AU2004233550A1 - A Building Panel and System - Google Patents

Description

0 0 A BUILDING PANEL AND SYSTEM oField of the Invention.

The present invention relates to building systems and in particular to o methods and apparatus for attaching a prefabricated wall to the frame of a building or other structure.

oBackground Art.

t Systems for building are well known and a wide variety of types of n system are available. Perhaps the most common building system is that used for Sconstruction of houses and other smaller structures and is known as a block wall construction.

Building blocks have been used for centuries to construct homes, office buildings, churches, and many other structures. Early building blocks were hewn from stone into appropriate shapes that were assembled together, typically using mortar, to form a wall. In modem times, various types of concrete blocks have been developed, which are typically formed by pouring a cement-based concrete mixture into a form and allowing the concrete to cure.

Generally, a block wall is assembled by first placing a layer of mortar upon the surface of a foundation. The blocks are then individually positioned in the mortar by a person such that a one-half inch layer of mortar is between each block and the foundation, and a one-half inch thick section of mortar separates end walls of adjacently positioned blocks to form a first tier of blocks conforming to the foundation design. The blocks are aligned and levelled by the individual by tapping upon respective upper, side or end walls until adjacent blocks are linearly arranged.

This process is obviously very time consuming and expensive.

This type of concrete block is strong and makes for a sturdy wall, but installing a traditional concrete block requires a skilled mason that must manually lift each block, and set each block using mortar to secure the blocks in place. This process is very labour-intensive.

While several different block designs have been used in the art, most of these are relatively small blocks that a construction worker must manually lift and put in place. Most require mortar.

This problem has been partially overcome by the provision of mortarless wall systems. The blocks in a course have inter-engaging small projections 2 0 and recesses to engage with complementary recesses and projections of the adjacent lateral blocks to prevent lateral displacement of the blocks in the course. Certain blocks of the course are also provided with small projections and recesses to engage o with the blocks of a course beneath and/or above, to prevent lateral displacement of the courses.

o Installation of the blocks in a mortarless wall is also time-consuming '4Th because they must follow an appropriate pattern to match with the positions of the en hanging members and the supporting structure.

A further type of building system uses an external cement rendered wall system with a built-in insulating quality. The system uses a panel of layered construction with four elements. The first layer is an enhanced expanded polystyrene insulation board impregnated with an insect repellent compound and fire retardant.

This is mechanically fixed to the timber or steel stud frame or a reinforced concrete or masonry wall. The surface of the polystyrene insulation layer is etched and primed ready to accept the reinforced render. The polystyrene layer is located abutting the stud frame of the building and is attached there using screws applied through the polystyrene layer. The remaining layers are then applied.

The second layer is a polymer modified cement render material, reinforced with alkali resistant fibreglass 1 60g mesh. The third layer is finished render. This render material is a polymer modified cement render, creating an excellent adhesion and strength. The outer layer is an acrylic membrane. This is a 100% acrylic tinted texture finish allowing the outside of the panel to be coloured or textured.

Panel walls such as these offer excellent thermal properties as well as sound insulation. They are much more quickly assembled than block walls, whether mortarless or not. They are lightweight with excellent impact strength and offer a wide variety of finishes to match a user's requirements.

However, the construction of systems such as the above panel system requires that the layers of the panel be applied on site once the polystyrene base material is in place on the stud frame. This causes additional delay as the render and acrylic layers canrnot be applied until the polystyrene layer is in place or the screw attachments would be required to be inserted through the render layers as well. This would affect the sealing capabilities of the wall.

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0 It would also be desirable for a building system to have the attributes of the panel system discussed above and to have an attractive, finished look that does not require covering or painting, but that also could be stained to look like many different o types of rocks or stones or to match a desired colour scheme, which is easy to fit and requires only minimal construction on site.

oIt will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part Cf of the common general knowledge in the art in Australia or in any other country.

Summary of the Invention.

The present invention is directed to a building system and apparatus, which may at least partially overcome at least one of the abovementioned disadvantages or provide the consumer with a useful or commercial choice.

In one form, the invention resides in a building panel including a sheet member with two substantially planar surfaces, the sheet member having a plurality of bracket members attached thereto relative to a first planar surface, each bracket member attached relative to the sheet member using an attachment assembly, at least part of which extends at least partially through the sheet member.

In a second form, the invention resides in a method for manufacturing a building panel including the steps of providing a sheet member having two substantially planar surfaces, applying rail members to a first planar surface of the sheet member using an attachment assembly, at least part of which extends at least partially through the sheet member, applying a layer of material to the second planar surface and attaching a plurality of bracket members relative to rail members to facilitate attachment of the building panel to a building frame.

The building panel according to the invention will preferably be manufactured in standard dimensions and one example of these dimensions is 5000mm in length by 2400mm in height. Other dimensions may be used.

The building panel according to the invention will suitably be adapted to be attached to the timber frame of a building during construction thereof.

The sheet member will preferably be a single layer to which other layers can be applied. Typically, a finished sheet member may have a layered construction with four layers. The first layer may be an enhanced expanded polystyrene insulation board impregnated with an insect repellent compound and fire 4

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0retardant. This layer may form the base to which the other layers are applied. The second surface of the polystyrene insulation layer is preferably etched and primed ready to accept a reinforced render layer to cover the attachment means. The o polystyrene layer is suitably located adjacent the stud frame of the building and is attached there using the brackets and attachment means secured through the 0polystyrene layer. The remaining finishing layers can then be applied to the sheet tf member.

n The first layer is generally between 1cm and 20cm in thickness. The first layer is the sheet member to which the attachment assembly is suitably attached.

All remaining layers are preferably located adjacent the second surface of the panel. The second layer is suitably a polymer modified cement render material, reinforced with alkali resistant fibreglass 160g mesh. The third layer is suitably finished render. This render material is preferably a polymer modified cement render, creating an excellent adhesion and strength. The outer layer is typically an acrylic membrane. This could be a 100% acrylic tinted texture finish allowing the outside of the panel to be coloured or textured. Any of the layers may be painted to finish the panel's appearance. The render layer is generally approximately between 2mm and in thickness.

The first planar surface of the panel may also be coated with one or more layers of material. Suitably, the first planar surface may have a protective surface treatment applied to it.

The sheet member has a plurality of bracket members attached thereto relative to a first planar surface. Each bracket member is attached relative to the sheet member using an attachment assembly. At least part of the attachment assembly extends through the sheet member from the second planar surface.

Preferably, each bracket is attached to an attachment assembly. Each attachment assembly may include a channel member which is in turn attached to the sheet member. The channel is typically attached to the first side of the first layer using a plurality of elongate attachment members. Each elongate attachment member suitably extends through the first layer from the second side of the first layer to make the attachment more secure by the anchorage of the members through the first layer.

Typically, the elongate members extend from a second side of the first layer, through 0 the thickness of the first layer to secure the channel to the first side of the first layer.

The remaining finishing layers may then be applied over the first layer.

Typically, each elongate attachment member. may be provided with an oenlarged head portion. This enlarged head portion may prevent the attachment members being pulled through the first layer of the sheet member when force is O applied. The elongate attachment members suitably extend through the first layer iwith enlarged head portions on the second side of the first layer and the channel on the n first side. Annular members or washers, typically plastic, may be associated with the enlarged head portions of the attachment members to increase the effective surface O 10 area of the head portions to which forces can be spread. Typically, the attachment members will be screws or the like. The screws will typically be electroplated.

The channel members may each have a substantially U-shaped crosssection, having a pair of sidewalls, each with a free end, and a base wall. The base wall is preferably the portion to which the elongate attachment members are secured.

There may be a lateral flange extending outwardly from the free end of the sidewalls of the channel.

There will generally be more than one channel member attached to each sheet member. Typically, the channel members will be spaced over the height of the sheet member by distances calculated relative to the thickness of the sheet member. For example, for a panel 2400 mm in height and having a first layer in thickness, the spacing may be approximately 600mm between the centres of the channels. As the thickness of the first layer of the sheet member increases, the centres of the channels can be spaced further apart, and as the thickness of the first layer of the sheet member decreases, the centres of the channels can be more closely spaced.

The channel members are preferably oriented parallel to the length of the panel. In most structures, the frame members are oriented substantially vertically and by orienting the channel members lengthwise, the bracket members can be placed on the channel members to account for the different spacings between frame members. However, it is anticipated that the channel members may be angled relative to the frame members and still function as required.

The brackets will suitably be manufactured from galvanised iron or a similar material. The brackets will generally have a substantially U-shaped portion with a pair of spaced apart sidewalls adapted to receive a frame member of a building 6 0 between them, and a channel attachment portion. The sidewalls will typically have at least one opening therein to allow a nail or similar securing members to be driven through the opening and into the frame member to secure the panel relative to the oframe.

The channel attachment portion is suitably correspondingly shaped to attach, and be secured, to the flanges of the channel. Generally, the channel t attachment portion will include a pair of wall members which are designed to fit over n the flanges of the channel to secure the bracket to the channel. The brackets are suitably attached to the channels after the panel is delivered to the site to facilitate flat packing of the panels during transport. The brackets preferably snap fit onto the channel or they may be slid onto the channel.

More than one panel according to the invention will generally be used in construction of a building and once fitted in place, the only further work required may be sealing of the edges of the panels to each other or to the surrounding surfaces such as the slab and/or upper extremity.

When panels according to the invention are used, a decrease in the amount of time spent in the construction may be realised as the panels may be transported on site and once in place and the brackets secured to the frame members of the building, there is suitably nothing further required. This is due to the rail members being secured to the panel during the manufacture of the panel and the panel already being provided with the outer finishing layers prior to the transport of the panels to the building site.

Brief Description of the Drawings.

Various embodiments of the invention will be described with reference to the following drawings, in which: Figure 1 is a side elevation view of a panel according to a preferred embodiment of the invention, with representative dimensions.

Figure 2 is a side elevation enlarged detail view of a bracket member and attachment assembly according to a preferred embodiment of the invention.

Figure 3 is an elevation view of a first side of a panel according to the present invention with the brackets not attached.

Figure 4 is an elevation view of a second side of the panel illustrated in Figure 3 with representative dimensions.

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Detailed Description of the Preferred Embodiment.

oAccording to a preferred aspect of the present invention, a building panel 10 and system is provided.

o As illustrated in Figures 1 and 2 in particular, the building panel of the preferred embodiment includes a sheet member 11 with two substantially planar Osurfaces (illustrated in Figures 3 and 4).

IC The panel member 10 is a single layer to which other layers are n applied. A finished sheet member according to the preferred embodiment has a layered construction with four layers. The first layer 14 is an expanded polystyrene O 10 insulation board impregnated with an insect repellent compound and fire retardant.

This layer 14 forms the base to which the other layers are applied and also is the simplest form of the sheet member 11 to which the attachment assembly is attached.

The outer surface of the polystyrene insulation layer 14 is etched and primed ready to accept a reinforced render layer to cover the attachment means used to attach the brackets 12 to the sheet 11. During construction, the polystyrene layer 14 is suitably located adjacent the stud frame 13 of the building and is attached there using the brackets 12 and attachment means secured through the polystyrene layer 14. The remaining finishing layers can then be applied to the sheet member 11.

The first layer is generally approximately 60mm in thickness.

The remaining layers are applied to the second or outer surface of the panel. The second layer is suitably a polymer modified cement render material, reinforced with alkali resistant fibreglass 160g mesh. The third layer 15 is suitably finished render. This render material is preferably a polymer modified cement render, creating an excellent adhesion and strength. The outer layer is typically an acrylic membrane or paint. This could be a 100% acrylic tinted texture finish allowing the outside of the panel to be coloured or textured. The render layer is generally approximately 6mm in thickness.

The panel 10 of the preferred embodiment is 5000mm in length by 2400mm in height. The building panel 10 is provided with bracket members 12 adapted to be attached to the timber frame 13 of a building during construction thereof.

The sheet member 11 has a plurality of bracket members 12 attached thereto relative to a first inner surface. Each bracket member 12 is attached relative to 8

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0 the sheet member using an attachment assembly and at least part of the attachment assembly extends through the sheet member 11 from the second outer surface.

Each attachment assembly of the preferred embodiment includes a channel member 16 which is attached to the sheet member 11. The channel 11 is attached to the inner surface of the panel using a plurality of elongate attachment o members, generally screws. Each screw extends through the first layer from the outer surface of the first layer to make the attachment more secure by the anchorage of the n members through the first layer. Each screw has an enlarged head portion. Annular Smembers or washers 17, typically plastic, are associated with the enlarged head O 10 portions of the screw to increase the effective surface area of the head portions to which forces can be spread.

The remaining finishing layers are then applied over the outer surface of the first layer, covering the screw head and the washers 17.

The channel members 16 each have a substantially U-shaped crosssection, having a pair of sidewalls, each with a free end, and a base wall. The screws extending through the panel attach to the base wall. There is a lateral flange extending outwardly from the free end of the sidewalls of the channel 16.

There is a plurality of channel members 16 attached to each sheet member, as seen in Figure 3. The channel members 16 are spaced over the height of the sheet member 11, the separation between the members 16 calculated relative to the thickness of the sheet member 11. For example, for a panel 2400 mm in height and having a first layer 60mm in thickness, the spacing is approximately 600mm between the centres of the channels 16.

The channel members 16 are oriented parallel to the length of the panel. In most structures, the frame members 13 are oriented substantially vertically and by orienting the channel members 16 lengthwise, the bracket members 16 can be adjusted on the channel members to account for the different spacings between frame members 13.

The brackets 12 are manufactured from galvanised iron or a similar material. Each bracket 12 has a substantially U-shaped portion with a pair of spaced apart sidewalls adapted to receive a frame member 13 of a building between them, and a channel attachment portion. The sidewalls have opening 18 therein to allow a nail 9 0 or similar securing member to be driven through the opening 18 and into the frame member 13 to secure the panel 10 relative to the frame 13.

The channel attachment portion is correspondingly shaped to attach, oand be secured, to the flanges of the channel member 16. Generally, the channel attachment portion includes a pair of wall members which are designed to fit over the O flanges of the channel member 16 to secure the bracket 12 to the channel 16. The I brackets 12 are suitably attached to the channels 16 after the panel is delivered to the e site to facilitate flat packing of the panels 10 during transport. The brackets 12 ipreferably snap fit or slide onto the channel 16.

O 10 In use, the panels are manufactured with the channels attached thereto and then the render layer applied to finish the panels. They can then be transported to the building site. Once on site, the bracket members are fitted to the channels and the panels placed adjacent the frame to which it is to be attached. The position of the bracket members can then be adjusted to match the frame member spacings and the brackets are then nailed or screwed to the frame. No further finishing except about the edges of the panel is required.

In the present specification and claims, the word "comprising" and its derivatives including "comprises" and "comprise" include each of the stated integers but does not exclude the inclusion of one or more further integers.

Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

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 its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

Claims (21)

1. A building panel including a sheet member with two substantially planar surfaces, the sheet member having a plurality of bracket members attached o thereto relative to a first planar surface, each bracket member attached relative to the sheet member using an attachment assembly, at least part of which oextends at least partially through the sheet member. t

2. A building panel according to claim 1 wherein the sheet member has a layered econstruction.

S3. A building panel according to claim I or claim 2 wherein the sheet member includes an expanded polystyrene layer.

4. A building panel according to any one of the preceding claims wherein one surface of the sheet member is etched and primed to accept a render layer.

A building panel according to any one of the preceding claims wherein a portion of the attachment assembly extends through the sheet member and a finishing layer is applied to the sheet member to cover an expose portion of the attachment assembly.

6. A building panel according to claim 1 wherein the sheet member is a single layer to which other layers can be applied.

7. A building panel according to any one of claims 4 to 6 wherein applied layers are located adjacent an outer surface of the panel.

8. A building panel according to claim 7 wherein a second layer of polymer modified cement render material, reinforced with fibreglass mesh is applied.

9. A building panel according to claim 8 wherein a third layer of finished render is applied.

10. A building panel according to claim 9 wherein the third layer is a polymer modified cement render material.

11. A building panel according to either claim 9 or 10 wherein an outer layer of acrylic membrane is applied.

12. A building panel according to any one of the preceding claims wherein an inner surface of the sheet member has a protective surface treatment applied to it.

13. A building panel according to any one of the preceding claims wherein each attachment assembly includes a channel member attached to the sheet member, 11 O O 0 attached to an inner side of the sheet member using a plurality of elongate attachment members, each elongate attachment member extending through the sheet member from an outer portion of the sheet member.

14. A building panel according to claim 13 wherein the elongate attachment members each have an enlarged head portion, and extend through at least one O layer of the sheet member with finishing layers applied over the at least one layer to cover the enlarged head portions. n

15. A building panel according to claim 14 further including annular members I associated with the enlarged head portions of the attachment members. O 10

16. A building panel according to any one of claims 13 to 15 wherein the channel members each have a substantially U-shaped cross-section, having a pair of sidewalls, each with a free end and a lateral flange extending outwardly from the free end and a base wall to which the elongate attachment members attach.

17. A building panel according to any one of claims 13 to 16 wherein more than one channel member is attached to each sheet member, the channel members spaced over the height of the sheet member by distances calculated relative to the thickness of the sheet member.

18. A building panel according to any one of the preceding claims wherein the brackets have a substantially U-shaped portion with a pair of spaced apart sidewalls adapted to receive a frame member of a building between them.

19. A building panel according to claim 18 when dependant on either claim 16 or 17 wherein the bracket members further include a channel attachment portion, correspondingly shaped to attach, and be secured, to the flanges of the channel.

A method for manufacturing a building panel including the steps of providing a sheet member having two substantially planar surfaces, applying channel members to a first planar surface of the sheet member using an attachment assembly, at least part of which extends at least partially through the sheet member, applying a layer of material to the second planar surface and attaching a plurality of bracket members relative to rail members to facilitate attachment of the building panel to a building frame.

21. A method according to claim 20 wherein the panel is manufactured with the channel members attached thereto and the layer of material is applied to finish the panel, prior to transport to a building site, once on site, fixing the bracket 12 O 0 members to the channel members and fixing the panel adjacent the frame to Swhich it is to be attached. Dated this 1 st day of December 2004 Poly Products Aust Pty Ltd SBy its Patent Attorneys in CULLEN CO Cc, 0 0 ci