Note: Descriptions are shown in the official language in which they were submitted.
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BUILDING PANEL AND CONSTRUCTION METHOD
The invention relates to a building panel and a method of building using
said panel. In particular, although not exclusively, the invention relates to
a
building panel that may be connected with one or more like panels to
construct a structure such as a wall, floor, ceiling, fence or the like.
BACKGROUND TO THE INVENTION
In the construction industry, walls, floors, ceilings and the like may be
constructed using a wide variety of techniques. For example, walls may be
constructed using conventional bricks held together with mortar, which is
placed between adjacent bricks and between adjacent, alternately staggered
layers of brickwork. However, this process is time-consuming, labour
intensive, expensive, and often requires a large amount of preparation before,
and finishing after, the wall or the like is formed.
One alternative to conventional bricks are mortarless bricks or blocks,
such as the concrete mortarless blocks disclosed in United States Patent US
6,189,282 assigned to Building Works Inc.. To construct, for example, a wall,
the concrete blocks are placed directly on top of each other without
staggering
alternate layers such that cavities or cavities extending through the depth of
the blocks are aligned. Each block comprises a pair of locking channels at
each end. Adjacent blocks and adjacent layers of blocks are secured
together by inserting locking members into apertures formed by the locking
channels of adjacent blocks. Concrete, or other settable material, may then
be poured directly into the cavities to reinforce the wall. Steel reinforcing
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members may be additionally inserted vertically and/or horizontally into the
wall structure through horizontally and vertically disposed passages.
This system allows the concrete to pass relatively uninhibited through
the aligned cavities thus reducing the risk of creating voids within the
cavities
unoccupied by concrete. This system is also quicker than the conventional
bricks and mortar method described above since the blocks can be aligned
directly on top of each other and do not require a layer of mortar between
adjacent blocks or layers thereof. However, time is still wasted in having to
directly align the blocks and insert the locking members into the locking
channels. Furthermore, the blocks are of a comparable size to bricks and
therefore a substantial amount of time is needed to complete even a fairly
small sized wall. Concrete blocks are also heavy compared with
conventionally sized bricks and therefore building walls and the like with
such
blocks is still labour intensive. The prior art is replete with such blocks
utilizing various shapes of locking channel and locking member, yet all share
the aforementioned drawbacks.
An alternative to the aforementioned bricks and blocks for constructing
walls, floors and the like are building panels. Many types of building panels
have a large surface area and therefore, one advantage of using building
panels is that large areas of wall, ceiling and the like can be constructed in
a
shorter period of time compared with construction times using bricks and
blocks. However, any reduction in construction time achieved using panels is
dependent on, inter alia, the amount of preparation required in advance of
fixing the panels.
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Conventionally, a wooden frame, boxing or formwork must first be
constructed to which various types of panelling, such as plasterboard,
weatherboard or the like may in some manner be affixed. Hence, erection of
walls, ceiling and/or floors or the like cannot proceed until the formwork is
in
place. Furthermore, fixing and positioning of the formwork and panelling
needs to be carefully coordinated to enable services such as gas, electricity
and water to route the necessary conduits therefor between the formwork and
panelling. These factors serve to substantially reduce any time saved using
conventional building panels.
One type of building panel and a method of construction using such
panels is disclosed in United States Patent 5,397,516 assigned to Thermo
Cement Engineering Corp., which discloses generally square shaped
cementitious panels used as an inner and outer skin of a wall, between which
a skeleton of steel reinforcing rods is arranged. Concrete may then be poured
between the cementitious panels thus encasing the steel.
Apart from the production process for the panels disclosed in US
5,397,516 being somewhat laborious, the resulting panels are heavy and
difficult to manoeuvre in a construction environment, resulting in minimal
timesavings, if any, in using the panels. Another drawback of this
construction method is that pouring of concrete within the cavity between the
panels often does not achieve 100% filling of the cavity due to the formation
of
voids. Indeed, with many prior art construction systems, up to about 30% of
the cavity can remain unfilled with concrete.
Further problems of many prior art panel systems are their complex
design, such as the building panel and connection system disclosed in United
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States Patent 6,314,704, assigned to American Structural Composites, Inc.,
and the consequently high cost. Many of the interlocking systems also fail to
easily and/or neatly lock together. In many cases, users of such systems
have to modify the interlocking mechanisms in order to fit the components
together in a satisfactory manner. Furthermore, many panels, although
providing structural integrity for a wall, floor or ceiling or the like, do
not
comprise either an interior and/or exterior finished surface. Therefore,
additional time and expense is required to achieve a finished, presentable
surface.
A yet further problem of many of the prior art systems is that they are
not waterproof and therefore an additional waterproof membrane is
necessary. Such membranes are often susceptible to puncturing, which
renders the membrane useless, and therefore additional protection for the
membrane itself is required.
Hence, there is a need for a building system and/or method that
addresses, or at least ameliorates, at least some, if not all of the
aforementioned problems. In particular, there is a need for a building system
and/or method that can be used to efficiently construct walls, floors and/or
ceilings or the like, which is easy to handle and fit together, requiring the
minimum of expertise.
DISCLOSURE OF THE INVENTION
In one form, although it need not be the only or indeed the broadest
form, the invention resides in a building panel comprising:
a plurality of spaced apart walls forming a plurality of cells;
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Received 03 December 2003
apertures in said walls such that said walls forming each said cell
include at least two apertures;
a substantially planar skin disposed adjacent and substantially
perpendicular to said walls such that said cells are open on a side opposite
5 . said planar skin; and
a projection extending beyond at least one perimeter portion of said
walls.
Suitably, said projection is formed by a portion of said skin.
The skin may have a beveled edge. Preferably, the beveled edge is
provided on at least two opposite edges of the skin.
Suitably, the panel may comprise a slot along a perimeter portion of the
length and/or the width of the panel, said slot sized and shaped to receive
said projection of an adjacent panel.
Suitably, said slot may lie partially or continuously along a length
and/or width of the panel.
The skin preferably covers the same area as the panel, but is
preferably ofFset relative to the panel.
Preferably, the cells have a square cross section, but may suitably be
rectangular, hexagonal, circular, or any other desired shape.
Suitably, the walls and the skin are rigid.
Preferably, the apertures in the walls are aligned and are preferably
adapted to facilitate the passage therethrough of reinforcing members,
conduits, pipes, cables and the like.
Suitably, the panel may comprise perimeter walls, which together
define a quadrilateral. Particularly, the perimeter walls together may define
a
AMEI~~E~ SHEET
IF'EA/AU
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6
rectangle.
Further features of the building panel will become apparent from the
detailed description.
In another form, the invention resides in a method of constructing a
building structure in a particular orientation from a plurality of building
panels,
each building panel comprising:
a plurality of spaced apart walls forming a plurality of cells;
apertures in said walls such that said walls forming each said cell
include at least two apertures;
a substantially planar skin disposed adjacent and substantially
perpendicular to said walls such that said cells are open on a side opposite
said planar skin; and
a projection extending beyond at least one perimeter portion of said
walls;
said method including the steps of:
securing a first panel in said orientation; and
abutting a second panel against said first panel such that the projection
of the first panel overlaps the second panel.
Suitably, a beveled edge of the skin of the first panel abuts against a
beveled edge of the skin of the second panel. Alternatively, a slot of the
second panel accommodates the projection of the first panel.
Preferably, the apertures in the walls of the first panel align with
corresponding apertures in the walls of said second panel.
The method may further include the step of securing said first and
second panels together with fastening means.
~M~~~~~ ~H~~°
PCT/AU03/00245
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7
The method may further include the steps of securing a third and
further panels to said first and/or second panels.
Preferably, the method further includes the step of routing one or more
reinforcing members through the aligned apertures of said walls.
Suitably, the method further includes the step of filling at least one cell
with settable material.
The method may further include the step of placing one or more inserts
in one or more of the cells prior to filling the cells with settable material
to
prevent ingress of the settable material to said cells) containing the
insert(s).
The method may further include the step of routing one or more
conduits, pipes, cables or the like through the aligned apertures of the
walls.
In another form, the invention resides in a method of constructing a
building structure in a particular orientation from a plurality of building
panels,
each building panel comprising:
a plurality of spaced apart walls forming a plurality of cells;
apertures in said walls such that said walls forming each said cell
include at least two apertures;
a substantially planar skin disposed adjacent and substantially
perpendicular to said walls such that said cells are open on a side opposite
said planar skin; and
a projection extending beyond at least one perimeter portion of said
walls;
said method including the steps of:
securing a first of said building panels in said orientation; and
securing a second of said building panels in said orientation spaced
~~~l~l~~~? 9H~~'
B~~f'~~~
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7a
apart from said first building panel.
The method may further comprise the step of securing said second
building panel such that said plurality of cells of said second panel face
said plurality of cells of said first panel.
The method may further comprise the step of coupling said first and
second building panels with reinforcing members.
i~Ei~~~~~ HEED'
n
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Further features of the methods of the present invention will become
apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
To assist in understanding the invention and to enable a person skilled
in the art to put the invention into practical effect preferred embodiments of
the invention will be described by way of example only with reference to the
accompanying drawings, wherein:
FIG 1 shows a perspective view of a building panel in accordance with
a first embodiment of the present invention;
FIG 2 shows a first sectional view of the building panel in FIG 1;
FIG 3 shows a second sectional view of the building panel in FIG 1;
FIG 4 shows a plan view of the building panel in FIG 1;
FIG 5 shows a construction method using a plurality of the building
panels shown in FIG 1;
FIG 6 shows another construction method using a plurality of the
building panels shown in FIG 1;
FIG 7 shows a perspective view of a building panel in accordance with
a second embodiment of the present invention;
FIG 8 shows a partial side view of two of the building panels in FIG 7
coupled together;
FIG 9 shows a further construction method using a plurality of the
building panels shown in FIG 7; and
FIG 10 shows another partial side view of two of the building panels in
FIG 7 coupled together.
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DETAILED DESCRIPTION OF THE INVENTION
A building panel 2 in accordance with the present invention is shown in
FIG 1. In a first embodiment, the building panel comprises a plurality of
spaced apart walls 4 arranged such that they create a plurality of cells or
cavities 10. The cells 10 can be clearly seen, for example, in the perspective
views in FIGS 1 and 5 and in the plan view of the panel in FIG 4.
In the embodiment shown in FIG 1, the panel comprises a first set 6 of
substantially parallel, spaced apart walls lying substantially perpendicular
to a
second set 8 of substantially parallel, spaced apart walls. An example of one
of the walls constituting the first set 6 of walls is depicted in FIG 2. An
example of one of the walls constituting the second set 8 of walls is depicted
in FIG 3.
It will become apparent that the present invention is not limited to the
walls 4 of the panel 2 being arranged in the manner shown in FIG 1. For
example, the walls need not be arranged substantially perpendicular to each
other and could instead be arranged at some other relative angle whilst
maintaining the inventive function of the panel.
Also, the cells 10 are not limited to having a square cross section. The
cells 10 may be of any shape that allows the easy passage of conduits and
the like through apertures therein, as described below. The cells should also
be of a shape that allows containment of settable material within the cell
once
the material has set. Hence, it is envisaged that the cells could be
rectangular, triangular, circular, hexagonal, or any other desired shape.
The walls 4 of the panel 2 comprise a plurality of apertures 12, as
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shown particularly in FIG 2 and FIG 3. The apertures 12 are preferably of
various diameters to allow the passage therethrough of reinforcing members,
such as steel reinforcing rods, and conduits, wires, pipes, cables and the
like
for services such as gas, electricity, water and air conditioning. The
apertures
5 12 in the walls comprising the first set 6 are aligned with each other to
enable
a straight pipe or the like to be easily routed through the panel 2, passing
through each wall in the first set of walls. The apertures in the walls
comprising the second set 8 are also aligned with each other for the same
reason. Hence, cables, conduits and the like may be routed through the
10 panel in any desired manner. An example of the alignment of the apertures
12 in the walls 4 is clearly shown in FIG 4.
FIGS 2 and 3 show just one assortment of aperture diameters in
two different configurations. However, it will be appreciated that the present
invention is not limited to the diameter of the apertures selected, the number
of apertures per wall or the configuration of the apertures. The diameter,
number and configuration of the apertures may be selected according to the
particular application for which the panel is being used and a second
embodiment of the panel comprising a different aperture arrangement and
configuration is described hereinafter. However, the aperture diameters can
be selected to allow the easy passage of conduits, piping, or the like
therethrough, whilst securely maintaining the conduits and the like in
position.
Furthermore, the apertures are not limited to being circular in shape and may
be shaped according to the cross-sectional shape of the conduit or the like to
be passed therethrough. Hence, for example, the apertures may be of any
regular or irregular polygon or other shape to allow passage therethrough of
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conduits, pipes, reinforcing members or the like of that shape. However,
corresponding sets of apertures 12 in first and second wall sets are at
different levels to enable reinforcing members and/or utility conduits or the
like
to be routed through the panel without being impeded by other reinforcing
members and/or utility conduits or the like passing through the panel in, for
example, a perpendicular direction.
The building panel 2 also comprises a substantially planar skin or
planar surface 14 on one face of the panel. The skin 14 may be of the same
area as that enclosed by the perimeter walls 16, but offset with respect to
the
perimeter walls 16 such that the skin 14 forms a projection 15 extending
beyond at least one of the perimeter walls 16. Preferably, the skin 14 extends
beyond two of the perimeter walls, as shown in the embodiment shown in, for
example, FIGS 1 and 4. The skin 14 is positioned with respect to the walls 4
such that the skin seals one side of many of the cells 10, with the opposite
side of the cell being open. Some of the cells, such as cell 10a, are only
partially covered on one side by the skin 14, as shown in FIG 4.
The offset of the skin 14 relative to the walls 4 enables a plurality of
panels 2 to be accurately aligned with each other in the construction of a
wall,
floor, ceiling, fence or the like using the panels, as described later herein.
Accurate and snug alignment of the panels is further facilitated by beveled
edge 18 of the skin 14, most clearly visible in FIG 3. The bevel may be
angled at substantially 45 degrees to the plane of the skin 14, although other
angles may alternatively be selected. Other angles may be preferred
depending on the application for which the panels are being used. The
beveled edge 18 is provided on at least two opposite edges of the skin 14,
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such that the beveled edges 18 on the opposite edges are parallel. The
beveled edges may also be provided on the remaining two opposite edges of
the skin 14, the angles of the edges on the remaining opposite edges again
being parallel.
Construction of, for example, a wall using the panels of the present
invention will now be described.
The panels 2 may be set in, for example, a conventional concrete
foundation. A first panel may be aligned at the desired angle, which
conventionally will be substantially vertical in the case of a wall structure.
Alternatively, the first panel may be placed in any orientation corresponding
to
the desired orientation of the resultant wall, floor, or the like. The first
panel
may be set with either the longer side or the shorter side running vertically
and the selected orientation for the first panel will determine the
orientation of
the other panels forming, in this example, the wall. Once a first panel is
positioned, subsequent panels can be positioned adjacent the first panel.
Accurate and snug alignment is achieved by virtue of the projection 15 of the
skin 14 and the beveled edge 18, as described above.
With reference to FIG 5, when two panels are brought adjacent each
other, the projection 15 of a first panel 2a abuts the skin 14 of a second
panel
2b. Part of the walls of panel 2b rest on the projection 15 of the panel 2a,
such as parts of the walls defining cell 10a. The overlap of portions of the
walls 4 of panel 2b with the projection 15 of adjacent panel 2a contributes to
the structural integrity of the wall, floor or the like, constructed from the
panels
and creates an effectively continuous skin for the walls 4.
Once two adjacent panels are correctly aligned and positioned, they
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may be joined together with any conventional fastening means applicable to
the material from which the panels are formed, which is discussed later
herein. The panels may be, for example, glued, clipped, bolted or screwed
together using any suitable fastening means that securely holds the panels in
position and the present invention is not limited to the type of fastening
means
employed.
Depending on the particular application, once a number of panels are
fixed in position as described above, reinforcing members, such as steel
reinforcing rods 20, as shown in FIG 5, may be passed through the
appropriate apertures in the panel in a vertical and/or horizontal direction.
Conduits, pipes, cables and the like may also be passed through the desired
apertures. The apertures selected depend on the services) being routed
through the panel and, for example, the location in the panel at which, for
example, service outlets, are required. For example, apertures suitable for
e.g., water pipes may be present at, for example, 100mm intervals along the
panel 2. Hence, there is a large degree of flexibility in where services are
routed through each panel, thus addressing one of the problems exhibited by
the prior art building systems.
Alternatively, once the reinforcing members have been inserted
through the panel, the relevant services personnel may choose not to route
the relevant service conduits or the like through the panel at that time, but
delay until a later time. In this case, to prevent the desired cells from
being
filled with concrete or other settable material, an insert, such as a
polystyrene
or polyurethane block or the like may be inserted into those cells required
for
routing the services. The inserts can then easily be removed later, thus
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leaving a vacant cell.
In the case of passing wires or cables through the panel when concrete
or other settable material is also going to be used, conduits for the wires
may
be passed through the relevant apertures 12. Wires can then be threaded
through the conduits and replaced at a later date with ease, if and when
necessary.
Another advantage of the present invention over the prior art is
exhibited when concrete or other settable material is used. All of the cells
10
of the panel 2 are open on one side to allow the uriinhibited access for
concrete or the like, thus minimizing the prior art problem of voids being
created and concrete not completely filling the relevant cells. The apertures
12 in the walls 4 further facilitate communication of the concrete or the like
throughout the panel 2 into the desired cells 10.
The panels of the present invention may be used for single or multiple
thickness walls, floors, fences, ceilings or the like. Application of the
panels of
the present invention in a double thickness wall will now be described with
reference to FIG 6.
Using the panels of the present invention, two single thickness walls
30, 32 may be constructed parallel to each other, each wall being constructed
as described above for the single thickness wall. The two walls may be
constructed with the cells 10 of each wall facing each other, such that the
skins 14 of each wall face away from each other. Reinforcing members, such
as steel reinforcing rods 20, may then be passed through the apertures 12 of
the walls 4 horizontally and/or vertically. With reference to FIG 6, loops 34
of
reinforcing material, such as steel reinforcing rods, may be looped around the
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horizontal and/or vertical reinforcing members of each wall 30, 32 to both
secure the two walls together and to act as spacers between the two walls.
The loops 34 of reinforcing material may be over-looped as shown to prevent
running of the looped rod. Conventional ties may also be employed to help
5 prevent the loops from pulling apart. This arrangement prevents movement of
the two walls relative to each other and the cell openings are still
accessible to
concrete or other settable material that may be subsequently poured between
the two walls to provide further reinforcement.
It will be appreciated that the invention is not limited to the particular
10 reinforcing members around which the loops 34 are passed. With reference
to FIG 6, the loops 34 may alternatively or additionally be looped around
reinforcing rods running through the panel closer to the skin 14, such as
reinforcing rods running through aperture 36. In such a case, loops 34 extend
further into the cells 10. Therefore, when concrete or the like is poured into
15 the cells, the loops 34 are embedded in a greater depth of concrete, thus
providing greater strength.
Another embodiment of the panel of the present invention is shown in
FIGS 7, 8 and 10 and another construction method using these panels in
accordance with the present invention is shown in FIG 9. Like reference
numerals refer to like features of the first embodiment and construction
method.
Building panel 2 comprises a plurality of spaced apart walls 4 arranged
such that they create a plurality of cells or cavities 10. A first set 6 of
substantially parallel, spaced apart walls lie substantially perpendicular to
a
second set 8 of substantially parallel, spaced aparfi walls. Substantially
planar
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skin or substantially planar surface 14 is positioned with respect to the
walls 4
such that the skin seals one side of many of the cells 10, with the opposite
side of the cell being open. Some of the cells, such as cell 10a, are only
partially covered on one side by the skin 14, as shown in FIG 7.
Walls 4 of the panel 2 comprise a plurality of apertures 12. The
apertures may be in the form of apertures 40 in second wall set 8 and be of
any desired shape and/or size to allow the passage therethrough of
reinforcing members, such as steel reinforcing rods, and conduits, wires,
pipes, cables and the like for services such as gas, electricity, water and
air
conditioning as described above. The apertures may alternatively be in the
form of apertures 42 in second wall set 8, apertures 42 being open at one end
and substantially forming a U-shape. Similar shaped apertures 44 may also
be present in first wall set 6. The U-shaped apertures are most clearly
visible
in FIGS 8-10. However, the apertures 42, 44 are clearly not limited to
substantially forming a U-shape and may have any desired shape to
accommodate the reinforcing members and/or utility conduits or the like
routed through the panel.
Apertures 12 in the walls comprising the first set 6 are aligned with
each other to enable a straight pipe or the like to be easily routed through
the
panel 2, passing through each wall in the first set of walls. The apertures in
the walls comprising the second set 8 are also aligned with each other for the
same reason. Hence, cables, conduits and the like may be routed through
the panel in any desired manner.
Apertures 40, 42, 44 are at different levels above skin 14 to enable
reinforcing members and/or utility conduits or the like to be routed through
the
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panel without being impeded by other reinforcing members and/or utility
conduits or the like passing through the panel in, for example, a
perpendicular
direction.
The substantially planar skin 14 forming one face of the panel extends
beyond a perimeter portion of first walls 6 and/or second walls 8. In this
embodiment, perimeter portions are in the form of ends 46 of first walls 6 and
ends 48 of second walls 8. Skin 14 may extend beyond the perimeter portion
of first walls 6 at least at one end of the panel. Alternatively, or
additionally,
skin 14 may extend beyond the perimeter portion of second walls 8 at least at
one end of the panel.
With reference to FIGS 7 and 8, a projection 15 extends beyond a
perimeter portion of first walls 6 and/or second walls 8. Projection 15 may
lie
partially or continuously along a length or width respectively of one side of
the
panel. Preferably, projections 15 extend beyond perimeter portions of both
first and second walls 6, 8 respectively, as shown in FIG 7. Preferably,
projections 15 lie along a full length and a full width of the panel, as shown
in
FIG 7.
With reference to FIGS 7 and 8, a slot 50 is formed in the panel along a
perimeter portion of a length and/or width of the panel 2. Slot 50 is sized
and
shaped to receive projection 15 of another panel, as shown in FIG 8, to
facilitate fitting together and alignment of adjacent panels. Slot 50 may lie
partially or continuously along a length and/or width respectively of the
panel
and will correspond to the continuous or partial nature of the projections)
15.
With reference to FIG 10, slot 50 in panel 2a accommodates projection
15 of adjacent panel 2b. Slot 50a of panel 2b accommodates projection 15a
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of panel 2a. Recess 52 of panel 2b accommodates projection 15b of panel
2a.
Referring to the embodiment in FIG 8, adjacent panels fit together such
that the number of apertures 44 in first walls 6 is the same for each cell 10.
Similarly, with reference to FIG 10, the number of apertures 40, 42 in second
walls 8 is the same for each cell. Ends 46 of first walls 6 and ends 48 of
second walls 8 are shaped such that when two adjacent panels abut,
apertures 44a are formed in first walls 6, as shown in FIG 8, and/or apertures
42a are formed in second walls 8, as shown in FIG 10, where two adjacent
panels abut. The panels of the second embodiment may be secured together
by the same means as the first embodiment as described above.
FIG 9 shows the construction of a wall or the like using panels of the
second embodiment. In this example, apertures 40 of second walls 8 overlap.
Reinforcing members and/or utility conduits and the like may be passed
through these apertures. Overlapping the panels in this manner enables a
strong wall or the like. With such a wall, the wall doesn't occupy as much
volume as some prior art alts of comparable strength and therefore realizes
larger room spaces. It will be appreciated that panels of the second
embodiment need not be overlapped in this manner to produce walls, ceilings,
or the like. The panels may be space apart and reinforcing loops may
alternatively be employed. Of course, walls, floors and the like may be
produced using single layers of panels according to the second embodiment.
The panels 2 of the present invention may be produced from any
suitable plastics material, which is preferably recycled plastic, in
accordance
with any suitable methods know to those skilled in the relevant art. More than
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600 known different grades of plastics may be used for the panels.
Alternatively, conventional aluminium or other metals or metal composites
may be used for the panels if required for particular applications.
Alternatively, the panels may be produced from alternative materials, e.g.,
for
more lightweight applications. When produced from suitable plastics material,
a panel according to the invention of dimensions 600x1200mm has a mass of
only about 4-5kg, making the panels very easy to maneuver. The panels may
also be made from fire retardant materials and/or have soundproofing
characteristics, the level of each being selectable according to the materials
from which the panels are manufactured.
The panels may be produced to the required dimensions and shape as
determined by the particular application. For example, although the panel is
shown in the drawings as substantially rectangular in shape, the perimeter
walls 16 of the panel 2 may define a square, a quadrilateral or any other
shape appropriate for the application, providing the panels tessellate and
allow for the routing of reinforcing members, conduits and the like easily
therethrough, as described above.
The skin 14 of the panel may be produced to any desired thickness,
which also may be selected according to the application. In particular, since
the skin of the panels may serve as the finished surface, visible once
construction is complete, the skin may be protected against ultraviolet
radiation in accordance with known methods to resist deterioration of the skin
when exposed to sunlight. The skin may comprise any form of finish such as
a powder coating as desired, including any desired colour and/or texture. The
particular finish will depend on the application and the material from which
the
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panel is formed. The compatibility of the finish and the material will be
familiar
to one skilled in the relevant art.
Hence, the panel of the present invention addresses another problem
of the prior art. Since the skin may act as the finished surface, no further
work
5 needs to be carried out, or materials used, on the skin. The skin is also
waterproof, thus obviating the need for an additional waterproof membrane
and associated protection.
Where the panels are produced from, for example, plastics materials or
metals, the panels do not absorb moisture, for example, from the settable
10 material used with the panels, which is a problem associated with some of
the
prior art panels. Therefore, the settable material can set naturally without
having moisture extracted therefrom by the panels, which could jeopardize the
strength and integrity of the settable material.
Furthermore, the snug and accurate alignment of the panels results in
15 only a fine, virtually imperceptible line delineating adjacent panels, thus
resulting in an aesthetically pleasing surface finish. The panels are also
vermin proof, which is a major consideration in many environments.
The panels of the present invention are easy to manoeuvre due to their
lightweight construction and their non-complex design avoids the alignment
20 and interlocking problems of the prior art.
The construction methods for double thickness walls according to the
present invention also enables the overall wall thickness to be less than
conventional double thickness walls, allowing larger internal floor spaces to
be
realized. This can be achieved by virtue of looping the reinforcing members in
the manner described above or by overlapping of the panels as shown in FIG
CA 02497156 2005-02-28
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21
9.
The strength of the paneling is achieved by virtue of the combination of
the panel walls, the grid of reinforcing members passing through the walls and
the efficient filling of the cells with concrete or other settable material,
which
minimizes the existence of strength reducing voids within the concrete.
A further advantage of the panels of the present invention over much of
the prior art is their simplicity of use. A wall or the like may be erected
efficiently using the panels of the present invention without a large degree
of
expertise. Consequently, the Applicants estimate that approximately 50
metres of wall approximately 3 metres in height may be erected per day using
the panels of the present invention in accordance with the described method.
Throughout the specification the aim has been to describe the
invention without limiting the invention to any one embodiment or specific
collection of features. Persons skilled in the relevant art may realize
variations
from the specific embodiments that will nonetheless fall within the scope of
the invention.
