AU2007205805B2

AU2007205805B2 - A Wall Panel Assembly

Info

Publication number: AU2007205805B2
Application number: AU2007205805A
Authority: AU
Inventors: Mark Winfield
Original assignee: Pearls Miihome IP Pty Ltd
Current assignee: Pearls Miihome IP Pty Ltd
Priority date: 2007-08-14
Filing date: 2007-08-14
Publication date: 2014-07-10
Anticipated expiration: 2027-08-14
Also published as: AU2007205805A1; AU2013221996B2; AU2013221996A1

Abstract

The present invention relates to a wall panel assembly for building construction. The wall panel assembly includes a wall panel, in turn, including a core and skin layers extending along opposing sides of the core. The skin layers define one or more retainers for retaining a support. The support is retained between the retainers and the core. Typically, the skin layers define a pair of retainers for retaining opposite sides of the support within their confines. The support may be a vertically-oriented bent strip of metal. Figure 2 .9.. / *-. .1' t , . . '. 9 ci V77~ k) * .. l I a. .' . *9 *~* 4-1.*

Description

AUSTRALIA PATENTS ACT 1990 COMPLETE SPECIFICATION STANDARD PATENT A WALL PANEL ASSEMBLY The following statement is a full description of this invention including the best method of performing it known to me: .1I A WALL PANEL ASSEMBLY TECHNICAL FIELD 5 The present invention generally relates to panelized walls for building construction. BACKGROUND 10 The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge. It is advantageous to construct buildings such as houses both quickly and 15 using a minimum of materials with a view of reducing costs. Many modern buildings are constructed with prefabricated wall, floor, or roof panels that can be assembled together at the building site. Wall panels may typically include a polystyrene core and a pair of metal skin 20 layers located on either side of the core as shown, for example, in US 4,184,301 and US 4,123, 885. The wall panels define mating formations along their upright edges to facilitate mating of the wall panels together to form a panelized wall. 25 The particular construction of wall panels varies in practice. For some wall panels, downward forces on the wall panels, such as during cyclonic conditions for example, can undesirably cause the metal skin layers to peel away from the core at its extremities. 30 The wall panels may also define an upper recess in their top edge for accommodating a horizontal support beam as shown, for example, in Figure 5C of US 5,588,269. The support beam would extend along the recesses of serially arranged wall panels and be supported by the upright edges of the panels.

2 Some prefabricated wall panels may define openings such as doorways or windows. In practice, the support beam extending along the upper recesses defined in the serially arranged panels can act as a lintel to provide additional support to wall panel portions proximal to the openings. 5 SUMMARY OF THE INVENTION According to one aspect of the present invention, there is provided a wall panel assembly for building construction, the wall panel assembly including: 10 a wall panel including: a core having opposing sides and an edge portion extending between the opposing sides, the edge portion comprising a pair of outer faces and a core recess defined between the outer faces; and skin layers extending along the opposing sides of the core, the 15 skin layers defining one or more retainers, and the core recess being defined between the retainers; and a support for being retained at least partially within the core recess, wherein the support defines a support recess for being received within the core recess. 20 The skin layers may define a pair of retainers. The support may include a restrictor which can engage with the retainers to restrict separation between the retainers. The restrictor may define a pair of peripheral retaining feet portions for extending into respective retainers. 25 The support may define a support recess for being received within a wall panel recess. The support may be elongate and define: 30 a crotch portion defining a base of the support recess; a pair of parallel thigh portions for extending from the crotch portion to define opposite walls of the support recess; a pair of shin portions for oppositely extending from respective thigh portions and along the wall panel; and 3 the pair of parallel retaining feet portions for extending from the shin portions and into respective retainers. The support may include a pair of foldable tab portions at either end. 5 The wall panel may define a pair of grooves at an opposite end to the retainers. Each retainer may form a tongue for engaging with a corresponding groove of another wall panel. 10 The specification also describes a wall panel assembly for building construction, the wall panel assembly including: a wall panel defining an elongate wall panel recess; and a support defining a support recess for locating within the wall panel recess and for receiving a bearer. 15 The bearer may be a lintel or a horizontal beam. The wall panel assembly may further include the bearer received within the support recess so as to be superposed with an opening defined in the wall panel. The support may be of greater length than the bearer. The support may substantially span the length 20 of the wall panel. In one embodiment, the support includes a cover for covering the wall panel. The cover may be elongate and define a pair of peripheral retaining feet portions for extending downwardly on either side of the wall panel. 25 The support may be elongate and define: a crotch portion defining a base of the support recess; a pair of parallel thigh portions for extending upwardly from the crotch portion to define opposite walls of the support recess; 30 a pair of shin portions for oppositely extending from respective thigh portions and along the top of the wall panel; and the pair of parallel retaining feet portions for extending downwardly from the shin portions.

3a The wall panel recess may include a gutter formed in the middle of a top edge of the wall panel. The wall panel may define an opening. The opening may be either a doorway 5 or a window.

4 The panel may include a core and a pair of skin layers located on either side of the core. The core may be formed from polystyrene material. Each skin layer may be formed from metal material. 5 The wall panel assembly may further include fastening means for fastening the support to the wall panel. The fastening means may include a plurality of nails or screws. According to another aspect of the present invention, there is provided a 10 building including the wall panel assembly. According to another aspect of the invention, there is provided a method for assembling a wall panel assembly for building construction, the wall panel assembly having a wall panel including a core and skin layers sides of the 15 core, the skin layers defining one or more retainers and a support for being retained between and the core, the method including the steps of: orienting the wall panel into an upright position; positioning the vertical support between the skin layers. 20 BRIEF DESCRIPTION OF THE DRAWINGS Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed 25 Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows: Figure 1 is a sectional plan view of a prefabricated wall panel; 30 Figure 2 is a sectional plan view of a panelized wall including a pair of separated wall panel assemblies in accordance with an embodiment of the present invention; 5 Figure 3 is a perspective view showing a vertical support for one of the wall panel assemblies of Figure 2; Figure 4 is a sectional side view of a house including the wall panel 5 assemblies of Figure 2; Figure 5 is a sectional side view of an upper portion of one of the wall panel assemblies of Figure 2; 10 Figure 6 is a perspective view of an upper portion of the wall panel assemblies of Figure 2; Figure 7 is a perspective view of the corner of a house wall including a pair of wall panel assemblies in accordance with the embodiment; 15 Figure 8 is a perspective view of an upper corner of one of the wall panel assemblies of Figure 2; Figure 9 is a partially-sectioned front view of a house including the wall panel 20 assemblies of Figure 2; and Figure 10 is a sectional side view of a house showing further wall panel assembly embodiments in accordance with the present invention. 25 DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Figure 1 shows a type of prefabricated wall panel 2 for constructing a panelized wall of a house. The wall panel 2 includes a planar core 4 and a pair of skin layers 6a,b attached to either side face of the core 4. The core 4 is 30 made from polystyrene material and the skin layers 6 are formed from metal material. The core 4 defines an endless gutter or recess 8 which extends around each of its four edges. Each skin layer 6 extends beyond the core 4 to define a tongue 10 at one vertical edge of the panel 2. Each skin layer 6 also 6 defines a groove 12 at the other vertical edge. Each groove 12 can form a complementary fit with a corresponding tongue 10 of an adjacent wall panel 2. A pair of separated wall panels 2 is shown in Figure 2 which can be engaged 5 together when forming the panelized wall. Adjacent wall panels 2 can be pushed together in upright positions, edge to edge, so that the pair of tongues 10a,b engage in respective grooves 12a,b to facilitate lateral stability of the panelized wall. 10 According to an embodiment of the present invention, there is provided a wall panel assembly 20 as shown in Figure 2. The wall panel assembly 20 includes the wall panel 2 and a vertical support 22 for being retained between the tongues 10a and the core 4. Gaps are defined between respective free ends of the skin layers 6a,b and the core 4. In use, the vertical support 22 can 15 be slid into the gaps to support the wall panel 2 at its edge, and is retained between the tongues 10a,b and the core 4. Turning briefly to Figure 3, the vertical support 22 is elongate and can be formed by bending a strip of metal sheet. The vertical support 22 is symmetric 20 and defines a vertical support recess which, in turn, can be received within the wall panel recess 8. Examining the shape of the vertical support 22 in detail with particular reference to Figure 2, the support 22 generally defines: a crotch panel 24 25 defining a base of the vertical support recess; a pair of parallel thigh panels 26 extending from the crotch panel 24 to define opposite walls of the vertical support recess; a pair of shin panels 28 oppositely extending from respective thigh panels 26 and along the vertical edge of the wall panel 2; and a pair of parallel retaining feet panels 30 extending from the shin panels 28 and behind 30 respective tongues 10. The vertical support 22 restricts separation between the tongues 10 by virtue of the feet panels 30 being received in respective tongues 10. In use, the skin layers 6 are thereby impeded from peeling away from the core 4 along the 7 vertical edges of the wall panel 2 by the retaining feet panels 30. In turn, the separation of the grooves 12 is also restricted by virtue of the tongues 10 being mated within the grooves 12. 5 The vertical support 22 further defines a pair of foldable tabs 32 which extend from either end of the crotch panel 24. Each mounting tab 32 defines a mounting hole 34 and its function is described in detail below. Figure 4 shows a house 40 including the panelized wall formed from serially 10 arranged wall panel assemblies 20. The wall panel 2 defines a window 42. The wall panel assembly 20 includes a horizontal support 44, in turn, defining a horizontal support recess. The horizontal support recess is received within the wall panel recess 8 extending along the top edge of the wall panel 2. A horizontal beam or bearer 46 is received within the support recess of the 15 horizontal support 44 to form an even bearing face for bearing the weight of a roof truss 48. Turning to Figure 5, the horizontal support 44 covers or caps the top of the wall panel 2. The horizontal support 44 is elongate, symmetric and can be 20 formed by bending a strip of metal sheet. Examining the shape of the horizontal support 44 in detail, the support 44 defines: a crotch panel 50 defining a base of the horizontal support recess; a pair of parallel thigh panels 52 extending upwardly from the crotch panel 50 to define opposite walls of the horizontal support recess; a pair of shin panels 54 oppositely extending from 25 respective thigh panels 52 and along the top edge of the wall panel 2; and a pair of parallel retaining feet panels 56 extending downwardly from the shin panels 54. The retaining feet panels 56 contain the skin layers 6a,b and impede the skin 30 layers 6 from peeling away from the core 4 at the top edge of the wall panel 4. Returning briefly to Figure 4, the wall panel assembly 20 further includes a base channel member 58 fast with a concrete slab 60 of the house 40. The base of the wall panel 2 rests in the channel member 58 so that the skin 8 layers 6 are also impeded from peeling away from the core 4 at the bottom edge of the wall panel 4. As can best be seen in Figure 6, the wall panel assembly 20 further includes a 5 plurality of fasteners 62 for fastening the horizontal support 44 to the wall panel 2. Each fastener may be a nail or a screw which extends through a foot panel 56 of the support 44, the skin layer 6 and into the core 4. As can best be seen in Figure 6, the horizontal support 44 extends along the 10 entire length of the top edge of the wall panel 2. However, the bearer 46 need not extend along the entire length of the horizontal support recess 64 defined by the horizontal support 44. Turning now to Figure 7, the bearer 46 can be received within the horizontal 15 support recess 64 and superposed with the window 42 defined in the wall panel 2. In this manner, the bearer 46 effectively forms a lintel for the window 42. The horizontal support 44 spans the entire length of the wall panel 2. The bearer 46 need not extend along the entire length of the horizontal support recess 64 (and therefore the horizontal support 44), thereby saving on bearer 20 material, and the horizontal support 44 provides the additional support required to support the roof truss 48. Bearers 46 can be located within adjoining horizontal supports 44, fitted to respective wall panels 2, so that they are superposed with any openings such 25 as windows and doorways. Common bearers 46 need not continuously extend between multiple wall panels 2 and can instead be superposed with openings only so as to effectively form a segmented lintel. Figure 8 shows an upper corner of the wall panel assembly 20 in detail. The 30 horizontal support 44 is fitted to the top edge of the wall panel 2, within the horizontally extending wall panel recess, and supports the bearer 46. The vertical support 22 is fitted to the side edge of the wall panel 2, within the vertically extending wall panel recess, and is retained between the tongues 1Oa,1Ob and the core 4 of the wall panel 2.

9 The shank of a threaded bolt 70 extends through the tubular bearer 46, horizontal support 44, and the top mounting tab 32 of the vertical support 22 (via mounting hole 34). A nut can be fastened to the threaded tail of the bolt 5 70 to hold the bearer 46, horizontal support 44 and the top mounting tab 32 together. Similarly, the bottom mounting tab 32 of the vertical support 22 can be fastened to the concrete slab 60 of the house 40 using an embedded shaft and nut arrangement 72. 10 Figure 9 shows the house 40 including the wall panel assembly 20. A person skilled in the art will appreciate that many embodiments and variations can be made without departing from the ambit of the present invention. 15 In the preferred embodiment, the wall panel core 4 defined a central recess 8 or gutter in its top edge (see Figure 10b). The horizontal support 44 was received in the central recess 8 and covered the top of the wall panel 2. In turn, the bearer 46 was received within a horizontally extending support 20 recess defined by the horizontal support 44. In alternative embodiments, an upper recess may be defined at a top corner of the wall panel 2 and may be either external or internal to the house 40 as shown in Figures 10a and 10c respectively. In each case, a horizontal support 25 44 defining a support recess is located within the elongate wall panel recess. In turn, the support recess receives a bearer 46. The horizontal support 44 covers the wall panel 2 and defines downwardly extending retaining feet panels at its periphery. 30 In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of 10 its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

Claims

1. A wall panel assembly for building construction, the wall panel assembly including: a wall panel including: a core having opposing sides and an edge portion extending between the opposing sides, the edge portion comprising a pair of outer faces and a core recess defined between the outer faces; and skin layers extending along the opposing sides of the core, the skin layers defining one or more retainers, and the core recess being defined between the retainers; and a support for being retained at least partially within the core recess, wherein the support defines a support recess for being received within the core recess.

2. A wall panel assembly as claimed in claim 1, wherein the skin layers define a pair of retainers.

3. A wall panel assembly as claimed in claim 2, wherein the support includes a restrictor which can engage with the retainers to restrict separation between the retainers.

4. A wall panel assembly as claimed in claim 3, wherein the restrictor defines a pair of peripheral retaining feet portions for extending into respective retainers.

5. A wall panel assembly as claimed in claim 1, wherein the support is elongate.

6. A wall panel assembly as claimed in claim 5, wherein the support defines: a crotch portion defining a base of the support recess; a pair of parallel thigh portions for extending from the crotch portion to define opposite walls of the support recess; 12 a pair of shin portions for oppositely extending from respective thigh portions and along the outer faces; and a pair of parallel retaining feet portions for extending from the shin portions and into respective retainers, wherein the shin portions extend between respective thigh portions and respective feet portions.

7. A wall panel assembly as claimed in claim 5, wherein the support includes a pair of foldable tab portions at either end.

8. A wall panel assembly as claimed in claim 1, wherein the skin layers define a pair of retainers at one end and the wall panel defines a pair of grooves at an opposite end to the retainers.

9. A wall panel assembly as claimed in claim 8, wherein each retainer forms a tongue for engaging with a corresponding groove of another wall panel.

10. A wall panel assembly as claimed in any one of the preceding claims, wherein the wall panel defines an elongate wall panel recess; and the assembly further includes a further support defining a further support recess for locating within the wall panel recess and for receiving a bearer.

11. A wall panel assembly as claimed in claim 10, further including the bearer received within the further support recess so as to be superposed with an opening defined in the wall panel.

12. A wall panel assembly as claimed in claim 10, wherein the further support includes a cover for covering the wall panel, and the cover is elongate and defines a pair of peripheral retaining feet portions for extending downwardly on either side of the wall panel.

13. A wall panel assembly as claimed in any one of the preceding claims, wherein a base portion of the core recess is substantially planar. 13

14. A wall panel assembly as claimed in any one of the preceding claims, wherein the core recess is substantially rectangular in cross section.

15. A wall panel assembly as claimed in any one of the preceding claims, wherein the support is formed of folded material.

16. A wall panel assembly as claimed in any one of the preceding claims, wherein the support is formed of folded sheet metal.

17. A wall panel assembly as claimed in any one of the preceding claims, wherein the support is retained partially within the core recess and extends outwardly from respective sides of the support recess and along the outer faces.

18. A wall panel assembly as claimed in any one of the preceding claims, wherein the outer faces lie in a common plane.

19. A wall panel assembly as claimed in claim 20 or 21, wherein the support is formed with 90 degree folds.

20. A wall panel assembly as claimed in claim 20 or 21, wherein the support recess is defined by parallel folds.