EP1889981B1

EP1889981B1 - Partition wall and method of construction

Info

Publication number: EP1889981B1
Application number: EP20070253031
Authority: EP
Inventors: Roger Alfred Bullivant
Original assignee: Buchan Concrete Solutions Ltd
Current assignee: BUCHAN CONCRETE SOLUTIONS LIMITED
Priority date: 2006-08-04
Filing date: 2007-08-01
Publication date: 2012-07-18
Anticipated expiration: 2027-08-01
Also published as: ES2391302T3; EP1889981A2; GB2440532A; GB0615509D0; GB2440532B; EP1889981A3

Description

The present invention relates to internal partition walls.
Internal partition walls are non-load-bearing divisions provided inside a building. They serve to divide up the space between load-bearing structures into separate rooms.
DE29924488U1 describes prefabricated partition wall panels incorporating horizontal and vertical channels for the passage of cables and services. The partition wall panels Include a monolithic core, surface components and stiffening and connecting members used to fix to the floor or ceiling. The ends of the panels are profiled so as to fit together.
US2107145A describes wall structures formed of tongue and grooved precast slabs of cementitious material with reinforcements therein. The reinforcements are utilised as a tying or doweling means between slabs and wooden wedges are used to prevent lateral movement of the wall. Full height mullions and filler slabs are used to form window and door apertures.
CA1031532A1 describes prefabricated flat panels for partition walls in buildings, each panel comprising a lightweight core and an outer lining. The core is a rectangular parallelepiped made from a material such as plaster exhibiting a reduced weight through the use of a large amount of light materials such as chips or wastes of bark or wood, balls or spherical pellets of expanded polystyrene or the like and is provided on at least its longitudinal edges with longitudinal grooves into which open sloping cylindrical cavities or recesses adapted to form a herringbone-pattern joint. Both major faces of the core being are provided with a facing such as a bonded fibre-board liner sheet.
DE10050446A1 describes a method for manufacturing non-load bearing internal partition walls. The wall panels can be prefabricated off site and then installed at the construction site. The lightweight construction of the wall panels essentially consists of comminuted cement-bound Polysterol (polystyrene concrete), cement and water. The internal wall panels can be held in place by brackets, which embrace the panel and are fixed to the floor.
The present invention provides an internal partition wall panel having an edge shaped to meet an edge of another like panel to define a boundary between the panels, the boundary being meandering in the direction from one panel face to the other panel face, a plurality of fixings for use in securing the panel in position, the fixings each having a first portion for locating to a panel, a second portion for securing to a neighbouring structure, and a connecting portion connecting the first portion and second portion, to fix the panel, in use, relative to the neighbouring structure, wherein the first portion locates a panel, in use, by engaging the panel edge, and wherein a lower fixing for attachment, in use, to the bottom edge of the panel has a first portion which locates a panel, in use, by penetrating the panel edge, and an upper fixing for attachment, in use, to the top edge of the panel has a first portion which locates a panel, in use, by embracing the panel edge.
The meandering boundary may include a plurality of straight legs. The meandering boundary may include at least three straight legs, or at least five straight legs.
The edges may be complementary in form. The panel may have a first, male edge which is complementary in form with a second, female edge. Each panel may have a first, male edge and a second, female edge.
The complementary form of the edges may cause the adjacent panels to adopt a preferred relative alignment when brought together.
The shaped edge may be a vertical edge in the installed panel. Preferably, the top and bottom edges of the panel are planar.
The panel may be formed of a settable material, such as a cementitious material. The settable material may be a cement mix or a plaster mix or a mixture of these materials. The settable material may contain beads of thermal insulating material, such as a polymer material. The insulating material may be polystyrene.
The second portion may provide holes for elongate fixings.
The connecting portion may be a plate. The first and/or second portions may be formed by deforming the material of the plate from the plane of the plate. The material may be deformed using a stamping, punching or folding operation.
In another aspect, the invention provides a method of forming an internal partition wall, including providing a plurality of internal partition wall panels, each having an edge being formed to meet an edge of another like panel to define a boundary between the panels, the boundary being meandering in the direction from one panel face (32) to the other panel face, positioning the panels in edge-to-edge relationship at the line of the wall, providing a plurality of fixings for use in securing each panel into position, the fixings each having a first portion for locating to a panel, a second portion for securing to a neighbouring structure, and a connecting portion connecting the first portion and second portion, to fix the panel, in use, relative to the neighbouring structure, the first portion locating to a panel, in use, by engaging the panel edge, and securing the panels in position by means of at least one lower fixing which attaches, in use, to the bottom edge of the panel, the or each lower fixing having a first portion which locates a panel, in use, by penetrating the panel edge, and at least one upper fixing which attaches, in use, to the top edge of the panel, the or each upper fixing having a first portion which locates a panel, in use, by embracing the panel edge.
The panels and fixings may form an internal partition wall system as defined above.
Examples of the present invention will now be described in more detail, by way of example only, and with reference to the accompanying drawings, in which:

Fig. 1 is a partial perspective view, part cut-away, of an internal partition wall formed in accordance with the present invention;
Fig. 2 is an enlarged part of Fig. 1, at the top of the wall panels;
Fig. 3 is a view equivalent to Fig. 2, showing an alternative edge profile, and Fig. 3a is a diagrammatic representation of a modified version of the profile of Fig. 3, viewed along the edge;
Fig. 4 is a perspective view of a fixing used at the top of the wall panels;
Fig. 5 is an enlarged view of part of Fig. 1, at the bottom of the wall panels; and
Fig. 6 is a perspective view of a fixing used at the foot of the wall panels.

Fig. 1 illustrates an internal partition wall panel system 10 formed from panels 12 secured in position between the floor 14 and ceiling 16 by fixings 18,20.
The panels 12 are each alike, being generally rectangular and planar and installed in a generally vertical orientation with their longer dimension upright. Upper fixings 18 are used to secure the upper edge 22 of each panel to the ceiling 18. Lower fixings 20 are used to secure the lower edge 24 of each panel to the floor 14.
Neighbouring panels 12 meet at their vertical edges 26, 28. In this example, each panel is formed with a first, male edge 26 and a second, female edge 28. In Fig. 1, one male edge 26 is exposed in the view, as is one female edge 28. The shape of the edges 26, 28 is preferably constant along the vertical length of the edges and can therefore be described in more detail by reference to the enlarged view of Fig. 2, which shows a male edge 26 interfitted with a female edge 28.
Turning to Fig. 2, the male edge 26 has a meandering shape formed of five straight legs. Two straight legs 30 extend in from opposite faces 32 of the panel 12, generally perpendicular to the plane of the panel 12. The straight legs 30 meet respective intermediate legs 34 at concavities 36. The intermediate legs 34 extend away from the main body of the panel 12, meeting a middle leg 38 at edges 40. The middle leg 38 is parallel with the straight legs 30, generally perpendicular to the plane of the panels 12. Thus, there are five legs defining the meandering shape of the male edge 26, resulting in a prominent land 42 inboard of the planar faces of the panels 12.
The female edge 28 is complementary in form to the male edge 26. Thus, the edge 28 has straight legs 44 extending in from the planar faces of the panel 12, generally perpendicular to the plane of the panel 12, and meeting intermediate legs 46 at edges 48. The intermediate legs 46 extend in from the edges 48 toward the main body of the panel 12, creating a concave channel, and meeting a middle leg 50 forming the base of the channel.
It can be understood from the above description that by providing complementary male and female edges 26, 28, it is possible to fit the land 42 of a male edge 46 into the channel of a female edge 28 of another panel 12. The form and complementary nature of the edges 26, 28 provides a number of effects, as follows. The boundary between the panels 12 follows a meandering path in the direction from one face 32 to the other face 32, so that any gap which may exist between adjacent panels 12 will not be straight. The joint formed in this manner is expected to be a relatively poor conductor of heat, sound and fire, by virtue of this meandering shape. In addition, the process of installation, to be described more fully below, is simplified because the form of the edges will cause adjacent panels to adopt a preferred relative alignment when panel edges 26, 28 are brought together. A worker will feel the panels slotting together as they approach this preferred relative alignment. Furthermore, the interfitment of the edges 26, 28 provides increased stability to the finished wall, by providing some securement of each panel 12 to its neighbours.
In this example, the panels are formed of a cement mix but other cementitious or settable materials could be used. For example, a plaster mix may be used. A combined mix of plaster and cement could be used. Panels with constant edge profiles along their lengths can conveniently be formed by a moulding or extrusion process.
The use of settable materials for forming the panels allows other material to be incorporated into the panels. For example, thermal insulating material may be incorporated in the panels, in the form of beads of material. This may be a polymer material. Polystyrene is an example of an insulating material which may be incorporated in bead form. Many thermal insulating materials will also provide enhanced insulating of other parameters, such as sound and/or fire.
In this example, the vertical edges 26, 28 of the panels 12 are profiled in the manner which has been described, whereas the upper and lower edges 22, 24 are planar and generally perpendicular to the faces 32.
The profiles described for the edges 26, 28 are complementary and different. Conveniently, each panel 12 will have a male edge 26 and a female edge 28, so that all panels can be identical. In an alternative, each panel could be formed either with two male edges 26, or two female edges 28, in which case a wall would be constructed by alternating male and female panels.
An alternative shape for the vertical edges of the panels 12 is illustrated in Fig. 3, which otherwise corresponds with Fig. 2. In this example, each panel has two identical edges having a three-legged form in which two straight legs 52 are joined by an intermediate leg 54. It can readily be understood that this alternative geometry provides another form of meandering boundary, with expected improvements in heat, sound and fire insulation. Ease of installation and achieving relative alignment between panels is also improved over a flat edge, as is stability, but the interfitting of the edges of Fig. 3 is less secure than the interfitting of the edges of Fig. 2, so that the reliability of attaining a preferred alignment, and the stability achieved during use, may both be less than in relation to the embodiment of Fig. 2.
In the example of Fig. 3, the intermediate leg 54 has a diagonal orientation relative to the legs 52 and the plane of the panels 12. Another alternative is illustrated in Fig. 3a, differing from the example of Fig. 3 in that the intermediate leg 54' is perpendicular to the straight legs 52'. '
Panels are installed using the fixings 18, 20, illustrated in more detail in Figs. 4 and 6. The upper fixing 18 is an article which has a first portion indicated generally at 56 for locating to a panel, a second portion indicated generally at 58 for securing to a neighbouring structure (in this case the ceiling 16) and a connecting portion 60 connecting the first and second portions, to fix the panel 12, in use, relative to the ceiling 16. In more detail, the upper fixing 18 is formed from a plate by bending strips 62 up from the plane of the connecting portion 60 to form walls between which the upper edge 22 of the panel 12 may be embraced, with the strips 62 extending across the faces 32 of the panel 12. Tags 64, left in the plane of the portion 60 when the strips 62 are bent up, are provided with apertures 66 for receiving screws, nails or other elongate fixings, for securing the fixing 18 to the ceiling 16.
Accordingly, the upper edge 22 can be secured to the ceiling 16 by fitting at least one upper fixing 18 over the upper edge 22, with the upper edge 22 received between the strips 62, and thereafter securing the fixing 18 to the ceiling 16 by means of elongate fixings through the apertures 64.
Deforming the material of the plate to form the strips 62, leaving the tags 64, may be achieved by a stamping, punching or folding operation.
A lower fixing 20 is illustrated in more detail in Figs. 5 and 6. The fixing 20 is in the form of a plate 68 forming the connecting portion of the fixing 20. The first portion for locating to a panel 12 is formed as an array of teeth 70 bent out from the plane of the plate 68 to leave slots 72. The second portion for securing to a neighbouring structure (in this example, the floor 14) is formed by apertures 74, for receiving screws, nails or other elongate fixings. Accordingly, the lower fixing 20 may be secured to the floor 14, prior to the introduction of a panel 12, by means of the apertures 74 and appropriate elongate fixings. A panel 12, introduced from above, can then be pressed down onto the upwardly projecting teeth 70, until they penetrate the panel lower edge 24, thereafter holding the lower edge 24.
In a preferred example for installing an internal partition wall, a set of lower fixings 20 is secured to the floor 14 along the desired line of the partition wall. A first panel 12 can then be introduced and pressed down onto the lower fixing 20. This secures the lower edge 24. The panel 12 can then be raised to the vertical position, if not already vertical. Upper fixings 18 may be placed over the upper edge 22, before the panel 12 is raised to the vertical position, so that as the upper edge 22 approaches the ceiling 16, it becomes a relatively simple matter to introduce elongate fixings through the apertures 66 in the tags 64, to secure the upper fixing 18 to the ceiling 16, thereby also fixing the upper edge 22, relative to the ceiling 16.
Another panel 12 can then be introduced by aligning the edge of the new panel to the edge of the old panel, to interfit the edges 26, 28, for example. After reaching the correct alignment, the new panel can be pressed down onto a lower fixing 20 already secured to the floor 14, and upper fixings 18 provided on the upper edge 22 can be secured to the ceiling 16 by means of appropriate elongate fixings. As this process continues, the internal partition wall is quickly, neatly and securely constructed from a series of panels 12.
Thus, one example of the invention is an internal partition wall system comprising panels 12 as described above, fixings 18, 20 as described above, the panels 12 meeting edge-to-edge, as has been described, to be secured in position by the fixings 18, 20. In addition, the interfitment of the edges further enhances the securement of the panels 12.
When panels of the type described above are used for forming an internal partition wall, by placing them edge-to-edge along the line of the wall, the use of the materials described above is expected to provide a number of advantages. Pre-forming the panels, for example in the manner described, facilitates easy, quick and clean installation. Using a cement and/or plaster based mix incorporating beads of polystyrene or other insulating material provides a panel which is light and can thus be easily and safely handled, but provides good characteristics of thermal, acoustic and fire insulation. Panels can readily be remodelled on site, for example to cut apertures for doors or windows, channels for installation of services etc.
It can be understood from the above description that many variations and modifications can be made to the examples described above, without departing from the scope of the present invention as defined by the appended claims. In particular, many different materials can be used for the construction of the panels and fixings. The detailed shapes and forms of the fixings and panels (particularly the panel edges) can be widely varied, according to the performance required of the partition wall being constructed. Other materials could be incorporated in the panels, such as rubber or rubber-based materials, and in bead, granule, strip or sheet form.

Claims

An internal partition wall system (10) comprising:
an internal partition wall panel (12) having an edge (26) shaped to meet an edge (28) of another like panel (12) to define a boundary between the panels (12), the boundary being meandering in the direction from one panel face (32) to the other panel face (32),

a plurality of fixings (18, 20) for use in securing the panel (12) in position, the fixings each having a first portion (56, 70) for locating to a panel, a second portion (58, 74) for securing to a neighbouring structure (14, 16), and a connecting portion (60, 68) connecting the first portion (56, 70) and second portion (58, 74), to fix the panel (12), in use, relative to the neighbouring structure (14, 16), wherein the first portion (56, 70) locates a panel (12), in use, by engaging the panel edge (22, 24), characterised in that

a lower fixing (20) for attachment, in use, to the bottom edge (24) of the panel (12) has a first portion (70) which locates a panel (12), in use, by penetrating the panel edge (24), and an upper fixing (18) for attachment, in use, to the top edge (22) of the panel (12) has a first portion (56) which locates a panel (12), in use, by embracing the panel edge (22).
A system according to claim 1, wherein the meandering boundary includes a plurality of straight legs (30, 34, 38, 52, 54, 52', 54').
A system according to claim 2, wherein the meandering boundary includes at least three straight legs (52, 54, 52', 54').
A system according to claim 2, wherein the meandering boundary includes at least five straight legs (30, 34, 38).
A system according to any preceding claim, wherein the edges (26, 28) are complementary in form.
A system according to claim 5, wherein the panel (12) has a first, male edge (26) which is complementary in form with a second, female edge (28).
A system according to claim 5 or 6, wherein each panel (12) has a first, male edge (26) and a second, female edge (28).
A system according to claim 5, 6 or 7, wherein the complementary form of the edges (26, 28) cause the adjacent panels (12) to adopt a preferred relative alignment when brought together.
A system according to any preceding claim, wherein the shaped edge (26, 28) is a vertical edge in the installed panel (12).
A system according to claim 9, wherein the top and bottom edges (22, 24) of the panel (12) are planar.
A system according to any preceding claim, wherein the panel (12) is formed of a settable material.
A system according to claim 11, wherein the settable material is cementitious.
A system according to claim 11 or 12, wherein the settable material is a cement mix or a plaster mix or a mixture of these materials.
A system according to claim 11, 12 or 13, wherein the settable material contains beads of thermal insulating material.
A system according to claim 14, wherein the insulating material is a polymer material.
A system according to claim 14 or 15, wherein the insulating material is polystyrene.
A system according to any preceding claim, wherein the second portion (58, 74) provides holes for elongate fixings.
A system according to any preceding claim, wherein the connecting portion (60, 68) is a plate.
A system according to claim 18, wherein the first and/or second portions (56, 58, 70, 74) are formed by deforming the material of the plate (60, 68) from the plane of the plate (60, 68).
A system according to claim 19, wherein the material is deformed using a stamping, punching or folding operation.
A method of forming an internal partition wall, including providing a plurality of internal partition wall panels (12), each having an edge (26) being formed to meet an edge (28) of another like panel (12) to define a boundary between the panels (12), the boundary being meandering In the direction from one panel face (32) to the other panel face (32), positioning the panels (12) in edge-to-edge relationship at the line of the wall, providing a plurality of fixings (18, 20) for use in securing each panel (12) into position, the fixings each having a first portion (56, 70) for locating to a panel (12), a second portion (58, 74) for securing to a neighbouring structure (14, 16), and a connecting portion (60, 68) connecting the first portion (56, 70) and second portion (58, 74), to fix the panel (12), in use, relative to the neighbouring structure (14, 16), the first portion (56, 70) locating to a panel (12), in use, by engaging the panel edge (22, 24), and securing the panels (12) in position by means of at least one lower fixing (20) which attaches, in use, to the bottom edge (24) of the panel (12), the or each lower fixing (20) having a first portion (70) which locates a panel (12), in use, by penetrating the panel edge (24), and at least one upper fixing (18) which attaches, in use, to the top edge (22) of the panel (12), the or each upper fixing (18) having a first portion (56) which locates a panel (12), in use, by embracing the panel edge (22).
A method according to claim 21, wherein the panels and fixings form an internal partition wall system according to any of claims 1 to 20.