AU2013204418A1 - An improved building panel - Google Patents

Abstract

An improved building panel for transportable housing, in which the panel includes two back to back skins connected via a prong and rod assembly and filled with lightweight concrete and adapted for the inclusion of an insulating layer within the panel. The prong and rod assembly forms a framework support which allows the use of lightweight concrete without compromising the integrity of the structure, allowing easy assembly and transportation. co

Description

1 An improved building panel TECHNICAL FIELD [0001] This invention relates to an improved building panel consisting of two panel skins connected by prongs and rods and filled with lightweight concrete. BACKGROUND ART [0002] In building construction it is possible for wall structures and panels to be made from concrete components as they generally are cost effective, energy efficient and durable. In particular concrete building structures are often used for low-income housing and transportable and temporary housing such as those used for mining accommodation. [0003] The disadvantage of traditional concrete structures is the relative weight of the structure compared to a wood-frame and in particular the difficulty and cost associated with the transport of the structure. It would be advantageous if the building frame is constructed entirely in the factory and then transported to the building site, however current concrete structures are too heavy for such transport. However, if less concrete is used in the panel or frame it does not provide sufficient density and strength to support the structure. There is also a danger that the concrete may become cracked or damaged during transportation. [0004] It would therefore be advantageous for such a structure to maintain the advantages of concrete panels, however be light enough to allow for transport. It would be further advantageous for the panel system to be easily assembled by a low-skilled labourer and include an insulating layer of material.

2 [0005] Currently there is no building panel of lightweight concrete containing an insulating layer known to the Applicant with the improvements described herein [0006] It should be noted that any one of the aspects mentioned above may include any of the features of any of the other aspects mentioned above and may include any of the features of any of the embodiments described below as appropriate. SUMMARY OF THE INVENTION [0007] Therefore, according to one aspect, the present invention provides an improved building panel including a first and a second skin, each skin comprising a flat surface on the outer side and a connecting means on the inner side, the connecting means of each skin adapted to fixedly and spatially engage the two skins together, forming a cavity therein; [0008] In an embodiment, the connecting means is a protruding prongs or a plurality of protruding prongs; [0009] In an embodiment, each protruding prong contains at least one aperture; [0010] In an embodiment, wherein at least one prong aperture on the first skin aligns with another prong aperture on the second skin forming a common aperture for the insertion of a connecting rod; [0011] In an embodiment, wherein the prong contains a plurality of apertures on a first skin which can be aligned with one or a plurality of apertures on a second skin for the insertion of a connecting rod; 3 [0012] In an embodiment, according to any of the above claims wherein the first and second skins contains a plurality of prongs and an aperture on the prongs of the first skin align with an aperture on the prongs of the second skin forming a plurality of aligned apertures for the insertion of rods; [0013] In an embodiment, according to any of the above claims wherein the cavity is filled with a material; [0014] In an embodiment, according to any of the above claims wherein the material is lightweight concrete; [0015] In an embodiment, according to any of the above claims wherein there is an insulating layer within the cavity; [0016] In an embodiment, according to any of the above claims wherein the insulating layer is foam or polystyrene; [0017] In an embodiment, according to any of the above claims comprising, at least two skins, each skin comprising a flat surface on the outer side and a number of projecting prongs on the inner side connecting the two skins and forming a cavity therein, prongs which rest adjacent to one another and contain aligning apertures within the cavity, rods which are adapted to be inserted through the aligned apertures; and lightweight concrete encasing the prongs and rods; 4 [0018] In an embodiment, according to any of the above claims comprising, at least two skins, each skin comprising a flat surface on the outer side and a number of projecting prongs on the inner side connecting the two skins and forming a cavity therein, prongs which rest adjacent to one another and contain aligning apertures within the cavity, rods which are adapted to be inserted through the aligned apertures; and lightweight concrete encasing the prongs and rods; and [0019] In an embodiment, a method of constructing a wall comprising a panel as defined by any of the above claims and then filling with lightweight concrete.

5 BRIEF DESCRIPTION OF THE DRAWINGS [0020] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various implementations of the invention and, together with the description, serve to explain the advantages and principles of the invention. In the drawings: [0021] Figure 1 is a cross-sectional view of a building panel consisting of two panel skins connected by prongs and rods and lightweight concrete filling the cavity defining an embodiment of the invention; [0022] Figure 2 is a cross-sectional view of a building panel consisting of two panel skins connected by prongs and rods, a layer of insulating foam therein and lightweight concrete filling the remaining cavity defining an embodiment of the invention; [0023] Figure 3 is a perspective view of two unconnected panel skins, with prongs being visible on one panel skin; [0024] Figure 4 is a part perspective view of a building panel consisting of two panel skins with the central apertures aligned and a rod connecting the skins through the centrally aligned aperture defining an embodiment of the invention; and [0025] Figure 5 is a perspective view of a building panel consisting of two panel skins secured by prongs and rods and filled with lightweight concrete according to an embodiment of the invention. LIST OF COMPONENTS 20 building panel 22 panel skin 24 prong 26 aperture 28 rod 6 30 lightweight concrete 32 base for prongs 34 insulating material DESCRIPTION OF EMBODIMENTS [0026] The following detailed description of the invention refers to the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts. Dimensions of certain parts shown in the drawings may have been modified and/or exaggerated for the purposes of clarity or illustration. [0027] Turning now to the drawings there is illustrated in Figure 1 a building panel 20 containing two panel skins 22. It is a preferred embodiment of the invention that each panel skin 22 has a dimension of 1200x600x4mm and is constructed from high impact polystyrene resin, however it is to be understood that the invention includes panels of any size or materials. [0028] Each panel skin 22 consists of a flat surface on the obverse outer side and a number of projecting prongs 24 on the reverse inner side. Thus, when constructed to form the panel, the reverse inner sides of each panel skin face one another and form a cavity. The prongs 24 may be regularly spaced on each skin 22 so to align to one another, with a slight offset determined by the thickness and/or placement of the prong 24. Thus the corresponding prongs 24 on either skin 22 overlap, allowing the skins 22 to connect and form the cavity therein. [0029] The prongs 24 further contain regularly spaced cylindrical apertures 26 which align with one another once the skins have been joined and the prongs 24 of each skin are aligned. Cylindrical tapered end rods 28 can then be inserted through the aligned apertures 26 to securely connect the skins 22 together and prevent independent movement on either the vertical or horizontal plane. It is a preferred embodiment of the invention that the apertures 26 are of a slightly smaller diameter than the outer diameter of the rods 28 so that when screwed into place the rods 28 cut their way through the 7 prongs 24 creating a tight inference fit. In an alternate embodiment of the invention, the rods 24 are externally threaded and when taper cut will thread securely through the apertures 26. [0030] In an embodiment of the invention the prongs 24 are designed with several apertures 26 so that the rods 28 can be inserted at different positions allowing for the creation of differing thicknesses of the structure enclosed by the panels. Therefore, the same panel system and skin structure can be used for various building models and eliminates the need for separate constructions of skins 22 to suit the construction of a range of panels. The single panel structure adapted to construct panels of varying thickness can therefore lower production cost and increase user efficiency. [0031] Such an embodiment of the invention is illustrated in Figure 1, wherein each prong 24 contains two cylindrical apertures which are aligned with the two cylindrical apertures of the corresponding prong 24 of the other skin 22. When connected, the cavity between the skins 22 is defined by the length of the overlapping, aligned prongs. The user can therefore insert a rod 28 through either of the aligned apertures 26, or rods through both if required. Such an embodiment is useful when panels of a narrower size are required, or for panels that do not require additional insulating materials. It is to be understood that the prongs 24 can contain any number of apertures. [0032] A further embodiment of the invention is illustrated in Figure 2, wherein each prong 24 contains two cylindrical apertures, however only one aperture 26 of each corresponding prong 24 is aligned. When connected, the cavity between the skins 22 is defined by the length of the conjoined prongs 24 and therefore provides a larger cavity than when both apertures are aligned. The user can therefore insert a rod 28 through the centrally aligned apertures 26 [0033] The use of this tight inference fit is therefore an improvement over the prior art by using standard deformed reinforcing rods to hold the skins 22 together. Therefore, the present invention is an improvement over the prior art where both sides of the skins 22 are brought together and held in place by the centrally located rods 28, inserted vertically through the confluence of the skins 22 and so brought together to create the 8 panel 20. By assembling back to back panel skins 22 and inserting rods 28 through the prongs 24 in order to connect the skins 22, a continuous cavity and homogenous single unit is created, ready to be filled with material [0034] Illustrated in Figure 3 is a perspective view of two skins 22 which are not yet connected, and in which the plurality of prongs 22 can be seen on the reverse inner side of one skin 22. As illustrated, there can be several rows of prongs 24 on horizontal planes which would correspond with the prongs 24 on the other skin 22. As illustrated, the prongs 24 can be part of a larger framework attached to the inner side of the skin 22, in which there are a plurality of prongs 24 attached to a base 32 extruding from the inner wall of the skin 22. [0035] It is a preferred embodiment of the invention that the prongs 24 and base 32 are on a horizontal plane, with the rods 28 inserted through the aligned apertures on a vertical plane. However, it is to be understood that the prongs 24 and base 32 could be on a vertical plane of the inner side of the skin 22 and perform the same function, with the rods 28 being inserted through the aligned apertures on a horizontal plane. [0036] Illustrated in Figure 4 is a perspective view of the two skins 22 connected according to an embodiment of the invention. In this embodiment, a single aperture 26 of each prong 24 is aligned with its counterpart on the opposite skin 22, and rods 28 have been inserted through the aligned apertures. As illustrated, all of the prongs 24 are aligned with the prongs 24 above and below them allowing for the insertion of the rods 28. Thus the panel skins 22 are securely connected to form the framework of the building panel 20. [0037] The structure of the present invention allows movement of the panel faces when filled with dense materials such as concrete 30, which in the prior art may cause an unsightly random bowing effect in the finished walls. In the present invention, however, the rods 28 secure the prongs 24 and panel skins 22 together firmly and create a cavity designed to be filled with any flowable mouldable material including insulating foams and expanding foams for insulating and acoustic purposes and create a solid panel 20.

9 [0038] Concrete 30 would typically be used as a filler material and the formwork created by the skins 22, prongs 24 and rods 28 remain in place with the obverse sides of the skins 22 making the surface of the structure. The concrete 30 can therefore be poured directly into the cavity created by the panel skins 22, prongs 24 and rods 28 to create the solid structure of the panel. As the rods 28 within the structure hold the skins 22 together there is no need for the use of external formwork as the forces exerted by the filling material are evenly distributed in all directions and held by each skin 22 in conjunction with its opposite. Illustrated in Figure 5 is the building panel 20 consisting of the two skins 22 in which the cavity has been filled with lightweight concrete. It is to be understood that the rods 28 are present in the drawing for illustrative purposes, and in a preferred embodiment the height of the rods 28 would not exceed the height of the skins 22. [0039] In order to facilitate the filling of the panels with concrete of many types, particularly concrete of a large aggregate size, the filled side of the panel is relatively smooth and free of projections so that no obstruction is caused to the free flowing of the concrete in the filling process. This prevents the creation of voids and pockets commonly caused in the prior art due to the extreme number of projections into the filled space. [0040] Due to this design there is no or little need for the vibrating of the walls during filling. Vibrating can be removed by the use of a low level of plasticiser as an alternative. This further increases cost-effectiveness and takes away the risk of over vibrating, which can cause bursting of the panels due to aggregation and dewatering of the wet concrete. A further advantage is that given the ease in constructing the panel and adding the concrete, potentially the panel could be constructed by a lower skilled labourer at a lower cost without complicated building processes. [0041] It is a preferred embodiment of the invention that lightweight concrete is used as the filler material. This has the advantage of being more cost effective given that it is cheaper than aggregate concrete, and has environmental benefits as aggregates require crushing and overall lightweight concrete has a lower C02 burden than 10 aggregate concrete. The invention, therefore, is more environmentally friendly and has a lower carbon footprint than traditional concrete structures. [0042] As lightweight concrete has a lower density and weight than standard concrete, the overall weight of the panel 20 is less than one constructed with standard concrete. As such, the entire structure can be assembled in the factory and transported to the building site as it is not too heavy to be transported on trucks. As such, no assembly of the panels 20 or structure is required on-site and the assembly and transport costs from the factory are less than they would be had the structure been assembled on-site with the need for skilled workers. As it has a lower density, lightweight concrete is not as strong as standard concrete, however the advantage of the present invention is that the support strength is provided through the combination of the panel structure including the skins 22, prongs 24, rods 28 and lightweight concrete 30. Using the wide variety of strengths available with lightweight concrete the panel provides a suitable strength and durability for a wide variety of building applications , but at a lower weight allowing it to be assembled and transported easily, and at a lower cost than standard concrete. [0043] In an embodiment of the invention, custom fit service conduits can also be placed in the panel 20 or structure at the time of assembly at the factory before the pouring of the concrete 30. When the structure is assembled on-site, this is time consuming as the structure needs to be assembled by one user, the service conduits need to be installed by another user, and only then can the concrete be poured. Given that the users may not all be available at the same time, the assembly of the structure is fragmented and vulnerable to the weather conditions. The advantage of the present invention is that all of this work can be done at the factory in a timely manner and before the structure is transported to the site, and reducing the time of skilled trades. Placing the conduits inside the panel 20 and secured by the concrete also ensures that all services have maximum protection after installation. [0044] When the cavity is filled with concrete 30 the outer skin 22 becomes the permanent skin of the structure wall, which is automatically water and termite proof and can then be painted, rendered or tiled to suit any architectural facade look. It is a preferred embodiment that the obverse sides of the skin 22 are created with a patina to 11 mimic a slight texture to facilitate the adhesion of various finishing surfaces to the panel 22. [0045] In an embodiment of the invention, the panel 20 can also contain a reinforcing mesh (not shown) inside the cavity and encased in the concrete 30 to further support the panel structure. The structure using the panels is therefore strong and durable and has all the advantages of standard concrete panels, however is more cost effective, environmentally friendly is easier to construct and requires minimal maintenance due to the panel configuration and use of lightweight concrete. [0046] In an alternate embodiment of the invention, the structure can be manufactured and tailor made then assembled and flat-packed at the factory, then transported to the building site in kit form and constructed on-site. [0047] In an embodiment of the invention the panel contains an insulating layer such as polystyrene or foam 34 to further increase the energy efficiency to the structure as illustrated in Figure 2. This foam 34 is inserted into the cavity prior to the concrete 30, and is encased complexly within the panel 20 with concrete 30 on either side. This adds a further insulating property to the structure and increases energy efficiency. [0048] In this alternate embodiment of the invention briefly discussed above, the panel 20 is so placed that the prongs 24 only overlap with one set of apertures 26 securely connected by a central rod 28 acting as the connecting means between the panel skins 22. This is used when the panel width is required to be larger due to the type of structure or to allow for the additional insulating layer 34. This central rod 36 is located through a different alignment of apertures 26 in the prongs 24 that form part of the panel skins 22 and line up to facilitate insertion of the rods 28 when the panels are placed back to back. The prongs 24 have been designed so as not to interfere with each other at either of the two possible connection points created by the placement of multiple apertures 26 in the prongs 24. This is an improvement on the prior art where projections interfered with each other at certain connection points, causing distortion of the panels and interfering with the ease of assembly particularly in the horizontal direction.

12 [0049] In an embodiment of the invention, to enable the panel skins 22 to be inserted together vertically to make a continuous wall, a rectangular groove and prong system is created along the horizontal edge, making a discrete rectangular box the edges of which are flush with the panel edge. Each rectangular box 38 receives a tapered prong and tab and is repeated at 100mm to ensure a precise location between adjoining vertical panels. The tolerances in this system are the minimum consistent with ease of assembly but do not allow for free movement of the panel wall along the panel face adjacent to the panel join. This system removes the possibility of joint movement and thus allows for the seamless addition of third party coatings, such as render, without the development of cracks at the joint face. This is consistent with popular render coatings common in modern domestic and commercial buildings and opens up the market to an expanded number of possible buyers previously prevented from using the system due to joint movement. [0050] In order to allow the close placement of the panels 22 horizontally without disturbing the rectangular boxes described above the vertical joins have a tab bayonet design that allows first insertion horizontally to a "home" depth and then a vertical travel at 900 to a depth consistent with the tapered box 28 described above. Combined, they ensure the panels can be connected in one manner only. This is an improvement over the prior art where panels could be joined incorrectly, requiring time consuming disassembly and if necessary discarding and re assembly. The possibility of this expensive process occurring is completely removed with this invention as there is only one connection means. [0051] In the summary of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprising" is used in the sense of "including", i.e. the features specified may be associated with further features in various embodiments of the invention.

Claims (13)

1. A panel comprising a first and a second skin, each skin comprising a flat surface on the outer side and a connecting means on the inner side, the connecting means of each skin adapted to fixedly and spatially engage the two skins together, forming a cavity therein.

2. A panel according to claim 1 wherein the connecting means is a protruding prongs or a plurality of protruding prongs.

3. A panel according to any of the above claims wherein each protruding prong contains at least one aperture.

4. A panel according to any of the above claims wherein at least one prong aperture on the first skin aligns with another prong aperture on the second skin forming a common aperture for the insertion of a connecting rod.

5. A panel according to any of the above claims wherein the prong contains a plurality of apertures on a first skin which can be aligned with one or a plurality of apertures on a second skin for the insertion of a connecting rod.

6. A building panel according to any of the above claims wherein the first and second skins contains a plurality of prongs and an aperture on the prongs of the first skin align with an aperture on the prongs of the second skin forming a plurality of aligned apertures for the insertion of rods .

7. A building panel according to any of the above claims wherein the cavity is filled with a material.

8. A building panel according to any of the above claims wherein the material is lightweight concrete.

9. A building panel according to any of the above claims wherein there is an insulating layer within the cavity.

10. A building panel according to any of the above claims wherein the insulating layer is foam or polystyrene.

11. A building panel according to any of the above claims comprising; 14 at least two skins, each skin comprising a flat surface on the outer side and a number of projecting prongs on the inner side connecting the two skins and forming a cavity therein; prongs which rest adjacent to one another and contain aligning apertures within the cavity; rods which are adapted to be inserted through the aligned apertures; and lightweight concrete encasing the prongs and rods.

12. A building panel according to any of the above claims comprising; at least two skins, each skin comprising a flat surface on the outer side and a number of projecting prongs on the inner side connecting the two skins and forming a cavity therein; prongs which are adapted rest adjacent to one another and contain aligning apertures within the cavity; rods are adapted to be inserted through the aligned apertures an insulating layer within the cavity; lightweight concrete encasing the insulating layer, prongs and rods.

13. A method of constructing a wall comprising a panel as defined by any of the above claims and then filling with lightweight concrete.