AU2009100337A4

AU2009100337A4 - Prefabricated interlocking wall construction panel

Info

Publication number: AU2009100337A4
Application number: AU2009100337A
Authority: AU
Inventors: Allan Charles Hockley
Original assignee: ALLAN HOCKLEY
Current assignee: ALLAN HOCKLEY
Priority date: 2009-04-10
Filing date: 2009-04-10
Publication date: 2009-07-09
Anticipated expiration: 2017-04-10
Also published as: AU2009100337B4

Description

ProvisIonaI Spedficaon Prefabricated Interlocking Wall Construction Panel, ho invrtkw1 hs *Ovflqbw in Uwt % *0A" *frrwn The invention is described in the following statement and within Drawings Fig 1, an exploded view of the invention, Fig's 2, 3, 4, 5, 6, Cross sectional profile of the invention. Fig 7, Internal wall installation method, Fig 8 Perimeter wall 5 installation method, Fig 9Structural tie down method, Fig 10 section AA of structural tie down method, Fig1 I exploded view of steel forming mold incorporating invention and Fig 12 cutaway drawing of the invention. 10 The invention relates to the field of prefabricated wall construction panels, and more specifically to light weight prefabricated panels being encased in a cold formed galvanized steel frame and filled with polyurethane expanded block foam (core). This is then encased on each side by 15 construction claddings such as Plasterboard and Hardietex. The materials are placed within a steel forming mold special made for the purpose and the core is allowed to expand until it reaches its total expandable volume. As the panel is encased in the forming mold, and the net internal volume is 20 less that the fully expanded volume of the core material, it is under considerable pressure and thus become denser that if it where unrestrained by the forming mold. The core material is highly adhesive, and forms a strong bond 25 with all components of the invention. This gives the invention Pg1 Page 1 o inventon is descried in the fonhowing statement when constructed as per the following detailed description, offers an extremely hi insulation value, large time savings during on site erection, lower all of life maintenance costs due to its resistance to insect infestations , excellent resistance to o soft body impacts, low flammability and is fully recyclable in its constituent parts. This makes the invention an excellent environmentally friendly choice as a construction component. Detailed Description of the Prefabricated Wall Construction Panel: For conveyance sake it is assumed that the invention as described below has on overall dimension of 1230mm in width, 2700mm in length and an overall thickness of 98mm. The invention can be fabricated up to 1350mm wide, 6000mm in length and 300mm in overall thickness Figi represents an explode view of key components of the 5 invention and their relationship in typical wall construction. 1 represents the female profile formed within the invention; this is incorporated vertically into each panel. This is formed on one side and acts a lock, 1 a represents the bottom horizontal profile for the invention. This allows the invention to be locked into the floor profiles 2, 4 and 5. 1a also aligns each panel section squarely to each other. 2 represents the male profile formed within the invention; this is ss incorporated vertically into each panel on the opposite side as the female profile and forms the interlocking profile. 3 represents the cap profile of the invention; this forms the horizontal top section of the invention and allow for the ring beam 15 to be placed squarely around the perimeter of the completed system. 4 represents the internal joiner profile; this profile is fastened to the floor at the required spacing's for intermittent wall sections to be installed. 4 can also used in conjunction with panel sections and can be aligned vertical, aligning wall sections at 'o wall junctions. (00) Page 2 AHN 38 113 072 766 e invention is described in the following Statement 5 represents the perimeter profile; this profile is installed around the perimeter of the flooring, allowing the walls to be aligned with the edge of the floor and also acting as both moisture and insect barrier. ' 6 represents the core material utilized within the invention. This not only adds to the overall robustness of the invention, but acts as insulation. This material and installation method will be explained in detail further in this document. 7 and 8 represent the types of construction cladding used in the > invention detailed later in this document. Many types of construction boards and sheeting can be utilized in the invention. This could be cement sheeting, plasterboard, fire resistant plasterboard, steel cladding, timber veneers or particle board. In the description below 7 represents 7.5mm cement 5 sheeting and 8 represents internal plasterboard. 14 is a typical concrete floor, but could also represent a raised timber floor or a suspended slab floor. 15 represents the steel ring beam. This is a continuous steel section that acts as a restraint and also as a support for roof o trusses and second level flooring if required. The invention incorporates G2s Grade galvanized steel frame, typically 1.2mm in sectional thicknessla and cold folded mechanically into sections1,2,3,4,5, that may interlock in such a 5 manner that they form a tight fit and allow for minimal movement. Fig 2 shows a female profile 1, incorporating a 1.2mm thick ia steel sheet. This is cold formed by either break pressing or roll 100 forming the section in the following manner. A flange of the profile is folded at right angles to form a side flangel.1 being Y2 the width of the total web length. A second flangel.2 is folded at right angles to the first flange in the as yet unformed web at 113 of the total web length. A third flange 1.3 is formed at a 1o5 further 1 3 'd width of the web and at right angle to the previous angle. A forth Flange 1.4 is formed at 1/3 of the total web and at opposite right angles to the previous angle. A fifth flange 1.5 is formed at 1

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3 rd of the total width of the web and at right angles to the previous angle. A sixth flange 1.6 is formed at o 1 1

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3 rd of the total width of the web and at opposite right angles to 9(0109) page 3 ABN 38t1M0M2755 a invention is described in the folowing statement the previous angle. A sixth flange 1.6 is formed at 1/3d of the total width of the web and at opposite right angles to the previous angle. A final seventh flange 1.7 is formed at 1/3d of the total width of the web and at right angles to the previous angle. The length of this last flange is %4 the width of the total web length thus formed. The ratio of flanges to web results in strong sectional properties developed from a relatively thin section of steel. The section is o fundamentally C section in profile with an included section centrally. Fig 3 shows a Male profile 2, incorporating a 1.2mm thick 1 a steel sheet. This is cold formed by either break pressing or roll .s forming the section as above. A flange of the profile is folded at right angles to form a side flange 2.1 being Y the width of the total web length. A second flange 2.2 is folded at opposite right angles to the first flange in the as yet unformed web at 1

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3 rd of the total web length. A third flange 2.3 is formed at a further o 1/3d width of the web and at opposite right angle to the previous angle. A forth Flange 2.4 is formed at 1/3 of the total web and at right angles to the previous angle. A fifth flange 1.5 is formed at 1/30 of the total width of the web and at opposite right angles to the previous angle. A sixth flange 1.6 is formed at 1

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3 rd of the total width of the web and at opposite right angles to the previous angle. A final seventh flange 1.7 is formed at 1/ 3 rd of the total width of the web and at opposite right angles to the previous angle. The length of this last flange is % the width of the total web length thus formed, 140 Fig 4 shows a cap profile 3 overall web lengths are the same as I and 2 with %A the web length as a flange on either side. 3.1 shows the flanges formed at right angles to the web 3.2 and parallel to each other 45 Fig 5 shows the internal joiner profile 4. This profile has the same web properties and ratios as the male profile 2 with both side flanges removed. This is utilized as an aligning profile allowing the invention to be installed firmly in a nominated [50 position. 4 is also used as a placement profile for (0102 Pagec4 AHN,3a 13 0727,55 ie invention is described in the following statement interlocking wall sections of the invention at right angles to each other. Fig 6 shows a perimeter profile 5. This profile has the same 5 web properties and ratios as the male profile 2 with one leg of the flange removed to allow for the profile to be placed around the perimeter of a structure. This has the effect of aligning the invention with the floor perimeter, becomes a moisture barrier and prevents the ingress of insects to the dwelling. This profile 6o can be utilized on either concrete flooring of raised timber flooring systems. Figi represents an explode view of key components of the invention there relationship in wall construction. 65 I represents the female profile formed within the invention; this is incorporated into each panel. This is formed on one side and acts a lock. 1a represents the bottom horizontal profile for the invention. 7o This allows the invention to be locked into the floor profiles 4 and 5. Ia also aligns each panel section squarely to each other. 2 represents the male profile formed within the invention; this is incorporated into each panel on the opposite side as the female profile and forms the interlocking profile. 3 represents the cap profile of the invention; this forms the horizontal top section of the invention and allow for the ring beam 15 to be placed squarely around the perimeter of the completed system. o 4 represents the internal joiner profile; this profile is fastened to the floor at the required spacing's for intermittent wall sections to be installed. 4 can also used in conjunction with panel sections and can be aligned vertical, aligning wall sections at wall junctions. 186 5 represents the perimeter profile; this profile is installed around the perimeter of the flooring, allowing the walls to be aligned with the edge of the floor and also acting as both moisture and insect barrier. 6 represents the core material utilized within the invention. 190 This not only adds to the overall robustness of the invention, (010q) PageS5 AM 38 113O0Y2lSS e -invention is descibed In tHe fafowine statement but acts as insulation. This material and installation method will be explained in detail further in this document. 7 and 8 represent the types of construction cladding used in the invention detailed later in this document. Many types of s construction boards and sheeting can be utilized in the invention. This could be cement sheeting, plasterboard, fire resistant plasterboard, steel cladding, timber veneers or particle board. In the description below 7 represents 7.5mm cement sheeting and 8 represents internal plasterboard, 00 14 is a typical concrete floor, but could also represent a raised timber floor or a suspended slab floor. 15 represents the steel ring beam. This is a continuous steel section that acts as a restraint and also as a support for roof trusses and second level flooring if required. 05 Referring now in particular to the embodiment of the invention shown in Fig 12. This is an exploded view of all components utilized in the fabrication of the invention.1, and 2 are vertical support members with 3 and 1.1 forming the horizontal support 1o sections. All these are made of cut lengths of galvanized steel sheeting or coil steel of similar thickness and grade ,G2s grade, and 1.2mm thick typically Ia. The sections are set out forming a rectangle of the proposed final dimensions. These are then welded 22 on each web and each side to form a secure 5 mechanical bond. This welded section then forms the basic planar frame which is the structural basis for the invention and also forms a mold to accept the core material. Fig 12 also shows a penetration 3a formed within 3 to allow 20 for services conduitsl8 to be installed. The location and size of 18 are determined at design stage to allow for the correct type number and size to be installed. Threaded rod connectors are welded to 2, one on each end and 20mm from the cut end. 10 is to allow for the structural tie down rods 9 to be inserted 225 prior to the final placement of the invention. 10 is welded into place prior to the fabrication of the planar frame for ease of construction. Fig 11. Depicts a basic forming mold 20, and provides a cut 30 away view of the invention prior to containment within said g (010g) Page 6 AM .8 AB 113O072756 he invention is described in the fIlowing statement forming mold, For convenience sake we will assume that one sheet of James Hardie's, Hardietex 7 is used on one side and one sheet of Boral 13mm FireSTOP plasterboard sheeting 8 is used on the opposing side of this particular panel. 5 The forming mold 20 has 2 pressure plates constructed of mild steel section being 75mm in height, 50mm in width and 6mm in wall thickness. These are welded in a rectangular form to a sheet of mild steel 6mm in thickness and to the dimensional 40 size of the invention, in this case 1200mm in width and 2700mm in length. Another steel section is then welded centrally for lateral bracing. One side of the forming mold 20 is placed horizontally upon a 45 reinforced bench, with the steel sheeting facing the top of the relief A sheet of construction sheeting 7 is placed face down inside of 20 and allowed to rest on the inside the steel sheet face of 20. This sheet is squared to 20 to ensure correct alignment of the invention. The planar frame described earlier 5O is then placed on top of 7 and checked for square against the forming mold. All services conduits 18 are checked against the quality assurance plan, and signed off by the supervisor. The next phase is to insert the core material 6 into the body of the invention. The core material 6 comprises two parts. One is a Polyolo and the other is an Isocyanate. These are mixed in the ratio specified by the manufacturer, once mixed the chemicals undergo a reaction forming the expanded block foam core material 6. The core 6 material is inserted after mixing but before reaction occurs into the forming mold and spread evenly over the surface of the construction sheet 7. As soon as the core 6 is spread to a uniform thickness, construction sheet 8 is placed on the planar frame and squared. The second half of the forming mold 20 is then secured into place with a series of bolts 265 21 and tightened to form a seal between 7, the planar frame, and 8. The core material then expands to fill the cavity formed between construction sheets 7, 8 and the planar frame 0 consisting of 1, Ia, 2 and 3. After the manufacturers (O19) Page 7 ABN 3a 132 755 ie invention is descnbed in the following statement recommended curing time has elapsed, the forming molds 20 are released from the invention. The invention is now ready for use. 5 Now we will examine the method for installing the invention. The invention is substantially installed as per the construction codes require for the hold down for lightweight steel structures and there relevant structural components. so Fig 7 shows a cut away section of one panel of the invention and the method for securing the invention to a concrete slab. This segment also represents the invention as a partition wall. The construction sheeting 8 is plasterboard in this instance although a combination af many sheeting types are possible, 8s The internal joiner profile 4 is secured to the slab 14 by the use of a construction anchor 11. In this case a 50 x 8 Nylock anchor is nominated. Other anchoring systems can be employed, dependant on the method and type required by the engineer. A 10mm bead of Hi strength construction adhesive 12 is applied 90 to 4 and the invention is placed upon 4 interlocking with the Female edge profile Ia. Fig 8 depicts the method of installation of the invention utilized in an external wall. Shown is a configuration of the invention utilising 7.5 mm Compressed cement sheeting 7 on the external face and 13 mm plasterboard as the internal lining 8. Two 10mm bead of Hi strength construction adhesive 12 similar to Selleys Seal N Flex is applied to the inside face of the perimeter edge profile 5 prior to installation. This acts as both 00 an adhesive and moisture barrier. The perimeter edge profile 5 is then fastened to the concrete slab 14 on the vertical flange with a Nylock anchor 11 at 600mm spacing's. The continuous hold down method employed on the bottom of 305 the invention comprises a cut length of threaded rod 9, a threaded rod connector 10 and a predrilled penetration into the slab 14 filled with an epoxy chemical anchor system 13. We will assume that in the case shown that 9 and 10 are 16mm in diameter, the penetration into 14 is 18mm in diameter and 10 the 13 is Ramset 200 Epoxy Grout. 9(0109) Page 8 MBN -411-3 OT2IS56 The invention is described In the following statement The threaded rod connector 10 was welded into position prior to the fabrication of the invention. A length of threaded rod 9 is screwed all the way through the threaded rod connector 10 on the bottom of the invention and protruded a minimum of 125mm 315 past the female edge profilela. A 10mm bead of Hi strength construction adhesive 12 is then applied to the horizontal web of the perimeter edge profile 5 prior to installation. This bead is places on the upper edge of the outside facing flange and acts as both an adhesive and moisture barrier. The invention is then 320 lowered into place, allowing for the threaded rod 6 the perimeter edge profile 5 and the female edge profile 1 a to align and lick into place. This can be taped lightly from the top to ensure that the profiles and Ia lock together. 325 Now onto the top hold down method employed for the invention. Fig's 9 and 10 are assumed to be of two panels similar in configuration and of construction as Fig 8 and assumed to represent an external wall. Fig 10 depicts two panels of the invention placed adjacent to each other. It is also 330 assumed that the bottom of the invention has been secures and that 12 and 13 have cured as per the manufacturers recommendation. Fig 9 depicts a cut away representation of the invention 35 detailing the method of providing continuous tie down method employed, whilst Fig 10 depicts a plan view cutaway representation of Fig 9 and incorporated two panels of the invention. The cut away is taken at point A/A in Fig 9.The threaded rod connector 10 was welded into position prior to the 340 fabrication of the invention. A length of threaded rod 9 is screwed all the way through the threaded rod connector 10 on the top of the invention and protruded a minimum of 125mm past the top cap profile 3. A ring beam 15, fabricated from a section of square hollow section steel, is placed in alignment 345 with the invention. The threaded rod 9 passes through a pre drilled penetration being 2mm larger that the threaded rod 9. The exact spacing's for the pre drilled holes are dependent on the engineering requirements for the invention and site conditions. A square washer 17 and a nut 16 are placed on the 350 threaded rod 9 and tightened to fit. 0900)page 9 AN8102 he invention is desrbed in the following statement Fig 10 depicts adjacent panels of the invention in their final configuration. The threaded rod connector 10 is shown in its welded position with the threaded rod in place 9. Also shown * are the services conduit 18 and allocated services 19. 55 Let us assume that one panel of the invention has been placed as per Fig 8, and another panel is now ready for final placement. A 10 mm bead of Hi strength construction adhesive 12 is placed on the central flange of the female edge profile 1. 360 The second panel is prepared as per the description of Fig 8, and slid into place with the male profile 2 sliding into the female profile as shown. The second panel may require a small tap in the direction of the first panel to ensure that the profile 1 and 2 lock together. 65 After a series of panels of the invention have been placed in a linear configuration, securing of the ring beam 15 should take place as per Fig 9. This allows 12 and 13 to cure as per the manufacturer's recommendation. 170 It will become apparent to those skilled in the art that this type of construction method utilising the invention will allow for the rapid erection of the invention and a full and positive structural hold method. By the simple means of cutting into the face of the invention windows and doors can easily be installed, again creating time savings. Although the invention has been described and illustrated in detail, it is understood that these specific embodiments and i methods are offered merely by way as an example and that the concept of the invention is limited in scope only by the appended claims. 3 95 90 (O1O) Page 10 AONs a113 072755 The invention is described in the following statement Claims in relation for the invention will outline: that the invention in the specification above, by its use of a polyurethane core can greatly enhance the insulation properties of construction panels. The core, by its increased 395 density during its construction also makes the invention extremely resistant to soft body impact and is self supporting, thus making the invention extremely robust and resistant to damage caused by mistreatment. Further to this, the galvanized steel profile sections that encase the invention will w00 dramatically increase the speed of construction on site. As the panel simplifies the installation of wall systems due to its ability to self align along a predefined length of edge and internal profile, less qualified trades-persons are required. This means that in remote areas, and with minimal Ws supervision, the invention can easily be configured to form a dwelling or other structures. 410 415 420 9(0109) Page 11 A3N 113 072 755

Claims

1. A prefabricated load baring wall panel for constructing the walls of a building comprising: (a) At least lease two vertical support members in a ,25 parallel special arrangement each of said members to contain either a male or female profile as described above (b) A first horizontal support member welded into place t30 on the assumed bottom of the two vertical members and substantially like the female section of the vertical female member. A second horizontal member welded to the two vertical members at the assumed top of said members. This horizontal member is 35 sectional a C type profile as described above. The vertical and horizontal sections when welded form a rectangular framework. (c) A sheet of construction sheeting is placed on either side of said rectangular framework as substantially 140 create a void therewith in. (d) A light weight ridged foam panel is formed by the insertion of a two part polyurethane liquid akin to the description above, allowed to expand within the void previously formed and incased in a pressure mold s S constructed for the purpose. Said foam adheres to the surfaces to the rectangular steel frame and the construction panels so encased, solidifying to form a self supporting panel. [50 The prefabricated wall panel according to claim 1 further comprises two threaded rod joiners welded to said male vertical profile in such a manner to allow for the insertion , via apertures in the horizontal section made for the purpose thereof, of metal 455 threaded rods for securing the panel into final construction configuration and position.

Also cut into the horizontal sections as required are penetrations suitable for the insertion of conduits for the intention of supply of services to said panel. 9 (1M page Ask 4$8113Qk215M The invention is described in the following statement

3. The cross sectional profile of the steel vertical sections and the bottom horizontal section are fabricated in such a way as to allow the sections to interlock in such a manner that allows for adjoining as5 panels constructed as per claim 1 to remain in a planar configuration suitable for use as a load baiting wall. 470

4. The prefabricated wall panel according to claim 1 wherein the foam core has a thickness equivalent to the thickness of the steel sections in profile. 475

5 The prefabricated wall panel as, outlined in claim 1, has a sheet of selected construction sheeting on each side and adhered by the bonding properties of the foam core material to the rectangular frame substantially creating the said wall panel 480

6. Steel sectional profiles are constructed in the manner described above for the purpose of locating and securing the panels constructed as in claim 1 into their gs final construction configuration and position. These sections are identified as (a) perimeter edge profile 5 and (b) intemal joiner profile 4. 490 495 500