GB2447896A

GB2447896A - A wall Panel

Info

Publication number: GB2447896A
Application number: GB0705697A
Authority: GB
Inventors: Glenn Williams
Original assignee: Individual
Current assignee: Individual
Priority date: 2007-03-24
Filing date: 2007-03-24
Publication date: 2008-10-01
Anticipated expiration: 2027-03-24
Also published as: GB2447896B; GB0705697D0

Abstract

A panel 101 for providing a surface of a wall, comprises a mineral core sheet 203, a pair of laminas 207 and 209, and an edge strip 211. The core sheet has two opposing large faces 204 separated by a plurality of narrow edges 206. The laminas are bonded to the large faces of the core sheet, and an edge strip is bonded to the plurality of edges 206. The mineral core is preferably made from desulphurised gypsum and recycled paper fibres. The laminas are preferably paper impregnated with thermosetting synthetic resins and bonded using a polyurethane adhesive. The edge strips are preferably a plastics PVC (polyvinyl chloride) material that is bonded to the core edges using a hot melt adhesive. Alternatively MDF strips are mounted to the core and the PVC strips bonded to the MDF. A later embodiment relates to a method of manufacturing said panel as well as a claim to a wall comprising a plurality of vertically extending hollow members (601a, 601b figure 7), a plurality of elongate cross members (704a, 704b figure 8) and a plurality of panels (101a, 101b figure 7).

Description

A Panel

Technical Field

The present invention relates to a panel for providing a surface of a wall, a method of manufacturing a panel, a wall comprising panels and a framework and a kit of parts for constructing such a wall. In particular, the panels and wall are suitable for use within offices, shops, other public or commercial buildings, or domestic buildings.

Background of the Invention

Properties are normally fitted out using traditional methods whereby wall panels are installed on metal or timber stud work using screws that are inserted from the front (exposed face) completely through the wall panel material into the supporting metal or limber framework. The screw heads normally located near the edge of the panels are countersunk then filled and rubbed down to achieve a smooth finish. The panel joints (between each panel) would also be filled and rubbed down to achieve a smooth and level finish indeed the process of preparing the joints normally covers the screw heads. This process of filling and rubbing down may repeat several times before achieving a satisfactory finish suitable for decorating. When the preparation work has been completed satisfactorily the wall panels would normally be finished either by decorating using paint or wall tiles. The stud work comes in full lengths and is cut to fit on site as a permanent installation to form new walls or dry line existing walls.

This method of installation is not only time consuming requiring considerable expertise on site but is not friendly to the environment. This is due to the excessive amount of material modification required on site to create a finished wall and the considerable amount of different operations carried out by various tradesmen. The materials normally used in traditional methods of construction are in themselves not environmentally friendly, having not normally being constructed of recycled materials or manufactured from sustainable sources. There is also a considerable amount of site wastage resulting from site operations which is normally disposed to landfill.

Once fitted it is difficult to dismantle and is normally demolished and again disposed to landfill.

Properties can also be fitted out using merchandising or point of sale systems either in addition to the traditional methods detailed above or as an alternative. The problem with these systems are that they are intended specifically for display purposes only and are not suitable as walling systems in the true sense. This prohibits them from being used as supporting structures for ceilings or as partition walls with doors and the like. They certainly do not achieve any fire rating which limits their usefulness in this area even further.

Brief Summary of the Invention

According to an aspect of the invention there is provided a panel for providing a surface of a wall, comprising: a core sheet comprising a mineral compound, said core sheet having two opposing large faces separated by a plurality of narrow edges; a pair of laminas bonded to said large faces of said core sheet; and an edge strip bonded to a plurality of said edges.

Brief Description of the Several Views of the Drawings Figure 1 shows a rectangular panel 101; Figure 2 shows a portion 201 and an edge 102 of the panel 101 in cross-section; Figure 2A shows a processing guide table relating to the production of the panel 101; Figure 3 shows portions of the bracket 401A adjacent its upper end 402, and lower end 403; Figure 4 shows the panel 101 from the rear with a pair of extended steel brackets 401A and 401 B attached; Figure 5 shows, in cross-section, a portion of the bracket 401A and the panel 101 assembled together; Figure 6 shows three panels lOlA, IOIB and IOIC of the type shown in Figure 4 in use; Figure 7 shows a cut-away view of the panels I OIA and 101 B of Figure 6 along with supporting framework 701 Figure 8 shows that part of the framework 701 enclosed by the dashed circle 702 of Figure 7; Figure 9 shows a partial cross-sectional top view of the panels lOlA and lOIB, and vertical tubular member 601A; Figure 10 shows a part of the framework 701 without the panels 101 or boards 705, 706; Figure 11 shows a partial cross-sectional top view of the panels lOlA and IOIB, and vertical tubular member 601A being used to form a partition wall 1100; and Figure 12 shows an adjustable end for use in a framework.

Description of the Best Mode for Carrying out the Invention Figures 1, 2and2A A rectangular panel 101 is shown in Figure 1, while a portion 201 and an edge 102 of that panel is shown in cross-section in Figure 2. A processing guide table relating to the production of the panel 101 is shown in Figure 2A.

The panel 101 has four edges 102, 103, 104 and 105. As will be described below, in use two edges 102 and 104 are arranged vertically and the other two edges, 103 and 105 are arranged horizontally. The panel has a front face 106 and a rear face 202, bounded by the four edges.

The panel 101 is formed with a solid core sheet 203 comprising a mineral compound. In the present case, the core sheet is formed of a mixture 80% de-sulphurised gypsum (a by-product of power stations) and 20% re-cycled paper fibres and water. However1 it is envisaged that other sheet material incorporating gypsum may be used.

The core sheet 203 has two parallel large faces 204 and 205 separated by four narrow edges 206. A lamina 207 is bonded to the large face 204 by a layer of adhesive 208, while a similar lamina 209 is bonded to the other large face 205 by adhesive 210. The laminas 207 and 209 are each formed of layers of paper impregnated with thermosetting synthetic resins, can be other wood or metal finishes (for example as sold under the trademark Formica). The adhesive 208, 210 is polyurethane, for example Apollo A751 0 moisture curing polyurethane.

An edge strip 211 is bonded to each of the edges 206 of the core sheet 203 by adhesive 212. The edge strip 211 is a plastics material, and typically is formed of PVC (polyvinyl chloride) of the type currently used for covering edges of other boards, such as MDF. The adhesive 212 is a hot-melt adhesive.

The panel 101 is manufactured as follows. Firstly an oversized sheet of material is cut for the core. This material may be Ferrnacetl gypsum fibre board as manufactured by XeIla Trockenbau-Systeme GmbH. This sheet is then cleaned to ensure it is free from dust, grease and other contaminants before primer is evenly applied over the entire surface of both large faces 204 and 205. The primer may be applied by spraying, brushing, roflering, etc. The primer that is used is Apollo A624 water based adhesive mixed in the ratio 50:50 with water. The reason for diluting with water is to allow good penetration of the primer into the surfaces being covered.

After the primer is dry (0.5 hour to 1 hour), Apollo A7510 moisture curing polyurethane is evenly applied to one of the two large faces, e.g. 204.

The application may be done by trowel, notched scraper, hand-roller coater, an automatic bead applicator, etc. The amount of adhesive that is applied is in the range 80-l40grams per square metre.

Once the adhesive has been applied it is over-misted with water. The weight of water used is in the range 5-15% of the weight of the applied adhesive. (Excessive amounts of water should be avoided.) The maximum amount of time the primed and glued panel can be left open or exposed before having the lamina 207 applied is dependent on the temperature of the core sheet 203 and is indicated on the second row (Open Time mins.) on the processing guide table shown in Figure 2A.

The lamina 207 is then located on the adhesive coated face. This should be done as soon as the water has been applied, to minimise water evaporation, and placed under pressure (within a range of 0.5-0.9 bar) within the maximum time limits as previously described. The time limits indicated on the third row of the aforementioned table (Cure Time mins.) apply to the time limits the panel is kept in the hot press. The temperature bands refer to the temperature of the core sheet 203 and not the press temperature. So, for example, if the press temperature was set to 30 C and the resuttant temperature of the core sheet 203, allowing for heat dissipating through the lamina 207, adhesive (208) and primer is 20 C, pressure should be applied with the press for a duration equal to the Cure Time minutes (i.e. 30 minutes) as indicated on aforementioned table. It can be clearly seen that if the press temperature is increased the cure time required within the press is proportionately reduced.

When the adhesive is sufficiently cured to permit handling of the assembly, it is turned over. The second lamina 209 is then bonded to the second face 205 using the same process.

The open time and cure time to permit handling will vary according to temperature, weight of adhesive applied, weight of over-mist and substrates being bonded. However, as an example, for the weight of adhesive, and over-mist given above, with a temperature of 20 C, the open time will typically be 11 minutes and the cure time 30 minutes from over-misting.

After the polyurethane adhesive is fully cured (typically 2 to 4 hours), the oversized composite panel is cut to size (typically using a circular saw), and then loaded into an edge banding machine pre-loaded with PVC edging strip of the required width. This machine is of a known type commonly used to apply edge bands to edges of other laminated boards such as MDF.

The machine is then used to prepare the edges of the composite panel by uhoggingu i.e. the machine takes a fine shaving off the edges of the composite panel. After the hogging stage, the composite panel is removed from the machine and the edges are primed in the same manner as described above for the large faces.

The composite panel is then replaced in the edge banding machine, and PVC edge strips are applied using a hot-melt adhesive, to produce the complete panel 101.

In order to make the panel 101 useable within a modular walling system, brackets may be attached. However, due to the mechanical properties of the gypsum fibre core conventional methods of attaching brackets have found not to be successful. A method of attaching brackets to the panel 101 is therefore described below with reference to Figure 3, 4 and 5.

In an alternative embodiment, a pre-primed wood-based board is bonded in strips to the edges of the core sheet 203. The wood-based board is typically MDF (medium density fibreboard). The strips of MDF are sufficiently wide to accept the fixing brackets being used.

With the MDF strips attached, both the core sheet and the MDF strips are laminated with the laminas 207 and 209 as described above. The resulting composite panel is cut to size and PVC edge strips are applied using the edge banding machine, as described above.

It may be noted that when the panel is laminated, the MDF strips and panel core tend to swell disproportionately when the adhesive is applied. To compensate for this problem, the MDF strips are made with a thickness that is slightly less than the thickness of the core sheet.

If this alternative panel is used, mounting brackets are attached to the panel by screwing directly into the MDF, to provide a relatively a stronger fixing than that described below for panel 101.

In one alternative embodiment, MDF strips are attached to all four edges of the core sheet to produce a panel that has particularly good adhesion of its PVC edging strips. Thus, in this embodiment the core sheet is "picture framed" by the MDF. As all the PVC edge strips are bonded to MDF, they may be applied by an edge banding machine in the conventional manner.

Due to the above mentioned swelling of the MDF on application of adhesive, the MDF strips are applied as separate components, rather than cutting a hole out of a large sheet of MDF. This allows some differential movement between the core sheet and the MDF and therefore does not restrict the core sheet and cause it to bow or bulge.

Figures 3,4 and 5 The panel 101 is shown from the rear in Figure 4 with a pair of extended steel brackets 401A and 401B attached. The two brackets differ from one another in that one is left handed and the other right handed (i.e. they are mirror images of each other). However, in all other aspects the two brackets are the same and therefore only bracket 401A will be described below.

Portions of the bracket 401A adjacent its upper end 402, and lower end 403 are shown in greater detail in Figure 3, and a portion of the bracket 401A and the panel 101 assembled together are shown in cross-section in Figure 5.

The bracket 401A generally has an L-shaped cross-section as shown in Figure 5. Hook shaped teeth 404 to 411 (inclusive) extend from one part of the L-shape while the other part defines spaced holes 412. The lower end of the bracket has a foot 413 that is perpendicular to both parts of the L-shape.

The foot is itself provided with a pair of holes 414.

The bracket 401A is assembled onto the panel by screws 415 which pass through the holes 412, 414 and into the panel. As will be understood from viewing Figures 3 and 4, the foot 413 is located against the bottom edge of the panel while the L-shaped portion of the bracket is parallel with the right edge 102. The spacing of the bracket from the right edge 102 depends upon its purpose, as will be described below, with reference to higher numbered Figures.

To rigidly, and securely, fix the bracket 401A to the panel 101, the panel is first drilled with an array of holes corresponding with the holes 412, 414 of the bracket. Such a drilled hole 416 is shown in Figure 5, and, as may be seen, the holes do not penetrate the front lamina 207.

After drilling the holes 416, a self-hardening compound (such as Gripfihl adhesive made by Laybond) is injected into the holes. The bracket is then placed in the required position against the panel 101, and high threaded screws are inserted into the holes while the self-hardening compound is still soft. The self-hardening compound hardens around the threads of the screws and provides a strong bond.

In the present case the brackets 401A and 4018 extend over the majority of the length of the panel. However, other embodiments are envisaged in which more brackets of shorter length are used.

Figure6 Three panels lOlA, IOIB and IOIC of the type shown in Figure 4 are shown in use in Figure 6. The panels form the interior face of a wall 602, and in the present example are being used within a shop. Consequently, the wall supports a shelf 603 and a clothes rails 604 for displaying goods (not shown).

The panels lOlA, 1016 and IO1C are supported from a framework including vertical tubes 601A, 601B as will be described below. The vertical tubes have an array of holes that receive the hooked teeth 404 to 411 of the brackets 401A and 401 B. The relative dimensions of the holes and the position of the brackets in this example has resulted in a gap being provided between the edges of adjacent panels. Consequently, the vertical tubes are also accessible for use to support other items, such as the shelf 602, the clothes rail 603, etc. Figures 7,8 and 12 The panels lOlA and IOIB of Figure 6 are shown along with supporting framework 701 in the cut-away view of Figure 7. A part of the framework 701 (shown within dashed circle 702 of Figure 7) is shown in Figure 8. An adjustable end for use in a framework is shown in Figure 12.

The framework 701 comprises a number of vertically arranged tubular members, such as 601A and 601 B formed of box section steel.

Each of the tubular members 601 has four sides, and each side defines an array of through holes 703. The holes 703 are evenly spaced along the length of the members 601 in groups.of three, such as holes 703A, 703B and 703C arranged side by side. Each group of three is similarly configured, being formed as three rectangular holes of similar height; the outer two holes (703A, 703C) also having the same width while the middle hole (703B) being wider.

The framework 701 also comprises cross members 704, such as 704A and 7048. These members 704 have the form of a U-shaped channel which defines hook-shaped teeth at either end. These hook-shaped teeth have a similar form to those of the brackets 401A and 4018, and both the teeth of the brackets 401 and the cross members 704 are configured to hook into the outer pair of holes in the tubular members 601. These cross members have three similarly sized cut-outs along the bottom face (not shown), one at either end of the cross member and one in the middle, to allow for the passing through of services.

As shown, the cross members extend between a pair of vertical tubular members 601 to form the framework 701. Once the framework is formed the panels lOlA, IOIB etc. are attached to the framework by locating the teeth of their brackets 40 IA, 401 B in the holes of the tubular member 601 and hooking in place. It should therefore be understood that the wall 602 may be dismantled by unhooking the panels 101 and cross members 704 from the vertical tubular members 601. (After dismantling the components of the wall may then be re-used in the construction of a new wall.) Where a standard length cross member cannot be installed due to decreased spacing of the vertical tube members, say for an end of run or corner scenario the cross members are cut to the required size using a hacksaw and an adjustable end 1201 (shown in Figure 12) is fitted within the cross member itself. The adjustable end 1201, like the cross members 704, is in the form of a U-shaped channel which has hooked teeth at one end, for connection to a tubular member 601. The adjustable end is screwed in two locations through the pre-drilled holes on the bottom horizontal plane into the cut cross member. This in effect creates a bespoke length of cross bar extending between a pair of vertical tubular members. In addition, the system may provide a doorframe which has a pair of vertical tube members and a pair of cross braces, one at the top of the vertical tube members and one just above door head height. A door frame normally of timber construction is screw fixed into the vertical tube members. An architrave also normally of timber construction is fitted over the door frame and wall panel. A door can then be hung using hinges onto the door frame in the normal manner. An alternative configuration incorporates a glazed screen module rather than a door.

A header board 705 and skirting board 706 may be seen in Figure 6 and 7 (and in Figure 8 in the case of the header board). Both of these boards reside between the panels 101 and the framework 701.

In the present example, both the header board and the skirting board have a similar construction to panel 101. However, it should be understood that they may be formed of other materials such as MDF.

When constructing the wall 602, the header board 705 is simply screwed to the upright tubular members 601.

The skirting board 706 is provided with a Z-shaped bracket, commonly known as an aluminium split batten, (not shown) running along its length and such that a narrow gap is formed between the bracket and the back face of the board itself. This allows the skirting board to be simply attached to a floor track (shown in Figure 10) by slotting the floor track into the gap as the board is lowered.

Figure 9 A partial cross-sectional top view of the panels I OIA and 101 B, and vertical tubular member 601A is shown in Figure 9.

As mentioned above, the panels lOlA and 1018 define a gap 901 due to the relative positioning of the brackets 40 IA, 401 B on the panels and the outer holes 703A and 703C in the tubular member 601A. This allows access through the gap 901 between the panels to the central holes 703B in the vertical tubular member 601A. Thus, the central holes 703B may be used to receive teeth of other objects such as the shelf 603 and clothes rail 604.

Figure 9 also demonstrates a method of stabilising the framework, by strapping it to a fixed wall 902 of a building. This is done using a connector 903 which has teeth configured to hook into the tubular member 601, and an L-shaped wall strap 904, that is provided with an array of apertures (not shown). The connector 903 is hooked into the tubular member at the required height, and the wall strap is fixed to the wall 902 by one or more screws 906.

The wall strap is then rigidly fixed to the connector 903 by a pair of self drilling screws 905 inserted through respective apertures in the wall strap and screwed into the connector.

Once attached to the wall 902, the wall strap 904 may be bent (as shown at 907) out of the way, before the panels 101 are attached to the framework.

It will be understood that if the framework is to be dismantled, the wall strap 904 is unscrewed from the fixed wall 902 and the connector 903 unhooked from the tubular member 601.

Figure 10 A part of the framework 701 is shown without the panels 101 or boards 705, 706 in Figure 10. Consequently, it may be seen that in the present example there are three cross-members 704 extending between each of the pairs of upright tubular members 601.

It can be seen in Figure 10, the tubular members 601 stand within a floor track 1001; the floor track being a U-shaped channel that has a middle portion 1002 screwed to the floor and two upwardly extending side portions 1003A, 1003B. The skirting board 706 of Figure 6 and 7 was clipped on to the front side portion I 003A of this channel. In an alternative arrangement, where the framework 701 and panels are used to form a partition wall, the rear upwardly extending portion 1003B of the floor track 1001 is used to receive a second skirting board.

Figure 11 A partial cross-sectional top view of the panels lOlA and biB, and vertical tubular member 601A is shown in Figure 11 being used to form a partition wall 1100. Consequently, two more such panels I1O1A and IIOIB are supported from holes on the rear side of the vertical tubular member 601A.

The panels IIOIA and IIOIB are wider than panels lOlA and IOIB, but the spacing between their brackets 401A and 401B is the same as for panels lOlA and IOIB. Consequently, the panels I lOlA and 1 IOIB are able to be supported by the same tubular members as panels lOlA and IO1B, but they have abutting edges. I.e. they do not provide a gap to allow access to the holes of the vertical tubular members 601. By concealing all slots, panels 11 OIA and 1101 B may therefore provide a more aesthetically pleasing finish to the wall, similar to a more conventional wall but which in effect would prohibit the incorporation of other objects such as the shelf 603 and clothes rail 604.

Clearly, it would also be possible to construct a partition wall using panels of the same type as panel 1 OIA on both sides of the wall or using panels of the same type as panel 11O1A on both sides of the wall.

In a further alternative structure, the tubular members 601, the cross members 704 and panels configured with brackets, such as panels 101, are used to produce free standing retail unitary for supporting and displaying merchandising products.

Claims

Claims 1. A panel for providing a surface of a wall, comprising: a core

sheet comprising a mineral compound, said core sheet having two opposing large faces separated by a plurality of narrow edges; a pair of laminas bonded to said large faces of said core sheet; and an edge strip bonded to a plurality of said edges.
2. A panel according to claim 1, wherein at least one of said edges has an edge strip comprising wood-based board.
3. A panel according to claim I or claim 2, wherein said mineral compound comprises gypsum.
4. A panel according to any of claims I to 3, wherein said core sheet is formed of a mixture of gypsum and paper fibres.
5. A panel according to any of claims I to 4, wherein said laminas are substantially rigid.
6. A panel according to claim 5, wherein said laminas comprise of a plastics material.
7. A panel according to claim 6, wherein said plastics material is a thermoplastic.
8. A panel according to any of claims 2 to 7, wherein said edge strip comprises of a plastics material.
9. A panel according to claim 8, wherein said plastics material is polyvinyl chloride (PVC).
10. A panel according to any of claims I to 9, wherein said panel is provided with a plurality of brackets for connecting said panel to a framework, and said panel is provided with an array of holes that are filled with a material that receives a fixing for said brackets.

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11. A panel according to claim 10, wherein said brackets are located on one of said laminas.
12. A panel according to claim 10 or claim 11, wherein each said brackets define a hook for attaching to a hole formed in a wall of a tube.
13. A panel according to any of claims 1 to 12, wherein said laminas are bonded to said core sheet using polyurethane.
14. A panel according to any of claims I to 13, wherein a surface layer of said large faces of said core sheet contain a primer configured to provide bonding between said polyurethane and said core sheet.
15. A panel according to any of claims 2 to 14, wherein said edge strips are bonded to said core sheet with a hot-melt adhesive.
16. A panel according to any of claims 2 to 15, wherein a surface layer of said edges of said core sheet contain a primer configured to provide bonding between said hot-melt adhesive and said core sheet.
17. A wall comprising a panel according to any of claims Ito 16.
18. A method of manufacturing a panel, comprising the steps of: obtaining first sheet of material comprising a mineral compound; bonding a lamina to each one of two opposing faces of said first sheet to produce a multi-layered sheet; cutting said multi-layered sheet to produce an edge suitable for receiving an edge strip; priming said edge; and bonding an edge strip to said primed edge.
19. Awallcomprising: a plurality of vertically extending hollow members each hollow member having a series of holes spaced along at least three faces providing a first connecting means; a plurality of elongate cross members, each cross member having second connecting means at opposing ends connected to said first connecting means such that said cross members extend between pairs of said vertical hollow members to provide a framework; a plurality of panels, each panel having a front surface and a rear surface and a plurality of third connecting means rigidly fixed to said rear surface, said third connecting means connecting with said first connecting means of a pair of said hollow members such that said panels are located in front of said framework.
20. A wall according to claim 19, wherein said second connecting means and said third connecting means define a hook for hooking into said holes.
21. A wall according to claim 19 or claim 20, wherein said panels are in accordance with any of claims 1 to 17.
22. A wall according to any of claims 19 to 21, wherein said third connecting means are located such that a gap is formed between edges of adjacent panels attached to one of said vertical hollow members, such that said gap provides access to a plurality of said holes.
23. A wall according to any of claims 19 to 21, wherein said third connecting means are located such that adjacent panels attached to one of said vertical hollow members have abutting edges.
24. A wall according to any of claims 19 to 23, supporting a ceiling or bulkhead.
25. A wall according to any of claims 19 to 24, forming a partition wall.
26. A wall according to claim 25, comprising a door or glazed screen modules.
27. A wall according to any of claims 19 to 26, comprising component parts formed from recycled or previously used materials.
28. A kit of parts for constructing a wall according to any of claims 18 to 27, comprising: a plurality of said substantially elongate hollow members; a plurality of said elongate cross members; and a plurality of said panels.
29. A panel for providing a surface of a wall substantially as described herein with reference to the accompanying figures.
30. A method of manufacturing a panel substantially as described herein with reference to the accompanying figures.
31. A wall substantially as described herein with reference to the accompanying figures.
32. A walling system substantially as described herein with reference to the accompanying figures.