AU2010201021A1 - A Structural Panel - Google Patents

A Structural Panel Download PDF

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Publication number
AU2010201021A1
AU2010201021A1 AU2010201021A AU2010201021A AU2010201021A1 AU 2010201021 A1 AU2010201021 A1 AU 2010201021A1 AU 2010201021 A AU2010201021 A AU 2010201021A AU 2010201021 A AU2010201021 A AU 2010201021A AU 2010201021 A1 AU2010201021 A1 AU 2010201021A1
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AU
Australia
Prior art keywords
structural panel
sheets
middle layer
sheet
panel
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
AU2010201021A
Inventor
Anthony Paul Michael
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
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Filing date
Publication date
Priority claimed from AU2009901197A external-priority patent/AU2009901197A0/en
Application filed by Individual filed Critical Individual
Priority to AU2010201021A priority Critical patent/AU2010201021A1/en
Publication of AU2010201021A1 publication Critical patent/AU2010201021A1/en
Pending legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B13/045—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B13/08—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B13/12—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/302—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B29/005—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B29/007—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/02—Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/08—Corrugated paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/18—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by an internal layer formed of separate pieces of material which are juxtaposed side-by-side
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/05—Interconnection of layers the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0221—Vinyl resin
    • B32B2266/0228—Aromatic vinyl resin, e.g. styrenic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/08—Closed cell foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/712—Weather resistant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings

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  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Building Environments (AREA)

Description

AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Name of Applicant: ANTHONY PAUL MICHAEL Actual Inventor: ANTHONY PAUL MICHAEL Address for Service: Chrysiliou Law Patent and Trade Mark Attorneys 114-115/Biztek 20 Dale Street Brookvale, Sydney NSW 2100 Invention Title: A Structural Panel The following statement is a full description of this invention, including the best method of performing it known to me/us: o:\patents\applications\I 9244.doctp 1 A STRUCTURAL PANEL Technical Field This invention relates to a structural panel particularly suitable for use in, but not restricted to, areas which are frequently exposed to extreme weather, such as s cyclone or strong wind areas. Background of the Invention Houses or buildings in rural or non-urban and some urban areas are commonly built of various structural components which are economical and easy to install. These structural components typically include weatherboards, panels and 10 lightweight building materials which are susceptible to severe damage and distortion in extreme weather such as cyclones, typhoons, strong wind or storms during monsoon seasons. Previous attempts/means to overcome the above disadvantages include application of reinforcing means such as cyclone rods or cross braces to a conventional steel or 15 timber wall frame and cladding constructed using weatherboards, panels or the like. The application of reinforcing means, however, makes installation more complicated and increases material and labour costs. It is therefore an object of the present invention to provide a structural panel and a method of installing such a panel which may overcome or ameliorate the above 20 disadvantage, or which will at least provide a useful alternative. Summary of the Invention According to one aspect of the invention, there is provided a structural panel including: a first sheet; 2 a second sheet; and a middle layer located intermediate the first and second sheets; wherein at least one of the first and second sheets is bonded to the middle layer. Preferably both the first and second sheets have side portions extending beyond the 5 middle layer. It is also preferred that both the first and second sheets have top and/or bottom portions extending beyond the middle layer. The structural panel of the present invention is intended to be joined to a plurality of other structural panels to build a house or building. The house or building may be built of the structural panels without requiring all traditional framing or bracing, io or other special or unique building elements or fixing means. In one embodiment, studs may be included but noggins, for example, are not. The structural panel is easy and quick to install without compromising the rigidity and integrity of the building. In a preferred embodiment, one or more studs are provided and located 15 intermediate extending side portions of the first and second sheets, respectively. Preferably, the or each stud is an elongate member which spans a gap between the extending side potion of the first and second sheets. The extending side portion of the first and second sheets may be connected to opposing sides of the stud thereby adding further stability to the structure. The sheets may be connected to the stud by 20 way of fixing means such as screws or nails or other suitable means. The structural panel may be adapted to be supported by and connected to a flooring plate or board. The flooring plate in this embodiment is adapted to be affixed onto one or more concrete slabs or other flooring system. The structural panel may also be adapted to support a top plate which in turn supports a roof truss. Where the 25 structural panel includes extending top and/or bottom portions, these may assist in connection to a flooring plate or board or to a top plate.
3 In a preferred embodiment, the first sheet has an exterior grade finish. More preferably, the first sheet includes a high density fibreboard. It is preferred that the high density fibreboard is WeathertexTM. In this embodiment, the second sheet functions as an internal lining to a building 5 incorporating a plurality of the structural panels of the present invention. The second sheet may also be made of a high density fibreboard, plasterboard, or the like. The middle layer may be any suitable material but, preferably, includes an insulation material being an infill between the first and second sheets. The middle io layer may include one or more of the following: polystyrene, styrofoamTM, or corrugated cardboard, for example. At least one of the first and/or second sheets may be bonded to the middle layer by an adhesive such as glue, although other suitable attaching means may be used. Conveniently, one or more apertures are provided part way, or through the entire, 15 structural panel to facilitate installation of electricity cables or gas or plumbing pipes. The structural panel may include at least one cut-out for installation of a window or door. The window or door may be a product readily available in the market place. According to another aspect of the present invention, there is provided a house or 20 building including a plurality of the structural panels described above being joined to one another by joining means. Preferably, the joining means are provided to join the structural panel to an adjacent structural panel which may be aligned on the same plane with, or disposed at an angle to, the structural panel. Typically, the angle is 90 degrees.
4 In a preferred embodiment, the middle layer includes one or more removable extension bars. Preferably, the middle layer has a pair of extension bars running along its opposite lateral sides, respectively. When the structural panel is at an angle to the adjacent structural panel, a portion of the first and second sheet of both 5 panels needs to be removed so as to facilitate joining of tie two panels. In this case, the extension bar is removed from the middle layer of both panels so as to allow placement of a stud for stabilising the first and second panels. According to a further aspect of the present invention, there is provided a method of installing the structural panel described above, the method including the steps 10 of providing a bottom plate adapted to support the structural panel; affixing an extending portion of the first sheet to the bottom plate; affixing a second sheet onto the bottom plate with a middle layer of material spanning a gap between the first and second sheets; 15 placing one or more studs between the first and second sheets adjacent the middle layer of material; and affixing the first sheet to one side of the or each stud and the second sheet to an opposite side of the or each stud. The method includes a further step of providing a top plate adapted to engage and 20 rest on an upper extending portion of the first and second sheets. Brief Description of the Drawings The invention may be better understood from the following non-limiting description of preferred embodiments, in which; 5 Figure la is a side elevation of a panel structure in accordance with one embodiment of the invention, the panel structure being adapted to be installed horizontally; Figure Ib is an end view of the panel structure of Figure 1 a; a Figure 1 c is a plan view of the panel structure of Figure 1 a; Figure 2a is a side elevation of a panel structure in accordance with another embodiment of the invention, having one of the sheets removed, the panel structure being adapted to be installed vertically; Figure 2b is a plan view of the panel structure of Figure 2a; 10 Figure 2c is a plan view of the middle layer of Figure 2b; Figure 3 is a perspective view from top of the panel structure of Figure 1 a in use; and Figure 4 is a perspective view of the panel structure of Figure 1 a being joined to another structural panel. 15 Detailed Description of the Drawings Referring to Figures 1 a to c, a structural panel 10 includes first and second sheets 12 and 14. The first sheet 12 provides an internal surface 16 while the second sheet 14 provides an external surface 18. The structural panel 10 also includes a middle layer 20 located intermediate the first and second sheets 12 & 14. 20 In this embodiment, each of the first and second sheets 12 and 14 is bonded to the middle layer 20. The first sheet 12 is made of a specific type of high density or other internal grade panel. The second sheet 14 is a high density fibreboard with an exterior grade finish such as WeathertexTM which forms an external lining to a building incorporating a plurality of structural panels 10.
6 The middle layer 20 is a block of insulation material made of, for example, polystyrene or Styrofoam
TM
, being an infill between the first and second sheets 12 and 14. As best shown in Figure 1 c, the middle layer 20 has a plurality of indents 22 and recesses 24. The indents 22 and recesses 24 are in communication with 5 apertures (not shown) provided into part of the sheets 12 & 14 of structural panel 10 to facilitate installation of electricity cables and gas and plumbing pipes. Turning now to Figures 2a and b, another embodiment of structural panel 100 of the present invention is shown. Similar to the arrangement of the embodiment described above, a layer of insulation material 200 is sandwiched between sheets 10 120 & 140. The lateral sides of the layer of insulation material 200 in this embodiment are concealed respectively by two easily removable elongate extension bars 280 & 300 which are lightly glued onto the middle layer 200. Also, the layer of insulation material 200 has apertures 320 which serve the same purposes as the recesses 24 of the middle layer 20 described above. 15 Referring to Figures Ic and 2b, it can be observed that the sheets 12 and 14 or 120 and 140 of the structural panels 10 or 100 respectively are longer and wider than the layer of insulation material 20 or 200. Extending lower portions 42 and 420 respectively are designed to engage and be affixed to a flooring plate such as that shown as 106 in Figure 4 which is in turn laid over concrete slabs, for example. 20 Extending upper portions 40 and 400 respectively are configured to engage a top plate (not shown) which in turn supports a roof truss (not shown). As shown in Figures 3 and 4, the structural panel 100 is erected and joined to another structural panel 102 by way of joining means (not shown) provided at the corner 104. The panel structure 100 has cut-outs 108 & 110 of different dimensions 25 for installation of a window and a door. The cut-outs may be created on site, as desired.
7 An embodiment of the procedure of installing the panel structure of the present invention will now be described. The first step is to place a bottom plate 106 at a predetermined location on a construction site. The bottom plate 106 which is provided to support the structural panel 100 is fixed to the ground or to an 5 underlying structure such as a concrete slab. The first sheet 120 is then erected with its extending lower portion 420 affixed to the bottom plate. In a similar manner, the extending lower portion 420 of the second sheet 140 is directly or indirectly affixed to the bottom plate 106 after erection thereof opposite the first sheet 120. The middle layer of material is pre-adhered onto either or both of the first and/or 1a second sheets 120 and/or 140 and hence once the sheets 120 & 140 are placed on and affixed to the bottom plate 106, the middle layer of material 200 spans a gap between the first and second sheets 120 & 140. Referring to Figure 1 a and 2a, each of the structural panels 10 & 100 has extending side portions 41,43 and 410,430 respectively running along their respective lateral 15 edges. In the case of panel 100, studs 302 and 304 (refer to Figure 3) are placed between the side portions 41 & 43 and 410 & 430, respectively, adjacent the middle layer of material 200. The studs 302 and 304 are elongate members made of either steel or timber. The first sheet 120 is affixed to one lateral side of each stud 280 and 300 and the second sheet 140 to an opposite side, using fixing means such 20 as screws or nails. As such, the first and second sheets 120 & 140 are firmly bound to one another via the studs 302 and 304. It is contemplated that the sheets 120 and 140 may be affixed to the floor plate first before they are attached to the studs 302 and 304 respectively. These steps however may be carried out in a reverse order. 25 It should be appreciated that a plurality of structural panels of the present invention may be aligned on the same plane to form a structural wall. Alternatively, adjacent structural panels may be disposed at an angle to one another as shown in Figures 3 and 4. In the latter case, the embodiment shown in Figures 2a and b is to be 8 applied. To facilitate joining of adjacent structural panels 100 disposed at an angle to each other, the extending side portion of the internal (second) sheet 120 of both panels 200 needs to be removed. Also, as can be seen in Figures 2a and b, the middle layer 200 of each panel has two removable extension bars 280 & 300 which 5 run along the opposite lateral sides of the middle layer 200. Before the two structural panels 100 and 102 are placed at an angle (such as 90 degrees) to one another, one of the extension bars 280 or 300 (the one on the side to be joined) is removed. This should be a relatively easy exercise as the extension bars 280 & 300 are only lightly glued onto the middle layer 200. The removal of an extension bar io from both joining panels 100 and 102 provides a cavity for placement of the stud 302, 304 (refer to Figure 3) which facilitates securing of the first and second sheets 120 & 140 to one another. Once all of the structural panels required for the house or building are installed by repeating the same procedure as described above, a top plate (not shown) is 15 provided to engage and rest on the extending upper portions 40 or 400. The top plate is configured to support a roof truss. It should be appreciated that houses or buildings built of the structural panels of the present invention do not require all traditional framing or bracing. The arrangement and configuration of the sheets 120 & 140 together with the studs 302 & 304 mean 20 that the structural panel 10, 100 or 102 has high tensile and compression strengths which enable it to sustain in extreme weather. Now that preferred embodiments of the present invention have been described in some detail, it will be apparent to those skilled in the art that embodiments of the panel structure may offer at least the following advantages: 25 (1) easy and quick to install without compromising the rigidity and integrity of the house or building; 9 (2) only minimal tools, namely circular saw, nail gun and spirit level are required for installation; (3) no or less traditional framing, bracing, or hold down bolts are required; (4) minimal or no trade skills are required; 6 (5) no special (not readily or locally available) components, fixings or panels are required; (6) no setting for architectural joins for the second sheets which form the internal lining is required (this however is optional and may be included if required); (7) significantly reduction of transportation costs (only sheets in flat packs are 10 required to be transported to the construction site; ancillary components such as fixing means, studs, top and bottom plates, window or door frames etc. can be sourced locally); and (8) design or design changes can easily be done remotely or locally or at the construction site, ie. full design and inflexible remote prefabrication is not 15 required. Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. All such variations and modifications are to be considered within the scope and spirit of the present invention the nature of which is to be determined from the 20 foregoing description.

Claims (28)

1. A structural panel including: a first sheet; a second sheet; and 5 a middle layer located intermediate the first and second sheets; wherein at least one of the first and second sheets is bonded to the middle layer.
2. The structural panel of claim 1, wherein each of the first and second sheets has side portions extending beyond the middle layer. 10
3. The structural panel of either claim 1 or 2, wherein each of the first and second sheets has top and/or bottom portions extending beyond the middle layer.
4. The structural panel of claim 2 in combination with one or more studs located intermediate the extending side portions of the first and second 15 sheets, respectively.
5. The structural panel of claim 4, wherein the or each stud is an elongate member which spans a gap between the extending side potion of the first and second sheets.
6. The structural panel of either claim 4 or 5, wherein the extending side 20 portion of the first and second sheets is connected to opposing sides of the or each stud.
7. The structural panel of any one of claims 4 to 6, wherein the first and second sheets are connected to the stud by way of fixing means. l1
8. The structural panel of any one of the preceding claims in combination with a flooring plate or board adapted to be affixed onto one or more concrete slabs or other flooring system.
9. The structural panel of any one of the preceding claims, in combination with 5 a top plate which in turn supports a roof truss.
10. The structural panel of any one of the preceding claims, wherein the first sheet includes a high density fibreboard.
11. The structural panel of any one of the preceding claims, wherein the second sheet functions as an internal lining to a building. 10
12. The structural panel of any one of the preceding claims, wherein the second sheet is made of a high density fibreboard, plasterboard, or the like.
13. The structural panel of any one of the preceding claims, wherein the middle layer includes an insulation material.
14. The structural panel of claim 13, wherein the middle layer includes one or 15 more of the following: polystyrene, styrofoam m and corrugated cardboard.
15. The structural panel of any one of the preceding claims, wherein at least one of the first and second sheets is bonded to the middle layer by an adhesive.
16. The structural panel of any one of the preceding claims, which includes one or more apertures part way, or through the entire structural panel. 20
17. The structural panel of any one of the preceding claims, which includes at least one cut-out for installation of a window or door.
18. The structural panel of any one of the preceding claims, wherein the middle layer includes one or more removable extension bars. 12
19. The structural panel of claim 18, wherein there is a pair of extension bars running along opposite sides of the middle layer.
20. A house or building including a plurality of the structural panels of claim 1, the panels being joined to one another by joining means. 5
21. The house or building of claim 20, wherein the joining means are provided to join the structural panel to an adjacent structural panel which is aligned on the same plane with, or disposed at an angle to, the structural panel.
22. The house or building of claim 23, wherein the angle is 90 degrees.
23. A method of installing the structural panel of claim 18 or 19, the method 10 including the steps of: providing a bottom plate adapted to support the structural panel; affixing an extending portion of the first sheet to the bottom plate; affixing a second sheet onto the bottom plate with a middle layer of material spanning a gap between the first and second sheets; 15 placing one or more studs between the first and second sheets adjacent the middle layer of material; and affixing the first sheet to one side of the or each stud and the second sheet to an opposite side of the or each stud.
24. The method of claim 23, which includes a yet further step of joining the 20 panel to another panel, at least one of the extension bar being removed from the middle layer of both panels so as to allow placement of a stud.
25. The method of claim 24, which includes a yet further step of removing a portion of the first and second sheet of both panels so as to facilitate joining of the two panels. 13
26. The method of any one of claims 23 to 25, which includes a further step of providing a top plate adapted to engage and rest on an upper extending portion of the first and second sheets.
27. A structural panel substantially as herein described with reference to any 5 one of the accompanying drawings.
28. A method of installing a structural panel substantially as herein described with reference to any one of the accompanying drawings.
AU2010201021A 2009-03-19 2010-03-17 A Structural Panel Pending AU2010201021A1 (en)

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