AU729445B2

AU729445B2 - A building panel

Info

Publication number: AU729445B2
Application number: AU23665/97A
Authority: AU
Inventors: John Fick
Original assignee: Boral Australian Gypsum Ltd; Australian Gypsum Ltd
Current assignee: Knauf Gypsum Pty Ltd
Priority date: 1996-05-29
Filing date: 1997-05-28
Publication date: 2001-02-01
Anticipated expiration: 2017-05-28
Also published as: AU2366597A; JPH1061067A; CN1090272C; CN1174922A; AUPO013296A0

Description

S F Ref: 376406

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name and Address of Applicant: Boral Australian Gypsum Limited Thackeray Street Camellia New South Wales 2142

AUSTRALIA

John Fick Actual Inventor(s): Address for Service: Invention Title: ASSOCIATED PROVISIONAL [31) Application No(s) P00132 Spruson Ferguson, Patent Attorneys Level 33 St Martins Tower, 31 Market Street Sydney, New South Wales, 2000, Australia A Building Panel APPLICATION DETAILS [331 Country

AU

[32] Application Date 29 May 1996 The following statement is a full description of this invention, including the best method of performing it known to me/us:- 5815 A Building Panel Field of the Invention The following invention relates to pre-fabricated building panels. More particularly, though not exclusively, the invention relates to thermal and acoustic insulating building panels.

Background of the Invention Described in Australian Patent 568548 is a building panel which consists of a core of expanded cellular plastics material within which vertical columns formed from metal strips are embedded. The columns have a U-shaped transverse cross-section.

Still further, the panel has horizontally extending strips at the top and bottom of the panel.

Described in Australian Patent Application No. 45736/96 is an improvement to S. what is described in the above referenced Australian Patent. Application 45736/96 describes a building panel which consists of a core of plastics material having embedded is therein a series of vertical columns provided with a plurality of apertures so that the i expanded polystyrene foam can extend therethrough to join the segments of the panel together. In order to affix adjoining panels together to form a wall, the foam segments at the remote lateral edges are provided, for example, with a step configured to cooperate with a corresponding step at the edge foam segment of the adjoining panel.

Object of the Invention It is the object of the present invention to provide a building panel having a reinforcing channel member at least at one edge thereof, the channel serving not only to reinforce the panel, but to provide a means by which adjoining panels can be interengaged.

Se 25 Summary of the Invention There is disclosed herein a building panel comprising: a core of expanded plastics material of generally rectilinear configuration having two major generally parallel and coextensive surfaces, which are separated by the thickness of the core, and four edge surfaces joining the coextensive surfaces; a reinforcing channel member being arranged so as to extend along one of the edge surfaces, the channel member providing a recess; and wherein edge surface at the opposite side to said one edge surface of the panel comprises a protrusion which is to engage within the recess of a corresponding channel member of an adjoining panel, and said edge surface has a configuration confirming to the profile of the reinforcing member.

Preferably the protrusion is coextensive with the recess.

Preferably the channel member has a Z profile when viewed in transverse cross-section.

1N:1LIBLLIOO402:hrw -2- Preferably, the channel section provides a longitudinal groove into which said protrusion is receivable.

Preferably the protrusion is shaped to correspond with the shape of the groove.

Preferably, the channel member comprises a pair of opposed lips embedded into the core of the panel.

Alternatively, the channel member comprises a pair of folded lips, each adapted to reside within a respective rebate formed nearby the edge of the core of the panel.

Typically, the channel member is fabricated from 0.6 mm G550 steel.

However, alternative steel thicknesses or other metallic or plastics material can be used.

In an alternative construction, the channel member takes the form when viewed in transverse cross-section of an I beam.

Typically, the I beam is fabricated from 0.4 mm G550 steel.

Alternatively, other steel thicknesses can be used, as might other materials.

"s 15 There is further disclosed herein a wall being formed from a plurality of interengaged panels as disclosed above, the wall comprising a bottom rail being of Ushape when viewed in transverse cross-section; a plurality of said panels joined edge-to-edge and having their lower edges received by the bottom rail; and 20 a top rail being of generally inverted U-shape when viewed in transverse crosssection, the upper edges of the adjoining panels being received by the top rail.

Preferably the top rail is connected to the channel member by screws, nails, rivets, bolts, spot welding or the like.

Preferably the bottom rail is connected to the channel member by means of 25 screws, nails, rivets, bolts, spot welding or the like.

Brief Description of the Drawings Preferred forms of the present invention will now be described by way of example with reference to the accompanying drawings, wherein: Fig. 1 is a schematic plan view of a panel; Fig. 2 is a schematic plan/end elevational view of a reinforcing member; Fig. 3 is a schematic elevational view of a wall comprising a plurality of panels, each as shown in Fig. 1; Fig. 4 is a schematic end elevational view of the wall of Fig. 3; Fig. 5 is a schematic plan view of the wall of the Figs. 3 and 4; Fig. 6 is a schematic plan view of another wall panel; Fig. 7 is a schematic plan/end elevational view of a reinforcing member to be affixed to one edge of the panel of Fig. 6; Fig. 8 is a schematic elevational view of a wall fabricated from a plurality of panels, each as shown in Figs. 6 and 7; Fig. 9 is a schematic end elevational view. of the wall of Fig. 8; IN:\LIBLL]00402:hrw Fig. 10 is a schematic plan view of the wall of Figs. 8 and 9; and Fig. 11 is a schematic plan/end elevational view of another reinforcing member in place upon the edge of a panel core.

Description of the Preferred Embodiment s In Fig. 1 of the accompanying drawings there is depicted a wall panel Panel 10 comprises a core 11 formed of expanded plastics material such as expanded polystyrene having a density of 16 to 24 kg/m 3 Being formed of expanded plastics material, the core 11 has good thermal and acoustic insulating properties. To one end of the panel 10, there is affixed a reinforcing member 12. At the other end of the panel 10, there is provided a tongue 13 which extends throughout the entire length of that edge of panel 10. The tongue is generally tapered as shown. Extending between the tongue 14 and the respective opposed faces of the core 11 is pair of abutments 14. The 11 is generally of square or rectangular configuration and has major surfaces 22, to hand bottom edge surfaces 24 and side edge surfaces 23.

Fig. 2 depicts in more detail the reinforcement member 12. Reinforcement member 12 takes the form of a Z profile when viewed in transverse cross-section as depicted in Fig. 2. Member 12 can be fabricated from 0.6 mm G500 steel which is cold formed into the shape depicted. Member 12 can be galvanised. The reinforcement member 12 comprises a pair of opposed faces 15 extending at right S 20 angles from a respective pair of end strips 17. The faces 15 are co-planar with respect to the major surfaces 22. Each end strip continues with a respective tapered groove face 18 which each extend to a common inner surface 19. Surfaces 18 and 19 define a groove 22 into which the tongue 13 is receivable.

The distal edges of each face 15 can comprise a lip 16 to be embedded into the 25 foam core 11, or alternatively, the panel can be shaped to be inserted directly into the reinforcing member 12. For example an alternative configuration is shown in Fig. 11.

Each lip 16 in this configuration is folded back towards the respective face 15. This results in increased rigidity to the edge of face 15 and also provides a smooth transition between the surfaces of core 11 and the respective faces 15. In order to provide clearance for the lip 16, the core 11 is provided with a pair of opposed rebates 23 which extend throughout the length of the edge of core 11. To further aid in securing the reinforcement member 12 to the core 11, adhesive can be applied to one or more of the inner surfaces as indicated by the letter A. The adhesive is used to secure the reinforcement member 12 to the edge of core 11.

A constructed wall is shown in Figs 3, 4 and 5. The wall comprises a bottom rail 20 formed from U channel. At the upper edge of the wall there is provided a top rail 19 in the form of an inverted U channel having a widened entry region to receive the upper edges of the panels Individual panels 10 are placed into the bottom rail 20 and interconnected by moving one of the panels 10 longitudinally within the channel 12 until the tongue 13 of [N:\LIBLL0402:rvw one panel enters the groove 22 of the adjoining panel. The wall is extended by adding additional panels as described. The top rail 19 can then be placed at the upper edge of the adjoining panels. Alternatively, the top rail 19 can be placed into position prior to insertion of the panels longitudinally of the affixed top and bottom rails.

s Once in position, the top and bottom rails can be affixed to the respective top and bottom ends of the reinforcing members 12. Nails 21 can be used for this purpose.

Typically, two nails 21 can be provided at the top and bottom of each face of the panel (ie four nails in total at the top and four nails in total at the bottom of each reinforcing member 12). Alternatively, rivets, screws, nuts and bolts or spot welding for example can be used.

When the adjoining panels 11 are interconnected, the end strips 17 of the reinforcement member 12 is to abut the abutment surfaces 14 of the adjoining panel 11.

Turning now to Figs. 6 and 7, an alternative panel 60 is depicted. Panel also formed from expanded polystyrene foam comprises a pair of tongues 62 at each 5. is laterally opposed edge. The tongue 62 has a respective pair of tapered side walls 61.

To one edge of the core 60 there is affixed a reinforcing member 70 as shown in Fig.

7. Reinforcing member 70 is typically fabricated from 0.4 mm G550 steel cold formed o into the configuration depicted. The Reinforcing member 70 takes the general form of an I beam having a pair of end faces 73 and a web 71. Member 70 is typically 20 fabricated from a single piece of steel having opposed lengthwise edges 75 folded around into the respective positions depicted. Member 70 comprises a pair of opposed internal tapered faces 72 and end abutments 76. Likewise, at the opposed side of web 71, abutments 76 are provided as are internal tapered walls 74. Either side of the web 71 can be adhered to one of the edges 62 of the core 60 such that the respective surfaces 25 74, 76 (or 72, 76) abut the respective surfaces 61 and 62 of the core 60. Only one edge of the core 60 is to be provided with a reinforcing member 70. Adhesive can be applied to any of the surfaces indicated by the letter A.

With reference to Figs. 8, 9 and 10, a wall can be fabricated from the panels of Figs. 6 and 7 in the same manner as is the wall depicted in Figs. 3, 4 and It should be appreciated that modifications and alterations obvious to those skilled in the art are not to be considered as beyond the scope of the present invention.

For example, rather than providing a tongue and groove type interengagement between adjoining panels, a stepped type interengagement can be provided by choice of an appropriately shaped reinforcement member.

Furthermore, any shape of reinforcing member can be adopted without departing from the spirit and scope of the present invention.

IN:\LIBLLIOO402:hrv

Claims

1. A building panel comprising: a core of expanded plastics material of generally rectilinear configuration having two major generally parallel and coextensive surfaces, which are separated by the thickness of the core, and four edge surfaces joining the coextensive surfaces; a reinforcing channel member being arranged so as to extend along one of the edge surfaces, the channel member providing a recess; and wherein edge surface at the opposite side to said one edge surface of the panel comprises a protrusion which is to engage within the recess of a corresponding channel member of an adjoining panel, and said edge surface has a configuration confirming to the profile of the reinforcing member.

2. The building panel of claim 1, wherein the protrusion is coextensive with respect to the recess.

3. The panel of claim 1 or 2, wherein said recess is defined between a 15 pair of spaced coextensive recess surfaces. V

4. The panel of claim 3, wherein said recess surfaces are longitudinally parallel and diverge transversely toward an inner surface.

The panel of claim 3 or 4, wherein said reinforcing member has a pair of spaced longitudinally extending edge faces which are arranged so as to be generally 20 coextensive with the major surfaces of the board.

6. The panel of claim 5, further including a lip formed on each edge surface extending generally inwardly with respect to the core.

7. The panel of any one of claims 1 to 6, wherein said reinforcing member is formed of galvanised steel and has a transverse cross-section approximately 25 of a configuration.

8. The panel of any one of claims 1 to 7, wherein said one edge surface and the opposite edge surface thereof are intended to extend generally vertically so that the other two edge surfaces are arranged generally horizontally.

9. The panel of claim 5, wherein said reinforcing member is of a "I" transverse cross-section.

The panel of claim 9, wherein said protrusion has a pair of coextensive longitudinal sides which converge and said recess is defined between a pair of longitudinally coextensive surfaces which converge towards a base.

11. The panel of any one of claims 1 to 10, wherein said one edge surface and said opposite edge surface are intended to extend generally vertically, and the other side surfaces are intended to extend generally horizontally, with one of said other side surfaces, said panel further including a channel member having a shaped transverse cross-section attached to the core so as to extend along one of said other edge surfaces.

12. A wall consisting of a plurality of panels each as defined in any one of claims 1 to 11, wherein the panels are generally vertically oriented with each [N:\LIBLL10O402:hrw -6- reinforcing member having received within it the adjacent opposite edge surface of the adjacent panel.

13. A wall panel substantially as hereinbefore described with reference to Figures 1 to 5, Figures 6 and 7, Figures 8 and 9 or Figure 11. Dated 13 May, 1997 Boral Australian Gypsum Limited Patent Attorneys for the Applicant/Nominated Person SPRUSON FERGUSON I N:.L I BLL100402:hr-