Note: Descriptions are shown in the official language in which they were submitted.
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Title
A wall system.
Field of Invention
This invention relates to a wall system. A particularly preferred form of the
invention
relates to a wall system which can be used in the context of transportable
buildings.
Background
It is known from New Zealand patent No. 532620 (in the name Habode IP Limited)
to
create a building which can be shipped in the manner of a freight container.
The
building can then be assembled on site. Installation may involve swinging a
floor and a
roof outwards from a housing by way of pivot connections. More specifically,
the floor
may swing down and the roof may swing up. When the floor and roof have been
arranged in this way it is desirable to create a wall therebetween. It is
accordingly an
object of at least one form of the present invention to go at least some way
towards
facilitating this, or to provide the public with a useful choice. While
reference has been
made to New -Zealand patent No 532620, it should be understood that the
present
invention is not limited to buildings described in that document.
The term "comprising" or derivatives thereof, if and when used in this
document should
not be interpreted to exclude the possibility of other features.
Summary of the Invention
According to one aspect of the invention there is provided a method of
constructing at
least a part of an external weatherproof wall of a building comprising the
steps of:
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i) obtaining a structural post which has a first slot running along one side
thereof and a second slot running along an opposite side thereof, the
slots facing substantially different directions,
ii) obtaining a wall panel which has a first edge part and second edge part,
each edge part opposite the other,
iii) arranging the post so that it is substantially vertical between a roof
and a
floor with its slots running substantially vertically, and securing the post
in that disposition,
iv) arranging the wall panel so that its first edge part is fitted in the
first slot
in a watertight manner,
v) obtaining a second structural post with slots substantially the same as
for the first mentioned post and arranging and securing it between the
roof and floor so that one of the slots of that second post receives the
second edge part of the panel in a watertight manner,
vi) arranging a second panel with edge parts substantially the same as
those of the first mentioned panel so that one of the edge parts of that
second panel is within the other slot of the second post to create a
watertight fit therebetween, and
vii) repeating steps v) and vi) with but using further posts having
substantially similar slots and further panels having substantially similar
edge parts to substantially create the wall or part thereof,
the wall being such that it can be disassembled without the application of
destructive
force to the panels or posts.
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Preferably the posts are secured to the roof and floor with fixing members (eg
bolts)
and the panels are fitted to the posts without fixing members.
Preferably the slots of the posts and the edge parts of the panels are
complimentary to
enable female/male fitting therebetween.
Preferably the roof has a generally down facing channel, and an upper part of
each
post and/or an upper part of each panel is fitted into that channel. I
Preferably upper ends of the posts and/or panels are fitted into the channel
of the roof
and then swung downwards until they are substantially vertically oriented.
Preferably the channel is generally "fi" shaped.
Preferably the posts and/or panels are swung downwards onto an extrusion
forming
part of the floor after engaging the roof.
Preferably the floor has a generally shaped extrusion and a lower part of each
post and a lower part of each panel is fitted against that extrusion.
Preferably strips of sealing material are used to achieve watertight fittings
between the
panels and posts, and/or between the panels and the roof and floor, and/or
between
the posts and the roof and floor.
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Preferably the building can be disassembled and parts of the roof and floor
swung
inwards about hinges so that the building assumes the shape of a shipping
container.
According to a further aspect of the invention there is provided a
weatherproof wall or
part thereof formed according to a method as set out above.
According to a further aspect of the invention there is provided a kit of
parts suitable for
forming a weatherproof wall or part thereof by way of the method as set out
above, the
kit comprising the posts and panels, and optionally the channel and/or the
extrusion.
Description of the Drawings
Some preferred forms of the invention will now be described by way of example
and
with reference to the accompanying drawings, of which
Figure 1 is a perspective view of a portable building in a disassembled
state ready for shipping in the manner of a freight container,
Figure 2 is a perspective view of the building in a partially assembled
state,
Figures 3 & 4 are perspective views showing opposite sides of the building
when fully assembled,
Figure 5 is a perspective view of a panel used in assembling the building,
Figure 6 provides elevation views of various optional panels for use in the
building,
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Figures 7 & 8 illustrate the way panels may be erected to form a wall of the
building,
Figures 9 & 10 show a channel forming part of the building's roof in cross
section and in perspective respectively,
Figures 11 & 12 show a channel forming part of the building's floor in cross
section and in perspective respectively,
Figure 13 is a perspective view of a medial post forming part of the
building,
Figure 14 is a perspective view detailing part of the medial post,
Figure 15 is a transverse cross section view of the medial post,
Figure 16 shows perspective and cross sectional detail of a particular panel
forming part of the building,
Figure 17 is a perspective view showing detail of the way that the panel
engages the floor of the building, and
Figure 18 is a transverse cross section showing a corner post of the
building fitted with panels substantially at right angles to one
another.
Detailed Description
Figure 1 shows a portable building I in a disassembled state, substantially
arranged as
a 40 foot shipping container which conforms to ISO standards. When in its
figure 1
configuration the building 1 can be shipped as an upper or lower part of a
stack of
containers, and is thus able to withstand substantial compressive force.
Figure 2
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shows the building 1 in a partially assembled state with roof 2 and floor 3
extensions
proceeding outwards from a central part 4. When the building is in the
container
configuration shown in figure 1 the roof 2 and floor 3 extensions overlap one
another at
each side of the container. To achieve the figure 2 arrangement these roof 2
and fioor
3 extensions are swung up and down respectively by way of a series of hinges
5. As
shown in figure 2, corner posts 6 may be bolted in place to hold the floor and
roof 3
extensions with respect to one another.
When in a fully assembled state the building 1 may appear as shown in figures
3 and 4,
complete with a sun shade 7 and decking 8. The external walls of the building
are
created from a series of panels 9 and end and medial posts 6, 10. As shown,
some of
the panels incorporate windows and some do not. The pattern in which these
panels 9
are employed will depend on the requirements and preferences of the end user.
Figure 5 shows one of the panels 9 in more detail and figure 6 shows various
other
options for the panels in terms of size and shape. Figures 7 and 8 exemplify
the way
in which panels 9 and medial posts 10 are installed, either before or after
the corner
posts 6 are set in place. Referring to figure 7, a panel 9 (step 1) is taken
and is angled
(step 2) so that an upper edge 11 of the panel fits into a generally "fl"
shaped upper
channel 12 secured to the roof extension 2 (step 3). The profile of the
channel 12 is
shown in more detail in figures 9 and 10. The bottom edge 13 of the panel 9 is
then
l,.
swung down onto a lower extrusion or channel 14 which is generally r--j shaped
(step
4). The profile of the lower channel 14, which is secured to the floor
extension 3, is
shown in more detail in figures 11 and 12. The swing of the panel 9 down onto
the
lower channel 14 is interrupted when the panel is vertical by way of a water
stop or
ledge 15 (see figures 11 and 12) forming part of the lower channel 14. After
the panel
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is vertically aligned between the upper and lower channels 12 and 14 it is
slid sideways
(eg to the left of the page) to butt up against one of the posts 10 (step 5).
Referring to figure 8, a further post 10' is then taken (step 6) and inserted
between the
upper and lower channels 12 and 14, and then slid across to the panel 9 (steps
7 and
8), all in similar fashion to the way the panel 9 has been handled. Further
panels and
posts can be added in substantially the same way until the exterior wall of
the building
is complete. The arrangement is such that the sides of the posts 10/10'
provide
`female' slots for receiving complimentary `male' edges of the panels 9. These
are
fitted together in a water tight manner to prevent leaks into the interior of
the building.
Figure 13 provides more detail as to the profile of the medial posts 9. As
shown, each
post 9 has a tongue 16 at its upper end, and a further tongue 17 at its lower
end.
These tongues are bolted to the upper and lower channels 12 and 14
respectively.
Figure 14 shows a portion of the post 9 in perspective and figure 15 shows the
post in
transverse cross section.
It is not essential to start an external wall of the building from any
particular place, for
example it can be commenced from a corner of the building or from a mid
section of
the building's perimeter. The roof section 2 may need to be supported in some
way, for
example by way of a small crane or the like, until enough posts/panels are
installed to
give sufficient structural integrity to keep the roof extension 2 up.
Figure 16 provides detail of a preferred profile for the panels 9. As can be
seen, the
vertical and horizontal framing 18 of the panel is adapted to accommodate
double
cladding, whether it be in the form of panes of glass 19 or non-transparent
sheets 20
with insulation 21 therebetween. The non-transparent sheets are preferably
formed
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from plywood laminated with a suitable 'plastic aluminium' substance. Further
detail of
the panel 9 and the way it associates with the floor extension 3 is shown at
figure 17.
Figure 18 provides detail of one of the corner posts when arranged between two
panels
9 at right angles.
To assist in providing a water tight seal between the panels 9 and the rest of
the
building, the upper channels 12 are fitted with strips of rubber 22 pressed
within
generally 'C' shaped protrusions 23 (see figures 9 and 16). As shown in figure
16, the
bottom parts of the panels are sealed with respect to the lower channel 14 by
further
rubber strips 24. Rubber strips 25 or other suitable means are also employed
to seal
the panes of glass 19 and non-transparent sheets 20 with respect to the panel
framing
18. Additional rubber strips 26 (see figure 16) may also be employed to
provide a
water tight seal between the posts 6, 10 and the panels 9.
The posts 6, 10, the channels 12, 14 and the panel framing 18 may all be
formed as
aluminium extrusions or the like. While the medial and end posts 10, 6 have a
different
in transverse cross section their edge parts are preferably the same for
receiving the
panels 9. By following the installation steps described above a watertight
exterior wall
can be created in a short time, employing a pattern of panels in terms or
window
positioning which suits the preferences of an end user. The manner in which
the
exterior wall is created can be reversed so that it can be readily dismantled
and/or
modified without having to apply destructive force. Thus one does not have to
destroy
the wall to take it down or, destroy it in part and then rebuild it, to enable
disassembly
to or modification of the building. As will be appreciated, the wall can be
created by
simply bolting the posts 6, 9 in place and then slotting the panels in place,
one after the
other, without screws or bolts for the panels. Because the panels butt tightly
into and
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against the posts the rubber seals between the posts and panels ensure a
watertight
fit.
Those skilled in the art will appreciate that to enable disassembly of the
wall at least
one of the posts will have a profile slightly different to the others. As
shown at figures
14 and 15, most or the medial posts generally have an "H" profile. The post
(not
shown) which enables disassembly is similar except that it has one the "H"
tails 27
missing to give a generally "h" profile. The missing tail means that one of
the panels
can be swung outwards from the post inside the building to enable access to
the bolts
which proceed through the tongues 16 and 17 of that post. From there the wall
can be
disassembled panel after post. A capping (not shown) may be removably screwed
in
place over the area of the "missing tail" for aesthetic purposes when the wall
is in its
fully assembled state.
In some embodiments of the invention the panels 9 may have only a glass pane
or
panes, ie without a non-transparent sheet or sheets. In that case the panels
may thus
be windows only and in that event, and for the purposes of this document, the
arrangement should still be regarded as a wall or part thereof.
While some preferred forms of the invention have been described by way of
example it
should be appreciated that modifications and improvements can occur without
departing from the scope of the following claims.
