AU2008200147A1 - Partition Panel Assembly - Google Patents

Description

10-JAN2008 16:02 WRAY AND ASSOCIATES NO. 888 P. 5/26 P/00/011 28/5/91 Regulation 3.2

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT 0 a 0 a 0 Name of Applicant: Actual Inventor Address for service is: Starclan Pty Ltd Hugh Alexander Mackay WRAY ASSOCIATES Level 4, The Quadrant 1 William Street Perth, WA 6000 Attorney code: WR Invention Title: Partition Panel Assembly The following statement is a full description of this invention, including the best method of performing it known to me:- 1 COMS ID No: ARCS-174807 Received by IP Australia: Time 19:03 Date 2008-01-10 10-JAN2008 16:02 WRAY AND ASSOCIATES NO- 888 P. 05/26 -2- 00 o Partition Panel Assembly ct Field of the Invention The present invention relates to a panel and panel connectors, a plurality of which can be assembled to provide partitioning to a room.

t'- Background Art 00 Partitioning is typically required for big rooms such as offices in order to separate Sareas or provide separate working spaces for individuals. Different materials and partitioning assemblies are available and it is desirable to provide a partitioning panel assembly which is cheaper and easier to manufacture and install, as well as providing other advantages.

It is the object of the present invention to achieve the above desire or at least provide a useful alternative.

Disclosure of the Invention The present invention provides a partitioning panel comprising a core material having planar first and second faces bounded by first and second end faces and first and second side faces, the core having at least one connection formation formed at its side faces, the panel having first and second sheets respectively covering the planar faces of the panel.

The core preferably has at least one duct extending therethrough between the end faces. The core faces are preferably parallel. The core preferably includes a plurality of ducts which are spaced along the width of the panel between the side faces.

The core is preferably made from polystyrene material. The first and second sheets are preferably plasterboard sheets.

COMS ID No: ARCS-174807 Received by IP Australia: Time 19:03 Date 2008-01-10 JAN. 2008 16:03 WRAY AND ASSOCIATES NO. 888 P. 7/26 0 o The first and second sheets preferably cover the entire planar faces, respectively, between the end faces and side faces. The first and second sheets preferably extend past the end faces.

The panel preferably has a thickness of about 94 mm. The panel preferably has a width between 900 mm and 1360 mm and a length between 2400 mm and 3600 mm.

o The material for the first and second sheets preferably provide sound insulation, 00 waterproof or water repellent properties, fire resistance and impact resistance. A o number of empty cavities are preferably formed within the core, The cavities preferably include sound absorbing material or material which increases the strength, fire resistance and/or impact resistance of the core.

The panel preferably includes at least one additional layer of sheet material adjacent the first and/or second sheets, the additional layerqs) providing sound insulation, waterproof or water repellent properties, fire resistance and impact resistance.

The connection formation preferably comprises at least one recess formed along the length of the side faces. The at least one recess preferably extends along the entire length of the side face. The at least one connection recess is preferably substantially concave. Each recess preferably includes inclined side walls converging toward and joined by a bottom wall.

The present invention also provides an end connector for connecting the panel to a wall, the end connector being elongated to substantially correspond to the length of a side face recess of the panel, the end connector having an end face for attaching to the wall and a substantially convex surface corresponding to the panel side face recess for attaching to the panel side face recess, and an assembly comprising the panel and the end connector.

The substantially convex surface preferably comprises first and second inclined faces converging from the end face toward and joined by a base face.

COMS ID No: ARCS-174807 Received by II' Australia: Time 19:03 Date 2008-0-10 10-JAN.2008 16:03 WRAY AND ASSOCIATES NO. 888 P. 8/26 -4- 00 O0 The present invention also provides an inline connector for connecting two ^C adjacent inline panels, the inline connector being elongated to substantially ct correspond to the length of the side face recess of the panels, the inline connector having two substantially convex surfaces corresponding to the recesses of the side faces of the panels for attaching to the panel side face recess to connect the panels to each other, and an assembly comprising at least one panel and the inline connector.

0 o The substantially convex surfaces preferably face away from each other and each Ci 00 comprises first and second inclined faces converging toward and joined by a base S 10 face.

The present invention also provides a comer connector for connecting two adjacent panels which are substantially perpendicular to each other, the corner connector including an elongated comer portion which Is substantially rectangular in cross section, the comer portion having two extensions adjacent elongated perpendicular sides thereof, the extensions each formed to have a substantially convex surface corresponding to the recesses of the side faces of the panels for attaching to the panel side face recess to connect the panels to each other, and an assembly comprising at least one panel and the comer connector.

The present invention also provides a partitioning panel comprising a core material having planar first and second faces bounded by first and second end faces and first and second side faces, the core having at least one duct extending therethrough between the end faces, the core having at least one connection means formed at its side faces, and first and second sheets respectively covering the planar faces of the panel.

Brief Description of the Drawings Preferred forms of the present invention will now be described by way of examples only with reference to the accompanying schematic drawings wherein: COMS ID No: ARCS-174807 Received by IP Australia: Time 19:03 Date 2008-01-10 10-JAN-2008 16:03 10. JN. 208 1:03RAY AND ASSOCIATESNO88 P.92 NO, BBB P. 9/26 00 o Figure 1 shows a partition panel according to a preferred embodiment of the present invention; Figure 2 shows an end connector for connecting a panel to a wall; Figure 3 shows an inline connector for connecting a panel to an adjacent panel 6 inline therewith; o Figure 4 shows a corner connector for connecting a panel to an adjacent panel 00 arranged perpendicular thereto; 0 0 Figure 6 shows in cross-section view attachment Of a panel to the floor Figure 6 shows in cross-section view attachment of a panel to a ceiling joist; Figure 7 shows in plan view the connection of a panel to a wall using the end connector, Figure 8 shows In plan View the connection of a panel to a face of another panel using the end connector Figure 9 shows in plan view the connection of two adjacent panels inline with each other using an inhine connector Figure 10 shows in plan view the connection of a panel to another panel perpendicular thereto; Figure 11 shows in plan view the connection of a panel to another panel perpendicular thereto using the corner connector Figure 12 shows an example of an assembled partitioning panel assembly including three panels, an inline connector and a corner connector; Figure 13 shows in cross section the addition of skirting and an electrical box to a panel; COMS ID No: ARCS-174807 Received by IP Australia: Time 19:03 Date 2008-01-10 JAN. 2008 16:03 WRAY AND ASSOCIAI[S Na. 88 P. 10/2 6- 00 o Figures 14 to 16 show in plan View three examples of attaching a panel to a door (N jamb: Figure 17 shows in plan view an aperture, such as a window, out into the panel, Figure 18 shows in cross; section the attachment of a hanging fixture to a panel; Figure 19 shows the addition of a plumbing installation to a panel; h diino neecrclisalto oapnl n 0 o Figures 21 and 22 show in cross section top portions of panels unsupported at their top edges for partial height partitioning applications.

Best Mode(s) for Carrying Out the Invention Figure 1 shows a partitioning panel 20 according to a preferred embodiment of the present invention. The panel 20 comprises a corn 22 having parallel and opposing Planar faces 24 and 26 bounded by end faces 28 and 30 and side faces 32 and 34. A substantially concave recess 36 is formed along the entire length of each side face 32 and 34. Each recess 36 includes inclined side walls 38 converging toward and joined by a bottom wall 40. Hollow ducts 42 are formed through the core 22, the ducts 42 extending through the length of the core 22 between the end faces 28 and 30. In the panel 20, five parallel ducts 42 are formed which are spaced along the width of the panel 20 between the side faces 32 and 34, In the embodiment, the core 22 is made from polystyrene material.

The core planar faces 24 and 26 are respectively covered by skin sheet materials 44a and 44b, which in this embodiment are plasterboard sheets 44. The skins 44 cover the entire planar faces 24 and 26, respectively, between the end faces 28 and 30 and side faces 34 and 36. The skins 44 can also extend past the end faces 28 and 30 ifdesired.

The panel 20 shown in Figure 1 has a width of 000 mm and a thickness of 94 mm.

The panel 20 has a number of advantageous properties, including good thermal COMS ID No: ARCS-i 74807 Received by IP Australia: Time 19:03 Date 2008-01-10 10-JAN2008 16:04 WRAY AND ASSOCIATES NO. 888 P. 11/26-- 00-7insulation properties (R rating of good sound insulation (rating 38 dB), and high (N strength to weight ratio (weight approx 15 kg/m2). The panel 20 can be made into Sa number of predetermined width and lengths. The widths can be 900 mm, 1200 mm, or 1350 mm, with the lengths being 2400 mm, 2700 mm, 3000 mm, 3300 mm, or 3600 mm. Preferred thickness of the panel 20 is about 94 mm.

Figure 2 shows an end connector 50 for connecting the panel 20 to a wall. The end connector 50 is elongated to substantially correspond to the length of the O panel side face recesses 36. The end connector 50 includes a flat end face 00 and a substantially convex surface 52. The surface 52 comprises first and second S 10 inclined faces 53 converging from the end face 55 toward and joined by a base face 54.

Figure 3 shows an inline connector 60 for connecting two adjacent inline panels to each other as will be explained below. The inline connector 60 is similar to the end connector 50 but includes two of the substantially convex surfaces 52, marked as surfaces 52a and 52b, which face away from each other. The substantially convex surfaces 52a and 52b are shaped and of a length to correspond to the panel recesses 36.

Figure 4 shows an elongated corner connector 70 which includes a comer portion 72 which is substantially rectangular in cross section. The comer portion 72 includes two extensions 74a and 74b adjacent elongated perpendicular sides thereof, the extensions 74a and 74b each formed to have the substantially convex surface 52 (marked as surfaces 52a and 52b) similar to the connectors 50 and The other faces of the comer connector 70 without the extensions 74 are marked as fiat faces 73. The corner connector 70 is also of a length to substantially correspond to the panel recesses 36.

The use of the connectors 50, 60 and 70 will be explained further below.

Figure 5 shows installation of a panel 20 to a floor 80, Initially, a timber based base plate 82 is fixed to the floor 80 by any suitable means such as a nail 84. The base plate 82 has a width corresponding to the thickness of the core 22. The COMS ID No: ARCS-174807 Received by IP Australia: Time 19:03 Date 2008-01-10 10-JAN2008 16:04 WRAY AND ASSOCIATES NO. 888 P. 12/26 -8panel 20 is erected such that the core 22 rests on the base plate 82. In the panel embodiment shown, the skins 44 extend past the bottom edge of the core 22.

The base plate 82 has a height to provide a gap 86 between the floor 80 and the panel skins 44, the gap 86 being typically about 8 mm.

Figure 6 shows attachment of a panel 20 to a ceiling joist 90. A timber top plate 88 is bonded to the top of the panel 20 with construction adhesive. The panel 20 is then fixed to the ceiling joist 90 via suitable means such as a nail 92. Elongated corner pieces 94 can be attached between the ceiling 91 and the panel 20 to hide the details of the join.

Figure 7 shows attachment of a panel 20 to an existing wall 100. An end connector 50 is inserted into a panel side recess 36 with the connector substantially convex surface 52 attached to the panel substantially concave recess 36 via construction adhesive, The connector end face 55 together with the side surfaces of the panel 20 are then attached to the wall 100 via adhesive.

Silicon beads 102 can then be applied between the panel 20 and the wall 100 to seal the join.

Figure 8 shows attachment of a panel 20a to a planar skin 44a of another panel in a Junction. Attachment of the panel 20a to the panel 20b is similar to that as shown in Fig,7 except that the panel 20a in this case is attached by adhesive to the skin 44 of the panel Figure 9 shows the attachment of a panel 20a to another panel 20b, where the panels 20a and 20b are in line or co-extensive with each other. The first substantially convex surface 52a of an inline connector 60 is attached to a recess 36 of the panel 20a and the connector second surface 52b is attached to a recess 36 of the panel 20b via adhesive. Side surfaces of the panels 20a and adjacent the connector 60 can also be attached to each other via adhesive, Figure 10 shows in plan view the connection of a panel 20a to another panel which is perpendicular thereto. In this connection, the first skin 44a and the core 22 of panel 20a have been cut from the side surface 34 by a distance equal to the COMS ID No: ARCS-174807 Received by IP Australia: Time 19:03 Date 2008-01-10 JAN, 2008 16:04 WRAY AND ASSOCIATES NO. 888 P. 13/26 00 -9- 00 Sthickness of panel 20b. The second skin 44b of the panel 20a is not cut and Sattached to this skin 44b by adhesive are the side surfaces of the panel Figure 11 shows in plan view the connection of a panel 20a to another panel which is arranged perpendicular thereto using the corner connector 70. The first surface 52a of the comer connector 70 is attached to a recess 36 of the panel and the connector second surface 52b is attached to a recess 36 of the panel via adhesive. Side surfaces of the panels 20a and 20b adjacent the connector o are then attached to the comer portion 72 via adhesive. The other surfaces 73 of 00 the comer portion 72 are covered by cover members 96 which are elongated S 10 pieces of plasterboard sheet material similar to the skins 44.

In a modification of the above, the comer connector 70 can include three or four extensions 74 at adjacent sides thereof with each extension 74 formed to have the substantially convex surface 52, Such comer connectors will allow three or four panels 20 to be connected to each other via the connector to form T junctions or 4 way junctions.

Figure 12 shows an example of an assembled partitioning panel assembly 100 comprising inline panels 20a and 20b connected by an inline connector 60 and panel 20c perpendicular to the panel 20b and connected thereto by a comer connector 70. The ducts 42 allow for cables and wires for electrical, telephone and other services to extend through the panels 20 as required, It can thus be seen from the above that various partitioning configurations are possible with the panels 20 and connectors 50, 60 and 70. Further, with the modified comer connector described above having three or four extensions 74, various partition comer or junction configurations are possible.

Figure 13 is similar to Figure 5 and shows the addition of a skirting board 98 to cover the gap 86. An electrical box 110 can also be inserted and attached to the panel 20 by adhesive by cutting an appropriate shape hole in the skin 44a and a recess in the core 22.

COMS ID No: ARCS-174807 Received by IP Australia: Time 19:03 Date 2008-01-10 JAN. 2008 16:05 WRAY AND ASSOCIATES- NO. 838r-P. 14/26 0 o Figures 14 to 16 show in plan view three examples of attaching a panel 20 to a door jamb 112. In Figure 14, a shaped metal component 114 is received and attached to the panel recess 36, with the component 114 attached to the door o jamb 112 via at least one bolt 116. In Figure 15, the core side surface 34 is cut to receive a timber member 118 which is attached to the core 22 by adhesive, with the timber member 118 attached to the door jamb 112 via at least one screw 110.

Figure 16 shows the side portion of the panel 20 received in a standard metal o door frame 120.

o0 Figure 17 shows in plan view an aperture, such as a window 122. cut into the panel 20. A cut is made in the panel 20 as desired for the window 122, with the exposed cut surfaces lined with a suitable lining material 124 such as compressed board to which glazing frames 123 for the window 122 can be fixed.

Figure 18 shows in cross section the attachment of a hanging fixture 126 to the panel 20. As shown, apertures can be formed in the panel 20 by drilling, to which any suitable fixture 126 can be attached.

Figure 19 shows the additWon of a plumbing installation 128 to a panel 20. The skin 44a of the panel 20 is cut and portions of the core 22 are removed to accommodate the installation 125 which is bonded in place with construction adhesive. Figure 20 shows the addition of an electrical installation 130 to a panel 20 in a manner similar to that shown in Figure 19.

Figures 21 and 22 show in cross section top portions of panel 20 unsupported at the ceiling for partial height partitioning applications. In Figure 21, the top edge of the panel 20 is shown as being covered by an elongated Uimber capping 132. In Figure 22, the top edge is covered by a formed metal head channel 134. Wires 136 can also extend along the top edge if some of the core 22 is removed.

In alternative embodiments, the material for the skins 44 of the panel 20 can be chosen to have additional desired properties, such as providing increased sound insulation, better waterproof/repellent properties, fire resistance and impact resistance. Such materials are commercially available and sold by the CSR COMS ID No: ARCS-i 74807 Received by IP Australia: Time 19:03 Date 2008-01-10 IO.JAN-2008 16:05 WRAY AND ASSOCIATES NO. 88-- P. 15/26 00 -11- 0 o GYPROCK Company under the trade marks SOUNDCHEK, AQUACHEK, FYRCHEK and IMPACTCHEK.

ct SIt can be seen from the above that the panels and connectors of the preferred embodiment provide a versatile assembly for providing partitioning to a space as desired. The panels in particular can be modified in a number of ways as required to suit the needs of the application or to provide the desired functions and Sappearance.

00 Although preferred embodiments of the present invention have been described, it Swill be apparent to skilled persons that the invention can be embodied in other forms or that modifications can be made to the above embodiments. For example, to further improve the sound insulation properties of the panel, a number of empty cavities can be formed within the core 22. Such cavities can also contain sound absorbing material, or other material which increases the strength, fire resistance and/or impact resistance of the core 22 and panel 20 in general.

Further, the panel 20 can include an additional layer of sheet material adjacent the sheets 44a and 44b which provides sound insulation, waterproof or water repellent properties, fire resistance and impact resistance. Further, the connection between the panels and the connectors can be modified, such that the panels include concave side surfaces and the connectors include concave recesses therein for fitting of the concave side surfaces. In another embodiment, one side face can have a concave formation and the other side face can have a convex formation such that the panels can be attached directly to each other.

COMS ID No: ARCS-174807 Received by IP Australia: Time 19:03 Date 2008-01-10

Claims (18)

1. 3. The panel of claim 1 or 2 wherein the core faces are parallel.
2. 4. The panel of any one of the preceding claims wherein the core includes a plurality of ducts which are spaced along the width of the panel between the side faces. The panel of any one of the preceding claims wherein the core is made from polystyrene material.
3. 6. The panel of any one of the preceding claims wherein the first and second sheets are plasterboard sheets.
4. 7. The panel of any one of the preceding claims wherein the first and second sheets cover the entire planar faces, respectively, between the end faces and side faces.
5. 8. The panel of any one of the preceding claims wherein the first and second sheets extend past the end faces.
6. 9. The panel of any one of the preceding claims wherein the panel has a thickness of about 94 mm. COMS ID No: ARCS-174807 Received by IP Australia: Time 19:03 Date 2008-01-10 JAN. 2008 16:05 WRAY AND ASSOCIATES N. 888--P. 00 -13- 0 The panel of any one of the preceding claims wherein the panel has a width ^C between 900 mm and 1350 mm and a length between 2400 mm and 3600 c mm.
7. 11. The panel of any one of the preceding claims wherein the material for the first and second sheets provide sound insulation, waterproof or water repellent properties, fire resistance and impact resistance. S12. The panel of any one of the preceding claims wherein a number of empty 00 cavities are formed within the core. 0 Cl
8. 13. The panel of claim 16 wherein the cavities include sound absorbing material or material which increases the strength, fire resistance and/or impact resistance of the core.
9. 14. The panel of any one of the preceding claims wherein the panel includes at least one additional layer of sheet material adjacent the first and/or second sheets, the additional layer(s) providing sound insulation, waterproof or water repellent properties, fire resistance and impact resistance. panel of any one of the preceding claims wherein the connection formation comprises at least one recess formed along the length of the side faces.
10. 16. The panel of claim 15 wherein the at least one recess extends along the entire length of the side face.
11. 17.The panel of claim 15 or 16 wherein the at least one connection recess is substantially concave.
12. 18.The panel of any claim 17 wherein each recess includes inclined side walls converging toward and joined by a bottom wall.
13. 19. An assembly comprising the panel of any one of claims 15 to 18 and an end connector for connecting the panel to a wall, the end connector being COMS ID No: ARCS-174807 Received by IP Australia: Time 19:03 Date 2008-01-10 10-JAN-2008 16:06 10 JN 208 1:0RAY AND ASSOCIATES 'NO. 838 P. 18/2 6- -14- elongated to substantially correspond to the length of a side face recess of the panel, the end connector having an end face for attaching to the wall and a substantially convex surface corresponding to the panel side face recess for attaching to the panel side face recess.
14. 20. The assembly of claim 19 wherein the substantially convex surface comprises first and second incined faces converging from the end face toward and joined by a base face-
15. 21. An assembly comprising at least one panel according to any one of claims to 18 and an inline connector for connecting two adjacent inline panels, the inline connector being elongated to substantially correspond to the length of the side face recess of the panels, the inline connector having two substantially convex surfaces corresponding to the recesses of the side faces of the panels for attaching to the panel side face recess to connect the panels to each other.
16. 22. The assembly of claim 19 wherein the substantiaily convex surfaces face away from each other and each comprises first and second inclined faces converging toward and joined by a base face.
17. 23. An assembly comprising at least one panel accord ing to any one of claims to 18 and a corner connector for connecting two adjacent panels which are substantially perpendicular to each other, the corner connector including an elongated corner portion which is -substantially rectangular in cross section, the corner portion having two extensions adjacent elongated perpendicular sides thereof, the extensions each formed to have a substantially convex surface corresponding to the recesses of the side faces of the panels for attaching to the panel side face recess to connect the panels to each other.
18. 24. A partitioning panel comprising a core material having planar first and second faces bounded by first and second end faces and first and second side faces, the core having at least one duct extending therethrough between the end faces, the core having at least one connection means formed at its side faces, COMS ID No: ARCS-i 74807 Received by IP Australia: lime 19:03 Date 2008-01-10 10-JAN2008 16:06 WRAY AND ASSOCIATES NO, 838 P. 19/2 6 and first and second sheets respectively covering the planar faces of the panel. A partitioning panel substantially as herein described with reference to the accompanying drawings. t"- 0 00 'O COMS ID No: ARCS-174807 Received by IP Australia: Time 19:03 Date 2008-01-10