EP1054117A2

EP1054117A2 - Constructional element and constructional element system

Info

Publication number: EP1054117A2
Application number: EP00304256A
Authority: EP
Inventors: Michael James Paul Turner; Stefan Michael Nalborczyk
Original assignee: Gradient Insulations UK Ltd
Current assignee: Gradient Insulations UK Ltd
Priority date: 1999-05-21
Filing date: 2000-05-19
Publication date: 2000-11-22
Also published as: EP1054117A3; GB9911704D0

Abstract

A constructional element system (12) for a building comprises a composite panel (14) of thermally insulating material, which has a recess (24a, 24b, 24c) in an outer face thereof, and first and second fixing means (34, 44, 49) for fixing the panel (14) to a purlin (18) at the interior of the building and for fixing a facing (16) at an outer side of the panel respectively. In one embodiment, the respective heads (50) of the first and second fixing means are both received in a lipped channel section (46) in the recess, with a stem of the first fixing means (34) passing through a thermal break (36), the channel section (46) and the panel (14) to extend to the purlin (18). A threaded stem (54) of the second fixing means (49) extends out of the recess between the lips of the channel section (46) and through an opening in a bracket (56) attached to the facing (16).

Description

This invention relates to a constructional element, particularly in the form of a board or a panel for use in the construction industry, for example to form an outer face of a building. The invention also relates to a constructional element system incorporating such a constructional element.
Current board/panel systems for forming an external face of a building are typically of two distinct types, firstly a built-up type, in which a number of board/panel layers are secured together on-site, using single through fastening devices, and secondly a pre-formed type in which large assembled board/panel structures are secured to purlins of the building.
Both of these systems share a number of common problems including:
i) thermal bridging by fixing elements degrades any insulation properties of the boards/panels by allowing transfer of heat from internal to external faces thereof;
ii) fire resistance is degraded by the thermal bridging resulting in the necessity of fire resistant board or brickwork internally of the fasciae;
iii) difficulties in replacing damaged facing plates without replacing large sections of the system;
iv) the provision of decorative and securely fixed internal and external facing plates is not always provided for.
It is an object of the present invention to provide an improved constructional element and an improved system incorporating same.
According to a first aspect of the invention, there is provided a constructional element comprising oppositely facing first and second faces, and a recess in one of said faces such that, in use, a fixing means can extend through the element, having a fixing end thereof, terminating outward of said other face, and its other end received in said recess, so as not to protrude outwardly of said one of said faces.
Preferably the element comprises insulation material defining said one of said faces or insulation material between said first and second faces. Conveniently the recess is defined by a channel section fitted at said one of said faces. Desirably the section is inlet into said one of said faces.
According to another aspect of the present invention, there is provided a constructional element system comprising a constructional element having a first surface, a first fixing means and a second fixing means, said first surface having a recess therein, the first fixing means having a part received within said recess so as not to protrude outwardly of said first surface, a further part of the first fixing means extending through the element and, in use, fixing said element to a structural member, the second fixing means, in use, fixing a facing element to said constructional element at the side thereof remote from said structural member.
Preferably at least part of a channel section is mounted within said recess. More preferably said channel section is generally S-shaped. Alternatively said channel section may be a lipped channel section. More preferably the channel section is made of a metallic material. Even more preferably the channel section is made of steel or alternatively aluminium. Most preferably the channel section is an aluminium extrusion. Alternatively the channel section may be made from a plastics material.
Conveniently a thermal break is provided in the recess in contact with the fixing means. Desirably the constructional element includes thermally insulating material. More desirably the insulating material is of uniform density around the recesses. Typically the insulating material is rockwool.
The invention will now be described, by way of example, with reference to the accompanying drawings in which:
Figure 1 is a schematic diagram of part of a construction element system according to one aspect of the present invention, in an unassembled form, the system including a constructional element according to another aspect thereof,
Figure 2 is a schematic diagram of a first embodiment of a constructional element system according to the present invention, in an assembled form, and
Figure 3 is a schematic diagram of a second embodiment of a constructional element system according to the present invention, in an assembled form.
For a building, a constructional element system 12 of Figure 1 includes, in one embodiment, a composite board/panel 14, an outer facing plate or panel, i.e. cladding, 16 and structural members, typically purlins 18, at the inside of the building. The panel 14 comprises first and second thermally insulating sections 20, 22, typically of rockwool, with a liner sheet 23, typically a thin galvanised steel plate, secured on the common inner face of the sections forming the composite panel. The sections 20, 22 are keyed so as to mutually interlock horizontally. Various recesses are formed in an outer flat face 26 of the composite panel 14. A square recess 24a is provided in face 26 adjacent the lower edge surface of the section 20 of the panel 14, as viewed in its Figure 1 orientation. At the opposite, upper edge surface section 20, the face 26 is formed with an upwardly open square recess (step) 24b and moreover the inner flat face of the section 20 at a position aligned with recess 24b is similarly recessed (stepped) to interlock with the lower inner end of the section 22. The pan of the section 20 between the front and rear recesses at the upper end thereof is received against the base of a downwardly open square recess in the face 26 at the lower end of section 22, thereby interlocking the sections. At the upper end of section 22 is a square recess 24c in face 26. In this embodiment, all of the recesses can extend longitudinally along the length of the panel (as grooves), but one or more of them could be merely a single discrete recess at a fixed position along the panel length or a plurality of spaced such discrete recesses could be provided at one or each horizontal level. Inlet into the recesses 24a, 24b and 24c are respectively channel portions of a substantially S-shaped double channel section 28. Each section is preferably formed of an insulation core defining the flat outer surface of the section, and special fire resistant horizontal and vertical joints. The respective inner surfaces of the sections are preferably flat and in a common plane, thereby providing an inner face 30 to which the sheet 23 is secured. The outer faces of the sections 26 respectively need not be flat.
The outer facing plate 16 is adjacent the outer face 26 of the panel. The structural members 18, in this case Z-purlins, are adjacent the sheet 23 of the panel 14, spaced vertically so as to correspond to the respective positions of the channel sections 28.
Referring now to Figure 2, there is shown a fixing arrangement 32. The first and second insulating sections 20, 22 are keyed together so as to interlock. A first fixing element 34, such as a bolt, has a head in recess 24b spaced from the channel portion of section 28, with a stem of the first fixing element carrying a thermal break 36 also in recess 24b. The stem of the first fixing element 34 passes through the thermal break 36, the portion of the channel section 28 in the recess (without contacting it), the interlocking parts 38, 40 of the insulating sections 20, 22 and the liner sheet 23, to fix a purlin 18, for example by screw threaded means, so as to effect fastening of the panel 14 to the purlin 18.
The head of the fixing element 34 lies within a portion 42 of the S-shaped channel section 28 which is recessed with respect to the flat outer face 26 of the panel 14, and thus does not protrude beyond said outer face 26.
A second fixing element 44, such as a screw or threaded bolt, passes either from within or through the outer facing plate 16, through an outwardly disposed portion of the channel section 28, and into the panel 14 so as, in use, to effect the fastening of the facing plate 16 to the panel 14, for example in contact therewith. The facing plate can be cladding, roofing, curtain walling, rain screen etc. As shown schematically in Figure 2, the plate 16 is spaced from panel 14. In each of the embodiments of Figures 1 and 2, the section 28 is anchored in place by a leg thereof being held in a slot in the face 26.
It will be understood that the provision of a thermal break prevents transference of heat, from one face of the panel to the opposite face thereof, thereby providing enhanced insulation and fire resistance over current systems. The insulation core (such as rockwool) may not necessarily be of uniform density except beneath the bar/channel section to prevent over-compression of the panel by the first fixing means. It will further be appreciated that the channel section need not be S-shaped but could be of a box shape, a bar or an I-bar construction. It will also be appreciated that the insulating material need not be rockwool but may be any other insulating material, for example, fibreglass.
Referring now to Figure 3, which shows a second embodiment of the present invention, parts similar to those in Figures 1 and 2 will be accorded the same reference numerals. The S-shaped channel section 28 of the first embodiment has been replaced by a lipped channel section 46 which extends transversely (horizontally) to the longitudinal axis of the panel 14 and has respective lower and upper lips 47 and 48 at the face 26. A first, primary fixing element 34 passes from inside of the lipped channel section 46 through the thermal break 36, the section 46 (without contacting it), the panel 14 and the liner sheet 23 into the purlin 18. A second fixing or retaining element 49 has a head portion 50, which is retained within the lipped channel 46 by being wider than the opening between the lips 47 and 48, and a necked stem section 52 of approximately the same width as said opening which is received through said opening.
A threaded port 54 of the stem projects outwardly from the neck section 52, the stem being perpendicular to the panel 14. An L-shaped bracket 56 has a vertical elongate opening or a number of discrete vertically spaced openings (not shown) in an arm 57 which lies substantially parallel to the face 26. The stem 54 passes through the elongate opening and an internally threaded locking element 58 is screwed onto the stem 54 at the opposite side of the arm 57 to the panel 14. A further such locking element could be provided at the side adjacent the panel. A second, horizontal arm 60 of the L-shaped bracket 56 is attached to a rear surface of facing plate 16.
Sliding movement of the retaining element 49 horizontally within the lipped channel section 46 allows selected positioning of the facing plate 16 transversely to the panel 14. Similarly, movement of the L-shaped bracket 56 about the arm 54, using the elongate opening, allows vertical relative positioning of the facing plate 16, and movement of the locking element 58 along the stem allows movement of the facing plate 16 towards or away from the panel 14. There are thus three degrees of possible movement of the plate relative to the panel.
The system provides a convenient way of removing and replacing damaged facing sheets 16, as well as securing them to the flat outer surface of the panel. The panel provides insulation and fire resistance to comply with building regulations and the system provides a decorative and robust internal face to the building.

Claims

A constructional element system comprising a constructional element having a first surface, a fixing means and a second fixing means, said first surface having a recess therein, the first fixing means having a part received within said recess so as not to protrude outwardly of said first surface, a further part of the first fixing means extending through the element and, in use, fixing said element to a structural member, the second fixing means, m use, fixing a facing element to said constructional element at the side thereof remote from said structural member.
A system as claimed in Claim 1, wherein said recess is provided in said first surface at an end thereof.
A system as claimed in Claim 2, wherein said element is of composite form, compressing two interlocking sections such that an open side of said recess in one of said sections is closed by said other section.
A system as claimed in Claim 3, wherein a channel section is received in said recess.
A system as claimed in Claim 4, wherein said first fixing means has a head constituting said part received within said recess and said further part is a stem which extends through said channel section and interlocking parts of said two sections of the element.
A system as claimed in Claim 5, wherein a thermal break is received on said stem.
A system as claimed in any one of Claims 4 to 6, wherein said second fixing means extends into said first surface.
A system as claimed in Claim 7, wherein the second fixing means extends through part of a channel section member, which channel section member includes the channel section received in said recess.
A system as claimed in any one of Claims 1 to 8, wherein said recess extends along the length of the element.
A system as claimed in any one of Claims 1 to 8, wherein a plurality of said recesses are spaced apart in a row along the length of the element.
A system as claimed in Claim 1, wherein in said first surface said recess is at a position spaced from an end thereof.
A system as claimed in Claim 11, wherein a channel section is received in said recess.
A system as claimed in Claim 12, wherein said part of the first fixing means is a head and said further part of the first fixing means is a stem which extends through said channel section and said element.
A system as claimed in Claim 13, wherein a thermal break is received on said stem.
A system as claimed in any one of Claims 12 to 14, wherein said second fixing means extends into said first surface.
A system as claimed in Claim 15, wherein the second fixing means extends through part of a channel section member which includes said channel section received in said recess.
A system as claimed in any one of Claims 11 to 16, wherein said recess extends along the length of the element.
A system as claimed in Claim 1, wherein the element comprises at least two interlocking side-by-side panel sections which together define said first surface as a common flat surface.
A system as claimed in Claim 18, wherein the panel sections together define a common flat second surface oppositely disposed to said first surface.
A system as claimed in Claim 19, wherein a liner is secured to said second surface.
A system as claimed in any one of the preceding claims, wherein the constructional element comprises thermally insulating material.
A system as claimed in any one of Claims 1 to 7 or Claims 11 to 15, wherein a channel section of lipped channel form is received in said recess.
A system as claimed in Claim 22, wherein the spacing between the lips of said channel is such that it prevents a head of said second fixing means received in said recess passing therethrough, an at least partly threaded stem of said second fixing means extending from said head and through said spacing, and passing, in use, through an opening in a bracket attached to said facing element.
A system as claimed in Claim 23, wherein the recess and said channel section extend along the length of the element and said head is adjustably slidable along the length of the recess to adjust the position, in use, of said facing element.
A system as claimed in any one of Claims 22 to 24, wherein a liner is secured to a flat surface of the element opposite to said first surface.
A system as claimed in any one of Claims 22 to 25, wherein the constructional element comprises thermally insulating material.
A constructional element comprising oppositely facing first and second faces, and a recess in one of said faces such that, in use, a fixing means can extend through the element, having a fixing end thereof terminating outward of said other face, and its other end received in said recess, so as not to protrude outwardly of said one of said faces.
An element as claimed in Claim 27, wherein said recess is provided in said one face at an end thereof.
An element as claimed in Claim 27, wherein said recess is provided in said one face at a position spaced from an end thereof.
An element as claimed in Claim 27, wherein recesses are provided in said one face at one end thereof and at a position spaced from the other end thereof respectively.
An element as claimed in any one of Claims 28 to 30, wherein a channel section is received in the or each recess.
An element as claimed in Claim 31, wherein the channel section is of metallic material.
An element as claimed in any one of Claims 28 to 32, which comprises thermally insulating material.
An element as claimed in Claim 33, wherein the insulating material defines one of said first and second faces.
An element as claimed in any one of Claims 28 to 34, wherein a liner is secured to one of said first and second faces.
An element as claimed in any one of Claims 28 to 35, which is of composite form, comprising at least two interlocking side-by-side panel sections.