Note: Descriptions are shown in the official language in which they were submitted.
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BUILDING PANELS AND BUILDING SYSTEM USING SUCH PANELS
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.
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[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.
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[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.
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[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 lOmm and 150mm wide by lOmm to 150mm thick and
approximately between about 1200mm long to about 3600mm 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 50mm wide and between 2mm and 5mm depth.
Preferably the recess is between 35 and 40mm wide and between 2.0mm to 5mm
deep, and more preferably 37mm wide and 2.0mm deep.
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[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 2400mm, 2700mm or 3000mm high, and 1200mm wide, each with
a respective aperture centre at 400mm 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
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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 600mm centres, holes are provided in the floor to insert 45
degree
200mm 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
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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
600mm
or 1200mm 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] Figures la and lb show a building panel according to an embodiment
of the present invention.
[0039] Figures 2a and 2b show a building panel according to an embodiment
of the present invention.
[0040] Figures 3a and 3b show a building panel according to an embodiment
of the present invention.
[0041] Figures 4a and 4b show a building panel according to an embodiment
of the present invention.
[0042] Figures 5a and 5b show a building panel according to an embodiment
of the present invention.
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[0043] Figures 6a and 6b show a building panel according to an embodiment
of the present invention.
[0044] Figures 7a and 7b show a building panel according to an embodiment
of the present invention.
[0045] Figures 8a and 8b show a kitchen building panel according to an
embodiment of the present invention.
[0046] Figure 9 shows a building panel arrangement for a doorway
according
to an embodiment of the present invention.
[0047] Figures 10 and 11 show installation arrangements for a building
system incorporating panels according to an embodiment of the present
invention.
[0048] Figure 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] Figure 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] Figures 14 to 16 show top/bottom end views of a panel according to
alternative embodiments of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENT
[0051] Figures la through 8b show alternative building panels according
to
embodiments of the present invention.
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[0052] Figures la and lb 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] Figures la and lb 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] Figures 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.
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[0059] Figures 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 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 corner. With the central recess sufficiently
wide,
new edge recesses are formed.
[0060] Figures 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 figure 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] Figures 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 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, Figures 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 Figures 5a,5b, but in the factory to save material.
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[0064] Figures 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 Figures 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] Figure 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] Figure 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 68The 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 Figure 11, the building
panel
lOslots into a top channel 80 and bottom channel 62. The bottom channel is
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fastened directly into the concrete floor 66. The top channel is fixed
directly to the
ceiling beam 90.
[0070] Figure 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] Figures 13 to 16 show alternative forms of panels according to
embodiments of the present invention.
[0072] Figure 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 200mm and a width F preferably of 100mm, 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 190mm wide by 90mm 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] Figure 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 90mm depth G and
90mm 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 90/90mm steel or timber posts, or allow room for smaller
dimensioned posts and electrical and/or plumbing utilities.
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[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 50mm length by 30mm
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
150mm, 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] Figure 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] Figure 16 shows a further preferred embodiment of the panel 200
with
oval utility passageways 204 through the core as described in relation to
figure
14. These are preferably inset with their respective centres 150mm from the
edge of the panel, as indicated at J in Figure 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 50mm (K) by 30mm
(L) as shown in Figure 16, though other dimensions can be selected within the
core of the panel as required for a particular application.
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.
