AU2019200468A1 - Building panels - systems components & methods - Google Patents

Building panels - systems components & methods Download PDF

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Publication number
AU2019200468A1
AU2019200468A1 AU2019200468A AU2019200468A AU2019200468A1 AU 2019200468 A1 AU2019200468 A1 AU 2019200468A1 AU 2019200468 A AU2019200468 A AU 2019200468A AU 2019200468 A AU2019200468 A AU 2019200468A AU 2019200468 A1 AU2019200468 A1 AU 2019200468A1
Authority
AU
Australia
Prior art keywords
panel
frame
structural
modular building
channel
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.)
Abandoned
Application number
AU2019200468A
Inventor
Anton HUSIN-ALI
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.)
AUSSIB GROUPS Pty Ltd
Original Assignee
AUSSIB GROUPS Pty Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from AU2013234383A external-priority patent/AU2013234383A1/en
Priority claimed from AU2013903737A external-priority patent/AU2013903737A0/en
Application filed by AUSSIB GROUPS Pty Ltd filed Critical AUSSIB GROUPS Pty Ltd
Priority to AU2019200468A priority Critical patent/AU2019200468A1/en
Publication of AU2019200468A1 publication Critical patent/AU2019200468A1/en
Abandoned 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
    • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
    • E04C2/46—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose specially adapted for making walls
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H9/00—Buildings, groups of buildings or shelters adapted to withstand or provide protection against abnormal external influences, e.g. war-like action, earthquake or extreme climate
    • E04H9/14—Buildings, groups of buildings or shelters adapted to withstand or provide protection against abnormal external influences, e.g. war-like action, earthquake or extreme climate against other dangerous influences, e.g. tornadoes, floods
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/14—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements being composed of two or more materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/88—Insulating elements for both heat and sound
    • E04B1/90—Insulating elements for both heat and sound slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/92—Protection against other undesired influences or dangers
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/92—Protection against other undesired influences or dangers
    • E04B1/94—Protection against other undesired influences or dangers against fire
    • E04B1/941—Building elements specially adapted therefor
    • E04B1/942—Building elements specially adapted therefor slab-shaped
    • 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
    • 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
    • E04C2/292—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 sheet metal
    • 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
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • 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
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
    • E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/35—Extraordinary methods of construction, e.g. lift-slab, jack-block
    • E04B2001/3583—Extraordinary methods of construction, e.g. lift-slab, jack-block using permanent tensioning means, e.g. cables or rods, to assemble or rigidify structures (not pre- or poststressing concrete), e.g. by tying them around the structure
    • 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
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2002/3488—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by frame like structures
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A50/00—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE in human health protection, e.g. against extreme weather

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Business, Economics & Management (AREA)
  • Emergency Management (AREA)
  • Environmental & Geological Engineering (AREA)
  • Acoustics & Sound (AREA)
  • Building Environments (AREA)

Abstract

In one form there is provided a modular building panel 10 for use in forming walls. The panel comprises: an inner foam core 36 and a frame 12 surrounding the inner foam 5 core 36. The frame 12 is provided for standing upright to provide two primary faces 48 joined by a number of side portions 20. The side portions 29 of the frame 12 are provided by structural channel members 42 The structural channel members 4' provide a perimeter around the foam core 36, The structural channel members 42 providing flange portions 96 to allow rigid connection of the panel 10 using fasteners 10 extending through the primary faces [8 into the flange portions 98 to provide the panel 1Q with a desirable cyclone rating,

Description

BUILDING PANELS - SYSTEMS COMPONENTS & METHODS
Priority
Priority is claimed from Australian patent applications 2013903929, 2013903752, 2013903737 and 2013234383 applied for by AUSSIB GROUPS PTY LTD. Ail parts and elements of these docum en ts are hereby fully incorporated by reference for all purposes.
Field Of The invention
In one preferred form there is provided a building panel. Various systems, components and methods are provided.
Background to the Invention
Building construction generally requires both a consideration of cost and safety. In cyclone affected areas buildings may have to meet legislated cyclone rating requirements. Rating requirements include wind loading requirements and other requirements
It is against this background and the problems and difficulties associated therewith that the present invention has been developed.
IS Summary Of The Invention
According to one aspect of preferred embodiments herein described there is provided a modular building panel for use in forming walls, the panel comprising; an inner foam core and a frame surrounding the inner foam core; the frame for standing upright to provide two primary faces joined by a number of side portions; the side portions of the frame being provided by structural channel members; the structural channel members providing a perimeter around the foam core; the structural channel members providing flange portions to allow rigid connection of the panel using fasteners extending through the primary faces into the flange portions to provide the panel with a desirable cyclone rating.
Preferably the desirable cyclone rating correspondswith an external pressure loading of greater than 6 kPa.
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Preferably the desirable cyclone rating corresponds with an external pressure loading of greater than 7 kPa.
Preferably the flange portions are provided in the vicinity of the perimeter around the foam core,
Preferably the flange portions are provided in the vicinity of the periphery' of the frame.
Preferably the flange portions extend substantially around the full periphery of each primary face of the frame.
Preferably the structural channel members are metal structural channel members.
Preferably each structural channel member comprises a u-shaped channel member; 10 with the structural members being welded together in the frame.
Preferably each structural channel member comprises an extending channel portion provided by two flanges and abase portion; the base portion connecting the two flanges to form the channel; the base portion extending between the primary faces of the frame; the channel being generally perpendicular to the to the surface normal of the primary faces,
Preferably the frame includes at least one internal structural member provided as a vertical strut extending vertically when then frame is standing upright.
Preferably the panel includes a series of spaced apart internal structural members; each provided as a vertical strut extending vertically when then frame is standing upright.
Preferably the or each internal structural member comprises a structural channel member.
Preferably the structural channel members are formed from 1mm thick steel where the thickness is a base metal thickness.
Preferably the structural channel members are formed from steel between I to 1.2 mm 25 thick where the thickness is a base metal thickness.
Preferably the structural channel members are formed from steel between 1 to 1.5 mm thick where the thickness is a base metal thickness.
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Preferably the structural channel members are formed from steel between 1 to 2 mm thick where the thickness is a base metal thickness.
Preferably the structural channel members providing the perimeter have at least one of the structural channel members facing outwardly to provide a channel for receiving a corresponding panel and allowing fastening of the panels through the flange of the channel into an adjoining flange of the corresponding panel.
Preferably the structural channel members providing the perimeter have at least one of the structural channel members facing inwardly to provide a. projection for receiving a corresponding panel and allowing fastening of the panels through the flange of the channel of the corresponding panel into a corresponding flange ofthe projection.
Preferably the frame is rectangular; and the side portions of the frame comprise an upper side portion, a lower side portion and two lateral side portions when then frame is standing upright.
Preferably the panel is able to support a load on its primary face greater than 4 tonne 15 with a four point bend test.
Preferably the panel, when upright, is able to support a vertical load greater than 20 tonne.
Preferably the panel weighs at least 70 kg Preferably the panel weighs at least 80kg.
Preferably the panel primary faces of the panel each provide a surface area between 2.5 and 3.5 mA2.
Preferably the thickness of the panel is between 70mm and 90 mm thick.
Preferably the modular bui lding panel includes air-cell material in addition to the foam core.
Preferably the air cell material comprises sheet material that is laid between the structural channel members of the panel.
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Preferably the sheet material overlaps the structural channel members to substantially provide a relatively continuous layer of air-cell material behind at least one primary face of the panel, separated by the structural members.
According to one aspect of preferred embodiments herein described there is provided 5 corner piece of a modular building system comprising an elongate body providing a female channel and a male projection, the female channel and male projection extending along a substantial portion of the length of the elongate body.
Preferably the female channel and male projection define an L shaped cross-section in the corner piece.
Preferably the corner piece includes a u-shaped structural channel member, the opening of the u-shaped channel facing the female channel of the corner piece, the base of the u-shaped channel positioned adjacent a first wall face of the corner piece and one of the arms of the u-shaped channel positioned adjacent a second wall face of the corner piece, the second wall face being substantially at right angles to the first wall face to provide a outwardly facing corner.
Preferably the corner piece includes a hole for receiving a foundation securing rod.
Preferably the hole is provided centrally provided relative to the extension of the female channel portion and the extension of the male projection.
Preferably the corner piece includes a v-shaped portion providing two wall faces.
Preferably the female channel and the male projection are formed in a body of rigid foam material.
Preferably the body of rigid foam material is provided as an L-shaped extrusion.
According to one aspect of preferred embodiments herein described there is provided a modular building system comprising a first joiner having flange portions and a second joiner having flange portions wherein the first joiner is adapted to adapted to be receive fl ange portions of a number of upper side porti ons of a number of modular panel s and the second joiner is adapted to receive flange portions of a number of lower side portions of the modular panels.
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Preferably each modular panel comprises: an inner foam core and a frame surrounding the inner foam core; the frame for standing upright to provide· two primary faces joined by a number of side portions; the side portions of the frame being provided by structural channel members; the structural channel members providing a perimeter around the foam core; the structural channel members providing flange portions to allow rigid connection of the panel using fasteners extending through the primary faces into the flange portions to provide the panel with a desirable cyclone rating.
Preferably the joiners comprise u-shaped channel members.
Preferably the joiners are used to fix upper sides and lower sides of the modular panels.
According to one aspect of preferred embodiments herein described there is provided a method of constructing a wall comprising fixing a first joiner to lower side portions of a number of modular panels; and fixing a second joiner to upper side portions of the panels; the joiners having flange portions that receive flange portions of the modular panels on their upper and lower sides.
Preferably the joiners comprise u-shaped channel members.
According to one aspect of preferred embodiments herein described there is provided a modular building panel for use in forming walls, the panel comprising; an inner foam core and a rectangular frame surrounding the inner foam core; the rectangular frame for standing upright to provide two primary faces joined by an upper side portion, a lower side portion; and two lateral side portions; each of the side portions of the frame being provided by structural channel members; the structural channel members providing a perimeter around the foam core; the channel members providing flange portions to allow rigid connection of the panel using fasteners extending through the prim-ary' faces in the vicinity of the perimeter to provide the panel with a desirable cyclone rating.
According to one aspect of preferred embodiments herein described there is provided a modular building panel for use in forming walls, the panel comprising: a frame for surrounding an inner foam core; the frame for standing upright to provide two primary' faces joined by a number of side portions; the side portions of the frame being provided by structural channel members; the structural channel members for providing a
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According to one aspect of preferred embodiments herein described there is provided 5 a method of providing a modular building panel comprising: providing a wall facing; providing a frame having the structural channel members providing a perimeter for receiving a foam core; and applying a further wall to provide a mould for the foam core; and filling the mould to provide the foam core; wherein the structural channel members provide flange portions that lie against each wall facing; the flange portions allowing rigid connection of the panel to another panel or structural element using fasteners extending through the wall facings into the flange portions in the vicinity of the perimeter of the panel to provide the panel with a desirable cyclone rating.
According to one aspect of preferred embodiments herein described there is provided a modular building panel for use in providing a recess for a window, the panel comprising: a frame for standing upright to provide two primary faces joined by a number of side portions; the side portions of the frame being provided by structural channel members; the panel having vertical side that provides a stepped configuration where a portion of the side mates with another panel to provide a recess the recess extending between the two panels, the recess able to accommodate a window.
Preferably the recess is able to accommodate a window and a further panel than spans the two panels above the window.
Preferably the stepped configuration comprise a first step into the panel to accommodate and support the window and then a second further step into the panel to increase the depth of the recess to accommodate and support the further panel,
According to one aspect of preferred embodiments herein described there is provided a modular building panel for use in forming walls, the panel comprising·, an inner foam core and a frame surrounding the inner foam core; the frame for standing upright to provide two primary faces joined by a number of side portions; the side portions of the frame being provided by structural channel members; the structural channel members providing a perimeter around the foam core, the structural channel members providing
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Preferably the structural channel members comprise steel of a thickness from Fromto 2mm.
As will be discussed embodiments of the present invention are considered to provide number of preferred arrangements including:
(i) Modular building panels providing ‘extreme’ category’ cyclone rating compliance;
(ii) Modular building panels providing advantageous insulation and fire ratings;
(iii) Modular building panels having u-channel sections providing flange portions extending substantially along the periphery of the front and rear outward faces of the building panel to provide a band for fastening adjoining panels;
(i v) M odul e bui 1 di ng panel s havi ng a foam core an d an outer perip h ery provi ded by u-channel sections; one or more of the u-channel sections providing a channel facing inwardly into the panel and one or more of the u-channel sections facing outwardly away from the panel; and (v) Modular building panels that are advantageously able to accommodate windows.
It is to be recognised that other aspects, preferred forms and advantages of the present invention will be apparent from the present specification including the detai led description, drawings and claims.
Brief Description Of Drawings in order to facilitate a better understanding of the present invention, several preferred embodiments will now be described with reference to the accompanying drawings in which
Figure 1 provides a perspective view of a modular building panel according to a first preferred embodiment of the present invention;
Figure 2 provides a perspective view of the modular building panel shown in Figure l·.
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Figures 3 and 4 respectively provide a perspective and partial perspective view of the panel shown in Figure 1;
Figure 5 provides a further perspective view showing a foam core of the panel shown in Figure 1;
Figure 6 provides a partially exploded view of the panel shown in Figure 1;
Figures 7 to 16 provide further views of the panel shown in Figure 1, and portions thereof;
Figure 17 provides a view showing a joiner used in a system involving the panel shown in Figure 1;
Figure 18 provides a view illustrating how two panels shown in Figure 1 are advantageously fixed together;
Figures 19 and 20 provide further illustrative views of the panel shown in Figure 1;
Figure 21 illustrates the strength of one embodiment of the present invention;
Figure 22 illustrates a method according to another preferred embodiment of the 15 present i nventi on;
Figures 23a and 23b illustrate a comer piece according to a further preferred embodiment of the present invention;
Figures 23c and 23d illustrate a corner piece according to a further preferred embodiment of the present invention;
Figure 24 provides a view of a prototype for receiving the panel shown in Figure 1;
Figure 25 provides an exploded view' of a panel system according to another preferred embodiment of the present invention;
Figures 26 to 28 provide further views of the panel system shown in Figure 25;
Figures 29 to 32 show a panel according to a further preferred embodiment of the 2 5 present invent! on;
Figures 3.3 to 3 6 provide further illustrations of the panel system shown in Figure
25:
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Figures 37 to 39 illustrate a panel according to a further preferred embodiment of the present invention; and
Figures 36 to 44 illustrate yet further preferred embodiments of the present invention that provide a window structure.
Detailed Description Of The Embodiments
It is to be appreciated that each of the embodiments is specifically described and that the present invention i s not to be construed as being limited to any specific feature or element of any one of the embodiments. Neither is the present invention to be construed as being limited to any feature of a number of the embodiments or variations described in rel ation
1.0 to the embodiments.
Referring to Figure 1 there is shown a modular building panel 10 according to a first preferred embodiment of the present invention. The modular building panel 10 is able to advantageously fit together with other modular building panels 10 to provide a cyclone rated wall. In this embodiment the modular building panel 10 provides a cyclone rated panel able to withstand an external pressure loading of at least 6 kPa.
Referring to Figure 2 the modular· building panel 10 includes a frame „12. The frame „12 provides a number of frame partitions .14 for receiving foam material. Three frame partitions 14 are provided. The frame is about 1 2m in width 18 and about 2.4 m in height 1.6, Other embodiments provide different standard sizes such as a 1,2 x 2.7m modular panel.
Referring to Figures 3 and 4 the frame 12,, can be considered as providing two primary faces „18 joined by a number of side portions 20, The primary faces 18 comprise general outwardly facing faces of the frame .12. The primary faces .18 provide a forward outward face 22 and a rearward outward face 24, The forward Outward face 22 provides a surface normal 26. The rearward outward face 2,4 provides a surface normal 2.8. The building panel provides an upright wall and the surface normals 28,26 are horizontally orientated. The frame is of a rectangular shape having four side portions 20 that define the thickness of the frame 12.
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Returning to Figure 1 the panel 10 includes two sheet portions 30 that are each fixed to a corresponding primary face 18. of the frame 12. The sheet portions 30 are provided as rectangular sheets 30 that fit onto the primary faces 18 . The sheets 30 compri se fibre cement sheets as used in the building industry7. Of course other forms of sheet 30 could be readily applied including aluminium, calcium silicate, colour bond, timber and so forth.
The frame .12 and the sheet portions 30 provide a mould in which foam material is injected into and subsequently cured according to industry standard processes. The foam material provides a PIR-type core having advantageous insulative and fire resistant properties.
Referring to Figures 1 and 2, each frame partition 14 is provided with an inlet hole 32 for 10 admitting the foam material. During manufacture the foam material is injected through each inlet hole 32 into a corresponding partition 14 and cured.
Once the foam material has cured three foam cores 34 fill the frame partitions 14 and are visible through the holes 32 as shown in Figure 5,
Figure 6 provides a partially exploded view in which one of the sheets 20 is shown removed 15 from the panel 1.0. As shown in Figure 6, the frame 12 surrounds the three foam cores 34 disposed in the partitions 14. The three foam cores 3.4 form a foam core 36 having three separate portions.
Referring to Figure 9, the foam core 36 is surrounded, by the frame ,12. that provides a perimeter 38, The sheets 20 enclose the foam core 36 within the frame 1,2. Referring to
Figures 7 and 8 the perimeter 38 comprises a band 40 defined by the side portions 20 of the frame 12.
Referri ng to Figure 7S the frame 12 compri ses a number of structural channel members 42. The structural channel members 42 provide the frame 12 in the form of a grid 36. The structural channel members 42 provide the side portions 20, As would be apparent from the desired orientation of the panel 10, the frame 12 is provided for standing upright.
The frame 12 includes six (6) structural channel members 42 that are welded together to provide the frame .1.2. Referring to Figure 10, the structural channel members 42 are conceptually identifiable as shown by lines 44, The structural channel members 42 comprise six lengths of u-shaped metal channel that are welded together at locations 46,
The bases of the u-shaped metal channel (i.e, the connecting web) defines the perimeter 38
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The structural members 42 provide two horizontal lengths 52 and four vertical lengths 54. In other embodiments the frame .12 may be formed as one piece providing the structural members 42 without any·' welds or other joining. Structural members 42 are provided in both variations.
Referring to Figure 11, the stroctural channel members 42 provide an upper side portion 56, a lower side portion .58 a first lateral side portion 60 and a second lateral side portion 62 to form the frame 12, The interior of the frame 12 includes two structural channel members 42 that each provide an internal stmt 64. The internal struts 64 span from the lower side portion .5.8 to the upper side portion 5.6. The lateral side portion 60 is provided by a structural member 66 and the lateral portion 62 is provided by a structural member 68. The internal stmts 64 and structural members 68. provide a series 70 of vertically extending struts.
Figure 12 -provides a further view of the frame .1,2. Figure 13 provides a partial view of Figure 12. As shown each of the structural members 4.2 in the series 70 apart from the structural member 68 (providing the second lateral side portion 62) is provided in the form of a standard U-shaped channel.
Referring to Figure 14, each of the standard U-shaped channels comprises a base 72 that connects two flanges 74. The flanges 74. provide relatively flat surfaces 76 that face outwardly to provide an abutment for the sheets 20. The channels are about 70mm across the base 72 and have two flanges 74 on opposite sides, each flange being about 40mm deep.
Referring to Figure 15, the structural member 68 provides a projection 78 sized to fit within a channel provided by an adj acent panel of a similar form to the panel .1.0. The size of the channel in which the projection is sized to fit comprises the size of the channel 80 of the structural member 66 (See Figure 13).
As shown in Figure 15, the form of the structural member 68 provides a U-shaped channel having relatively narrow end 82 sized to fit within the channel of the other panel. The structural member 68 comprises base 84 connecting two flange portions 86 having an external width 88. The flange portions 86 extend outwardly to provide two further spaced
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2019200468 23 Jan 2019 apart portions 90 having a greater external width 92, The structural member 68 provides a U-shaped channel having two flanges of a stepped form.
In terms of the panel .1.0, the structural member .66 (providing the lateral side portion 60). provides an open channel 80 facing in a direction perpendicular to the normal direction of the primary faces 18. The channel 80 t s provi ded for receiving the equivalent of structural member 68 of another panel 10. Each of the structural members 42 in the series 70 provides a channel facing in a first direction 94. The channels are aligned and face in the same direction.
In the frame 12 each of the structural channel members 42 are provided bv u-shaped 10 channels of relatively thick steel. In the embodiment, the U-shaped channel comprises 1.0mm steel. When the foam is cured the sheets .20, Foam core 36 and frame 12 provide an advantageous modular bull ding panel 1.0 for cyclone environments. It is envisaged that the thickness of steel may range between 1 to 1,2mm (base metal thickness). This is of course dependent on the overall design of the panel. The thickness could of course be outside this range. For example the structural channel members 42 of the panel 10 may comprise galvanised steel of a thickness from 1mm to 2mm, depending on the required engineering characteristics,
With a panel approximately between 1 to 2 mt wide and 2 to 3m tall it has been found advantageous to provide two internal struts and weld each of the structural members together.
Returning to Figure 12, each of the structural members 42 have two flange portions 96 arranged to provide flat surfaces 98 aligned with the primary faces 18, The flat surfaces 96 are aligned in the sense of being generally parallel. The primary' faces .18 are general in the sense of defining a general shape, The difference in size between with width .88 and the width 92 in in this embodiment, may only be in the order of millimetres. Each of the flange portions 96 is in the vicinity of a corresponding primary faces .18. As such there is provided a forward flange portion 96 for the forward outward surface 24 and a rear flange portions for the rear outward surface 22 of the frame 12.
Figure 16 show's an upper side portion 56, a lower side portion 58, a first lateral side portion
60 an da second lateral side portion 62, The upper side portion 56 is provided by a structure
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2019200468 23 Jan 2019 channel member 100 . The lower side portion 58 is provided by a structural channel member j,02. The structural member 66, the structural member 68, the structural member 102 and the structural member 100 define a band 40 surrounding the foam core 36. The band 40 is provided by the base of each u-channel section,
Referring to Figure 17, the modular building panel .1.0 provides a channel 104 in each of the upper side portion 56, the lower side portion 58 and the lateral side portion 60. This allows the upper side portion 56 to receive a joiner 106 and for the lower side portion to receive a joiner 108. Thejoiner 108 is fixed to a foundation and the joiner 106 is fixed to a truss of roof. To fix the joiner 106 a number holes are drilled through the sheet 20 into the metal flanges 96 of the structure channel member 100,
The metal flanges 96 advantageously provide both strength and rigidity to the modular panel 10. A number of conventional panel s formed front fibre cement and foam material are considered not to meet cyclone rating requirements. With the provision of the metal uchannel members 42. a rigid wall can be advantageously provided with fasteners being provided in the vicinity of the periphery .1.1.0 of the primary faces 1.8.
The modular building panel .1.0 can be secured with advantageous strength and fracture resistant joins about the forward and rear periphery 110 of the panel 10, through the sheets 20 due to the provision of the structural members 42. The structural members 42 are provided in the form of m etal u-channel of an advantageous thickness.
Figure 18 illustrates how two panels 10 are advantageously fixed together. As shown there is provided a first panel 112 and a second panel .1,14. The first panel .112, includes a first structural channel member 116 that provides a projection by having the opening of the channel member 1.1.6 facing into the body 1.18 of the panel 1.1.2. The second panel 114 includes a second structural channel member .120 having the opening of the channel member 120 facing away from the body 122 of the panel 114, The first channel member 116 includes two flanges providing relatively flat outwardly facing surfaces 124, The second channel member 114 includes two flanges providing relatively flat inwardly facing surfaces .126. The panels .1.12 and 114 are brought together. The flanges of the first and second structure members comprise metal of a substantial thickness allowing for number of holes to be drilled in the flanges and for threaded fasteners 128 to be received therethrough.
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Referring to Figure 19, the panel 1,0 according includes a region 130 in the vicinity of the periphery .110 each primary face 1.8 of the frame ,12 allowing for robust connection of the panel 10 to adjoining panels or joiners. A workman can readily fasten a. screw type fasteners 132. through the regions 130 of adjoining panels 10 and construct a wall meeting cyclone rating requirements,
The regions 110 are located in the vicinity of the periphery 1.1.0. The regions .1,1,0 are provided by the flanges 96 of the structural members 42 providing the side portions 20. The regions 11.0 are located in the vicinity of the perimeter 38. The regions 110 define a relatively continuous band 13.4 on each side of the panel .10..
By using metal u-channel to provide the perimeter of the modular building panels the connection formed using the fasteners provides advantageous strength and fracture resistant properties suitable for providing a Cyclone D rated walls. The holes drilled into the metal flanges provided by the U-Channel are robust and are not prone to fracture of disintegration in cyclone conditions. The use of the vertically extending internal struts provides advantageous strength.
It will be appreciated that the embodiment provides a modular building panel 1.0 for use in forming walls such as the wall 136 of Figure 20. The panel 1.0 comprises an inner foam core 36 and a frame 12 surrounding the inner foam core 36. The frame .12 is provided for standing upright to provide two primary faces 18 joined by a number of side portions 20.
The side portions 20 of the frame 12 are provided by structural channel members 42 that provide perimeter 38 around the foam core 3,6. The structural channel members 42 provide flange portions 96 to allow rigid connection of the panel .10 to other panels or joiners using fasteners. The fasteners extend through the primary faces .1.8. through the flange portions 96. The flange portions 96 are located in the vicinity of the periphery .110 of the primary faces 18, The flange portions 96 are provided in the vicinity of the perimeter 38,
Each structural channel member 42 comprises a u-shaped channel member having a base that defines the hand 40 that surrounds the foam core 36, The structural members 42 are made from metal.
The structural members 42 are welded together in the frame to provide a welded grid for enclosing the foam core to provide the advantageous panel, Each structural channel
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2019200468 23 Jan 2019 member 42 compri ses an extending channel portion 42 provided by two flanges and a base portion. The base portions extend between the primary faces .1.8 and connect the two flanges to form a channel. Each of the channels provided by the structural members 96 is generally perpendicular to the surface normal of the primary faces 18.
Two internal structural members 64 provide vertical struts extending vertically when the frame is standing upright. The two internal structural members 64 provide a series 70 of spaced apart internal structural members 42. The perimeter 38. is provided by four of the structural channel members 42. The structural member 66 faces outwardly to provide a channel .1.90 for receiving a corresponding panel having a projection formed from metal u10 channel providing a lateral side. When abutted the flanges of the projection are located next to adjoining flanges of the channel. The flanges allow an advantageous connection between the two panels.
The weight of the U-channel is about 1.3 kg per meter. In a 1.2 by 2.4m panel there are about 12 m of u-channel which equates to about 16kg of structural member 34, A 90mm by 2.4 by 1.2 panel weighs about 65 kg without the metal structural members 34, The total weight is about 80 kg.
In embodiments it is considered that a walling system can be advantageously provided meeting the following standards:
• Wind Region A, Terrain Category 1 to ASl 170.2011 and AS40SS-2GI2 · Wind Region B, Terrain Category 1 to AS'l 170.2011 and AS4055-2012 • Cyclonic Wind Region C, Terrain Category 1 to ASl 170.2011 and AS4055-2012 » Cyclonic Wind Region D, Terrain Category 2 to ASl 170.2011 and AS4055-2Q12 •Tull internal pressure Cpi = 0.9 Cpe
The system is considered to allow for the following walling applications in the above wind regions of Austral i a:
• Load bearing for timber ’built up’ roof to AS 1684 • Load bearing for steel or timber truss roofs • Load bearing for metal roof cladding
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On the basis of the results of testing data, the applicant believes that such a structural certification is able to be provided with panels in the walling system (installed as per specifications and panel fixing requirements), comprising;
· 6 or lOmrn compressed Fibre Sheet (CFG) • 70 to 78 mm thick polyisocyanurate P,I.R. sandwich • Concealed 1,0mm BMT steel stud walling system • Up to 2.7m high • 1,2m wide
For the cyclonic wind regions C & D the external face of the building, once erected is preferably clad with Custom Orb or similar metal sheeting. The cladding is considered to prove a faster external finish to construction as no taping of joints, flushing and application of texture coatings is then required. The over-cladding is considered to provide additional debris protection to the building.
With a configuration of 6mm Calcium Silicate, 78mm Polyisocyanurate, and 6mm Calcium
Silicate, a number of R value calculations have been performed. The thermal performance of the proposed panel configuration was calculated using the following factors:
1) Component;R-Value or Resistivity; Source of Information
2) Polyisocyanurate; 38 m.KAV; National Research Council of Canada
3) Calcium Silicate; 10 m,K/W; National Institute of Standards and Technology (US); and
4) Other factors as listed in the Building code of Australia (BCA) requirements, namely
Commercial Buildings:
• Internal walls, conditioned space on both sides ~ no requirements.
• Internal walls, conditioned space to unconditioned space (protected) - R1 (Zones I, 2, 5 & 6), R1.5 (Zone 7), R2.5 (Zone 8).
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2019200468 23 Jan 2019 • Internal walls, conditioned space to unconditioned space (unprotected) R2.3 (Zones 1, 2, & 3), Rl..8 (Zones 4 & 5), R2.8 (Zone 7) and R3.8 (Zone 8).
• External Walls - R2.8 (Zones 1, 2 & 3 for Light-Med coloured walls, and zones 4 to 7) and R3.8 for Zone 8.
Residential Buildings:
• Internal Walls --- no requirements.
• External Walls - R2.8 (Zones 1 to 7 with some conditions) and R3.8 for Zone 8.
The panel was assessed for its material R-Value, which includes only the characteristics of the panel materials; and for their Total R-Value, which includes internal and external air films as would be applicable to each proposed application.
The calculated performance for the panel arrived at comprised:
1) Panel; Material R-Value; Total R-Value in Application
2) PIR Panel - (6+78+6); R3.1; R3,3
On the basis of the various assumptions it was concluded that the proposed panel satisfied the BCA thermal provisions for use in internal and external wall applications in all types of buildings for climate zones I to 7,
In order to satisfy' the requirements for Climate Zone 8. where a total R-Value of R3.8 is required an alternate panel size was considered to be required, For climate Zone 8a thicker panel (say 6+93+6) or the use of two panels with an air gap and a minimum of 85mm total thickness of Polyisocyannurate material was suggested. By varying the thicknesses panels with different properties may be provided.
The above calculations are based on a number of assumptions and are not to be construed as providing any form guarantee. Various R-values and loading strengths would be able to be calculated by standard mechanical engineering techniques.
Figure 21 illustrates the Strength of an embodiment of the present invention, A single panel between 1 and 1.5 m in width suppoiis a lateral load of greater than 4 tonne with the four
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2019200468 23 Jan 2019 point bend test shown. The vertical load bearing capacity of the panel is greater than 20 tonne (when upright). The panel when fixed in a panelling system is able to withstand cyclonic winds well in excess of 300 km/’hr.
Figure 22 illustrates a method 138 according to another preferred embodiment of the 5 present invention. The method .138 provides a process of manufacturing the modular building panels 10 and fixing the panels to provide a wall .140 . At block 142 the method
1.3§ comprises providing a wall facing in the form of a sheet. At block 144 the method includes providing structural channel members providing a perimeter for surrounding a foam core, the structural members forming a grid. At block .146 the method includes applying a further wall facing to provide a mould for the foam core. At block 148 the method includes filling the mould to provide the foam core.
The structural channel members provide flange portions that lie against each wall facing. The flange portions allow rigid connection of the panel to another panel or structural element using fasteners extending through the wall facings through the flange portions in the vicinity of the perimeter of the panel to provide the panel with a desirable cyclone rating. At block 150 the method includes fixing the panels using the flange portions to provide the wall 140.
It i s envisaged that emb odiments will he provi ded in widths of between 1 to 3 m, heights of between 1 to 3m and thicknesses of between 70 to 200mm. Various other sizes may be provided as well.
In this embodiment the structural channel members comprise 1 mm BMT steel u-channel. The foam material advantageously comprises polyisocyanuratefoam (PIR). Both PUR and PIR rigid foam panel systems are used for facades and roof elements for buildings. They have excellent thermal properties and mechanical/physicai properties, PIR also has significant fire resistant properties.
The panel 10 advantageously provides a PIR rigid foam core that provides both cyclone and fire resistant properties. The characteristics of various foams are available from providers such as BASF. Sandwich panel manufacturing and curing techniques follow industry practices. The method at block 148 employs a conventional a multiple shot type process.
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Figures 23a and 23b illustrates a corner piece 152 according to a further preferred embodiment of the present invention. The corner piece 152 comprises an elongate body 1.5.4 providing a female channel portion 156 and a male projection .158. The female channel portion 156 and male projection 158 are formed from a portion 160 provided in the shape of anL ,180. The elongate body 154 includes a first member 162 and a second member ,164 that provide a v-shaped portion 166, The first member 1,62 and the second member 1.64 provide wall faces 168, In this embodiment, the wall faces .1.68 comprise fibre cement.
The portion 160 is provided as a body of rigid foam material 170 that extends along the length of the corner piece 152. Within the portion 1,60 there is provided a hole .1,82. for receiving a foundation rod.
The hole includes a conduit 172 in the form of a plastic tube 184 that allows the smooth passage of the foundation rod. The foundation rod serves to hold the corner portion ,152 in an upright position.
In the embodiment the hole 182 is located centrally relative to the extension .174 of the 15 female channel portion .1.5.6 and the extension 1.76 of the male projection .1.5.8. The extensions are longitudinal as shown in Figure 23b.
Referring to Figures 23c and 23d there is shown a further preferred embodiment of the present invention i n the form of a corner piece ,152’. The comer piece .152’. is sim ilar to the corner piece 1.5.2 and for this reason similar numerals are used. Advantageously the corner piece 152’ further includes a structural support channel member .175.
The channel member .175 comprises u-shaped channel that has the open end of the channel facing the opening of the female channel portion ,156’.. The base 177 ofthe u-shaped channel .175 is positioned adjacent the wall face 181. and is aligned with the opening of the female channel portion 1.56’ ,
The arm ,183 of the u-shaped channel is positioned adjacent the wall face .185 and is substantially aligned with the front ofthe male projection 158’. The u-shaped channel 175. includes a number of holes therein to allow the foam material to flow and readily bond to both the wall face 1,§1 and 1,8.5. and the facing surfaces ofthe u-shaped channel 175 during forming.
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In this embodiment, the holes are provided in the base 177 and the arms of the u-shaped channel extendi ng therefrom . The u-shaped channel extends the height of the corner piece 152/,
The corner piece 152/ provides a comer of advantageous strength due to the provision of 5 the u-shaped channel .175. Thus there is provided a corner piece 152’. comprising an elongate body 154’ providing a female channel 156’ and a male projection 158’ at right angles to one another. The female channel 156/ and male projection 158’ extend along the length of the elongate body as does the u-shaped channel 17.5, The opening of the u-shaped channel 175 faces the female channel .156’ of the corner piece. The base 177 of the u10 shaped channel ,175’ is positioned against the first wall face 181 of the corner piece 15 Γ and the arm 183 of the u-shaped channel .1,7.5 is positioned adjacent the second wall face 1.85. of the corner piece .1/52/
As shown the second wall face 185 is substantially at right· angles to the first wall face 1,8.1 to provide an outwardly facing corner. The wall faces comprise fibre cement portions connected at right angl e s.
The use of the u-shaped channel 17.5 provides the comer piece ,1,52/ with advantageous strength and, in this embodiment, extends the full length of the comer piece 152’.
Figure 24 illustrates a basic prototype, the female channel portion 156 provides a channel for receiving a projection 78 of a structural member of a panel 1.0.
The male projection ,158 is of an external width 178 equivalent to the external with of the projection 78 (eg width 88). The male projection 1.58 i$ arranged at 90 degrees to the female channel portion 156 to allow for the provision of a corner bend. The v-shaped portion 166 is provided for abutting sheets 26 as shown in Figure 23b.
In some embodiments a number of holes 1,82 are provided in the panel members themselves. The holes 182 provide an aperture through which a bar can be introduced to further hold the modular panels .1,0 in position.
Referring to Figure 25 there is provided a panel system 186 according to yet another preferred embodiment of the present invention. The panel system includes two elongate joiners 18.8 each having two flanges 190. A number of modular panels ,1,92 are provided having a channel 194 in their upper sides ,196 and a channel 198 in their lower sides 200.
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The channels 194 and 198 are able to receive the joiners 188 in the manner previously described and be readily fixed with a metal to metal join. The metal to metal join is considered to he advantageous and be able to provide a desirable cyclone rating as previously described. In this embodiment the joiners comprise 1,8 mm BMT u-shaped channels, It is envisaged that the channels may range up to say 2.5mm in various embodiments. Vari ous other sizes are of course possible.
Figure 26 shows how the joiners 188 could be attached to foundations 202, Figure 27 provides a further view. Figure 28 shows how a corner piece .152 could he attached to a truss 206 of a roof 20.4 in the system 186.
Figures 29 to 32 show a plurality of lifting holes 208 provided as part of a panel 210 according to a further preferred embodiment of the present invention. The lifting holes 208 are provided in the flange portions 212 of the structural channel portions in the top portion 214 of the panel 210. The flange portions 212 are of a strength that is able to accommodate the holes .208 and support the lifting of the panel 210. The flange portions
212. are about 40mm tall. The flange portions 2.1.2 are sufficiently strong to support lifting of the panels. The lifting holes 208 are sized to receive a number of shackles 214. Two pairs of lifting holes 208 are provided on the flange portions 212 of the upper side 21.4 (top) of the panel 210. In various embodiment the flange portions are at least 30mra tall.
Figures 33 to 36 provide further illustrations of the panel system 184. The panel system .184 provides a modular building system comprising a first joiner having flange portions and a second joiner having flange portions wherein the first joiner is adapted to adapted to be receive flange portions of a number of upper side portions of a number of modular panels and the second joiner is adapted to receive flange portions of a number of lower side portions of the modular panels.
The joiners could be provides as rectangular projection in other embodiments rather than a u-channel. In both cases flanges are provided for a metal to metal join.
Other embodiments may provide a mechanical inversion where the channels 194 provide projections. In such a case the joiners would receive the upper and lower sides of the modular panels.
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The method of joining involves fixing a first joiner to lower side portions of a number of modular panels; and fixing a second joiner to upper side portions of the panels; thejoiners having flange portions that receive flange portions of the modular panels on their upper and
The various panels and methods herein described are provided with desirable cyclone characteristics. The provision of the flange portions allow rigid connection of the panel using fasteners extending through the primary faces into the flange portions to provide the panel with a desirable cyclone rating. The panel is able to withstand a high pressure loading.
Figures 37 to 39 illustrate a panel 220 according to another preferred embodiment of the present invention. Figure 37 provides a partial view showing the provision of an aircell layer 222 in the panel 220. The air-cell |a>er 222 comprises three sheets 225 of air-cell material 224. The sheets 225 are fitted into the three areas 226 defined by the metal vertical struts 228. The air-cell material 224 comprises insulating material having a number of insulating isolated cells to limit heat transmission.
The use of air-cell insulating materi al is considered to be advantageous for the reason that it is considered to increase the R value and improve the sound characteristics of the panel. The air-cell material is considered to possibly increase the R-value by 1.0 (approximately). With a panel that would otherwise have an R-value of 3,3 this means that the panel would have an R value of 4.3, The air cell layer provides a further layer in combination with the foam core.
Apart from the air-cell layer 222. the panel 220 is of the same form as the panel 10 previously described. Air cell material is well known. It is often provided in rolled form and could be provided by supplied such as King Span Insulation (w w. kingspani nsul aft on. com.. an).
Again the fire resistant foam core comprises PIR material. The method of manufacture involves positioning the three sheets of air-cell material before the foam i s introduced and cured. The outer sheets 2T5..comprise fibre cement sheets as used in the building industry.
Figure 39 provides a cross-sectional view in the plane A-A of Figure 37, As show there are provided four vertical u-shaped rigid metal struts 230 defining three intermediate areas
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232. Each sheet of air-cell material is positioned against an outer sheet of the panel 220 and covers the portion 235 of the u-shaped channel spanning the corresponding area 232. The sheets of air-cell material overlap with the u-shaped metal stmts 230 as shown
Consequently there is a panel 220 having insulating air-cell material 224 in addition to the 5 foam core. The air cell material 224 comprises sheet material that is laid between the structural channel members 228 of the panel . In the panel 220, three sheets 225 of ai r-cell material are provided that occupy three pri m ary areas 232 of the panel 220. The sheets 225 overlap the structural channel members 230 to substantially provide a relatively continuous layer of air-cell material behind at least one primary face of the panel as highlighted in
Figure 39. The sheets 225 in the panel 220 are separated by the structural members
Figures 40 to 44 illustrate a window system 250 according to a further preferred embodiment of the present invention. The window system 250 comprises two panels 254 each having a recess 252 in a side thereof. The recesses 252 are each of a stepped configuration 256 to allow the insertion of a window when the panels are adjacent one another. Advantageously, following this a further panel 255 is able to be positioned above the window to span the two panels 254.
In the window system 250 there is provide a first panel 258 and a second panel 260. A lower side portion 268 of the first panel 262 is arranged to mate with a lower side portion 270 of the second panel 264.
The lower side portion 268 comprises a u-shaped portion providing a female channel 2.72. The lower side portion 270 comprises a u-shaped portion providing a male projection 274 sized to fit within the female channel 272.
Each panel 254 is provided for providing a recess 278 for a window. Each panel 254 provides a frame 280 for standing upright to provide two primary faces j oined by a number of side portions 284. As with the panel 10, the side portions 284 of the frame 280 are provided by u-shaped structural channel members of the type previously described.
Each panel 276 has a vertical side 286 that faces the vertical side of the other panel. The vertical sides 286 each provide a stepped configuration. The stepped configuration provides a first step 288 and a second step 290.
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The first step 288 is of a first depth for supporting a window. The second step 290 is positioned above the first step 288 and is of a greater depth for supporting the further panel .255 (the connecting panel 292).
Referring to Figure 41, the lower portions of each vertical side 286 mates with the other 5 panel to provide a mating join 296, This is similar to the arrangement of Figure 18. The recess between the panels 276 is accordingly able to accommodate a window and a further panel 255 that spans the two panels above the window.
In some embodiments there may only be a single step such that a further panel 298 is not required. Along the vertical sides 286 extending up from the ground, each panel 254 includes a female channel above the lower portion 268,270 of each panel. Only one of the lower portions provides a male projection for mating in the female channel of the other panel. The further panel 255 may rest on a member 298 that spans the recess and rests on the second steps 290 that provide a supporting abutment. As would be apparent various side portions could in various embodiments be male or female.
In this embodiment the stepped configuration comprise a first step 228 into the panels to accommodate and support the window and then a second further step .230 into the panels to increase the depth of the recess to accommodate and support the further panel. The upwardly facing abutments provided by the first step 228 for the window are female. The upwardly facing abutments provided by the second step 230 are also female.
The structural channel members of the embodiments described are made from metal as shown to provide advantageous panels, comer pieces and so forth. In embodiments, modular panels can be provided to fit together to provide advantageous cyclone rated and other buildings.
As noted above embodiments of the present i nventi on are consi dered to provide number of preferred arrangements including;
(i) Modular building panels providing ‘extreme’ category cyclone rating compliance;
(ii) Modular building panels providing advantageous insulation and fire ratings;
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2019200468 23 Jan 2019 (iii) Modular building panels having u-channel sections providing flange portions extending substantially along the periphery of the front and rear outward faces of the building panel to provide a band for fastening adjoining panels; and (iv) Module building panels having a foam core and an outer periphery' provided by u-channel sections; one or more of the u-channel sections providing a channel facing inwardly into the panel and one or more of the u-channel sections facing outwardly away front the panel.
As would be apparent; various alterations and equivalent forms may be provided without departing from the spirit and scope of the present invention. This includes modifications within the scope of the appended claims along with all modifications, alternative constructions and equivalents.
There is no intention to limit the present invention to the specific embodiments shown in the drawings. The present invention is to be construed beneficially to the applicant and the invention given its full scope.
In the present specification, the presence of particular features does not preclude the existence of further features. The words ‘comprising’, ‘including’ and ‘having’ are to be construed in an inclusive rather than an exclusive sense.
It is to be recognised that any discussion in the present specification is intended to explain the context of the present invention. It is not to be taken as an admission that the material discussed formed part of the prior art base or relevant general knowledge in any particular country1 or region,

Claims (17)

  1. THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:
    1. A modular building panel for use in forming walls, the panel comprising: an inner foam core and a frame surrounding the inner foam core; the frame for standing upright to provide two primary faces joined by a number of side
    5 portions; the side portions of the frame being provided by structural channel members; the structural channel members providing a perimeter around the foam core; the structural channel members providing flange portions to allow rigid connection of the panel using fasteners extending through the primary faces into the flange portions to provide the panel with a desirable cyclone
    10 rating.
  2. 2. A modular building panel as claimed in claim 1 wherein the desirable cyclone rating corresponds with an external pressure loading of greater than 6 kPa.
  3. 3. A modular building panel as claimed in claim 1 or 2 wherein the desirable cyclone rating corresponds with an external pressure loading of greater than 7
    15 kPa.
  4. 4. A modular building panel as claimed in claim 1, 2 or 3 wherein the flange portions are provided in the vicinity of the perimeter around the foam core
  5. 5. A modular building panel as claimed in. any one of claims 1 to 4 wherein the flange portions are provided in the vicinity of the periphery' of the frame.
    20
  6. 6. A modular building panel as claimed in any one of claims 1 to 5 wherein the flange portions extend substantially around the full periphery of each primary face of the frame.
  7. 7. A modular building panel as claimed in any one of claims 1 to 6 wherein each structural channel member comprises a u-shaped channel member; with the
    2.5 structural members being welded together in the frame;
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  8. 8. A modular bui lding panel as claimed in any one of claims 1 to 7 wherein each structural channel member comprises an extending channel portion provided by two flanges and a base portion; the base portion connecting the two flanges to form the channel; the base portion extending between the primary' faces of the
    5 frame; the channel being generally perpendicular to the to the surface normal of the primary faces.
  9. 9. A modular building panel as claimed in any one of claims 1 to 8 wherein the frame includes at least one internal structural member provided as a vertical strut extending vertically when then frame is standing upright.
  10. 10 10. A modular building panel as claimed in any one of claims I to 9 wherein the panel includes a series of spaced apart internal structural members; each provided as a vertical strut extending vertically when then frame is standing upright.
  11. 11. A modular building panel as claimed in claim 9 or 10 wherein the or each
    15 internal structural member comprises a structural channel member.
  12. 12. A modular building panel as claimed in any one of claim 1 to Π wherein the structural channel members are formed from 1mm thick steel where the thickness is a base metal thickness.
  13. 13. A modular building panel as claimed in any one of claim 1 to fl wherein the
    20 structural channel members are formed from steel between 1 to 1,2 mm thick where the thickness is a base metal thickness.
  14. 14. A modular building panel as claimed in any one of claim 1 to 11 wherein the structural channel members are formed from steel between 1 to 1.5 mm thick where the thickness i s a base metal thickness,
    25 15, A modular building panel as claimed in any one of claims I to 14 wherein the structural channel members providing the perimeter have at least one of the
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    16.
    10 17.
    18,
    19.
    20.
    21.
    22.
    structural channel members facing outwardly to provide a channel for receiving a corresponding panel and allowing fastening of the panels through the flange of the channel into an adjoining flange of the corresponding panel.
    A modular buildi ng panel as claimed in any one of claims 1 to 15 wherein the structural channel members providing the perimeter have at least one of the structural channel members facing inwardly to provide a projection for receiving an corresponding panel and allowing fastening of the panels through the flange of the channel of the corresponding panel into a corresponding flange of the projection .
    A modular building panel as claimed in any one of claims 1 to 16 wherein the frame is rectangular; and the side portions of the frame comprise an upper side portion, a lower side portion and two lateral side portions when then frame is standing upright.
    A modular building panel as claimed in any one of claims 1 to 17 wherein the panel is able to support a load on its primary face greater than 4 tonne with a four poi nt bend test.
    A modular building panel as claimed in any one of claims 1 to 18 wherein the panel, when upright, is able to support a vertical load greater than 20 tonne.
    A modular building panel as claimed in any one of claims 1 to 19 where the panel weigh at least 70 kg
    A modular building panel as claimed in any one of claims 1 to 20 wherein the panel weighs at least 80kg.
    A modular building panel primary' faces of the panel each provide a surface area between 2.5 and 3.5 ιηΛ2
    WO 2015/042665
    PCT/AU2014/050250
    2019200468 23 Jan 2019
    23. A modular building panel as claimed in any one of claims 1 to 22 wherein the panel is between 70mm and 90 mm thick,
    24, A modular building panel as claimed in any one of claims 1 to 23 including aircell material in addition to the foam core,
    5 25. A modular building panel as claimed in claim 24 wherein the air cell material comprises sheet material that is laid between the structural channel members of the panel.
    26. A modular' building panel as claimed in claim 24 or 25 wherein the sheet material overlaps the structural channel members to substantially provide a
    10 relatively continuous layer of air-cell material behind at least one primary face of the panel , separated by the structural members.
    27. A corner piece of a modular building system comprising an elongate body providing a female channel and a male projection; the female channel and male projection extending along a substantial portion of the length of the elongate
  15. 15 body
    28. A corner piece as claimed in claim 27 wherein the female channel and male projection define an L shaped cross-section in the corner piece,
    29. A corner piece as claimed in claim 27 or claim 28 including a u-shaped structural channel member, the opening of the u-shaped channel facing the
    2.0 female channel of the corner piece, the base of the u-shaped channel positioned adjacent a first wall face of the corner piece and one of the arms of the u-shaped channel positioned adjacent a second wall face of the corner piece, the second wall face being substantially at right angles to the first wall face to provide a outwardly facing comer.
    25 30, A corner piece as claimed in any one of claim 27 to 29 wherein the corner piece includes a hole for receiving a foundation securing rod.
    WO 2015/042665
    PCT/AU2014/050250
    2019200468 23 Jan 2019
    31. A comer piece as claimed in claim 30 wherein the hole is provided centrally provided relative to the extension of the female channel portion and the extension of the male projection.
    32. A corner piece as claimed in any one of claims 27 to 31 includes a v-shaped
    5 portion providing two wall faces.
    33. A corner piece as claimed in any one of claims 27 to 32 wherein the female channel and the male projection are formed in a unitary piece of rigid foam material,
    34. A corner piece as claimed in any one of claims 27 to 33 wherein the female
    10 channel and the male projection are formed in a body of rigid foam material.
    35. A corner piece as claimed in an}? one of claims 27 to 34 wherein the body of rigid foam material is provided as an L-shaped extrusion.
    36. A modular building system comprising a first joiner having flange portions and a second joiner having flange portions wherein the first joiner is adapted to
    IS adapted to be receive flange portions of a number of upper side portions of a number of modular panels and the second joiner is adapted to receive flange portions of a number of lower side portions of the modular panels,
    37. A modular building system as claimed in claim 36 wherein each modular panel comprises: an inner foam core and a frame surrounding the inner foam core; the
    2.0 frame for standing upright to provide two primary faces joined by a number of side portions; the side portions of the frame being provided by structural channel members; the structural channel members providing a perimeter around the foam core; the structural channel members providing flange portions to allow rigid connection of the panel using fasteners extending through the primary
    25 faces into the flange portions to provide the panel with a desirable cyclone rating.
    WO 2015/042665
    PCT/AU2014/050250
    2019200468 23 Jan 2019
    38. A modular building system as claimed in claim 36 or 37 wherein the joiners comprise u-shaped channel members.
    39. A modular building system as claimed in any one of claims 36 to 38 wherein the joiners are used to fix upper sides and lower sides of the modular panels.
    5 40. A method of constructing a wall comprising fixing a first joiner to lower side portions of a number of modular panels; and fixing a second joiner to upper side portions of the panels; the joiners having flange portions that receive flange portions of the modular panels on their upper and lower sides.
    41, A method as claimed in claim 40 wherein the joiners comprise u-shaped channel
    10 members.
    42, A modular building panel for use in forming walls, the panel comprising: an inner foam core and a rectangular frame surrounding the inner foam core; the rectangular frame for standing upright to provide two primary faces joined by an upper side portion, a lower side portion; and two lateral side portions; each
    15 of the side portions of the frame being provided by structural channel members;
    the structural channel members providing a perimeter around the foam core; the channel members providing flange portions to allow rigid connection of the panel using fasteners extending through the primary' faces in the vicinity of the perimeter to provide the panel with a desirable cyclone rating.
  16. 20 43. A modular building panel for use in forming walls, the panel comprising: a frame for surrounding an inner foam core; the frame for standing upright to provide two primary faces joined by a number of side portions; the side portions of the frame being provided by structural channel members; the structural channel members for providing a perimeter around the foam core; the structural
  17. 25 channel members providing flange portions to allow rigid connection of the panel using fasteners extending through the primary faces into the flange portions.
    WO 2015/042665
    PCT/AU2014/050250
    2019200468 23 Jan 2019
    44, A method of providing a modular building panel comprising: providing a wall facing; providing a frame having the structural channel members providing a perimeter for receiving a foam core; and applying a further wall to provide a mould for the foam core, and filling the mould to provide the foam core;
    5 wherein the structural channel members provide flange portions that lie against each wall facing; the flange portions allowing rigid connection of the panel to another panel or structural element using fasteners extending through the wall facings into the flange portions in the vicinity of the perimeter of the panel to provide the panel with a desirable cyclone rating,
    10 45, A modular building panel for use in providing a recess for a window, the panel comprising: a frame for standing upright to provide two primary faces joined by a number of side portions; the side portions of the frame being provided by structural channel members; the panel having vertical side that provides a stepped configuration where a portion of the side mates with another panel to
    15 provide a recess the recess extending between the two panels, the recess able to accommodate a window.
    46. A modular building panel as claimed in claim 45 wherein the recess is able to accommodate a window and a further panel than spans the two panels above the window.
    20 47. A modular building panel as claimed in claim 45 or 46 wherein the stepped configuration comprise a first step into the panel to accommodate and support the window and then a second further step into the panel to increase the depth of the recess to accommodate and support the further panel,
    48. A modular building panel for use in forming walls, the panel comprising: an
    25 inner foam core and a frame surrounding the inner foam core; the frame for standing upright to provide two primary faces joined by a number of side portions; the side portions of the frame being provided by structural channel members; the structural channel members providing a perimeter around the
    WO 2015/042665
    PCT/AU2014/050250
    2019200468 23 Jan 2019 foam core; the structural channel members providing flange portions to allow rigid connection of the panel using fasteners extending through the primary' faces into the flange portions.
AU2019200468A 2013-09-26 2019-01-23 Building panels - systems components & methods Abandoned AU2019200468A1 (en)

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AU2013234383 2013-09-26
AU2013234383A AU2013234383A1 (en) 2013-09-26 2013-09-26 Building panels – systems components & methods
AU2013903752 2013-09-27
AU2013903737A AU2013903737A0 (en) 2013-09-27 Building panels – systems components & methods
AU2013903737 2013-09-27
AU2013903752A AU2013903752A0 (en) 2013-09-27 Building panels – systems components & methods
AU2013903929 2013-10-12
AU2013903929A AU2013903929A0 (en) 2013-10-12 Building panels – systems components & methods
AU2014328484A AU2014328484A1 (en) 2013-09-26 2014-09-26 Building panels - systems components & methods
PCT/AU2014/050250 WO2015042665A1 (en) 2013-09-26 2014-09-26 Building panels – systems components & methods
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