AU2006100786A4 - A Panel - Google Patents

Description

A PANEL FIELD OF THE INVENTION The present invention relates to panels and particularly to lightweight prefabricated panels used in building construction.

BACKGROUND ART NSystems for buildings are well known and a wide variety of types of systems are available. Perhaps the most common building system is that used for construction of houses and other smaller structures and is known as a block wall

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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 interengaging small projections 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 with the blocks of a course beneath and/or above to prevent lateral displacement of the courses.

Installation of the blocks in a mortarless wall is also time-consuming IN because they must follow an appropriate pattern to match with the positions of the 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

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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.

Further layers are then added to complete the wall panel such as finished render. This render material is a polymer modified cement render creating an excellent adhesion and strength.

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.

One of the main problems in the use of the prior art panel walls is the adhesion between the panel and the render material. It is known in the art to use a chemical bonding agent to increase the quality and strength of the bond between the panel and the render material but these chemicals are expensive and also add to the environmental impact of the wall panel, particularly the long term effects when the building is demolished.

Polystyrene board specifically for the external cladding of buildings have previously consisted of flat or minimally textured surfaces with few if any systems for joining subsequent sheets. The invention has been specifically developed in order to provide an improved individual polystyrene board which forms the basis for a simple, effective, integrated cladding system and an improved surface texture for the bonding of external treatments.

OBJECT OF THE INVENTION The present invention is directed to a panel, which may at least partially overcome the abovementioned disadvantages or provide the consumer with a useful or commercial choice.

In one form, the invention resides in a panel for use in building or 0N construction, the panel including a first face and a second face separated by the thickness of the panel, such that at least one of the first or second faces provided with 2at least one portion of surface texturing adapted to provide increased surface area for Sbonding external treatments to the panel.

N 10 The panel of the invention may be manufactured in any shape desired.

Preferably however, the panel of the preferred embodiment will be substantially rectangular. In this configuration, the panel will typically have a first face, and an opposed second face which are generally parallel to each other. The panel will also preferably have a pair of opposing end edges and a top and a bottom edge.

The panel may be manufactured from a material which is both lightweight and strong. For this reason, a light metal may be used but a plastics material is more preferred. The most preferred material used in construction is expanded polystyrene but other plastics material can be used.

The panel may include one or more layers of material and the layers of material may be different to one another. For example, the panel may include reinforcement material, an anti-termite layer, insulation layers or the like. However, a monolithic construction is preferred utilizing a single material for the cross-section of the panel. This type of construction is preferred for ease of construction and also structural integrity.

When the preferred plastics material is used, the ideal manufacturing method used will be extrusion. The panel of the preferred embodiment will have a constant cross-sectional shape which also suits the panel to extrusion. The extrusion can be formed in a continuous length which can then be cut to required dimension (length) for use.

The dimensions of the panel will be related to function and the use to which the panel is to be put. This is particularly the case with the thickness of the panel. For example, a thinner panel or approximately 25 mm thickness may be used as a finishing panel similar to a plasterboard panel. A thicker panel, such as one with a thickness of approximately 150 mm, may be used as an insulation panel, for soundproofing or as a structural panel for the wall itself.

The panel of the invention has a first face and a second face. Normally, these faces will be oriented substantially vertically in use and will be the wall faces.

When the panel is used according to the preferred use as an external wall or cladding N system, at least one of the faces of the panel will typically be exposed to the elements.

Therefore, at least one of the faces will be exposed to dirt, grime, water and other 2liquids and also more problematic environments such as acid rain.

The outer face of the panel at least will therefore normally require some

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10 form of surface treatment, for example paint, waterproofing, rendering layer or the like.

In order to provide increased surface area for bonding external treatments to the panel, at least one and preferably both of the first and second faces are provided with surface texturing. Preferably, an aggressive, shaped surface texturing over and above the texturing of the material used to form the faces of the panel is provided.

Typically, the shaped texturing will be provided to the panel during the manufacturing of the panel, and preferably by the cross-section shape of the die through which the extrusion is formed.

The shape of the texturing may be important in the retention of the surface treatment. Preferably the shape of the texturing includes corrugations. The corrugations may be of any cross-sectional shape for example waveform, sinusoidal and may be arcuate or rectilinear. Preferably, a linear repeating pattern is used.

Typically, the texturing will substantially cover entirely the face of the panel upon which it is provided.

Further, the texturing will be oriented in a particular direction relative to the orientation of the panel to maximize the retention effect to the surface treatment. As stated above, it is preferred that the linear pattern extends in a direction other than vertically as vertically extending grooves may allow the surface treatment to pool and create "runs" down the panel, particularly when the surface treatment has not yet set or dried. Therefore, vertically extending grooves are not preferred.

According to the most preferred embodiment, the corrugations will extend substantially horizontally across the faces when the panel is properly located for use.

An attachment system will also typically be provided to allow each panel to be easily located and secured to each adjacent panel. According to the most preferred form, the attachment system will be a tongue and groove joint system, more correctly termed a mortice and tenon system.

O) Each wall panel preferably has at least one opening (the groove or mortice of the system) in at least one edge of the wall panel adapted to receive a corresponding extension member (the tongue or tenon of the system) provided on an Cadjacent panel therein. There will suitably be an opening formed in at least the

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N 10 bottom edge. More preferably, at least two of either the top, bottom or side edges will be provided with at least one opening. Normally, the bottom edge and one of the side edges will be provided with at least one opening.

Each wall panel preferably has at least one extension member extending from at least one edge of the wall panel adapted to be received in a corresponding at least one opening provided on an adjacent panel. There will suitably be an extension member formed in at least the top edge. More preferably, at least two of either the top, bottom or side edges will be provided with at least one extension member. Normally, the top edge and one of the side edges will be provided with at least extension member.

Each panel will typically be provided with an extension member or tongue extending therefrom on one edge and on the opposed edge, an opening may be provided. During erection, the wall panels are positioned such that the tongue of a panel is received in the opening of an adjacent panel. Fasteners may be used to fix the tongue in the opening. The openings will typically be elongate slots or similar adapted to receive a substantially planar member of the preferred embodiment of the extension member therein.

The types of fasteners which may be used in the panel of the present invention include mechanical fasteners and/or adhesive fastening means.

The openings may be formed approximately centrally across the edge(s) of the panel during construction or they may be cut into the panel at a later stage. A single opening may extend substantially over the length and/or height of the wall panel or there may be more than one opening spaced apart over the length of the respective edge.

In use, the panels are located adjacent to one another with the corresponding portions of the mortice and tenon system engaging one another. If the engagement portions are provided on end edge as well as top and bottom edges, the panels can be stacked to form an upwardly extending wall as well as a laterally extending wall.

O BRIEF DESCRIPTION OF THE DRAWINGS 00 Various embodiments of the invention will be described with reference to the following drawings, in which: Figure 1 is a perspective view from one edge of the panel according to C 10 a preferred embodiment showing preferred characteristics of the individual panel.

Figure 2 is a detail front view illustrating a preferred form of interlocking joining system according to an aspect of the invention.

Figure 3 is a front view illustrating an individual panel according to a preferred embodiment of the present invention in its application in a wall.

Figure 4 is a detailed perspective view of a first end of a panel according to a preferred embodiment of the invention.

Figure 5 is a detailed perspective view of a second end of a panel according to a preferred embodiment of the invention.

BEST MODE In one broad form, the present invention provides a lightweight cladding panel for use in building or construction.

According to a preferred embodiment illustrated in Figure 1 in particular, the panel includes a first face 11 and a second face 12 separated by the thickness of the panel 10, and at least one of the first or second faces are provided with surface texturing 13 adapted to provide increased surface area for bonding external treatments to the panel.

The panel of the invention may be manufactured in any shape desired but will be substantially rectangular as illustrated. In this configuration, the panel has a first face, and an opposed second face which are parallel to each other. The panel also has a pair of opposing end edges and a top and a bottom edge.

The panel may be manufactured from a material which is both lightweight and strong. The most preferred material used in construction is expanded polystyrene. A monolithic construction utilizing a single material for the crosssection of the panel is also used in the illustrated embodiment as can be best seen from Figures 4 and The panel of the illustrated embodiment has a constant cross-sectional shape which also suits the panel to extrusion. The extrusion can be formed in a continuous length which can then be cut to required dimension (length) for use.

00 The dimensions of the panel will be related to function and the use to which the panel is to be put. This is particularly the case with the thickness of the panel. For example, a thinner panel or approximately 25 mm thickness may be used Oas a finishing panel similar to a plasterboard panel. A thicker panel, such as one with

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I 10 a thickness of approximately 150 mm, may be used as an insulation panel, for soundproofing or as a structural panel for the wall itself.

The first 11 and second 12 faces will be oriented substantially vertically in use. When the panel is used according to the preferred use as an external wall or cladding system, one of the faces of the panel will be exposed to the elements.

In order to provide increased surface area for bonding external treatments to the panel, both of the first 11 and second 12 faces of the illustrated embodiment are provided with surface texturing 13, which is an aggressive, shaped surface texturing over and above the texturing of the material used to form the faces of the panel The shaped texturing of the embodiment illustrated in Figures 4 and was provided to the panel during the manufacturing of the panel by the cross-sectional shape of the die through which the extrusion was formed.

The shape of the texturing includes corrugations. The corrugations illustrated are substantially waveform, or sinusoidal but may be of any cross-sectional shape. Preferably, a linear repeating pattern is used and the texturing substantially covers entirely the faces of the panel upon which it is provided.

Further, the texturing is oriented in a particular direction relative to the orientation of the panel to maximize the retention effect to the surface treatment. As illustrated in Figure 3 particularly, the linear pattern extends in a direction other than vertically as vertically extending grooves may allow the surface treatment to pool and create "runs" down the panel, particularly when the surface treatment has not yet set or dried. Therefore, as seen in Figure 3, the corrugations extend substantially horizontally across the faces 11, 12 when the panel is properly located for use.

An attachment system will also typically be provided to allow each panel to be easily located and secured to each adjacent panel. According to the most Spreferred form illustrated in Figure 2 in particular, the attachment system is a tongue and groove joint system, more correctly termed a mortice and tenon system.

Each panel 10 has an opening 14 (the groove or mortice of the system)

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00 in an edge of the panel 10 adapted to receive a corresponding extension member (the tongue or tenon of the system) provided on an adjacent panel. The opening 14 of the illustrated embodiment is formed in the bottom edge of the panel.

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Each panel 10 has an extension member 15 extending from an edge of N, 10 the panel 10 adapted to be received in a corresponding opening 14 provided on an adjacent panel. The extension member of the illustrated embodiment is formed in the top edge.

Each panel of the illustrated embodiment is provided with an extension member 15 or tongue extending therefrom on one edge and on the opposed edge, an opening 14 is provided. During erection, the wall panels are positioned such that the tongue 15 of a panel is received in the opening 14 of an adjacent panel. Fasteners are used to fix the tongue in the opening. The openings 14 are elongate slots or similar adapted to receive a substantially planar member of the preferred embodiment of the extension member 15 therein.

The openings are formed approximately centrally across the edge of the panel during construction and extend substantially over the length and/or height of the wall panel.

In use, the panels 10 are located adjacent to one another with the corresponding portions of the mortice and tenon system engaging one another. In practice, where panels are to be stacked to create an upwardly extending wall. The joints 16 between adjacent panels will be staggered as the wall extends upwardly.

Surface treatments such as rendering can then be applied to the panel and the texturing of the faces assist in the retention of the render material, both during the setting time and once set.

In the present specification and claims (if any), 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 IN 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 C 10 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 (if any) appropriately interpreted by those skilled in the art.

Claims (4)

1. 2. A panel according to claim 1 wherein the panel is a monolithic, single material 2panel of expanded polystyrene.
2. 3. A panel according to either claim 1 or claim 2 wherein an aggressive, shaped S 10 surface texturing over and above the texturing of the material used to form the faces of the panel is provided.
3. 4. A panel according to any one of the preceding claims wherein the surface texturing includes a linear repeating pattern which is in a direction other than vertically.
4. 5. A panel according to any one of the preceding claims wherein an attachment system is provided to allow each panel to be easily located and secured to each adjacent panel, the attachment system including a mortice and tenon provided on edges of respective adjacent panels.