel may include one or multiple apertures through
the core material from one end edge to the opposite end edge. Thus,
one panel can either be cut down along one or both of the apertures
to create panel portions, or the single large panel can be used to
span a wide wall space. For example, a single panel may be 2400 mm,
2700 mm or 3000 mm high, and 1200 mm wide, each with a respective
aperture centre at 400 mm centres on the end faces and inboard from
a respective longitudinal side edge.
[0028] The panel may have a sandwich construction, with a core of a
thermal insulation material and external first and second faces
formed of sheet material. The insulation material may be a foam
material, preferably expanded polystyrene. The panel face material
may be of gypsum and/or cement based material.
[0029] The sheet facing material may be bonded to the core by
adhesive. The sheet facing material may extend over the peripheral
recess around the edges of the face of each sheet of core material.
Thus, joiners between adjacent sheets set into the recess across
adjoining sheets may be hidden behind the facing sheet material
which creates a continuous external surface.
[0030] Multiple building panels may be used to form a doorway or
window opening. For example, two of the panels may be provided
spaced apart to create a door or window opening width, and one or
more similar panels provided extending over the top of the opening
to create the doorway or window opening.
[0031] The building system according to a further aspect of the
present invention may include multiple building panels. The system
may include connection means connecting a top plate to a floor
structure or floor plate. For example, the aperture channel
extending vertically between adjacent panels may have a rod
inserted therein, the rod connected to a top fixing and lower
fixing. The rod ties the top plate to the floor, which can
preferably assist in cyclone proofing the building, especially the
roof by assisting in tying the roof through to the floor.
[0032] The floor may include a surround around a concrete base. The
surround may be of plastic or metal material. Plastic is beneficial
because it is non-corrosive. The surround is known as a perimeter
channel and it provides form work for the pouring of the concrete
floor (slab). Once the concrete is set, the perimeter channel may
not be removable from the concrete floor.
[0033] At 600 mm centres, holes are provided in the floor to insert
45 degree 200 mm crank bolts which in turn are engulfed by the
concrete as it is poured. When the concrete is set, these bolts
anchor a coupler bolt and tie down rod at each point around the
floor. Thus, the roof is tied to the floor via the tie down rods
passing through the panels and bolted into the concrete floor.
[0034] The metal or plastic perimeter channel may include a
respective steel or plastic beam structure creating a floor
perimeter arrangement. The rod(s) may connect to the beam
structure, though preferably are fixed into the concrete floor via
anchor bolts set into the concrete.
[0035] When the perimeter channel arrangement is used, a rubber or
rubberised seal may be provided between the perimeter channel and
the bottom plate. If no perimeter channel is used, the rubber or
rubberised seal may be provided between the concrete floor and
bottom plate.
[0036] Chemical anchors may be provided in the concrete floor
wherever a connection to one of the rods is required. This is
preferably either every 600 mm or 1200 mm into the concrete to hold
the tie down rods.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] Embodiments of the present invention will hereinafter be
described with reference to the accompanying drawings, in
which:
[0038] FIGS. 1a and 1b show a building panel according to an
embodiment of the present invention.
[0039] FIGS. 2a and 2b show a building panel according to an
embodiment of the present invention.
[0040] FIGS. 3a and 3b show a building panel according to an
embodiment of the present invention.
[0041] FIGS. 4a and 4b show a building panel according to an
embodiment of the present invention.
[0042] FIGS. 5a and 5b show a building panel according to an
embodiment of the present invention.
[0043] FIGS. 6a and 6b show a building panel according to an
embodiment of the present invention.
[0044] FIGS. 7a and 7b show a building panel according to an
embodiment of the present invention.
[0045] FIGS. 8a and 8b show a kitchen building panel according to
an embodiment of the present invention.
[0046] FIG. 9 shows a building panel arrangement for a doorway
according to an embodiment of the present invention.
[0047] FIGS. 10 and 11 show installation arrangements for a
building system incorporating panels according to an embodiment of
the present invention.
[0048] FIG. 12 shows a corner arrangement with two mitre edge
panels forming an aperture channel therebetween and having a
strengthener plate over the external corner edge.
[0049] FIG. 13 shows an end on view of a panel according to an
embodiment of the present invention including a longitudinal recess
to receive a lintel, such as over a window, door or garage
opening.
[0050] FIGS. 14 to 16 show top/bottom end views of a panel
according to alternative embodiments of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENT
[0051] FIGS. 1a through 8b show alternative building panels
according to embodiments of the present invention.
[0052] FIGS. 1a and 1b show a building panel 10 with first 12 and
second 14 facing sheets of a compressed, solid cement based
material. Other materials, such as a gypsum based material, can be
used. The core 16 is of expanded polystyrene. The facing sheets are
bonded to the core using an adhesive.
[0053] FIGS. 1a and 1b show the recess 26 formed in the core
material such that, when the facing sheets are applied, a narrow
channel is created. This channel can hide a connecting panel/plate
between adjacent panels.
[0054] A slot 18,20 is provided on the opposed side edges of the
panel 10. When these slots abut to corresponding slots on adjacent
panels, a channel is formed to receive a support member, such as a
steel rod extending the length of the panels. Such a support member
can be tied to a floor and a top plate to add structural strength
and rigidity to a building system incorporating the panels.
[0055] FIGS. 2a and 2b show a central channel 22 extending through
the interior length of the panel from a top edge 30 to a bottom
edge 32. This central channel 22 can also receive a support member
as used in the abutted edge slots.
[0056] The edge recess 26 can extend along a central portion 28 of
the panel. This is preferably twice the width of the edge recess
26. Thus, when the panel is cut in half, the double width recess
forms two recesses of the same width as the edge recesses 26.
[0057] Also, when the panel is cut through along the a central
axis, the cut passes centrally through the rectilinear channel 22
to form two slots equivalent to the edge slots 18,20.
[0058] It will be appreciated that the central channel can be of
any desired cross sectional shape, though regular shapes are
preferred. For example, circular, square or diamond shapes.
[0059] FIGS. 3a and 3b show an alternative embodiment of a building
panel of the present invention, with a diamond shaped central
channel 24. In such an embodiment, when the panel is cut through at
a 45.degree. angle (lines A-A or B-B) with respect to the plane of
the building panel, a mitred edge face is formed with a square U
cross section slot is formed in each half. Thus, the two panel
halves can be used for a mitred 90.degree. corner. With the central
recess sufficiently wide, new edge recesses are formed.
[0060] FIGS. 4a and 4b show an alternative form of the building
panel 10 of the present invention. This is a wider panel with two
aperture channels 22a, 22b running through the core offset from the
centreline C-C. However, the concept of being able to cut the full
panel down through the channels 22a, 22b to form narrower panel
sizes and still retain the edge slot feature. Likewise the central
recess 28 in FIG. 3b becomes a pair of offset recesses 28a, 28b in
this panel. Other iterations using this same concept are envisaged
to fall within the scope of the present invention.
[0061] FIGS. 5a and 5b show a building panel 10 with facing sheets
12 and 14 and core 16 as described previously. The central aperture
channel 24 is diamond in cross section and extends through the
length of the core between the top 30 and bottom 32 end faces.
[0062] When cut diagonally e.g. at 45.degree. to normal to the
facing sheets, a pair of mitred sub-panels 10a, 10b are formed.
These have the square U shaped slot running along the newly formed
side edge of each sub-panel.
[0063] In the alternative, FIGS. 6a and 6b show a preformed mitred
edge panel that does not need cutting to form the mitre. Such a
panel can be supplied to site preformed from the factory to meet a
planned design rather than needing cutting onsite. It will be
appreciated that such a panel can be formed from a larger panel as
in FIGS. 5a, 5b, but in the factory to save material.
[0064] FIGS. 7a and 7b show a building panel 10 of the present
invention with mitred edges 40, 42 along each side edge. Thus, such
a panel can be preformed in the factory and transported to site
without the need for cutting onsite.
[0065] The panel in FIGS. 8a and 8b is designed for kitchens and/or
bathrooms, whereby kitchen cabinets or bathroom cabinets
respectively can be mounted to the panel. A steel plate 44 can be
retained in the recess 46 between the core material 16 and facing
sheet 12,14. Thus, cabinets, which are relatively heavy (especially
when loaded with items) is supported by fastenings through the
panel into the steel plate. Preferably the steel plate is
galvanised.
[0066] FIG. 9 shows a doorway construction using three panels of
the present invention. The doorway has two upright panels 10a, 10b
and a header panel 10c extending over them. Window openings can be
formed the same way.
[0067] FIG. 10 shows a building system arrangement 60 with a square
U channel section floor plate 62 bolted to a steel floor beam 64
that surrounds a concrete floor 66. The channel forms a bottom
plate and is bolted into the concrete floor using a bolt system 68.
The upright portions 70 of the bottom channel slot into the
recesses 26 behind the facing sheets 12,14 of the panel 10 to
create a smooth continuous surface with hidden connections.
[0068] A tie rod 72 passes through the aperture channel 74 through
the panel. The tie rod is fastened to a fixing plate 76 via a
fastening nut 78 to attach the tie rod to the top plate 80. The
fixing plate also attaches to a roof beam 86. The top plate has
elongate side portions similar to the bottom plate portions 70, but
these do not need to be concealed in the recesses 26 because they
are either hidden behind cornice 82 or are at facia board level
externally.
[0069] In an alternative embodiment shown in FIG. 11, the building
panel 10 slots into a top channel 80 and bottom channel 62. The
bottom channel is fastened directly into the concrete floor 66. The
top channel is fixed directly to the ceiling beam 90.
[0070] FIG. 12 shows a mitred corner using two mitred corner panels
10d, 10e forming a corner aperture channel 50 for a tie rod
strengthener member and having a corner strengthener 48 within the
recess 26.
[0071] FIGS. 13 to 16 show alternative forms of panels according to
embodiments of the present invention.
[0072] FIG. 13 shows a lintel panel 100. The panel 100 includes
sheet facings 12 and 14 similar to the embodiments described above.
One longitudinal side edge 102 includes a full length recess or
channel 104 to receive and cover a lintel (not shown). The recess
or channel has a depth E into the panel of preferably 200 mm and a
width F preferably of 100 mm, though other dimensions fall within
the scope of the present invention to suit the particular
application of the panel. It will be appreciated that the lintel
recess arrangement can have a recess of larger dimensions, such as
190 mm wide by 90 mm deep, or other dimensions to suit a required
application. The lintel recess can be within the core bounded on
three sides by core material, or can be exposed to the end edge and
to one side i.e. bounded by core material on only two sides.
[0073] FIG. 14 shows a top/bottom end/edge view of an alternative
an embodiment of the panel 200. The panel 200 has an enlarged
recess/channel 202 in one side edge. The recess/channel is
preferably of 90 mm depth G and 90 mm width H, though it will be
appreciated that other depths and widths can be accommodated
depending on the required application.
[0074] The extra width and depth compared with the recess/channel
18,20 previously described allows the panel edge to accommodate
larger structural supports, such as 90/90 mm steel or timber posts,
or allow room for smaller dimensioned posts and electrical and/or
plumbing utilities.
[0075] Inset from the edge recess 18,20 is at least one passage
passing through the core 16 form the top edge to the bottom edge.
Preferably this passage is oval in cross-section, though other
shapes are permitted. In a preferred form, the cross section is an
oval of around 50 mm length by 30 mm width.
[0076] The passage can accommodate electrical and plumbing
utilities. In a preferred arrangement, the passage is inset from
the edge of the panel by 150 mm, which passage can therefore be
utilised close to the edge of the panel, for connection of electric
light switches to the electrical cable positioned close to the edge
of walls and doors etc., but inset sufficiently from the panel edge
to allow for door frames and wall corners and still allow for panel
strength at the panel edge.
[0077] FIG. 15 shows a version of the panel 200 with two of the
larger edge recesses 202, one recess/channel 202a, 202b at each
opposed edge.
[0078] FIG. 16 shows a further preferred embodiment of the panel
200 with oval utility passageways 204 through the core as described
in relation to FIG. 14. These are preferably inset with their
respective centres 150 mm from the edge of the panel, as indicated
at J in FIG. 16. These allow the passages to be predictably found
for running utilities after the panel system has been erected. A
central channel 206 passes through the centre of the core 16.
[0079] Preferably each oval passageway has dimensions 50 mm (K) by
30 mm (L) as shown in FIG. 16, though other dimensions can be
selected within the core of the panel as required for a particular
application.
[0080] It will be appreciated that the oval cross section
passageways can be square in cross section or diamond or other
regular polygon to suit an application of the panels.
* * * * *