AU4438702A - A rail device for bricks - Google Patents

Description

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Applicants: HOXIN TRADING AUSTRALIA PTY LTD Invention Title: A RAIL DEVICE FOR BRICKS The following statement is a full description of this invention, including the best method of performing it known to us: 2 A PANEL COMPONENT FOR A WALL OF A BUILDING The present invention relates to the construction industry and is particularly concerned with earth quake resistant buildings.

An earth quake resistant brick and rail system has previously been developed which incorporates a metal rail which is adapted to receive a series of brick facing tiles.

The metal rails consist of a long narrow sheet of metal with one of its long side edges bent at 90' away from one of the major faces of the sheet of metal and then downwardly at 900 to form a narrow ledge with a skirting.

The rail as described above is nailed at each end to respective vertical posts of a building. Brick facing tiles having a groove along one side are then placed on the ledge so that the skirting fits into the groove.

A series of similar brick facing tiles are then located on the ledge of the rail in the same fashion.

By connecting a series of rails together side to side to form a series of horizontally extending rails, the side of a building may be formed with brick facing tiles which are then fixed in position by providing mortar between adjacent side faces of each of the brick facing tiles.

Because the brick facing tiles are located and supported in respective rails the rails are able to act as reinforcing should twisting forces be applied to the facing tiles in the event of an earthquake.

The above described brick and rail system suffers from problems such as corrosion of the rail system and damage to the brick facing tiles due to residual water trapped in each rail.

In colder climates the water can freeze and this can cause breakage of brick facing tiles.

Furthermore chemical erosion such as corrosion of the rail system can lead to serious damage and consequently impaired structural stability.

H: SueB\Kee\seci \p4570 spec. doc 20; 05,02 3 Another problem with the existing brick and rail system lies with the amount of labour required to connect a series of rails together.

This is because adjacent rails must be correctly aligned so that a channel is formed with a skirt for insertion in the groove of a facing brick and a ledge for supporting the opposite side of the brick facing tile.

European patent application 01/90377 discloses an earlier system for constructing buildings in earthquake regions utilising support plates for tiles. The invention disclosed in this patent has several drawbacks including the following: Each support plate consists of a series of windows with associated ledges. Eventually the weight of building blocks placed on these ledges leads to bending of the ledges. Furthermore moisture typically builds up behind the building blocks and there no where for this moisture to escape.

To deal with the issue of moisture build-up behind the building blocks, typically a waterproof sheet is placed between the building blocks and the support plate. The problem with this solution is that the waterproof sheet needs to be placed completely flat against the support plate without any crease. This requires a significant degree of skilled workmanship.

In addition to the above each of the ledges must be horizontally aligned otherwise adjacent building blocks will not be aligned and this will cause huge problems with forming a secure wall. Typically very skilled workmanship is required to ensure building blocks are correctly aligned and they are also located to minimise any air space behind the mortar which may allow build up of moisture. Typically the support plates described above only have a life span of 10 years before problems occur and repair work must take place.

British patent GB2231890 discloses an invention for a tile cladding system which is very similar to that H: \Sue ee speci4570 .spec ,oc 20/05102 4 shown in the above-referenced European patent application.

It likewise suffers from the same drawbacks.

The present invention is aimed at providing an improved panel component which at least provides an alternative to the prior art systems without all of their drawbacks.

According to the present invention there is provided a panel component for a wall of a building, comprising a plurality of panels each connected together along adjacent side edges prior to connection to a building, each panel having a generally planar major face, an upper and lower side edge with at least one side connected to an adjacent side of another panel of the panel component and a supporting surface for supporting building blocks and having openings for drainage of water.

According to another aspect of the present invention there is provided a panel component for a wall of a building, comprising a plurality of panel portions, each panel portion having a generally planar major face, an upper and lower side edge with at least one side integrally formed with an adjacent side of another panel section of the panel component and a supporting surface for supporting building blocks and having openings for drainage of water.

According to another aspect of the present invention there is provided a panel having a generally planar major face, an upper and lower side edge with at least one side edge adapted to be connected to an adjacent side edge of another panel, the panel component further comprising a supporting surface for supporting building blocks and having openings for drainage of water.

According to another aspect of the present invention there is provided a panel component for a wall comprising a plurality of generally planar major faces and a plurality of supporting surfaces with one major face located between two supporting surfaces, each supporting surface being adapted to support one or more building H: \Suee\Eep\sp1ci \[45F70. Iec dc 20/05 02 5 blocks and having openings for drainage of water.

Preferably the supporting surfaces extend outwardly from a lower side of each planar major face.

Preferably the upper and/or lower extent of each major face is bordered by a respective supporting surface.

The supporting surface is preferably in the form of a ledge.

Preferably the openings are located in the supporting surface.

According to another embodiment the openings are located on another part of the panel separate from the supporting surface.

Preferably the supporting surface comprises a ledge at a lower side of each panel.

It is noted that for convenience the panel component will be described primarily when used in a horizontal disposition with its major sides serving as upper and lower edges.

Preferably each ledge extends at substantially right angles to the major face.

It is preferred that each ledge is adapted to be narrower than the width of a building block which it is to support.

Each panel or panel component may have a spacer section between the major face and the supporting surface.

The spacer section may comprise a narrow ledge separated from the support surface by a spacer wall.

The spacer wall preferably has an abutment face adjacent-which, building blocks are adapted to abut.

Preferably the spacer wall is substantially parallel to the major face.

The spacer wall may be offset laterally with respect to the major face.

The narrow ledge may prevent building blocks from abutting against the major face.

Preferably the lower side edge includes a mortar face which is adapted to have mortar placed thereagainst H :\S1B ePF13c I -1F O sec oc20,:O0502 6 to thereby interconnect adjacent building blocks.

The mortar face preferably extends downwardly from the support surface.

The mortar face may extend downwardly from the outer edge of the support surface.

It is preferred that the openings each adjoin with a corner section interposing the support surface and the spacer wall.

The openings may be slots.

Preferably the mortar face extends at substantially right angles to the support surface.

The lower edge of the mortar face may be adapted to fit into a groove in a top face of a building block.

It is preferred that "building block" includes tiles, bricks, Besser blocks, beams of wood, metal or any other material which is able to act as a wall of a building.

The upper side edge of the major face preferably abuts a back face of a spacer wall and is connected thereto.

Preferably adjacent panels are connected together by crimping or welding or crinching.

It is preferred that the panel component comprises a plurality of similar panels.

According to another embodiment the panel component includes at least one panel of a different configuration to the other panels.

Preferably a panel component comprises three like panels.

The words "comprising, having, including" should be interpreted in an inclusive sense, meaning that additional features may also be added.

A preferred embodiment of the invention will now be described by way of example only with reference to the accompanying drawings in which: Figure 1 shows an angled view of a wall of a building formed from a panel component in accordance with 1i \}:ppC1 \145S 7 O. sp.doc 20,05 02 7 the present invention; Figure 2 shows an angled view of a panel of the panel component of the present invention; Figure 3 shows a side view of the panel shown in Figure 2; Figure 4 shows a side view of a top panel of a panel component in accordance with another embodiment of the present invention; Figure 5 shows a bottom panel of a panel component in accordance with a further embodiment of the present invention; Figure 6 shows a front angled view of a panel component according to another embodiment of the present invention; Figure 7 shows a side view of the panel shown in Figure 6; Figure 8 shows a front angled view of a panel according to a further embodiment of the present invention; Figure 9a shows a front view of a panel component according to a second embodiment of the present invention; Figure 9b shows a side view of part of a panel shown in Figure 9a; Figure 10 shows an angled view of a panel of the panel component shown in Figure 9a; Figure 11 shows a side view of the panel shown in Figure Figure 12 shows a side view of a top panel of the panel component shown in Figure 9a; Figure 13 shows a side view of a bottom panel of a panel component shown in Figure 9a; Figure 14 shows an angled side view of the panel component shown in Figure 9a; and Figure 15 shows an angled front and side view of a building block for use with the panel component shown in Figure 9a.

As shown in Figure 1 a panel component H: \Sue \Veep\sEP Ci\p45S0. spec .doc 20, 05/02 8 according to the present invention consists of a series of panels 11 which are connected together, typically by welding or crimping prior to attachment to building support structures.

Figure 2 shows one panel 11 which is part of the series of panels which together form a panel component Each panel 11 is formed from a generally rectangular sheet of metal which is galvanised Zincalum (a registered trademark of BHP Pty Ltd A51397) for corrosion resistance. In Figure 2 the panel is shown in a horizontal disposition ready for connection between two vertical beams of a building.

The panel 11 has an upper side edge 12, a lower side edge 13 and a right end edge 14.

The panel 11 has a major planar face 15 extending from the upper side edge 12 to a first bend 16 extending at right angles to the face 15 and forming a narrow ledge 17.

The narrow ledge 17 extends downwardly from its outer edge 18 at right angles forming a planar spacer wall which is parallel to planar face The vertical length of the spacer face 19 is approximately one quarter of the length of the major face The lower end of the spacer face 19 extends outwardly at right angles to form a wide ledge 20. The wide ledge 20 is provided with a series of drainage holes 21 which are in the form of slots which have their inner side edge co-terminus with the corner created between face 19 and ledge The outer edge of ledge 20 extends downwardly at right angles forming a guide rail wall 22.

As shown in Figure 1 a series of panels 11 are connected together by placing the upper side wall 12 of one panel behind spacer wall 19 of another panel so that the upper side edge 12 abuts underneath ledge 16.

A weld 23 is then created as shown in Figure 2 to H: \SueE\Kel)SPeC i\p45P70 sec. c 20/05,02 9 connect the abutting faces 15 and 19 together.

A preformed panel component can then be formed with two or more panels as shown in Figure 1 and this panel component can be connected to a building structure by fixing the ends of the panel component to vertical posts. Brick tiles 24 may then be located on each ledge of the panel component so that slot 25 in their upper side 26 slides under the lower side edge 13 of guide rail wall 22.

Adjacent pairs of panels 11 thus form a channel which houses a series of brick tiles 24. Because the panels are already connected together no further connection by nailing, riveting or any other means is required.

Once all brick tiles have been located in their respective channels a series of horizontal brick tiles is provided and these brick tiles are connected together by providing mortar 27 between adjacent horizontal rows of brick tiles.

By having panels connected together to form a panel component prior to fixing to a building support structure, labour, time and costs can be significantly reduced because a larger overall panel is created which does not require individual panels to be separately aligned and connected as in the prior art.

The narrow ledge 17 and spacer wall 19 prevent the rear face 28 of a block tile from abutting the major face 15 of the panel on which it is supported.

This has an advantage by preventing any moisture build up on the surface of the major face 15 from being in constant contact with the inner face 28 of the block tile 24.

Furthermore any water on the major face 15 is able to drain along ledge 17 down wall 19 and through drainage slots 21.

This prevents any build up of moisture on the panels thus reducing corrosion problems as well as mould H: 1:.5 p C \1,45P,70 s- e dC c 20 05 02 10 and mildew problems. Furthermore damage to brick tiles 24 is reduced as expansion and contraction of water due to freezing or vaporisation is mitigated.

The spacer wall 19 and ledge 17 also enable the abutting of adjacent panels so that a weld can be provided by overlapping adjacent panels but providing a generally planar surface for connection to a building structure.

Figure 4 shows a different type of panel 30 which is used to act as the uppermost panel in a panel component. This uppermost panel 30 has a generally planar major face 31 with its upper edge 23 bent outwardly at 900 to form an overhanging wall 33 which at its outermost end 34 bends downwardly at 900 to form a skirting wall Panel 30 may be used as a separate panel which is added to the uppermost panel component 10 to complete a side wall of a building. The lower end of the panel is connected to the upper side wall edge 12 of a panel component by nailing, riveting or any other suitable means and the configuration of the upper end enables the skirting wall 35 to locate in a slot of brick tiles.

As an alternative a panel component may be created which combines the panel 30 with one or more panels 11 to form a panel component specifically designed for use as the uppermost panel in a building structure.

Figure 5 shows an alternative panel 40 which is used as the lowermost panel in a building structure.

Panel 40 consists of a major face 41 which at its lower end is bent at right angles to form a horizontal wall 43 with a series of drainage slots 42 along its inner edge in a similar fashion to those described in relation to Figure 2.

Panel 40 may be connected at its upper end to the lowermost in a panel component or alternatively may be part of a panel component which is specifically for use as the lowermost panel component in a building.

The surface 41 is used to support a brick tile which is located at the bottom of a wall created by H SueB',E e c i 1)4 587, 0. spec. 2Oi05/C2 11 utilising panels of the type described above.

According to a variation to the present invention instead of connecting panels together to form a panel component, a panel component may be formed by a single panel with supporting surfaces added thereto as a series of ledges or shelves. Alternatively the panel and shelves may be formed as a single sheet by pressing and folding the panel at spaced intervals to form a series of supporting surfaces.

It should be noted that different embodiments of the invention in which optional features are described in relation to panels which are connected together to form a panel component are optional features which are also applicable to a panel component which is formed from a single sheet of material.

As shown in Figure 6 a panel component 50 may be formed from a single sheet of metal with ledges 51 and guide rail walls 52.

According to one method of forming the above panel component 50, planar metal mandrels may be used to form wall sections perpendicular to the planar major faces 53 and then a folding step may be utilised to form guide rail wall 52.

The number of mandrels used will determine the number of ledges 51/guide rail walls 52 which are formed for the panel component Figure 7 shows a side view of the panel component and more clearly indicates how the ledges 51 and guide rail walls 52 are oriented at right angles to each other.

Slots 54 are formed in the ledges 51 in a similar position to that described for the previous embodiments.

Figure 8 shows another embodiment of the invention in which a series of six panels are connected together to form a panel component The features of the panel component 60 are essentially the same as those described in relation to Figures 1 and 2.

H:IS-ER}:e-P\-P-Ci'p4570.spec-dc 20/05,02 12 By utilising panels and panel components as described above buildings can be created having resistance to earth quakes or other structurally challenging forces but which at the same time shortens the labour time required to build walls for this purpose as well as reduce the effects of damage caused by moisture build-up behind brick walls. Build up of mould, mildew and moss can also be reduced, thus reducing damage to bricks and mortar.

It is also noted that if each panel was created with drainage holes and then connected to a building structure it would be a significant problem lining adjacent panels so that drainage holes were also aligned.

If any mistakes are made then all fixings need to be removed and realignment initiated. By preforming a series of panels as a panel component alignment issues effectively disappear.

According to the second embodiment of the invention a panel shown in Figure 10 is provided with a ledge 61 having upwardly and downwardly extending guide rail walls 63, 62 extending in a progressive pattern along the length of the ledge 61.

Thus as shown in Figure 10 starting at the right hand side of the panel a first guide rail segment 62 extends vertically downwardly and this is followed by a second guide rail segment 63 which extends vertically upwardly. This is again followed by a downwardly extending guide rail segment 62 which in turn is followed by an upwardly extending guide rail segment 63 and so on until the opposite end of the panel 64.

The ledge 61 as in the first embodiment has a series of drainage holes As shown in Figure 9a a series of panels 64 are connected together in a similar fashion to that described previously to form a panel component 66 having a series of upwardly and downwardly extending guide rail segments 63, 62 extending from the outer edge of each of the ledges 61.

As shown in Figure 15 a building block 67 with H: >.dPeB,\F p 1 i c \P 45 70 p[e Io c 20105/02 13 grooves 68, 69 in upper and lower edges thereof is able to slide between adjacent ledges 61 as shown in Figure 9b so that the upwardly extending guide rail segments 63 of a lower ledge fit into the groove 69 and the downwardly extending guide rail segment 62 fit into the upper groove 68.

Typically the length of a building block segment 67 is sufficient to span twice the length of one of the guide rail segments. It follows therefore that the whole length of each of the grooves 68, 69 is not filled with a guide rail segment when positioned on part of one of the ledges of the panel component 66. Therefore where guide rail segments extend in opposite directions from each other on adjacent ledges, building blocks extending across the associated parts of the ledge are not retained on the ledge because they do not couple with a guide rail segment. However approximately half of each groove 68, 69 is coupled a guide rail segment and this is sufficient to provide alignment between adjacent building block components and provide a method of retaining the building block components on the ledges in addition to mortar.

Because each building block is retained on a ledge by upper and lower guide rail segments, additional stability is provided to a structure formed using the panel components particularly during an earthquake.

Without any guide rail segments there could be a tendency for the building blocks to move away from the ledges, thus requiring major repair to the building structure formed by the panel components and building blocks. Instead with the guide rail segments the building block components tend to be retained in the same position thus minimising damage and thus repair work required in the event of an earthquake.

As shown in Figure 11 a middle panel 70 may have a first bend 71 which is angled upwardly at 800 with respect to the major panel face 72, instead of at right angles as in the first embodiment shown in Figure 3. As If: R\IK-I)'-pCi 'p45H7U sp S dtOC 02 14 shown in Figures 12 and 13 the uppermost and lowermost panels are essentially the same as those of the first embodiment of the invention shown in Figures 4 and 5. It is noted however that in Figure 13 the outermost edge of the surface 43 may be provided with a series of upwardly extending guide rail segments 63 to fit into corresponding shaped grooves of a building block as shown in Figure An advantage of at least one of the above embodiments of the invention is that it is possible to make walls without any mortar being required to connect building blocks together. Therefore a panel may be provided with building blocks on each ledge without mortar. This obviously reduces the time and cost required to construct a wall. Furthermore there is no problem with cracking of mortar in the event of an earthquake.

Without mortar being used it is also noted that it is possible to replace cracked building blocks.

It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or in any other country.

H S re\}B -,pci \1,45PO sp c .do c 20 05. 02

Claims (17)

1. 2. The panel component as claimed in claim 1 wherein the supporting surfaces extend outwardly from a lower side of each planar major face.
2. 3. The panel component as claimed in claim 1 or claim 2 wherein the upper and/or lower extent of each major face is bordered by a respective supporting surface.
3. 4. The panel component as claimed in claim 3 wherein the supporting surface is in the form of a ledge. The panel component as claimed in claim 4 wherein the openings are slots located in the supporting surface.
4. 6. The panel component as claimed in claim including a spacer section between the major face and the supporting surface.
5. 7. The panel component as claimed in claim 6 wherein the spacer section comprises a narrow ledge separated from the support surface by a spacer wall.
6. 8. The panel component as claimed in claim 1 comprising a plurality of panels each having at least one generally planar major face, an upper and lower side edge with at least one side edge adapted to be connected to an adjacent side edge of another panel.
7. 9. The panel component as claimed in claim 8 wherein each panel component comprises at least one supporting surface. The panel component as claimed in claim 9 comprising a plurality of panel portions each panel portion having at least one generally planar major face, an upper and lower side edge with at least one side integrally formed with an adjacent side of another panel H \S-5 1:Hep\H )ci'45R7O.spec.(Icc 20/05,02
8. 16- section of the panel component. 11. The panel component as claimed in claim wherein each supporting surface is formed by a mandrel. 12. A panel component for a wall of a building comprising a plurality of panels each connected together along adjacent side edges prior to connection to a building, each panel having a generally planar major face, an upper and lower side edge with at least one side connected to an adjacent side of another panel of the panel component and a supporting surface for supporting building blocks and having openings for drainage of water. 13. The panel component as claimed in claim 12 wherein each panel has a spacer section between the major face and the supporting surface. 14. The panel component as claimed in claim 13 wherein the spacer section comprises a narrow ledge separated from the support surface by a spacer wall. The panel component as claimed in claim 14 wherein the spacer wall has an abutment face adjacent which building blocks are adapted to abut. 16. The panel component as claimed in claim wherein the spacer wall is substantially parallel to the major face.
9. 17. The panel component as claimed in claim 16 wherein the spacer wall is offset laterally with respect to the major face.
10. 18. The panel component as claimed in claim 17 wherein the lower side edge includes a mortar face which is adapted to have mortar placed thereagainst to thereby interconnect adjacent building blocks.
11. 19. The panel component as claimed in claim 18 wherein the openings each adjoin with a corner section interposing the support surface and the spacer wall. The panel component as claimed in claim 19 wherein the openings are slots.
12. 21. The panel component as claimed in claim 19 wherein the mortar face has a lower edge which is adapted ii: \5ueB ep c \Ip4570 slec l dc 20, 05 02 17 to fit into a groove in a top face of a building block.
13. 22. The panel component as claimed in claim 21 wherein the upper side edge of the major face of at least one panel abuts a back face of one spacer wall of an adjacent panel and is connected thereto.
14. 23. The panel component as claimed in claim 22 wherein adjacent panels are connected together by crinching.
15. 24. The panel component as claimed in claim 23 wherein at least one panel has a different configuration to other panels of the panel component. The panel as claimed in claim 12 wherein the supporting surface has a series of guide rails extending therefrom, which guide rails are adapted to be received in corresponding grooves of building blocks.
16. 26. The panel as claimed in claim 25 wherein the guide rails comprise a series of alternating upwardly and downwardly extending wall portions.
17. 27. A panel component substantially as hereinbefore described with reference to the accompanying drawings. Dated this 24th day of May 2002 HOXIN TRADING AUSTRALIA PTY LTD By their Patent Attorneys GRIFFITH HACK Fellows Institute of Patent and Trade Mark Attorneys of Australia H:\S.E\Keep\sP\C.1- 4 p.7Os Pc.doC 24,05/02