AU2016100991A4 - A Wall Assembly - Google Patents

Abstract

A wall assembly includes a track for fastening to a substrate. At least two panels have opposite top and bottom edges and opposite side edges, with each panel defining a recess in a bottom edge of the panel, the track being receivable in the recess when the panels are positioned side-by-side on the track. At least one connector is provided for fastening between the track and the top edges of the panels for securing the panels to the track. co 1/4 Co A o coo CCY) Coo 04 Co C LL0 CCo Tm(9 CD-

Description

A WALL ASSEMBLY

FIELD

[0001] Various embodiments of a wall assembly are described in this specification.

SUMMARY

[0002] Various embodiments of a wall assembly comprise a track for fastening to a substrate; at least two panels, each panel having opposite top and bottom edges and opposite side edges, with each panel defining a recess in a bottom edge of the panel, the track being receivable in the recess when the panels are positioned side-by-side on the track; and at least one connector for fastening between the track and the top edges of the panels for securing the panels to the track.

[0003] The wall assembly may include a clamp member for positioning on the top edges of the panels and engageable with the, or each, connector so that the panels can be clamped between the clamp member and the track.

[0004] The side edges may define complementary nesting formations so that adjacent side edges of the panels can nest together, with one connector being interposed between the adjacent side edges.

[0005] Each panel may be a composite panel, with a core interposed between outer sheets.

[0006] The sheets may be truncated at one side edge and may project beyond the core at the other side edge to define the complementary nesting formations in the form of complementary projections and recesses.

[0007] Various embodiments of a wall assembly comprise a track for fastening to a substrate; at least two panels, each panel having opposite top and bottom edges and opposite side edges, with each panel defining a recess in a bottom edge of the panel, the track being receivable in the recess when the panels are positioned side-by-side on the track; and at least one locator for each panel, the locators being fastenable to a ceiling above the substrate and being operable to engage the top edges of the panels when the panels are positioned side-by-side on the track.

[0008] The top edge of each panel may define a recess that extends along the top edge.

[0009] Each locator may include a sleeve that is mountable in the ceiling and a plunger that is positioned in the sleeve, the plunger being displaceable from an inoperative position in the sleeve and an operative position in which the plunger extends from the sleeve and into the recess in the top edge to locate the panels with respect to the ceiling.

[0010] The plunger of each locator may be capable of free displacement with respect to the sleeve and the locator may include a retaining device to retain the plunger in the operative position against gravity, the retaining device being operable to allow the plunger to drop into the operative position.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 shows a three-dimensional view of an exemplary embodiment of a wall assembly.

[0012] Figure 2 shows a three-dimensional view of part of a clamp member and tie rod assembly of the wall assembly of figure 1.

[0013] Figure 3 shows an exploded view of a panel of the wall assembly of figure 1.

[0014] Figure 3A shows part of the wall assembly, indicating overlap of reinforcing mesh.

[0015] Figure 4 shows a pair of panels of the wall assembly of figure 1.

[0016] Figure 5 shows an exploded view of one of the panels of figure 4.

[0017] Figure 6 shows a three-dimensional view of an exemplary embodiment of a wall assembly.

[0018] Figure 6A shows an example of a track for the wall assembly.

[0019] Figure 7 shows a three-dimensional view of part of the wall assembly of figure 6 illustrating a method for locating the wall assembly relative to a ceiling.

[0020] Figure 8 shows an exploded view of a floor mounting arrangement of an exemplary embodiment of a wall assembly.

[0021] Figure 9 shows an exploded view of a further floor mounting arrangement of an exemplary embodiment of a wall assembly.

DETAILED DESCRIPTION

[0022] In figure 1, reference numeral 10 generally indicates an exemplary embodiment of a wall assembly.

[0023] The wall assembly 10 includes a number of panels 12, two of which are shown, for convenience. Each panel 12 has opposite top and bottom edges 14, 16 and opposite side edges 18.1, 18.2.

[0024] The wall assembly 10 includes a track 20. The bottom edge 16 defines a recess 22 along its length. The track 20 is receivable in the recess 22 when the panels 12 are positioned side-by-side.

[0025] The wall assembly 10 includes connectors in the form of tie rods 24 that can be located between the edges 18.1 and 18.2 for fastening between the track 20 and the top edges 14 for securing the panels 12 to the track 20. The connectors can take other forms, such as straps.

[0026] A clamp member or clamp 26 can be positioned on the top edges 14. The clamp 26 is engageable with the tie rods so that the panels 12 can be clamped between the clamp 26 and the track 20. The clamp 26 can thus form a top rail for the wall assembly.

[0027] The side edges 18.2 define complementary nesting formations 28 so that adjacent side edges 18.1, 18.2 of the panels 12 can nest together, with one or more tie rods 24 being interposed between the adjacent side edges 18.1, 18.2.

[0028] Each panel 12 is a composite panel with a core 30 interposed between outer sheets 32.

[0029] The core 30 is sandwiched between two sheets 31 of reinforcing mesh. The reinforcing mesh can take any number of forms. For example, it can be a mesh of a plastics material or fibre glass. This is illustrated in figure 3A. As can be seen, the sheets 31 of adjacent panels 12 overlap in a zone 33. This serves to reinforce a joint between the panels 12. Furthermore, with the use of the glue or adhesive as set out below, the resultant wall assembly can effectively be a single, solid structure with exceptional racking and lateral capabilities.

[0030] The panels 12 are pre-meshed with the sheets 31. The panels 12 are rendered on site with the sheets 31 in the overlapping configuration.

[0031] The sheets 32 are truncated at one side edge 18.1 and project beyond the core 30 at the other side edge 18.2 to define the complementary nesting formations 28 in the form of complementary projections 34 and recesses 36 (figure 4).

[0032] The track 20 can take a number of different forms. In figure 1, the track 20 is shown generically. Thus, for example, the track 20 could be in the form of an elongate channel that is inverted so that a floor of the channel is spaced from the substrate. In this example, the recess 22 could be formed by removing a lower portion of the core 30 so that the sheets 32 extend downwardly beyond the core 30. Thus, the track 20 could be of a similar width to the core 30.

[0033] The clamp 26 can also be in the form of a channel member that opens downwardly so that a floor 38 of the clamp 26 bears against the top edge 14 while downwardly extending lips 40 of the clamp 26 over lie top portions of the sheets 32, respectively. The clamp 26 can thus form an end cap for the wall assembly 10.

[0034] The tie rods 24 pass through openings in the floor 38 and extend downwardly into the track 20. The tie rods 24 can be threaded into the track 20.

Upper ends 42 of the tie rods 24 are threaded so that nuts, such as wing nuts 44, can be threaded onto the upper ends 42 to bear against the track 20, so clamping the panels 12 between the track 20 and the clamp 26. The tie rods 24 can be fixed in other ways, for example, permanently with a suitable adhesive.

[0035] A number of brackets 46 are fastened to the clamp 26 so that the wall assembly 10 can be secured to a ceiling arrangement, or similar structure.

[0036] The nature of the panels 12 is illustrated in figures 3 to 5. The core 30 is of an expanded plastics material, such as polystyrene, Polyphen ® (a thermal insulation foam), polyurethane, or any other material that may be suitable for a specific purpose. The core 30 can also be of other materials, such as fire-resistant materials. The outer sheets 32 can be of a number of different building materials used for outer layers. For example, the outer sheets 32 can be of fibre cement.

[0037] The outer sheets 32 are fastened to the core 30 in a gluing operation. For example, a glue pattern on the core can include lines 35 of glue that extend top to bottom on the core 30. A glue pattern on each of the outer sheets 32 can include lines 37 of glue that extend side-to-side on the outer sheets 32. Thus, when the outer sheets 32 are pressed onto the core 30, the resultant gluing pattern provides a higher adhering strength to glue usage than would be the case if random or corresponding patterns were used.

[0038] In use, conventional fasteners can be used to locate the different components while the glue or adhesive reaches full strength.

[0039] The glue used may take different forms. One example of a suitable glue is a low-foaming polyurethane glue.

[0040] Optionally, a fibreglass mesh can be positioned between the core 30 and the respective outer sheets 32.

[0041] When the sides 18.1, 18.2 are glued together, glue is applied to all the surfaces prior to pushing the projections 18.1 into the recesses 18.2. Optionally, a fibreglass mesh can be interposed between the projections 18.1 and the recesses 18.2.

[0042] In figures 6 and 7, reference numeral 50 generally indicates an exemplary embodiment of a wall assembly. With reference to the preceding drawings, like reference numerals refer to like parts, unless otherwise specified.

[0043] The track 20 of the wall assembly 50 is the form of an inverted channel 52. A floor 54 of the channel 52 defines threaded openings 56 so that the tie rods 24 can be threaded into the track 20 to secure the panels 12, as described above.

[0044] Figure 6A illustrates an example of a track 51 that is also suitable for use with the wall assembly 50. The track 51 includes an inverted channel 53. A lip 55 projects horizontally from each wall 57 of the channel 53. The lips 55 define openings 59 so that screws or nails 61 can be used to fasten the track 51 to the substrate.

[0045] The wall assembly 50 includes a number of locators 58 that are fastenable to a ceiling, indicated with dotted lines at 60. The locators 58 are operable to engage the top edges 14 of the panels 12 when the panels 12 are positioned side-by-side on the track 20.

[0046] The top edge 14 of each panel 12 defines a recess 62 that extends along a length of the top edge 14.

[0047] Each locator 58 includes a sleeve 64 that is mountable in the ceiling and a plunger 66 that is positioned in the sleeve 64. The plunger 66 is displaceable from an inoperative position in the sleeve 64 and an operative position in which the plunger 66 extends from the sleeve 64 and into the recess 62 to locate the panels 12 with respect to the ceiling 60.

[0048] The plunger 66 of each locator 58 is capable of free displacement with respect to the sleeve 64. The locators 58 each include a retaining device 68 to retain the plunger 66 in the operative position against gravity, the retaining device 68 being operable to allow the plunger 66 to drop into the operative position. The retaining device 68 can be in the form of a pin or other obstructive device that can be at least partially withdrawn from the sleeve 64 to allow the plunger 66 to drop down into the operative position. If necessary, the plunger 66 can be spring-mounted in the sleeve 64 so that the plunger 66 can be driven into the operative position under action of the spring when the retaining device 68 is operated.

[0049] A pair of flanges or tabs 70 extend from a lower end of the sleeve 64 so that the sleeve 64 can be secured to an underside of the ceiling 60 via holes 72.1 defined in the tabs 70.

[0050] The retaining devices 68 are each obstruction members that are positioned in the sleeve 64 to obstruct or prevent the plunger 66 from dropping out of the sleeve 64. In use, once the panels 12 are positioned on the track 20, and secured to each other in the manner described above, the retaining devices 68 can be withdrawn from the sleeves 64, allowing the plunger to drop down into the recess 62, so serving to locate the wall assembly 50 relative to the ceiling 60.

[0051] In figure 8 there is shown one example of an assembly of the panel 12 and a track 72. With reference to the preceding drawings, like reference numerals refer to like parts, unless otherwise specified.

[0052] For the purposes of illustration, the substrate is represented by a component indicated with reference numeral 74. The substrate 74 can be in the form of a concrete slab with a stepped portion defining a shoulder 76. A damp proofing course 78 is positioned on the shoulder 76. The damp proofing course 78 can be in the form of a flashing of plastics material, for example.

[0053] The track 72 is positioned on the course 78. For example, the track 72 is in the form of a U-section channel that is positioned with one flange 80.1 and a web 82 abutting the damp course 78. The track 72 is secured to the substrate with fasteners 84 received through the web 82.

[0054] The panels 12 of the wall assembly 50 define a recess 86 extending along a length of the bottom edge 16. The recess 86 corresponds with another flange 80.2 so that the bottom edge 16 can be seated on the track 72 in a nesting manner.

[0055] A series of openings 87 are defined along a lower or bottom portion of the panel 12. The openings 87 are positioned so that fasteners 88 can be received through the openings 87 to engage the flange 80.2 to secure the panel 12 to the track 72. The fasteners 88 can be in the form of self-tapping fasteners. Furthermore, washers, for example PVC washers 89, can be arranged about the openings 87 for engagement with the fasteners 88.

[0056] The U-section channel of the track 72 and its position allows protection from moisture and corrosion while locating and securing each panel 12. This is as a result of the fact that exposure of the track 72 to the elements is minimised with the track 72 seated on the shoulder 76 and the flange 80.2 received in the recess 86.

[0057] It will be appreciated that, instead of the C-channel, an L-section can be used with an edge of one flange positioned in a corner of the shoulder 76 and another flange being positioned in the recess 86.

[0058] In figure 9, there is shown another example of an assembly of the panel 12 and a track 90. With reference to the preceding drawings, like reference numerals refer to like parts, unless otherwise specified.

[0059] In this example, a length of T-section 92 is positioned in the shoulder 76 with flanges of the T-section positioned on the shoulder 76. A web 94 of the T section 92 is received in the recess 86. The web 94 has openings 96 that can be brought into register with the openings 86 so that the panel 12 can be fastened to the T section 92 with the fasteners 88.

[0060] As with the track 72 and its position, the T-section 92 and its position provide panel security while minimising exposure of the track 92 to the elements.

[0061] The appended claims are to be considered as incorporated into the above description.

[0062] Throughout the specification, including the claims, where the context permits, the term “comprising” and variants thereof such as “comprise” or “comprises” are to be interpreted as including the stated integer or integers without necessarily excluding any other integers.

[0063] It is to be understood that the terminology employed above is for the purpose of description and should not be regarded as limiting. The described embodiments are intended to be illustrative of the invention, without limiting the scope thereof. The invention is capable of being practised with various modifications and additions as will readily occur to those skilled in the art.

[0064] Various substantially and specifically practical and useful exemplary embodiments of the claimed subject matter, are described herein, textually and/or graphically, including the best mode, if any, known to the inventors for carrying out the claimed subject matter. Variations (e.g., modifications and/or enhancements) of one or more embodiments described herein might become apparent to those of ordinary skill in the art upon reading this application. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the claimed subject matter to be practiced other than as specifically described herein. Accordingly, as permitted by law, the claimed subject matter includes and covers all equivalents of the claimed subject matter and all improvements to the claimed subject matter. Moreover, every combination of the above described elements, activities, and all possible variations thereof are encompassed by the claimed subject matter unless otherwise clearly indicated herein, clearly and specifically disclaimed, or otherwise clearly contradicted by context.

[0065] The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate one or more embodiments and does not pose a limitation on the scope of any claimed subject matter unless otherwise stated. No language in the specification should be construed as indicating any non-claimed subject matter as essential to the practice of the claimed subject matter.

[0066] Thus, regardless of the content of any portion (e.g., title, field, background, summary, description, abstract, drawing figure, etc.) of this application, unless clearly specified to the contrary, such as via explicit definition, assertion, or argument, or clearly contradicted by context, with respect to any claim, whether of this application and/or any claim of any application claiming priority hereto, and whether originally presented or otherwise: a. there is no requirement for the inclusion of any particular described or illustrated characteristic, function, activity, or element, any particular sequence of activities, or any particular interrelationship of elements; b. no characteristic, function, activity, or element is “essential”; c. any elements can be integrated, segregated, and/or duplicated; d. any activity can be repeated, any activity can be performed by multiple entities, and/or any activity can be performed in multiple jurisdictions; and e. any activity or element can be specifically excluded, the sequence of activities can vary, and/or the interrelationship of elements can vary.

[0067] The use of the terms “a”, “an”, “said”, “the”, and/or similar referents in the context of describing various embodiments (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted.

[0068] Moreover, when any number or range is described herein, unless clearly stated otherwise, that number or range is approximate. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value and each separate subrange defined by such separate values is incorporated into the specification as if it were individually recited herein. For example, if a range of 1 to 10 is described, that range includes all values therebetween, such as for example, 1.1,2.5, 3.335, 5, 6.179, 8.9999, etc., and includes all subranges therebetween, such as for example, 1 to 3.65, 2.8 to 8.14, 1.93 to 9, etc.

[0069] Words indicating direction or orientation, such as “front”, “rear”, “back”, etc., are used for convenience. The inventor(s) envisages that various embodiments can be used in a non-operative configuration, such as when presented for sale. Thus, such words are to be regarded as illustrative in nature, and not as restrictive.

[0070] Accordingly, every portion (e.g., title, field, background, summary, description, abstract, drawing figure, etc.) of this application, other than the claims themselves, is to be regarded as illustrative in nature, and not as restrictive, and the scope of subject matter protected by any patent that issues based on this application is defined only by the claims of that patent.

Claims (5)

1. A wall assembly that comprises: a track for fastening to a substrate; at least two panels, each panel having opposite top and bottom edges and opposite side edges, with each panel defining a recess in a bottom edge of the panel, the track being receivable in the recess when the panels are positioned side-by-side on the track; and at least one connector for fastening between the track and the top edges of the panels for securing the panels to the track.

2. The wall assembly as claimed in claim 1, which includes a clamp member for positioning on the top edges of the panels and engageable with the, or each, connector so that the panels can be clamped between the clamp member and the track.

3. The wall assembly as claimed in claim 1 or 2, in which the side edges define complementary nesting formations so that adjacent side edges of the panels can nest together, with one connector being interposed between the adjacent side edges.

4. The wall assembly as claimed in claim 3, in which the sheets are truncated at one side edge and project beyond the core at the other side edge to define the complementary nesting formations in the form of complementary projections and recesses.

5. A wall assembly that comprises: a track for fastening to a substrate; at least two panels, each panel having opposite top and bottom edges and opposite side edges, with each panel defining a recess in a bottom edge of the panel, the track being receivable in the recess when the panels are positioned side-by-side on the track; and at least one locator for each panel, the locators being fastenable to a ceiling above the substrate and being operable to engage the top edges of the panels when the panels are positioned side-by-side on the track.