GB2346626A

GB2346626A - A building panel

Info

Publication number: GB2346626A
Application number: GB9903132A
Authority: GB
Inventors: Ashley Thomas Beighton
Original assignee: SCHAL INTERNATIONAL MANAGEMENT
Current assignee: SCHAL INTERNATIONAL MANAGEMENT
Priority date: 1999-02-11
Filing date: 1999-02-11
Publication date: 2000-08-16
Also published as: GB9903132D0

Abstract

A building panel 2 comprising a metal frame 8 eg. steel, being filled with a fibre reinforced cementitious material 12 eg. concrete. Anchoring portions 10 extend into and are embedded in the cementitious material. Attachment means 13 are provided to allow panels to be connected together. A method and apparatus are disclosed for the manufacture of the panels. A method of constructing a building by means of inserting said panels into a prefabricated building frame (fig 5 not shown). A method of constructing a building by attaching the said panels together to form a module (fig. 6 not shown). Apertures for windows and doors may be provided in the panels (fig. 6 not shown).

Description

"Building Panels" THIS INVENTION relates to improvements in or relating to building panels, and a method and apparatus for their manufacture.

Many modem buildings are constructed using a method whereby the main supporting steel or concrete structure is first erected to produce a skeletal frame and the external and the internal walls are introduced afterwards. These walls are often composed of a braced framework which is assembled on site about the skeletal frame. Spaces for windows, doors and other fittings are allowed for in the framework.

Once the framework has been assembled, one surface of the framework is covered with boards to form the internal surface of the wall. A weatherproof or protective cladding might then be added to the other side of the framework (if this is exposed to the elements) to form the external surface of the wall. The internal boards can then be plastered, painted, papered or otherwise covered to be presentable as internal walls.

This method has disadvantages, including the fact that the framework, boards and cladding must be assembled on-site which is a laborious and timeconsuming task.

An alternative is to mould an entire wall or panel thereof either on-site or off-site from concrete, and then raise the wall into place. These panels have the advantage over clad frames that they can be readily made sufficiently robust to be load-bearing. However, this method also has disadvantages, either because of space restrictions on-site, the problems of providing the necessary infrastructure including a supply of concrete, the cost of the moulds required and the equipment needed to transport and lift the panels into place.

The present invention seeks to provide a building panel, a method of manufacturing building panels and an apparatus therefor which are readily manufactured to a required size, do not need further assembly and which are readily installed on-site.

Accordingly, one aspect of the present invention provides a building panel comprising a frame, the frame defining a volume and being at least partially filled with a cementitious material.

Preferably, the frame has an anchoring portion which protrudes inside the volume defined by the frame, and is at least partially embedded in the cementitious material.

Conveniently, the anchoring portion comprises a substantially planar projection.

Advantageously, the frame includes at least one attachment means to facilitate attachment of the building panel to other elements.

Preferably, the attachment means comprises a portion of the frame.

Conveniently, the frame comprises an anchoring portion and an attachment means which are formed as a unitary element.

Advantageously, the frame is made from metal.

Preferably, the metal is steel.

Conveniently, the metal is aluminium.

Preferably, the cementitious material is a fibre-reinforced cementitious material.

Conveniently, the cementitious material is a glass-reinforced cementitious material.

Preferably, the cementitious material is a concrete.

Another aspect of the present invention provides a method of manufacturing building panels comprising the steps of : constructing a frame of predetermined dimensions defining therein a volume; and applying a cementitious material into the volume defined by the frame such that the resultant building panel comprises the frame at least partially filled with the cementitious material.

Conveniently, the cementitious material is applied by spraying.

Preferably, the cementitious material is applied by pouring.

Advantageously, the method includes the step of embedding at least a portion of the frame in the cementitious material.

Preferably, the method includes the step of forming the building panel with a feature to receive another element.

Conveniently, the feature comprises an aperture to receive a window frame, a door frame or another fitting.

Advantageously, the manufacturing process is automated.

Preferably, the manufacturing process is a continuous process.

A further aspect of the present invention provides an apparatus for manufacturing building panels, comprising: means to construct a frame defining a volume; and application means to apply a cementitious material within the frame such that the volume defined by the frame is at least partially filled by the cementitious material.

Conveniently, the application means is a spray gun to apply the cementitious material by spraying.

Preferably, the application means is automated.

Advantageously, the movement and activation of the application means is controlled by a processor, the processor being pre-programmed with a set of instructions.

Conveniently, the application means is supported by a fixed guide rail.

Preferably, the application means is drivable along the guide rail.

Advantageously, a conveyor is provided and the frame is located on the conveyor to effect relative motion between the frame and the application means.

Conveniently, the application means is manually controllable.

Another aspect of the present invention provides a method of constructing a building including the steps of : erecting a skeletal load-bearing frame for a building; and inserting building panels embodying the invention into the frame of the building to form walls within the building.

A further aspect of the invention provides a method of constructing a three-dimensional room module comprising the step of attaching building panels embodying the invention to one another to form the room module.

In order that the invention may be more readily understood, embodiments thereof will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a view of a building panel embodying present invention and an apparatus for manufacturing the building panel; Figure 2 is a view of a stage of the manufacture of a building panel embodying the present invention; Figure 3 is a cross-section view of a building panel embodying the present invention ; Figure 4 is a cross-section view of two building panels embodying the present invention connected by a metal angle connector ; Figure 5 is a side-view of a skeletal frame of a building provided with a number of building panels embodying the present invention; and Figure 6 is a perspective view of a three-dimensional room module formed from a number of building panels embodying the present invention.

Figure 1 shows an apparatus 1 for the manufacture of a building panel 2 embodying the present invention. The apparatus comprises an elongate conveyor 3 upon which is mounted an endless belt 4. A fixed gantry 5 bridges the belt 4 and has an overhead guide rail 6 lying across and above the belt 4.

An applicator 7 is carried on the guide rail 6 and is drivable by a motor (not shown) so as to slide along the length of the guide rail 6 in a reciprocating motion between controlled limits. Thus, a controlled relative motion in an X-Y plane between the applicator 7 and the belt 4 is provided by a combination of : the motion of the belt 4 over the conveyor 3 along the longitudinal axis of the conveyor 3 provides the movement in the Y direction; and the motion of the applicator 7 along the guide rail 6 in a direction which is orthogonal to the longitudinal axis of the conveyor 3, i. e. along the transverse axis of the conveyor 3 provides the movement in the X direction.

Preferably, the movement between the belt 4 and the applicator 7 in the Y direction is a substantially constant motion.

Advantageously, the applicator 7 is a spray gun operable to spray a glassfibre-reinforced cement, for example containing Cem-FIL fibres (a Trade Mark of Cem-Fil International Ltd.), which solidifies as a cement which is typically 1/4 as dense as concrete. Methods of spraying glassfibre-reinforced cement are known in the art. It is possible for the applicator 7 to spray other types of cement which are not glassfibre-reinforced, but the use of glassfibre as the reinforcement is preferred. In another embodiment, the applicator 7 comprises an outlet from which a cementitious material can be poured.

In operation, a method of manufacturing a building panel 2 embodying the present invention comprises the step of constructing a frame to predetermined dimensions. These dimensions could be dictated by the size of the aperture in the skeletal frame of a building which is to be"filled"by the resultant building panel or array of building panels. In this example, the frame defines the perimeter of a building panel for a wall, and hence is rectangular in cross-section. The frame 8 has four elongate planar walls 9 defining a volume which is open on the uppermost and lowermost faces. The frame 8 is manufactured from metal and the walls 9 are joined together by conventional means such as welding. The inner surfaces of the walls 9 of the frame 8 are provided with an elongate projection 10 which extends along the full length of the surface of the frame 8 from which it protrudes. The projection 10 runs along but spaced apart from a free edge 11 of the wall 9.

Whilst the projection 10 is described as a single planar elongate shape, it is envisaged that other configurations of projection would be suitable, including a plurality of linear projections or projections formed with apertures or with textured surfaces to provide an improved keying surface. In another embodiment, the projection 10 comprises a series of individual projections rather than being a contiguous projection.

The resultant frame 8 is position on the belt 4 as shown in Figure 1.

The frame 8 is located on the belt 4 such that the free edges 11 of the walls 9 rest upon the belt 4 and the projections 10 which are spaced apart from the edges of the walls 9 are lowermost. Since the projections 10 are spaced apart from the free edges 11 of the walls 9, the projections 10 extend substantially parallel to and spaced apart from the belt 4.

The applicator 7 is operated either manually or by a pre-programmed set of commands controlled by a processor (not shown), to apply a cementitious material 12 into the rectangular confine defined by the frame 8. The frame is moved back and forth in the X direction between two limits dictated by the position of the walls 9 of the frame. The conveyor 3 is also operated to assist in this, by moving the frame 8 in a continuous movement in the Y direction under the applicator 7 so that the entire interior volume of the frame 8 may pass directly under the applicator 7. The applicator 7 applies sufficient cementitious material 12 into the frame 8 to partially fill (to a required depth) the frame 8 so that the projections 10 are covered by and thereby embedded in the cementitious material 12. A portion 13 of the walls 9 is left above the level of the cementitious material 12. Figure 2 shows a frame 8 which is approximately half-way through the application process, the frame 8 being moved by the belt 4 to position the remaining empty part of the frame to be partially filled with cementitious material.

Figure 3 is a plan view of a building panel 2 embodying the present invention produced by the above described method. The projections 10 that are embedded in the cement serve to key in and anchor the frame 8 and the solidified cementitious material 12 together. The portions 13 of the walls 9 which are above the level of the cementitious material 12 provide attachment means which can be used to secure the building panel 2 to other elements, including, for example, other building panels 2, or to a part of the skeletal frame of a building.

Two building panels of Figure 3 may be connected together at right angles (or any other required angle) to each other, by using metal angle connectors 14. Figure 4 shows two building panels 2 connected together substantially at right angles to one another by a metal angle connector 14. It is possible to use other cross-sections instead of angle connectors 14 to join building panels together such as hollow or extruded sections.

It is envisaged that frames 8 can be formed without portions 13 which would be above the level of the cementitious material 12 or that frames could be fully filled so that no parts of the walls 9 project from the completed building panel 2. In another embodiment, the portions 13 comprise a series of individual projections from the wall 9 rather than being a contiguous projection. Whilst the portion 13 is described as a single planar elongate shape, it is envisaged that other configurations of projection would be suitable, including a plurality of linear projections.

Owing to the flexibility of the method of the present invention, building panels may be manufactured to any size or shape required by a particular job.

All that is required is the dimensions of the building panel which can then be constructed and a cementitious material 12 applied by spraying, pouring or other convenient means within the confines of the frame.

The structural strength of the building panels 2 can be enhanced by forming raised protrusions or ribs in the surface of the cementitious material 12. Further, it is envisaged that an internal framework can be applied within the frame 8 to stiffen the resultant building panel. The internal framework could be fully or partially embedded in the cementitious material.

Building panels embodying the present invention may also be readily manufactured to include features, the method of the invention thereby offering an extremely versatile manufacturing process which can be tailored to meet the specification and requirements of a particular job. An example of a wall produced from building panels embodying the present invention is shown in Figure 5. The wall includes a building panel 15 pre-formed with an aperture to receive a window frame and another building panel 16 pre-formed with an aperture to receive a door frame.

Referring to Figure 6, by connecting building panels 2,15,16 embodying the present invention to one another and via hollow section connectors 19 in the manner described above, it is possible to create buildings of any desired complexity. The pre-formed building panels 2,15,16 can be assembled on site into three-dimensional room modules 17. It is even possible to assemble the room modules 17 off site and transport the room module 17 in an assembled condition onto the site for installation.

The decreased density of fibre-reinforced cement leads to cheaper and easier transportation and handling of the building panels. A further advantage of fibre-reinforced cement is that it produces a fine finish and so redecorating of the internal walls before habitation of the building is not necessary (although it is perfectly possible if this is desired).

The spraying method of application is particularly preferred and allows any shape or size of frame to be readily constructed and filled with fibrereinforced cement. This application method also lends itself to a continuous manufacturing process whereby unsprayed"empty"frames 8 are continually loaded onto the belt 4 for spraying and then curing. Automation of the process allows differently sized and shaped frames to be identifie by a processor which can then set the relevant commands to control the spraying and relative motion between the frame and the spray gun to fill each individual frame in the manner required. The method is especially well suited to use with computer aided design (CAD) and computer aided manufacture (CAM) techniques.

Claims

CLAIMS : 1. A building panel comprising a frame, the frame defining a volume and being at least partially filled with a cementitious material.
2. A building panel according to Claim 1, wherein the frame has an anchoring portion which protrudes inside the volume defined by the frame, and is at least partially embedded in the cementitious material.
3. A building panel according to Claim 2, wherein the anchoring portion comprises a substantially planar projection.
4. A building panel according to any preceding claim, wherein the frame includes at least one attachment means to facilitate attachment of the building panel to other elements.
5. A building panel according to Claim 4, wherein the attachment means comprises a portion of the frame.
6. A building panel according to any preceding claim, wherein the frame comprises an anchoring portion and an attachment means which are formed as a unitary element.
7. A building panel according to Claim 1, wherein the frame is made from metal.
8. A building panel according to Claim 1 or 7, wherein the cementitious material is a fibre-reinforced cementitious material.
9. A building panel according to any preceding claim, wherein the cementitious material is a concrete.
10. A building panel according to any preceding claim, wherein a framework is provided at least partially embedded within the cementitious material.
11. A building panel according to any preceding claim, wherein one or more raised protrusions are provided in the surface of the cementitious material to enhance the structural strength of the building panel.
12. A method of manufacturing building panels comprising the steps of : constructing a frame of predetermined dimensions defining therein a volume ; and applying a cementitious material into the volume defined by the frame such that the resultant building panel comprises the frame at least partially filled with the cementitious material.
13. A method according to Claim 12, wherein the cementitious material is applied by spraying.
14. A method according to Claim 12, wherein the cementitious material is applied by pouring.
15. A method according to any one of Claims 12 to 14, including the step of embedding at least a portion of the frame in the cementitious material.
16. A method according to any one of Claims 12 to 15, comprising the step of forming the building panel with a feature to receive another element.
17. A method according to Claim 16, wherein the feature comprises an aperture for a window frame, a door frame or other fitting.
18. A method according to any one of Claims 12 to 17, wherein the manufacturing process is automated.
19. A method according to any one of Claims 12 to 18, wherein the manufacturing process is a continuous process.
20. An apparatus for manufacturing building panels, comprising: means to construct a frame defining a volume; and application means to apply a cementitious material within the frame such that the volume defined by the frame is at least partially filled by the cementitious material.
21. An apparatus according to Claim 20, wherein the application means is a spray gun to apply the cementitious material by spraying.
22. An apparatus according to Claim 20, wherein the application means is a pourer to apply the cementitious material by pouring..
23. An apparatus according to any one of Claims 20 to 22, where the application means is manually controllable.
24. An apparatus according to any one of Claims 20 to 23, wherein the application means is automated.
25. An apparatus according to Claim 24, wherein the movement and activation of the application means is controlled by a processor, the processor being pre-programmed with a set of instructions.
26. An apparatus according to any one of Claims 20 to 25, wherein the application means is supported by a fixed guide rail.
27. An apparatus according to Claim 26, wherein the application means is drivable along the guide rail.
28. An apparatus according to any one of Claims 20 to 27, wherein a conveyor is provided and the frame is located on the conveyor to effect relative motion between the frame and the application means.
29. A method of constructing buildings comprising the steps of : erecting a skeletal loadbearing frame for a building; and inserting building panels according to any one of Claims 1 to 11 into the frame of the building to form walls in the building.
30. A method of constructing a three dimensional room module comprising the step of attaching building panels according to any one of Claims 1 to 11 to one another to form the room module.
31. A method of manufacturing building panels substantially as hereinbefore described, with reference to and as shown in the accompanying figures.
32. An apparatus for manufacturing building panels substantially as hereinbefore described, with reference to and as shown in the accompanying figures.
33. A building panel substantially as hereinbefore described, with reference to and as shown in the accompanying figures.
34. A method of constructing buildings substantially as hereinbefore described, with reference to and as shown in the accompanying figures.
35. Any novel feature or combination of features disclosed herein.