CN1103402C - Composite panels and methods of forming composite panels - Google Patents

Abstract

The present invention relates to a composite sheet and a method of forming a composite sheet. The composite sheet material (1) according to the invention comprises at least two spaced apart outer plies (2, 3) and a core ply (4) sandwiched therebetween, the outer plies (2, 3) and the core ply (4) being offset such that the outer plies extend beyond the core along a first edge of the sheet material by a predetermined edge (a) and the core ply extends beyond the core ply along an opposite edge of the sheet material by a substantially corresponding edge (B). The protruding portions of the outer laminate of one sheet are adapted to nest and locate in interlocking relation the complementarily shaped protruding cores of adjacent like sheets to form a composite sheet assembly. The composite board and the method for forming the composite board can overcome the defects of high cost, heavy material, low reconstruction flexibility and the like in the traditional building technology.

Description

Composite panels and methods of forming composite panels

technical field

The present invention relates to composite panels and also to methods of forming composite panels.

Background technique

In traditional house building, the construction of walls begins with the installation of a structural frame, usually made of wood. Next, the inside of this frame is covered with a suitable laminate such as cypress board, then finished to hide the seams and finally painted. The exterior walls are usually constructed with a brick veneer or with a suitable cladding material also fastened to a wooden frame. Common cladding materials include weatherboard, fiber reinforced cement, or aluminum. Roofs are usually constructed of corrugated iron or tiles, also set on wooden frames.

This traditional construction technique is particularly labor-intensive and costly for several reasons. For example, many craftsmen are required in multiple trades such as builders, bricklayers, carpenters, joiners, tilers and plasterers, which adds to the overall cost. Conventional technologies also rely heavily on expensive and soon-to-be-depleted material resources, especially wood, which drives up costs due to scarcity of supply. In addition, conventional houses basically have to be constructed on site according to architectural plans. Prefabricated or prefabricated buildings have very little scope and little flexibility to rebuild at low cost after they are built. In addition, if the house is going to be demolished, the possibility of recycling and reuse of building materials is very small, thus causing a lot of waste. Another disadvantage of traditional technology is that the built structure is not sound and thermally insulated. This often needs to be addressed later, such as adding facilities in the roof cavity, which again adds to the cost.

Current construction techniques produce relatively heavy buildings, especially when using bricks, roof tiles and wooden frames. Due to the weight of these materials, the support structure must be relatively large and strong, which adds further weight. The end result is that otherwise applicable lightweight materials do not have sufficient strength used in traditional house building techniques.

In order to overcome the problems referred to above, steel frame houses have been proposed. However, it has been found in practice that the resulting cost benefits are limited and most of the fundamental problems remain.

In order to further overcome the above problems, it has also been proposed to use composite panels. Such panels typically have laminates made of multiple materials to achieve the desired strength-weight properties, acoustical and thermal insulation properties, and the like. However, the main problem with this known manufacturing technique is that there is a practical limit to the maximum size of the sheet material. This in turn leads to the need to employ various techniques for joining smaller panels to form combined panel assemblies of the desired size. But in the past, poor technology for joining materials made such structures relatively weak. The consequence of this compromised structural integrity means that in practice the possible strength-to-weight properties offered by composite panels cannot be enhanced for large-scale applications, particularly in building construction. Consequently, composite panels have generally been used in the past to form interior partitions and non-load bearing walls that do not require great structural integrity. Therefore, fundamental problems encountered in traditional construction methods remain unresolved. There is therefore a continuing felt need for more efficient, less costly alternatives to existing house building techniques.

Contents of the invention

It is an object of the present invention to overcome or substantially overcome at least one of the above-mentioned disadvantages of the prior art.

Thus, according to a first aspect of the present invention, a composite panel comprises at least two spaced apart outer laminates and a core laminate sandwiched therebetween, the outer and core laminates being offset such that The outer laminate extends beyond the core laminate by a predetermined edge along the first edge of the sheet, and the core laminate extends beyond the outer laminate by a substantially corresponding edge along the opposite edge of the sheet, whereby the protruding portion of the outer laminate of a sheet fits interlockingly embedded and positioned by complementary shaped protruding core laminate portions of adjacent like panels to form a composite panel assembly, said composite panel further comprising a substantially U-shaped channel member, The channel members form studs for interlocking engagement with adjacent like panels to form the composite panel assembly as described.

In a preferred embodiment, said substantially U-shaped channel member covers the protruding portion of the core laminate to form a stud. The trough member is preferably defined by spaced apart flanges parallel to and abutting within the respective outer laminations along respective edges of the sheet, and an intermediate web extending between the flanges to cover Hold the protruding part of the core stack. The channel member is preferably arranged such that the flange extends edgewise between the core lamination and the associated outer lamination. In this way, the channel member is adapted to be pressed into place and substantially self-locating.

The channel members are preferably pressed from sheet metal and oriented in use to form vertically extending studs between adjacent wall panels, thereby providing structural integrity to the composite wall.

In an alternative construction, the channel members may be provided on opposite sides of the sheet so that the flanges are nested between the protruding portions of the outer laminations and the webs are spaced outwardly from the core laminations. In this construction, the groove member extends beyond the outer laminate to define a tongue similar to the protruding core on the opposite side of the sheet, while forming a concave edge, groove, laminated from the core. A longitudinal cavity bounded by the flanges and web of a member. The cavity can be used to conceal house service lines such as cables, water pipes, and telecommunication lines.

In a first preferred form of the invention, the core laminate is formed from expanded polystyrene foam, one external laminate is formed from plywood and the other external laminate is formed from gypsum fibreboard or gypsum rock. This embodiment of the invention is particularly suitable for use as an exterior wall, with the plywood plies facing outwards to receive a final weatherproof finish in situ. In this construction, an expanded steel mesh is preferably stapled to the plywood plies. A cement finish is then applied so that the expanded steel mesh acts as a reinforcement for the cement. A final protective coat is then applied. Interior gypsum fiberboard or gypsum rock formations are best finished conventionally to conceal joints and painted.

In a second preferred form of the invention, the two outer laminates may be formed from gypsum rock or gypsum fibreboard. Panels made according to this structure are particularly suitable for use as interior walls or partitions where weather resistance is not required.

In the foregoing embodiments of the invention, the outer laminate is preferably secured to the core laminate by means of a cross-linked polymer adhesive.

In a preferred embodiment, adjacent panels are secured in overlapping tongue-and-groove relationship by at least one fastener that passes through the outer lamination of one panel, through the flange or wall of the channel member The ribs extend into the core lamination of adjacent panels so that the adjacent panels and the intervening ribs are held together. A spaced row of threaded fasteners is provided along the overlapping edges of each adjacent pair of panels.

In a third preferred form of the invention, the foam core laminate may be sandwiched between the metal sheet outer layers. This arrangement is particularly suitable for use as roofing panels. The inner lamination is preferably constructed of flat sheet metal and the outer lamination is preferably of corrugated metal for added strength, improved drainage, and the traditional corrugated iron appearance. Roof capping strips, eaves, moldings, gutters, etc. can be assembled if required.

According to a second aspect of the present invention, a method of forming a composite panel comprises the steps of sandwiching a core laminate between spaced apart outer laminates such that the outer laminate extends beyond the core along a first edge of the panel laminating a predetermined edge such that the core lamination extends beyond a substantially corresponding edge of the outer lamination along opposite edges of the sheet to provide a substantially U-shaped channel member configured to complement the shape of an adjacent like sheet Studs of edge interlocking engagement whereby the projecting portion of an outer laminate of one panel is adapted to interlockably fit and position a complementary shaped projecting core of an adjacent like panel to form a composite panel assembly.

According to a third aspect of the present invention, a building structure includes interior and exterior walls each formed from interlocking composite panel assemblies substantially as hereinbefore described.

Preferably said building structure further includes a roof formed as said interlocking composite panel assemblies. A substantially U-shaped cover strip is preferably placed along the upper edge of the wall panels to provide added structural strength and facilitate fastening of the roof panels.

According to a fourth aspect of the present invention, a method of building a building structure comprises the steps of forming exterior walls, forming interior walls and forming a roof, each of which is formed from a series of interlocking composite panels substantially as described above, and arranging each The panels are fastened together to form a stable house structure.

The housing structure is preferably adapted to be assembled on a concrete slab. In this case, the lower edge of the outwardly facing outer laminate of each panel preferably extends downwardly beyond the core laminate and the inwardly facing laminate to form a right-angled rebate adapted to run along the concrete The corresponding edge parts of the base plate are placed. Fasteners such as "dyna-bolts" are also preferably provided through the outwardly facing exterior laminate and into the foundation slab side to prevent the building structure from being lifted during high wind conditions. In the preferred embodiment, the foundation Weatherproof flashing strips are provided between the panels and the overlying siding.

Description of drawings

Preferred embodiments of the present invention are now described, by way of example only, with reference to the following drawings.

Figure 1 is a perspective view showing a composite panel used as an exterior wall part in a building structure according to the present invention;

The perspective view of Fig. 2 represents the exterior wall panel of Fig. 1, which has an outer layer, and the outer layer has expanded steel mesh reinforcement and cement plastering at the end;

Figure 3 is a partial plan view showing a pair of panels as shown in Figures 1 and 2 interlocked and fastened together in a tongue and groove relationship to form a composite panel assembly according to the present invention;

Figure 4 is a perspective view showing the reinforced channel members or studs of the panels shown in Figures 1 and 2;

Figure 5 is a perspective view showing a composite panel similar to that shown in Figure 1, which is suitable for use as part of an interior wall according to the present invention;

Figure 6 is a plan view showing the use of reversely configured slab studs to connect adjacent panels in a female-to-female relationship, thereby defining a channel for concealed service lines;

Figure 7 is a partial perspective view showing a composite panel suitable for use as part of a roof assembly according to the present invention;

Figure 8 is a partial perspective view showing a composite panel suitable for use as a structural beam according to the present invention;

Figure 9 shows the use of a saddle suitable for mounting the beam of Figure 8 on an abutting wall;

Figure 10 shows a double-sided saddle adapted to mount coaxially aligned structural beams on opposite sides of an intermediate panel;

Figure 11 is a cross-sectional view illustrating the method of installing exterior wall panels on concrete foundation slabs according to the present invention;

Figure 12 is a front view showing the installation details of Figure 11;

Figure 13 is a plan view showing the detail of the wall-to-wall corner according to the present invention;

The cross-sectional view of Fig. 14 represents according to the fastening method of the wall on the roof of the present invention;

Figure 15 is a front view showing a house structure made of composite panels according to the invention.

Detailed ways

Referring first to Figures 1 to 4, the present invention provides a composite panel 1 comprising two spaced apart outer laminates 2 and 3 and a core laminate 4 sandwiched therebetween. The outer and core laminates are offset so that the edge portions 5 and 6 of the outer laminate extend beyond the core by a predetermined edge A along the first edge of the sheet. Likewise, the core laminate extends beyond a substantially corresponding edge B of the outer laminate along opposite edges of the sheet. This arrangement of the laminates defines a tongue and groove structure whereby the projections 5 and 6 of the outer laminate of panels are adapted to fit and position in interlocking relationship the complementary core projections 7 of adjacent like panels to The composite panel assembly shown in Figure 3 and described in more detail below is formed.

In a preferred embodiment, the core laminate 4 is formed of expanded polystyrene foam 20 mm to 100 mm thick, preferably 50 mm to 60 mm thick. In the embodiment shown in Figure 1, the outer laminate 2 is made of plywood about 3 mm thick and the other outer laminate 3 is made of gypsum fibreboard or gypsum rock and is about 10 mm thick. The outer laminates are bonded to the core with a special crosslinked polymer adhesive suitable for the purpose. This form of lumber is particularly suitable for use as exterior walls, with plywood layers facing outwards to receive weatherproof trim.

A preferred form of exterior finishing is shown in Figure 2, where a layer of expanded steel mesh 10 is stapled to the plywood laminate, followed by a cement render 11. In this way, the steel mesh acts as a reinforcement for the cement plaster. A final weather-resistant protective coat is then applied. The inwardly facing layers of gypsum fiberboard or gypsum rock are filled in joints, trimmed and finally painted in a manner known in the art.

In the preferred embodiment shown, a substantially U-shaped channel member 15 covers the protruding portion of the core laminate 4 to form a stud. It should however be noted that an alternative construction is also possible, wherein the U-shaped channel member is located in a groove formed by the protruding portions 5, 6 of the outer laminate along opposite edges of the sheet.

As shown in Figure 4, the channel member or stud 15 is defined by spaced apart flanges 16 and an intermediate web with a longitudinally extending tenon and tenon for added strength. It should be noted that the intermediate web may be intermittent, i.e. it may include one or more holes, perforations or similar structures along its The outer laminations 2 and 3 and adjacent to their inner sides, a web 17 extends between the flanges to cover the protruding portion 7 of the core lamination. The flanges extend edgewise between the core laminate and the associated outer laminate, and once pressed into place, the studs are essentially self-positioning, although preferably an adhesive is also used.

In this alternative construction, the U-shaped channel members 15 are set in grooves formed along the opposite edges of the sheet so that the web 17 is located adjacent to the core lamination and the flange 16 is located inside the outer laminations 2, 3 from the groove. Extend outward.

The channel members 15 are extruded sheet metal oriented in use to extend vertically between adjacent sheets in the wall to provide structural integrity.

In a preferred form of the invention, the standard dimensions of the exterior wall panels are approximately 900mm wide, 2500 to 4000mm high, and 65 to 90mm deep. It should be noted, however, that the panels can be made in any size or shape, depending on the application and production capabilities. Once fabricated, the panels can be cut as needed, for example, to accommodate windows, doors, beams, roof panels, and other configurations without compromising structural strength.

Fig. 5 shows a variant of the panel of Fig. 1, in which the two outer laminates 2 and 3 are substantially identical and consist of gypsum fibreboard or gypsum rock. Panels made according to this structure are particularly suitable for interior walls that do not need to be weatherproof.

Figure 6 shows a variation of the assembly in which the projections 5 and 6 of a pair of panels are butted together in a female-to-female relationship, with an additional channel member or stud 15 interposed so that the web of the channel is aligned with one of the panels. In this reversed configuration, the channel members project beyond the outer laminations of the panels on the left (as seen in the figure) in a manner similar to the protruding cores on the opposite side of the panels, forming a tongue. In this way, the left side panel engages the right side panel in a tongue and groove relationship. At the same time, the stud forms a longitudinal cavity or channel 20 which is delimited by the concave edge of the core stack of panels on the left, the flange of the channel and the web of the channel. This void can be used to conceal building service lines such as electrical cables, water pipes, telecommunication lines etc. without any separate wiring method and additional material and without weakening the overall structure.

As shown in Figure 3, adjacent panels are secured in overlapping tongue and groove relationship by means of a series of threaded fasteners 21, each threaded connection passing through an outer lamination of a panel, through a channel member or panel wall Adjacent flanges of the ribs and into the underlying core stack of adjacent panels to securely hold the panels together. A row of threaded fasteners thus extends along the adjoining edges of each adjacent pair of panels. The panels are also secured by means of top capping strips 22 which also serve to cover and seal the top surface of the wall panels and provide additional overall structural integrity. The cover strip is best shown in Figures 9, 11 and 14.

Figure 7 shows another variant in which a core laminate 4 of specially shaped foam is sandwiched between outer laminates 2 and 3 of metal sheets, the upper laminate 2 being corrugated for increased strength, Improving drainage and creating a traditional corrugated appearance, this arrangement is particularly suitable for use as roof panels 24 which, being substantially self-supporting, require no roof framing other than a central support as will be described below.

Figure 8 shows the situation where the basic components of the panel system are adapted to form a high strength, very light weight structural beam 25. The beam is thus formed as a long composite panel comprising the same outer laminates 2 and 3 as the panels above, which consist of plywood, preferably 3mm thick, sandwiched between an expanded polystyrene foam, preferably Preferably a core laminate 4 of 50 mm thickness. The laminate is bonded together using the same cross-linked polymer adhesive. A pair of channel members 15 are provided along the top and bottom of the beam respectively to provide additional bending strength. The channel members also serve as cover strips to seal and protect the softer foam core laminate. It has been found that such beams provide sufficient strength to support the composite panel roof structure described above without the need for additional frame trusses and without adding significantly to the overall weight or cost of the building.

FIG. 9 shows the use of a saddle 26 to anchor the structural beam shown in FIG. 8 to a vertical wall panel. The saddle is cut and folded from a straight section of 90° angled sheet metal using formwork, then hooked in place onto the upper edge of the wall panel and held in place with threaded fasteners, some of which Threaded fasteners are threaded into the top metal capping strip 22, some threaded fasteners are threaded directly into the panels, preferably vertical studs to form a direct metal to metal joint between the above mentioned primary structural members. This arrangement provides adequate support for structural beams without the need to cut grooves, recesses, or rebates into the panels themselves. This significantly speeds up construction without compromising structural integrity. A similar double-sided saddle 27 could also be used if the structural beam continued from the opposite side of the wall panel, as is often the case with interior walls. This situation is shown in FIG. 10 .

Figure 11 shows a situation where a panel is fastened to a concrete foundation slab 30 in building and building applications. The concrete slabs were first poured to size using traditional framing techniques. The lower surface of each cladding panel is made with tenon and tenon such that the lower edge 31 of the outer laminate 2 of each panel extends downwardly beyond the core laminate 4 and an edge C of the other facing outer laminate 3 . The 90° rebate thus obtained allows the panels to be placed along the outer edge of the foundation plate, the lower edge 31 of the outer laminate forming a reliable and precise lateral positioning. A correspondingly shaped flashing strip 32 is then placed along the edge of the foundation slab to provide weather protection and also to seal and protect the lower surface of the slab. The wall panels are then positioned as shown in Figure 11 so that the flashing strips are snugly sandwiched between the tenon and tenon of the panel and the corresponding edge of the foundation panel. At this stage the wall panels are held in place by dynamic bolts 34 or similar fasteners which pass through the lower edge of the outer laminate and directly into pre-drilled holes in the foundation plate.

A metal anchor strip 35 is used at the relative wallboard joint. As shown in FIG. 12 , the lower end 36 of the anchor strip is positioned so as to cover the outer vertical face of the foundation slab, while the upper end 37 of the anchor strip covers the wall panel, more specifically the vertical stud 15 . In this manner, a lower fastener such as a dynamic bolt 34 passes through the lower end 36 of the anchor strip, through the lower edge 31 of the outer laminate, and into the base plate. The upper fastener 21 passes through the upper end 37 of the anchor strip, through the adjacent outer laminate, through the underlying stud, and into the core. By this means, the entire panel assembly, and not just the outer laminate, is anchored directly to the foundation panel. Additionally, the studs are set up to transfer loads directly from the walls and roof to the concrete foundation. It has been found that the anchoring methods described above provide structures capable of withstanding extreme weather conditions, including tornado loads, which can damage many structures built according to conventional techniques.

FIG. 13 shows an enlarged corner detail showing the situation where the wall panels 1 are butted at 90 angles and joined together by means of metal corner strips 40 . Each face of the corner strip is fastened in the position shown in the underlying stud of the corresponding panel to cover the joint and provide additional structural strength.

FIG. 14 shows a preferred arrangement in which the angled roof panels 24 are secured to the vertical wall panels 1 by means of corner brackets 43 and 44 . As shown, threaded fasteners are used to secure the lower surface of each corner bracket 43 and 44 to the top molding and other parts of the wall panels, while the upper surface of the corner bracket is fastened to the underside of the roof sheeting. The seams are covered and internally sealed by means of overhanging eaves, while an external cover strip (not shown) may also be provided for heat insulation and protection against wind and rain.

Referring now briefly to the method of constructing a house or other building in accordance with the present invention, a concrete foundation slab 30 is first laid using conventional formwork techniques. Then, flashing strips 32 are placed around the base plate. The external wall panels 1 are then arranged such that the outer edge of the concrete foundation slab is embedded with tenon and tenon, and the lower edge 31 of each panel extends downward on the outer edge of the foundation slab. The wall panels are then secured to the foundation panels with dynamic bolts or similar fasteners and the anchor strips 35 are held in place across the joint between adjacent panels. At this stage, threaded fasteners are installed along the overlapping edges of each adjacent pair of panels. Then use corner strips to join the corners, as shown in Figure 13. The outer edges of the wall panels are then covered and sealed with U-shaped cover strips 40, as shown in Figures 9 and 11, which further increases the structural integrity of the panel assembly. Cut out window and door frames in siding if desired and trim with wood or aluminum framing members if desired. At this stage, the façade structure is completed, saving on decoration, which will be described below.

A main roof beam of the type shown in Figure 8 can then be added by means of saddles 26 and 27 as shown in Figures 9 and 10 respectively. Roof panels 24 of the type shown in FIG. 6 are then added, as shown in FIG. 14 . The roof structure is finished with cover strips 50 and gutters 51 as shown in FIG. 15 .

Then, use the interior wall panels shown in Figure 5 to form interior walls as required. Again space for interior windows and doors are cut out of the panels and framed as required. The internal joints between the gypsum fibreboards separating the boards are concealed using ordinary plastering techniques and finally painted. Treads and cornices can also be added as needed to conceal floor-wall and wall-roof joints, add weather protection and provide a traditional aesthetic look.

Exterior panels can also be weatherproofed and trimmed as desired. However, one specific recommended form of finishing involves the step of initially stapled expanded steel mesh 10 to the outer plywood laminate 2 before applying a cementitious finish 11 in which the expanded steel mesh acts as reinforcement ribs. The finish is painted last to give the appearance of a traditional cement-rendered brick-clad dwelling.

Advantageously, houses, factories or other structures constructed in accordance with the present invention can be completed in a short period of time, using only conventional construction techniques, and at a lower cost. Since the structure is very light, there are less demands on the foundation and structural frame, which in turn reduces material and labor costs. Since the full set of panels can be prefabricated off-site, minimal skilled labor can be used for construction and installation, further reducing costs. Due to the laminated structure of the boards, especially the basic use of polystyrene foam core, the building inherently has heat insulation and sound insulation performance far superior to that of traditional buildings, without the use of additional materials such as glass fiber materials. Due to the unique way in which the panels are anchored to the concrete foundation slab, the structure is particularly resistant to wind loads, even in cyclone conditions. Another advantage of structures constructed in accordance with the present invention resides in design flexibility. Even after the building has been completed, interior and exterior walls can be added, removed, or changed as required without the constraints of the underlying frame structure that exist in traditional structures.

Plus, the entire home can be disassembled, packed up, moved to another location, and rebuilt fairly easily. Even when the house is completely demolished, the individual panels and other components can simply be reused in the new project without wasting raw materials.

The reason for many of the above advantages is that the panels according to the present invention provide their own inherent structural integrity so that the system as a whole does not require separate frame work. Thus, the present invention clearly provides a practical, commercially significant improvement over the prior art.

Although the invention has been described with reference to specific embodiments, it will be appreciated by those skilled in the art that the invention may be embodied in many forms.

Claims (41)

1. A composite panel comprising at least two spaced apart outer laminates and a core laminate sandwiched therebetween, the outer and core laminates being offset such that the outer laminates run along the first The edge protrudes from the core by a predetermined edge and causes the core laminate to protrude beyond the outer laminate by a predetermined edge along opposite edges of the panels, whereby the protruding portion of the outer laminate of a panel is adapted to fit and position an opposite laminate in interlocking relationship. Complementarily shaped protruding cores of adjacent like panels to form a composite panel assembly, said composite panels further comprising a substantially U-shaped channel member configured for interlocking engagement with adjacent like panels to form The wall stud of the composite plate assembly. 2. A composite panel as claimed in claim 1, wherein the channel member covers the protruding portion of the core laminate to form a stud. 3. A composite panel as claimed in claim 1, wherein said channel members are defined by spaced apart flanges and an intermediate web, said flanges being arranged to overlap the outer edges along respective edges of the panels. The layers are parallel and close to their insides, the web extending between the flanges to cover the protruding portion of the core laminate. 4. A composite panel as claimed in claim 3, wherein the flanges extend marginally between the core laminate and the associated outer laminate so that the channel members are adapted to be pressed into place and substantially is automatically positioned. 5. A composite panel as claimed in claim 1, wherein said channel members are pressed from sheet metal and are oriented in use to form studs extending substantially vertically between adjacent panels so that Provides additional structural integrity to built-up panel assemblies when used to form built-up walls. 6. A composite panel as claimed in claim 3, wherein the channel members are arranged in reverse on said opposite side of the panel, the flanges are interposed between the protruding portions of the outer laminates, and the webs extend from the core laminate to spaced out. 7. A composite panel assembly as claimed in claim 6, wherein the opposing groove members extend beyond the outer laminate to define a tongue for engagement with like panels and, at the same time, form a concave edge laminated by the core , a cavity defined by the flange of the tank and the web of the tank, the cavity being suitable for concealing a building service line. 8. The composite panel of claim 1 wherein the core laminate is formed of expanded polystyrene foam, one of the outer laminates is formed of plywood and the other is formed of gypsum fibreboard. 9. A composite panel as claimed in claim 8, characterized in that the panel is suitable for use as an exterior wall with the plywood layers facing outwards. 10. A composite panel as claimed in claim 9, further comprising an expanded steel mesh applied to the outwardly facing plywood plies, the expanded steel mesh acting as reinforcement for the cement plaster. 11. The composite panel of claim 10, further comprising a final weatherproof protective paint coat applied to the cement render. 12. A composite panel as claimed in claim 11 wherein the inwardly facing layers of gypsum fiberboard are caulked and trimmed to conceal joints. 13. The composite panel of claim 1, wherein the core laminate is formed of expanded polystyrene foam and the two outer laminates are formed of gypsum fibreboard. 14. A composite panel as claimed in claim 13, characterized in that it is suitable for use as an interior wall or partition wall. 15. The composite panel of claim 1, wherein the outer laminate is secured to the core laminate by means of a cross-linked polymer adhesive. 16. The composite panel of claim 1 wherein adjoining panels of a panel assembly are secured in overlapping tongue and groove relationship by at least one fastener passing through the exterior of one panel Laminations pass through a flange of the channel member and into the core lamination of adjoining panels to secure the adjoining panels together. 17. The composite panel of claim 16, wherein a spaced row of threaded fasteners is provided along the overlapping edge of each adjacent pair of panels. 18. The composite panel according to claim 1, wherein the thickness of the core laminate is 20 mm to 100 mm. 19. A composite panel as claimed in claim 18, characterized in that the core laminate is formed of expanded polystyrene foam and has a thickness of 50 mm to 60 mm. 20. The composite board as claimed in claim 1, wherein the width of the board is about 600mm to 1200mm, the height is about 2500mm to 4000mm, and the depth is about 65mm to 90mm. 21. The composite panel of claim 1 comprising a foam core laminate sandwiched between outer laminates of metal sheets. 22. A composite panel as claimed in claim 21, suitable for use as a roofing panel. 23. A composite panel as claimed in claim 22, characterized in that the inwardly facing outer laminates are formed of substantially flat sheet metal and the outwardly facing outer laminates are formed of corrugated metal sheets. 24. A composite panel as claimed in claim 22, characterized in that it is assembled into an interlocking roof panel assembly using shingle, eaves and gutters as desired. 25. A composite panel as claimed in any one of claims 1 to 21 wherein the composite panel forms part of a composite panel assembly in which edges of adjacent composite panels interlock to form the walls of the building structure. 26. A composite panel as claimed in any one of claims 1 to 21 wherein the composite panel forms part of a composite panel assembly in which edges of adjacent composite panels interlock to form the roof of the building structure. 27. The composite panel of claim 26, wherein the structural beams are constructed from a core laminate of expanded polystyrene foam, an outer laminate of plywood, and a cover strip consisting of a covering The exposed longitudinal edges of the core laminate are formed by substantially U-shaped channel members. 28. The composite panel as claimed in claim 27, wherein the structural beam is anchored to the vertical wall panel by means of a saddle, the saddle is cut and folded from an originally straight metal gusset , eliminating the need for grooves, recesses, or tenon and tenon in the wall panels. 29. The composite panel of claim 25, wherein a substantially U-shaped cover strip is provided along the upper edge of the wall panel to provide additional structural strength to the wall panel and to facilitate tightness of the roof panel thereon. solid. 30. The composite panel of claim 25, wherein the building structure is adapted to be mounted on a concrete foundation slab. 31. The composite panel of claim 30, wherein the lower edge of the outwardly facing outer laminate of each wall panel extends downwardly beyond the core laminate and the inwardly facing outer laminate to define a substantially A right-angled tenon adapted to be placed along a corresponding edge portion of the concrete foundation slab. 32. The composite panel of claim 31, further comprising fasteners extending through the outwardly facing outer laminate and into the foundation panel to prevent lifting of the building structure during adverse weather conditions. 33. A composite panel as claimed in claim 32, wherein the wall panels are secured to the foundation panel by means of "dyna-bolts". 34. The composite panel of claim 30, further comprising weatherproof flashing strips disposed between the foundation panel and the overlying wall panels. 35. A method of forming a composite panel comprising the steps of sandwiching a core laminate between spaced apart outer laminates such that the outer laminate extends beyond the core along a first edge of the panel by a predetermined amount. and with the core laminate extending beyond a substantially corresponding edge portion of the outer laminate along opposite edges of the sheet, a substantially U-shaped channel member is formed to complement the shape of an adjacent like sheet Studs with interlocking edges. The protruding portion of the outer laminate of one panel is thus adapted to embed and position in interlocking relationship a complementary shaped protruding core of an adjacent like panel to form a composite panel assembly. 36. The method of claim 35, further comprising the additional steps of: forming exterior walls; forming interior walls; and forming a roof, each formed from a series of interlocking composite panels , to combine the individual panels to form a stable house structure. 37. The method of claim 36, further comprising the step of assembling the housing structure on a concrete foundation slab. 38. The method of claim 37, further comprising the step of: the outwardly facing outer laminate of each wall panel forming a lower portion extending downwardly beyond the core laminate and the inwardly facing outer laminate edge, thereby defining a substantially right-angled rebate adapted to be placed along a corresponding edge portion of the concrete foundation slab. 39. The method of claim 38, further comprising the step of installing fasteners through the exterior laminate and into one side of the foundation slab to prevent lifting of the building structure during adverse weather conditions . 40. The method of claim 39, wherein said fastener is a "dynamic bolt". 41. The method of claim 40, further comprising the step of providing weatherproof flashing between the foundation slab and the overlying wall panels.

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