GB2500472A - Wall panel with a protruding edge - Google Patents

Abstract

A wall panel 2, 3 comprises a first and second boards 4, 6 for forming opposing surfaces of a wall, where at least one side edge 24 of the first board 4 protrudes beyond a corresponding edge 26 of the second board 6. Preferably at each edge of the panel 2, 3 a side edge of one of the boards 4, 6 protrudes beyond the corresponding side edge of the other board 4, 6. Elongate studding 8, 10, 12, 14 may extend between the boards 4, 6, each studding 8, 10, 12, 14 providing first and second faces that are attached each to one of the boards 4, 6. Optionally, each board is attached along one edge to a first portion of the first face of one of the studdings 8, 10, 12, 14 and an adjacent board attaches to a second portion of the first face of the studding. The studdings 8, 10, 12, 14 may comprise a pair of studs and at least one spacer. The panels can be assembled by overlapping a protruding edge of a first board with an adjacent panel to abut against a corresponding side board thereof. The invention extends to a method of manufacturing a wall panel and a studding for a wall panel.

Description

Wall construction This invention relates to the construction of walls such as interior walls, and in particular to wall panels for forming such walls, and a system for constructing such walls using wall panels.

It is often necessary to construct interior walls within buildings to divide a large space into separate rooms. Interior walls are commonly built on-site using a stud wall construction. This involves fitting floor and head tracks, for example wooden batons, to the existing floor and ceiling structure. Vertical studs', which are commonly also made of wooden batons, are then attached between the tracks at suitable intervals. This provides a framework for attaching plaster boards, which form the opposing wall surfaces, to either side of the studs.

Sometimes, horizontal members or noggins' may be fitted between the studs to provide rigidity, or in a particular position to provide a frame for a door or an attachment point. Furthermore, two such studding frameworks may be provided adjacent each other to make a wall with a greater depth for strength or insulation purposes, known as a twin stud wall. Usually the first side board is fitted, and then any required services are fitted into the wall. The second side board is then attached, enclosing the studding and the services, and the board is then cut to provide the required access to the services. The joints between the wall boards are taped to secure the boards together, and the wall may then be skimmed and painted.

Such walls are commonly used to divide large spaces in buildings such as hospitals, schools or offices. The process is time consuming, and requires skilled craftsmen able to decipher technical drawings to complete the construction successfully to the required design. Thus the construction of the walls may cause a delay in finishing the building. Furthermore, stud walls tend to have poor sound insulation qualities. One reason for this is that the plaster boards need to be relatively thin and light so that they are easy to cut and manipulate on-site.

The present invention aims to alleviate these problems.

According to a first aspect of the present invention, there is provided a wall panel for forming a wall, the panel comprising first and second side boards for forming the opposing surfaces of the wall, wherein at least one side edge of the first board protrudes beyond a corresponding edge of the second board.

The invention thus provides pre-formed panels which can easily be assembled on-site, by overlapping the protruding edge of the first board with the adjacent panel to abut against the corresponding side board thereof The panels may be constructed off-site (with mechanical and electrical services integrated within the panels before delivery for installation), and the finished wall may be assembled easily (on-site), reducing the need for skilled labour and providing a better quality product with better performance.

Preferably, the panel comprises elongate studding extending between the boards, each studding providing first and second faces which are attached each to a respective one of the boards.

Thus the panels may provide a wall having a similar structure to a stud wall.

The studding preferably comprises edge studding extending substantially along the height of the panel adjacent each side edge of the panel. This arrangement provides rigidity to the panel.

Preferably, a side edge of one of the boards protrudes beyond the corresponding edge of the other board at both edges of the panel. Thus the panels may be joined by overlapping a board with the adjacent panel to abut against the corresponding side board of that panel at both edges thereof.

For example, the boards may be offset across the width of the panel, with a first side edge of each board protruding beyond a second side edge of the opposing board at each edge of the panel. This offset arrangement of the side boards allows the wall panels to interlock' with adjacent panels, for simple assembly, with the protruding first edge of each side board abutting against the second edge of the side board of the adjacent panel on each side of the panel.

The modular panel design facilitates the use of heavier materials for the wall board surfaces, since there may be no requirement to cut or work with the boards on-site. The panels may simply be manipulated into place using machinery such as a suction lift. The possibility of using heavier boards facilitates the use of boards of higher quality. For example, the boards may be made of stronger material and/or may have a high quality finished surface which does not require additional skimming or painting.

Preferably, the boards are of substantially equal width, and each board is attached along the second edge thereof to a first portion of the first side face of one of the studdings, leaving a second portion of the side face of the studding free for attachment to a board from an adjacent panel. At the other edge of the panel, the board is attached to the second side face of the other studding, with the second edge of the board protruding beyond the said other studding. The free second portion of the first side face of the studding, adjacent the first portion, is arranged for attachment to the protruding first edge of a board from an adjacent panel when abutted against the attached second edge of the board of the panel in question. The first edge of the adjacent panel may then simply be attached to the second portion of the side face of the studding.

Preferably, the second portion of the side face of the studding is adapted to receive fixings to attach the first edge of the adjacent panel.

Further intermediate studding having first and second faces attached to the opposing boards may be provided at intervals between the edge studdings to provide further rigidity. For example, studding may be provided at intervals of around 300mm across the width of the panel.

Alternatively, intermediate studdings can be provided at intervals between the edge studdings of between 300mm and 600mm, preferably between 350mm and 550mm, more preferably 400mm.

The panel may for example be approximately 600mm wide, with one intermediate studding. The boards may be attached to the studding by fixing means such as screws. The prefabricated nature of the wall panels of the invention facilitates the use of pre4ormed screw holes in the studding.

Preferably, the studdings each comprise a pair of studs spaced apart and aligned across the depth of the wall panel, which each provide one of the first and second side faces attached to the side boards. Spacers may be provided extending across the depth of the panel between the pair of studs. The spacers may be fixed to each stud of a pair, so as to maintain the spacing between the studs of each pair.

The spacers may each comprise a board, and may extend along the height of the panel, or may be shorter, in which case a plurality of such boards may be provided at intervals along the height of the studding. The dimensions of the spacer boards may thus be chosen to vary the distance between the studs and thus the depth of the wall to the required depth. With this arrangement, wall panels of different depths may be produced using spacers of different sizes, but otherwise using the same components. This facilitates a reduction in the production cost of the panels.

In a preferred embodiment, the spacers are smaller than the distance between the boards, and thus extend short of the side faces of the studs, such that the spacers are not in contact with the boards. Preferably the clearance between the spacer and each board is small, to maintain the rigidity of the structure and to enclose the side edges of the panel; for example the clearance may be a few millimetres. This arrangement reduces the direct contact between the materials of the wall panel for reducing sound transmission. With walls constructed on-site, it would be very difficult to build such a structure with a fine clearance, whereas the panel can be manufactured in a factory to very fine tolerances.

Also, since the joins between boards in the finished wall may be staggered, this also reduces the direct sound transmission path where the panels join. The second edge of each board may protrude beyond the studding by an amount equal to or greater than the width of the second portion of the stud side face. Where the amount is greater, a space will be formed between the edge studs of adjacent panels when the panels are fitted together. This can give the finished wall improved insulation qualities. For example, sound or heat insulation material may be placed in the space when the panels are fitted together.

The studs of each pair may each comprise channel sections, such as metal (e.g. steel) channels, with a first arm of each channel providing the first and second outer side faces respectively to which the boards are attached. The channel sections may thus be asymmetric, with the first arm which provides the attachment face being longer than the second arm of each channel, which is in the panel interior. Thus a saving of materials may be made. In traditional stud wall construction, a single type of studding tends to be provided on-site for single and double stud walls, the studding being symmetrical, such that this provides an advantage over traditional construction.

The channel sections of the edge studding may be oriented with the base of each channel section facing the side edge of the panel. Each spacer may be attached across the bases of the pair of studs. With spacers extending along the height of the panel, the interior of the panel may thus effectively be enclosed at the side edges by the spacers. The spacers may for example be made of the same board material as the side boards of the panels, and may be of the same thickness or may be thinner.

A strengthening member may be provided on the first surface of the studding spanning the first and second portions thereof. The strengthening member can enable performance benefits with respect to strength, acoustic dampening, and fire safety. For efficiency and convenience, the strengthening member may extend substantially along the height of the panel and substantially along the width of the first surface of the studding. For convenience and simplicity, the strengthening member may comprise a board, said board preferably being attached to said studding by means of fixings, preferably screws. For example the strengthening member may be made of the same board material as the side boards of the panels, and may be of the same thickness or may be thinner or thicker.

Insulation material may be provided inside the panel, for example adjacent one or both of the boards. This may for example comprise a layer of insulation material such as rockwool placed adjacent one or both of the insides surfaces of the side boards. The insulation material may for example be supported on or both edges thereof seated within the channel sections of the studs.

A further top board may be attached between the boards at the top edge of the panel further effectively to enclose the top edge of the panel. The top board may also be supported on studding such as a pair of studs extending across the inside surfaces of top edges of the boards.

Preferably, the panel comprises a channel, or recess, extending along a lower edge thereof for attachment to a floor rail. For example, a lower board may be attached to the lower edges of the studding effectively to enclose the lower edge of the panel. The side boards may each extend below the lower board to form the channel. In addition, a resilient member such as a sprung member may be provided in the channel for engaging the floor rail. For example, an elongate sprung member may be attached to the inside surface of the lower edge of one or both the boards, such as a sprung metal channel section. The sprung members may be arranged tightly to engage a floor rail therebetween.

Conveniently, at least one edge of the wall panel, the offset of the boards is substantially equal to the width of the finished wall panel. Thus, if the wall is required to have a square corner, an edge of one panel may be fitted at 90 degrees to the edge of another panel, with the inner and outer boards thereof abutting each other to make the corner.

In some embodiments, the panel may comprise top studding extending adjacent the top edge of the boards. The top studding may comprise a pair of studs attached to a spacer board as previously described, with the board optionally effectively enclosing the top edge of the panel.

This arrangement provides further rigidity to the panel of particular use in cases where the top edge of the panel is not to be attached directly to the ceiling structure of the building, for example where the building has a suspended ceiling.

According to a second aspect, the invention provides a method of manufacturing a wall panel, comprising providing two pairs of elongate edge studs, attaching the studs of each pair to at least one spacer such that the studs of each pair are spaced apart from each other by a predetermined distance, attaching a side board to one of the studs of each pair such that each pair of studs extends at or adjacent an edge of the panel, at least one side edge of the first board protruding beyond the corresponding edge of the second board.

Preferably, the boards are attached such that the side edge of one of the boards protrudes beyond the corresponding side edge of the other board at both edges of the panel. More preferably, the boards are attached in offset relation to each other, with one edge of each board protruding beyond each pair of studs, and the other edge of each board being attached to an outer face of each pair of studs.

In a third aspect, the invention provides a system for constructing a wall in a building, the system comprising: a plurality of wall panels; and a floor rail arranged to be attached to the floor; in which the floor rail and the lower edges of the panels are correspondingly shaped to engage, or interlock, with each other.

The floor rail may be tapered inwardly towards the upper edge thereof. For example it may be have a trapezoidal cross-section, or it may have a more rounded cross-section, in the manner of an inverted U-shape. The panels may each have a corresponding channel in a lower edge thereof. Thus the engaging, or interlocking, between each panel and the floor rail becomes tighter as the panel is lowered on to the track, and may be held tight by the weight of the panel.

The panels are preferably wall panels as defined above in accordance with the first aspect of the invention. Depending upon the side board offset and the position of edge studding, a space may be formed between the edge studding of adjacent panels when the panels are placed together with the boards abutting each other. In such embodiments, the system may also comprise a king' stud arranged to fit within the space between the edge studding of the panels. The king stud may be a larger stud, for example being a channel section, arranged to extend substantially across the depth of the adjacent wall panels, and across the width of the space between the edge studding of the panels, in order to add rigidity and strength to the finished wall. The king stud may be attached to the floor track by having a correspondingly shaped lower surface to engage, or interlock, therewith in a manner similar to the panels, or may simply comprise a channel in the lower surface thereof sized to fit over the floor track.

The system may also comprise a side connection rail, also having a width arranged to fit closely within the depth of the panels, between the boards. The side connection rail is arranged to fit within a space formed between the edge studding of a panel and the side boundary of the wall (for example an exterior wall of the building) when the protruding second edge of the respective board abuts against the boundary. For example, the side connection member may be a wooden beam attached to the structural wall of the building. The system preferably also comprises a filler board which is preferably formed of the same material as the side boards, and has the same height and thickness, and which has a width equal to the distance from the first edge of the board attached to the respective edge studding, and the protruding second edge of the opposing board. Thus the filler board is arranged to be attached to the second portion of the edge studding to fill the gap formed by the offset of the boards at the boundary of the finished wall.

Where the wall is to be fitted in a building where a false or suspended ceiling is provided, which may be the case when a ceiling space is required for services such as air conditioning ducts, the top edge of the wall may extend up to or beyond the suspended ceiling, but may not extend as far as the structural ceiling. In such cases, the king studs of the system may have a height greater than the height of the wall panels, and may be arranged to extend substantially to the level of the structural ceiling. The system may comprise a head support for each king stud, the head supports being arranged for attachment to the ceiling of the building structure. The head support preferably comprises a pair of edge abutment members spaced apart by a distance corresponding to the width of the king stud, so as closely to receive the top of the king stud. The head support may also comprise a further pair of side abutment members spaced apart by a distance corresponding to the depth of the king stud. The head support thus reduces any deflection of the king stud away from vertical, to help maintain the structure of the finished wall.

The system may also or alternatively comprise a top rail for securing to the ceiling of a building into which the wall is to be fitted, and a pair of pelmets for attachment to the top rail on either side thereof and depending therefrom. The top rail preferably has a width substantially similar to the width of the wall panels, and the pelmets are preferably attached each to one side thereof.

The pelmets may thus form a channel for receiving the top edge of the wall panels. The pelmets may have a height arranged to be longer than the difference between the height of the panels when fitted onto the floor rail and the height of the space in which the wall is to be fitted. Thus the pelmets may cover any gap between the wall and the ceiling.

The lower edges of the pelmets may have a chamfered or bull nose finish to improve the appearance thereof, for example where there is no false ceiling fitted. The abutment members of the head support may depend directly from the ceiling rail, or the head support may be a separate component which is arranged to be fixed to the ceiling rail.

According to a further aspect of the present invention, there is provided a studding for a wall panel, comprising: at least one elongate channel section having a base section, and first and second arms dependent therefrom; wherein said first arm is adapted to mount or accept (the side edges of) two boards each from a respective wall panel (along the length thereof), said boards abutted together. By providing such a studding the amount and therefore cost of material associated with building a wall panel may be reduced. The said first arm may extend further from said base than the second arm.

Preferably, the first arm comprises pre-formed holes for accepting fixing means to attach said boards. By providing such pre-drilled holes the construction of walls on-site may be simplified.

Preferably, the second arm comprises an inwardly projecting angle piece, and as such the stiffness of the studding may be improved.

Preferably, the studding further comprises a second such elongate channel section, and a spacer, wherein said spacer is attached to the base sections of said first and second channels to space them apart. The first arms of each channel section are preferably to the exterior of said studding.

The studding may further comprise a strengthening member attached to the first arm and adapted to be mounted between the first arm and said side edges of the two boards. The strengthening member can enable performance benefits with respect to strength, acoustic dampening, and fire safety. For efficiency and convenience, the strengthening member may extend substantially along the width of the first arm and the height of the stud. For convenience and simplicity, the strengthening member may comprise a board, said board preferably being attached to said studding by means of fixings, preferably screws. For example the strengthening member may be made of the same board material as the side boards of the panels, and may be of the same thickness or may be thinner or thicker.

According to a further aspect of the present invention there is provided a wall panel for forming a wall comprising: first and second boards for forming the opposing surfaces of the wall; elongate studding extending between the boards, each studding providing first and second faces which are attached each to a respective one of the boards, the studdings each comprising a pair of studs aligned across the depth of the wall panel, which each provide a respective one of the first and second surfaces; and at least one spacer extending across the depth of the panel between the pair of studs, and being fixed to each stud of a pair; wherein the at least one spacer is arranged such that the spacers are not in contact with said boards. By providing such a spacer, the sound insulation of the wall panel may be improved.

Preferably, each board is attached along the second edge thereof to a first portion of the first face of one of the studdings, a second portion of the face of the studding being arranged for attachment to a board of an adjacent panel. As such, a wall panel is provided that may be more easily used to construct a wall.

Preferably, the at least one spacer comprises a board. The board may be made of high density plasterboard type material, such as Rigidur HTM.

Preferably, the at least one spacer extends substantially along the height of the panel, and thus may improve the sound insulation properties of the wall panel.

Preferably, the clearance between the spacer and each board is preferably between 0.5mm and 5mm, more preferably between 1mm and 3mm, yet more preferably between 1.5mm and 2.5mm.

The studding may comprise a strengthening member provided on the first face of the studding.

The strengthening member can enable performance benefits with respect to strength, acoustic dampening, and fire safety. For efficiency and convenience, the strengthening member may extend substantially along the height of the studding and substantially along the width of the first surface of the studding. For convenience and simplicity, the strengthening member may comprise a board, said board preferably being attached to said studding by means of fixings, preferably screws. For example the strengthening member may be made of the same board material as the side boards of the panels, and may be of the same thickness or may be thinner or thicker.

A wall panel may comprise an acoustic attenuation feature. An acoustic quilt is an example of an acoustic attenuation feature. The acoustic attenuation feature is preferably a foam element, for example of low density foam and/or closed-cell foam, that is positioned between studding and/or board. Preferably the acoustic attenuation feature is attached with an adhesive covering.

Preferably the acoustic attenuation feature is foam tape. Preferably a stud and a board are mechanically connected with an acoustic attenuation feature between stud and board.

Several panels may be connected together to form a complete wall and lowered to a building.

Several panels may be combined together to form a volumetric shape without the need for the top or bottom being enclosed.

A wall panel may comprise provisions for mechanical or electrical services, including connections. The provisions may include an additional panel within the wall panel, preferably connectable to a king stud and/or header rail, for attachment of mechanical or electrical services.

According to a further aspect of the present invention there is provided a composite wall panel comprising first and second wall panels as described above, the wall panels forming the opposing surfaces of the composite wall panel. The composite wall panel can enable performance benefits with respect to strength, acoustic dampening, and fire safety.

Preferably the first and second wall panels are spaced apart. This can be beneficial for acoustic performance. For strength and design simplicity, a spacing member may be arranged to provide a gap between the first and second wall panels. For maintaining acoustic performance while keeping overall wall thickness low, the gap may be between 5 and 40 mm, and preferably between 10 and 30 mm, and yet more preferably approximately 20 mm.

According to a further aspect of the present invention there is provided a wall comprising a panel as described above. According to a further aspect of the present invention there is provided a building comprising a wall as described above.

Further features of the invention are characterised by the dependent claims.

The invention extends to a wall panel for forming a wall substantially as herein described with reference to the accompanying figures.

The invention extends to a method of manufacturing a wall panel substantially as herein described with reference to the accompanying figures.

The invention extends to a system for constructing a wall of a building substantially as herein described with reference to the accompanying figures.

The invention extends to a studding for a wall panel substantially as herein described with reference to Figures 4, 7, 10, 11, 12 and 15.

The invention extends to methods and/or apparatus substantially as herein described with reference to the accompanying drawings.

Any feature in one aspect of the invention may be applied to other aspects of the invention, in any appropriate combination. In particular, method aspects may be applied apparatus aspects, and vice versa.

In order that the present invention may be more readily understood, reference will now be made to the accompanying drawings, in which: Figure 1 is a perspective view of two wall panels according to one embodiment of the invention; Figure 2 is a cross-sectional view of a wall section comprising two wall panels according to a second embodiment of the invention; Figure 3 is a further cross-sectional view of the wall section of Figure 2; Figure 4 is a cross-sectional view of a join between wall panels according to a third embodiment of the invention; Figure 5 is a cross-sectional view of a corner wall corner section comprising two wall panels according to the invention; Figure 6 is a cross-sectional view of a wall boundary showing a wall panel as shown in Figure 2; Figure 7 is a cross-sectional view of a wall boundary showing a wall panel as shown in Figure 4; Figure 8 is a perspective view of two wall sections with a door aperture; Figure 9 is a cross-sectional view of the wall section of Figure 8 when assembled; Figure 10 is a cross-sectional view of a wall panel with a boundary section; Figures 11 to 13 are perspective views of channel sections suitable for use as a spring, a stud, and a king stud respectively in a system according to the invention; Figures 14 to 16 are cross-sectional views of the channel sections of Figures 11 to 13; Figures 17 to 19 are cross-sectional side views showing various stages of erection of a wall panel according to the invention; Figures 20 and 21 are cross-sectional side views of the lower edge of a panel and a floor rail; Figure 22 is a cross-sectional side view of the upper edge of a panel and a top rail; Figure 23 is a side view of a wall according to the invention; Figure 24 is a perspective view of a head support according to the invention; Figures 25 to 28 are cross-sectional views of wall panels with acoustic attenuation according to the invention; Figure 29 is a cross-sectional view of view of a wall panel with connection for mechanical or electrical services according to the invention Figure 30 is a cross-sectional view of adjoining panels with a standard stud according to an embodiment of the invention; Figure 31 is a cross-sectional view of adjoining panels with a strengthened stud according to another embodiment; Figure 32 is a cross-sectional view of adjoining panels with a simplified strengthened stud according to a further embodiment; Figure 33 is a perspective view of the adjoining panels with the strengthened stud of Figure 31; Figure 34 is a cross-sectional view of a composite panel according to a further embodiment with two subpanels; and Figure 35 is a front view of a system for constructing a wall of a building according to an embodiment of the invention.

Referring to Figure 1, two wall panels 2, 3 are shown for use in a system for constructing a wall.

With reference to the panel 2 shown nearest in the figure, each wall panel comprises opposed side boards 4, 6 shown here at the front and rear of the panel, for forming the front and rear wall surfaces. Elongate edge studding between the boards 4, 6 comprises first and second pairs of studs 8, 10 and 12, 14 extending along the height of the panel 2, shown here at the left and right side edges 16, 18 respectively thereof, each pair of studs being sandwiched between the boards 4, 6.

The boards may be formed of a material such as Rigidur HTM, and may have a thickness of for example about 15mm. The studs 8, 10, 12, 14 each comprise a metal channel shaped section having a base and a pair of arms. With reference to the pair of studs shown on the left, the outer aims of the studs provide first and second side faces 20, 22, which are attached to the inside surfaces of the rear and front side boards 4, 6 respectively. For example, the studs may include pie-formed screw holes, and the boards may be attached by means of screws (not shown).

The boards 4, 6 are offset with respect to each other such that, at the left hand edge 16 of the panel 2, a first edge 24 of the rear board 6 protrudes beyond the second edge 26 of the front board 4. Similarly, at the second edge 18 of the panel 2, the first edge 28 of the front board 4 protrudes beyond the second edge 30 of the rear board 6.

In this example, the second edge 26, 30 of each board extends part way across the side surface of the face of the respective stud to which it is attached, so as to cover a first portion of the face.

Thus a second portion 31 of the face is left exposed. As can be seen from the figure, at the rear of the panel, the protruding first edge 36 of a rear board 38 from an adjacent panel 3 may be placed abutting against the second edge 30 of the rear board 4, and may be attached to the exposed second portion of the studding ace, for example using screws, in order to construct the wall. At the same time, the protruding first edge 28 of the front board 4 of the panel 2 will abut against the second edge 36 of the front board 38 of the adjacent panel 3, and may be fixed to the exposed second portion 40 of the side face of the edge studding of the adjacent panel. A plurality of panels may therefore be assembled side by side to create a wall, with the protruding edges being attached to the edge studding of the adjacent panel.

Alternatively, one board may be wider than the other board, such that the first and second edges of one board protrude beyond the first and second edges of the other board. In this example, the wall is constructed by alternately erecting the wall panels from one side of the wall and then the other.

The studs 8, 10 and 12, 14 of each pair are joined by a spacer which here comprises a spacer board (e.g. 32). Each spacer board 32 is oriented across the depth of the panel 2 and extends along the length of the studs. Referring to the left hand studding, each spacer board 32, which may be of the same material as the side boards 4, 6, is attached across the base edges 33, 35 of each stud 8,10, for example by screws. The studs are oriented with their bases 33, 35 facing the edge 16 of the panel 2. In this way the spacer boards 32 effectively enclose each side edge 16, 18 of the panel 2. The spacer boards may be thinner than the side edge boards.

The spacer boards 32 assist in maintaining the depth of the panel 2. As shown in Figure 2 (in which like reference numerals are used for simplicity), further intermediate studding in the form of a further pair of studs 48, 50 joined with spacer boards 32 may be provided between the edge studding to increase the rigidity of the panel.

It can be seen that, depending upon the required depth of the wall to be constructed, the width of the spacer boards 32 and thus the distance between the studs of a pair may be varied. The other components making up the panel 2 may be the same, such that this provides a simple way of producing panels of different depths. The wall depth may for example be between about 100mm and 150mm.

The spacer boards 32 may have a width slightly smaller than the depth of the panel 2. Thus they do not extend fully across the bases 33, 35 of each of the pair of studs (e.g. 8, 10). Referring to Figure 2, in this way there will be a small clearance 42 between the spacer board 32 and the respective side board 6. The clearance, which may be just a few millimetres, is intended to mitigate sound transmission across the finished wall.

The studs also provide a seat for a layer of insulation material 46 to be placed against one or both of the side boards 4, 6. The material 46, such as a layer of rockwool, may be chosen to provide sound or heat insulation. The insulation material 46 may conveniently be placed with the edges thereof 52, 54 seated within the channels of the studding.

It can be seen that, in use, the amount of offset of the boards determines the size of a space 56 formed between the edge studding of adjacent panels 2, 3. As shown in Figure 3, in the finished wall, the system may include a larger stud, known as a king' stud 58, contained within the space 56. The king stud may also comprise an elongate metal channel section, or may alternatively be a simple wooden beam.

As shown also in Figures 13 and 16, the king stud may have a wide base 59 sized to fit across the depth of the space 56, and a pair of shorter depending arms 61, sized to fit between the adjacent studdings. Each arm may terminate in a short angle section 63 for rigidity. King studs may be provided in a space between each adjacent panel, or at larger intervals along the finished wall. For example king studs may be included at every second or third join between the panels. In an alternative join where a king stud is not required, as shown in Figure 4, the space may contain further insulation material 60.

The king studs assist in maintaining the structural rigidity of the finished wall. Where the building has a suspended ceiling with a gap between the structural ceiling and the internal walls, it may be required that the panels are of a smaller height than the distance between the floor and the ceiling of the building. In such a case, the king studs may extend above the top edges of the panels to anchor the wall to the ceiling, as will be described in more detail below.

Furthermore, king studs may be provided between selected panels where strength or anchorage is needed. For example, king studs may be provided at each side of a panel or panels which contain a door opening formed in a panel or panels as described below, but may be omitted along a remaining section of wall.

As also shown in Figure 4, the studs 62 may be asymmetric in shape. Thus the studs may have a base 64 attached to the spacer board 65, and inner and outer arms 66, 68. The outer arm 68 is longer than the inner arm 66, so as to provide a large side face for attaching the first and second edges 70, 72 of the adjacent panels to adjacent first and second portions thereof. Thus a saving of material may be made since the inner arm 66 need be long enough only to provide structural rigidity.

Figures 12 and 15 show an example of a suitable asymmetric stud section. It can be seen that the inner arm 66 may be halt as long as the outer arm 68, with the base being a little shorter than the inner arm. The outer arm 68 may terminate in a small angle piece 70 to maintain the rigidity of the channel.

Referring again to Figure 1 it can be seen that, in use of the system, the wall panels may be mounted on a floor rail 72 arranged to be attached to the floor. The floor rail 72 comprises for example a wooden batten extending along the centre line of the intended position of the wall.

The panels 2, 3 are each provided along the lower edge 76 thereof with a corresponding recess 78 for receiving the floor rail 72. The recess is formed between a pair of sprung members 80 extending along the lower edge of the inside surface of each of the side boards 4, 6.

A lower board 82 extends along the lower edge of the panel to form the top of the channel, and is attached to the lower edges of the studding and/or the spacer boards 32. The lower board 82 has a width extending substantially across the depth of the panel, with a small clearance 83 with respect to the side boards 4, 6 (see Figure 21), in a similar manner to the spacer boards 32.

Thus the lower board effectively encloses the interior of the panel at the lower edge. The sprung members 80 may be mounted on or against the lower board 82, and are arranged such that the recess formed therebetween has a depth arranged to fit tightly over the floor rail 72.

Referring also to Figures 21 and 22, the floor rail may have a substantially square cross-section, but with a slight taper so as to be narrower at the top edge 84 than at the bottom edge 86. The floor rail 72 may alternatively or in addition have rounded upper corners. The sprung members are substantially channel shaped in cross section, and may be made of metal (see also Figures 12 and 14). The base 88 of each member 80 may be attached to the lower board 82, and an outer arm 85 may be attached to the respective side board (e.g. 4), and terminated in an outward angle piece 90 extending along the lower surface of the side board 4, which may also or alternatively be attached thereto. The inner arm 92 of each sprung member 80 terminates in a small inwardly projecting angle piece 94.

When the panel is lowered onto the floor rail 72, the angle pieces 94 ride over the top edge 84 of the floor rail 72. Further downward movement of the panel causes the inner arms 92 to deflect inwardly, as shown in Figure 22. Because of the resilience of the sprung members 80, the panel is thus retained tightly on the floor rail 72.

Figure 5 shows a right angled corner in the wall formed between two panels 96, 98. The first panel 96 is similar to that shown in Figure 2, but is modified such that the right hand edge studding is positioned further inwardly of the panel, with the second edge 100 of the inner side board 101 attached across the second surface 102 of the studding and projecting past the spacer board 104. This arrangement allows the second panel 98 to be positioned perpendicularly to fit within the space created by the panel offset. Thus the length of the panel offset is substantially equal to the width of the panel, as shown by dimension x in the figure.

The first panel may comprise a further corner stud 106 for attaching the inner board 108 of the second panel to the inner board 101 of the first panel. This may be a further metal channel section. The protruding first edge 110 of the outer board 112 of the second panel may be shortened to be flush with the spacer board 114 of the edge studding, so that the spacer board 114 may be attached to the outer board 116 of the first panel, with the outer boards abutting to form a finished corner.

Figure 6 illustrates the arrangement at the boundary of the wall. In this case, the panel 124 is abutted against the boundary wall 118 of the building, with the protruding edge 120 of one side wall 122 meeting the boundary wall. At the opposite side of the panel 124, a gap is formed between the second edge 126 of the other side board 128 and the boundary wall. A filler board may be provided to cover the gap. The filler board 130 has a width substantially equal to the board offset, so as to abut against the second edge 126 of the side board 128 and against the boundary wall. The filler board 130 may be formed of the same material as the side boards, having the same thickness, and being of the same height.

A side rail 132 may be attached to the boundary wall 118. The side rail 132 may for example be a wooden beam. The side rail 132 has a depth arranged to fit closely across the depth of the panel, and a width arranged to fit within the space between the spacer board 133 of the edge studding and the protruding edge 120 of the side board. It can be seen that the panel 124 may be placed against the boundary wall 118 over the side rail 132 before the filler board is attached to the studding in the usual manner to create a finished wall edge.

Alternatively, as shown in Figure 7, the side rail 134 may have a smaller width, allowing space for a layer 136 of insulation material between the edge spacer board 138 and the rail 134.

As shown in Figure 8, if a doorway or other aperture such as an access panel is required, this may be formed by providing panels 136, 138 with cutouts. For a doorway, a rectangular cutout 140, 142 is made in a lower corner of each panel. At the side edge 145 of each cutout 140, 142 further studding 144 may be provided, as can be seen from Figure 9. The studding 144 may mount a spacer board 146 as described above, thereby creating a finished edge wall across the depth of the cutout. Further studding and spacer boards may also be provided along the top edge 147 of each cutout in a similar way to provide a finished top edge of the doorway. A door 148 may then be mounted to the further studding 144.

An access panel may be formed in a similar way, with studding and spacer boards provided around the edges.

Where a simple finished side edge is required, as shown in Figure 10, an edge piece 150 may be provided. The edge piece comprises a pair of studs 152 and a spacer board 154. The edge piece may be fitted onto the protruding edge 156 of the panel side board so that the spacer board 154 is flush with the edge 156. A filler board as shown in Figure 6 may then be used to fill the gap between the second edge 158 of the opposing side board and the surface of the spacer board 154 to create a finished wall edge.

As shown in Figure 23, the panels may also comprise top studding at the top edge thereof comprising a pair of top studs 160, and a top spacer board 162, running along the top edge and fixed in the manner described above, preferably with a small clearance, such that the top spacer board 162 is flush with the top edge 164 of each of the side boards 166 of the panel. The top board thus effectively encloses the interior of the panel at the top edge thereof Top studding may be provided in particular where the wall is to be fitted with a gap between the top of the panels and the structural ceiling.

Where no gap is required between the wall and the ceiling, a top rail 168 may be provided for attachment to the ceiling above the wall panels. The top rail 168 may for example comprise a wooden beam of rectangular cross section. The top rail 168 has a width arranged to be substantially equal to the depth of the wall panels. On either side of the top rail 168 a pair of pelmets 170 depend therefrom. It can be seen that, when a wall panel is fitted below the ceiling rail, the pelmets 170 hold the top edge of the panel in position.

Figures 17 to 19 show how a wall panel may be assembled to the top and bottom rails 171, 172.

In use of the system to construct a wall, the ceiling and floor rails 171, 172 are first attached, one vertically above the other to the ceiling 174 and floor 176 respectively of the space to be divided by the wall. A first pelmet 178 is attached along one edge (here the left) of the ceiling rail 172.

The panel 180 may be a very heavy unit, which requires a machine such as a suction lift to move it. For example the panel may be up to about 4m in height.

The panel 180 is first presented on the opposite side (here the right) of the floor rail 171 in a position tipped away from the vertical towards the right with the corner of the right hand lower edge 180 on resting the floor 176 adjacent the floor rail 171 (Figure 17).

The panel 180 is then manipulated towards an upright position. As it tips upright, the inner arm 182 of the left hand sprung member rides over the left top edge of the floor rail 171, with the inner arm 182 being deflected inwardly, whilst the inner arm 186 of the right sprung member is also pushed inwards by engaging the right hand edge of the floor rail 171 (Figure 18).

When the panel reaches the fully upright position shown in Figure 19, the floor rail 171 is received in the channel 188 between the sprung members, with the inner arms 182, 186 of the sprung members bearing against the sides of the floor rail 171. Thus the panel 180 is held tightly around the floor rail. In this position, the left hand top edge 190 of the side board of the panel bears against the left hand pelmet 192. There is a clearance between the top edge of the panel and the ceiling rail, which may for example be around 40mm thick.

After the required number of panels have been erected in this way, preferably with king studs between at least some of the panels, the right hand pelmet 194 may then be attached to the ceiling rail 172 to bear against the right hand top edge 196 of the side boards, such that the top edges of the wall panels are held in position. A false or suspended ceiling 198 may then be supported below the ceiling 174, and below the lower edges of the pelmets 192, 194, such that the pelmet is hidden from view.

Alternatively, referring to Figures 23 and 24, the top edge 198 of the assembled panels may be supported by head supports 200 for the king studs 202. Each head support 200 is arranged for attachment to the structural ceiling 174 above the position of each king stud 202. The king studs 202 have a length greater than the height of the panels so as to extend above the top edge 198 thereof when assembled.

Each head support 200 comprises a ceiling channel 204 for attachment to the ceiling 206. Two side abutment members 208 are fixed in the channel spaced apart so as closely to receive the top of the king stud therebetween. At the top edge, the king stud also abuts against the edges 210 of the ceiling channel 204. Thus the head support 200 retains the king stud in position so as to support the assembled wall. The king studs may extend beyond a suspended ceiling into the service space 212, whilst the wall panels 214 may extend only as far as or just beyond the suspended ceiling. In order to provide a required gap for the provision of services, there may be a section 216 of free' wall comprising e.g. three panels, having a length for example of about 3Gm. In the free section 216 where no king studs are present between the panels 214, the panels preferably comprise top studding 218 as described above.

With the system according to the invention, a high build rate can be achieved. For example, a build rate of about 6 panels per hour might be achieved with a two man team, each panel being about 4.5m2; or 27m2 per hour. The traditional build rate for stud walls is 75m2 in 8 hours, or 9m2 per hour. Thus the time taken to install the walls may be reduced by about 60%.

Furthermore the interior walls of a building which are required to form a given layout can be constructed with this system using only a small number of different panels.

Figures 25 to 27 show panels with features to improve the acoustic performance of the individual panels and the system as a whole. Low density foam 2500 (preferably closed-cell foam) with adhesive coverings is positioned between various stud and panel elements. The adhesive coverings are sufficiently strong to prevent shear or flexing. The low density foam with adhesive coverings provides the advantage of reducing the panel stiffness, resulting in enhanced acoustic performance. Walls made in a factory as a panel allow mechanical pressure to engage the board/stud/adhesive layers together; this is difficult to perform correctly on site. Ordinarily boards and studs are directly fixed to one another with screws, in which case no advantage is achieved regarding acoustic performance.

To achieve acoustic attenuation, foam tape is laid between the panels, vertical studs and plasterboard on all connecting faces. For horizontal studs the floor and header track are fixed with screws as described above. When two panels are positioned together the vertical joint is fixed with screws in the normal method for partitioning. The adhesive closed-cell foams break direct sound paths across the studs, and the reduction of screw fixings improves sound attenuation. No stud is connected across the wall from board to board. Fishing is reduced.

Figure 28 illustrates the connection of two panels to one another. Due to the staggered stud arrangement two boards are never directly connected, but always have two foam layers between the two outer boards. The staggered stud arrangement results in the panels not being acoustically connected, while ensuring that all panels are mechanically connected on all four edges.

The panel is supported and secured on all four outer edges, maintaining wall strength and integrity. In case the panel is subjected to fire, the plasterboard delaminates from the centre stud, reducing thermal heat transfer, thus improving insulation performance.

Figure 29 shows the inner flank of the vertical stud section with connection for mechanical or electrical supports, providing an additional internal fire or acoustic barrier and maintaining a disconnected sound path.

A module containing mechanical and electrical services can have several panels connected forming part of a wall. When the module is installed within a building and connected to the soffit, the panel(s) can be disconnected and supported by the king stud and a header rail, removing the need for the module to support the partition wall. This is useful to protect the mechanical or electrical services from being pulled from the soffit, e.g. in a bomb blast; or to remove sway or side loading on the mechanical or electrical services.

Figure 30 is a cross-sectional view showing the join between adjacent panels having a standard stud, similar to the stud 62 shown in Figure 4. Figures 31 and 32 are cross-sectional views showing panels with a strengthened stud 320 and a simplified strengthened stud 322 respectively. Figure 33 is a perspective view of the right hand panel having a strengthened stud 320 of Figure 31, mounted on a floor rail. The strengthened studs 320 322 have in common a strengthening board 300 adjacent an outer side face or arm 305 of the stud so as to run behind the joint lines 302 of abutting boards 312 314 of two panels when joined together. The strengthened studs 320 322 can provide the following benefits: * Stiffening of the joint line 302 which in turn reduces joint deflection, This can enable the use of relatively long panels, for example 7.5m in length. The ability to make long panels can be beneficial as it can reduce the amount of work required to install and connect the panels to form a wall.

* Improving the joint line fire resistance * Due to the board mass across the joint line the acoustic performance can be improved.

Tests have shown an improvement of+3dB for the weighted sound reduction index Rw of a wall of panels. In particular, the added stiffness gives a low correction factor Ctr accounting for low transmission of low frequency sound.

The strengthening board 300 may have substantially same dimensions as the outer face 305 of the stud 320. The strengthening board 300 may have substantially same thickness as the facing board 312 (for example 12 mm or 15 mm), and may be of the same material as the facing board 312 (for example gypsum plasterboard). In one example, the outer face 305 of the stud 320 is 60 mm wide, and the strengthening board 300 overlaps the joint on either side by 30 mm.

The alternative simplified strengthened stud 322 shown in Figure 32 does not have two channel sections 304 306 like the standard and strengthened stud 62 320; instead, it has a single channel section 308, the arms of which are each attached to the opposing boards 310 312 of the panel. The simplified strengthened stud 322 thus does not require a spacer board 65. A strengthening board 301 is provided between the first arm 307 and the stud and the panel boards 312, 314. The simplified strengthened stud 322 can provide a panel that is thinner and requires less material than a panel with either the standard or strengthened stud 62 320; it nevertheless can provide similar stiffness and acoustic performance as a panel with the standard stud 62, due to the beneficial effects of the strengthening board 301. As already described above, insulation material can be seated within the channel sections of the studs.

Figure 34 is a cross-sectional view of a fortified or composite (double) panel with two subpanels 340 342 which may each comprise a wall panel as described above. In the illustrated example, two relatively slender subpanels 340 342 with the simplified strengthened stud 322 are installed as a pair, with an air gap 344 between the subpanels. A spacing part 346 is placed between the two subpanels 340 342 to form the air gap.

Figure 6 illustrates the arrangement at the boundary of the wall. In this case, the panel 124 is abutted against the boundary wall 118 of the building, with the protruding edge 120 of one side wall 122 meeting the boundary wall. At the opposite side of the panel 124, a gap is formed between the second edge 126 of the other side board 128 and the boundary wall. A filler board may be provided to cover the gap. The filler board 130 has a width substantially equal to the board offset, so as to abut against the second edge 126 of the side board 128 and against the boundary wall. The filler board 130 may be formed of the same material as the side boards, having the same thickness, and being of the same height.

A side rail 132 may be attached to the boundary wall 118. The side rail 132 may for example be a wooden beam. The side rail 132 has a depth arranged to fit closely across the depth of the panel, and a width arranged to fit within the space between the spacer board 133 of the edge studding and the protruding edge 120 of the side board. It can be seen that the panel 124 may be placed against the boundary wall 118 over the side rail 132 before the filler board is attached to the studding in the usual manner to create a finished wall edge.

The fortified or composite (double) panel is attached to a boundary wall in a similar manner analogous to a single panel as described with reference to Figures 6 and 7. Briefly, a filler board 352 may be provided to cover the gap formed between the outer boards and the boundary wall.

The fortified or composite (double) panels can be held in place by floor rails, top rails and/or side rails as described above.

This fortified panel can provide the following benefits compared to the standard (unfortified, single) panel: * Increased fire performance: the additional boards 348 provide an additional barrier against fire.

* Increased acoustic performance: the additional boards 348 provide an additional barrier against sound transmission.

* Due to the layering of the panel, only a negligible increase in materials is required.

* Increased secured by design' protection: the boards 348 are continuous directly behind the outward joint lines 302, which can deter from gaining unauthorised access through a panel. In addition if a steel mesh is included for the purposes of security and protection, the steel mesh can be arranged along the inner board layers 348. Therefore for insertion of fixings such as sockets 350 cutting steel mesh is not necessary, and hence

introduction of a security weakness is avoided.

* Eliminates problematic electrical outlet socket positioning: in the illustrated example, two back to back opposed sockets 350 are shown; due to the presence of two solid inner board layers 348 high acoustic and fire performance as well as security is maintained in the otherwise weakened socket region.

* Services can be routed through one board layer, as with the single panel designs described above.

The design can hence mitigate many of the negative aspects associated with traditional designs.

In the illustrated example the air gap 344 is 20mm. This value provides good space efficiency while maintaining the beneficial properties. The individual panels 340 342 are for example 100 mm thick, or less, giving an overall thickness of the fortified panel of 220 mm. This is thinner than a typical traditional dry lining wall design, yet can provide similar or better performance with respect to acoustic dampening, fire safety, and security.

Fabrication of the panels described above can take place in a factory setting, allowing full integration with traditional site-installed partition systems. The finished wall can be pre-fabricated to a large extent, and delivered to the site in long sections of up to for example 6m length; at the site, the walls are positioned in the build as necessary, with little further work required to obtain a completed wall. The panels can be not merely fabricated off-site, they can be finished off-site down to the level of including fittings for the final wall, as described in more detail below.

Fabrication of the panels in a factory setting can enable many benefits: * Better quality product with better performance than site installed systems * Fully integrated solution with mechanical, electrical and plumbing features preinstalled in the factory * Speed of on-site construction * Ease of planning and preparation * Better environmental properties: no cutting of board on site, dust-zero waste * Safe * More of the construction can take place in the factory environment, reducing for example weather disruption Requirement for skilled work on site, and risk of errors on site, reduced * Digital engineering possible The panels are particularly suitable for modular panelised internal partition walling. The panels can for example be made from high density gypsum board with no paper face, which can give good resistance to moisture exposure as well as good mechanical strength; this can enable fully integrated electrical and mechanical services to be factory installed.

In one example, a large format panel is made from 2.4m wide boards to form a wall up to 4.Om high by up to 7.5m in length. The large panel can be transported vertically and lifted by crane to preinstalled floor tracks. Such a larger format panel has only few joints and can be pretaped and filled in the factory, ready for final jointing and painting on site. A large panel is typically installed prior to the slab above being placed.

In another example, a small format panel is made from 1.2m wide boards to form a wall up to 4.Om high by up to 1.2m wide. The small panel can be transported horizontally and mechanically manoeuvred over the preinstalled tapered floor track system. A small panel can be installed after the slab above has been placed. Panels can be filled taped and jointed in the factory ready for site finishing, but extra care and attention is needed on site to maximise the benefits.

Panels can be factory manufactured using CAD/CAM modelling combined with robotic main assembly and machining. Thereby electrical and mechanical penetrations can be positioned accurately and quickly while allowing for later client configurations of embedded services.

The ability to incorporate (integrated within the panels) mechanical and electrical services within the factory is advantageous. Services can be pre-installed inside the panels, tested, and on delivery are ready for connection to the main service distribution routes. Panels can be prepared ready with suitable mechanical supports for surface mounted services; in this way panels can be configured to form bathrooms, kitchens or bedrooms with en-suite.

Regarding following the fire strategy of the construction scheme, factory manufacture can enable wall penetrations can be accurately positioned and cut, then lined to secure the fire integrity of the panel. This can remove the risk of following trades not fully adhering to the fire strategy. The panels can incorporate large apertures for ventilation ducts that incorporate a fire stopping strategy to eliminate collapse maintaining the fire certification.

Figure 35 is a front view of a wall panel system for constructing a wall of a building, the system including the following preferred features (as also discussed in more detail above): Head Rail 360: fixed to the top of the panel. This provides a fire barrier to the inside of the panel, and stiffens the panel. The head rail is adapted on the large format panel to include the panel lifting point.

* Deflection Head 362: has flanking boards on either side which overlap with the panel and provide acoustic dampening, fire safety, and security.

* Base Track 364: a wooden floor track can be engaged between two mild steel sections to provide a positive location for a panel.

* Facing boards 366: have no horizontal joints; this provides stiffness and strength to the panel.

* Vertical Stud(s) 368: are fixed to facing board with jack point screws on a 250 mm pitch, Stud spacing is typically on a 600 mm pitch. Vertical and horizontal studs are not attached to each other 376.

* Board to Studs 370: screws are positioned for examplel5 mm from the edge of the board and sit on a 30 mm area of flat stud; this enhance product strength and performance * Vertical Joints 372: are filled with a suitable acoustic and fire quilt. Although the joint geometry is different from other systems, the jointing process is the same. The joint line can be glued for additional strength, for example on a large panel format wall.

* Acoustic and Fire Quilt 374: secured to the head rail to prevent the quilt from sagging during the panel life. On site the quilt is placed in the vertical panel-to-panel joint and in the head deflection cavity.

Claims (72)

1. Claims 1. A wall panel for forming a wall, the panel comprising: first and second boards for forming the opposing surfaces of the wall, wherein at least one side edge of the first board protrudes beyond a corresponding edge of the second board.
2. 2. A wall panel according to Claim 1, wherein, at each edge of the panel, a side edge of one of the boards protrudes beyond the corresponding side edge of the other board.
3. 3. A wall panel according to Claim 1, wherein the boards are offset across the width of the panel, with a first side edge of each board protruding beyond a second side edge of the opposing board.
4. 4. A wall panel according to Claim 1, 2 or 3, further comprising elongate studding extending between the boards, each studding providing first and second faces which are attached each to a respective one of the boards.
5. 5. A wall panel according to Claim 4, wherein said studding comprises edge studding extending along the height of the panel adjacent each side of the panel.
6. 6. A wall panel according to any of the preceding claims, wherein the first and second boards are of substantially equal width.
7. 7. A wall panel according to Claim 4, 5 or 6, wherein each board is attached along a second edge thereof to a first portion of the first surface of one of the studdings, a second portion of the surface of the studding being arranged for attachment to a board of an adjacent panel.
8. 8. A wall panel according to Claim 7, wherein each board is attached along a first edge thereof to the second surface of a respective edge studding, with the second edge of the board protruding beyond the respective edge studding.
9. 9. A wall panel according to Claim 7 or 8, wherein the second portion of the first surface of the studding, adjacent the first portion, is arranged for attachment to the protruding first edge of a board from an adjacent panel when abutted against the attached second edge of the board of the panel, the second edge of each board protruding by an amount equal to or greater than the width of the second portion of the studding surface.
10. 10. A wall panel according to Claim 9, the second edge of each board protruding by an amount greater than the width of the second portion of the stud surface, wherein a space is formed between the edge studs of adjacent panels when the panels are fitted together, said space preferably being adapted to receive a king stud.
11. 11. A wall panel according to any of Claims 7 to 10, wherein the second portion of the side face of the studding is adapted to receive fixings for attaching the first edge of a board of an adjacent panel.
12. 12. A wall panel according to any of Claims 5, or 6 to 11 when dependent on Claim 5, further comprising intermediate studding between the edge studdings having first and second surfaces attached to the opposing boards.
13. 13. A wall panel according to Claim 12, said intermediate studdings being provided at intervals between the edge studdings of between 300mm and 600mm, preferably between 350mm and 550mm, more preferably 400mm.
14. 14. A wall panel according any of Claims 5 or 6 to 13 when dependent on ClaimS, said boards being attached to said studdings by means of fixings, preferably screws.
15. 15. A wall panel according to Claim 14, wherein each of said studdings are provided with pre-formed screw holes.
16. 16. A wall panel according to any Claims 5, or 6 to 15 when dependent on Claim 5, wherein the studdings each comprise a pair of studs aligned across the depth of the wall panel, which each provide a respective one of the first and second surfaces.
17. 17. A wall panel according to Claim 16, the studdings further comprising at least one spacer extending across the depth of the panel between the pair of studs, and being fixed to each stud of the pair.
18. 18. A wall panel according to Claim 16 or 17, the at least one spacer comprising a board.
19. 19. A wall panel according to Claim 16, 17 or 18, the at least one spacer extending substantially along the height of the panel.
20. 20. A wall panel according to any of Claims 16 to 19, said at least one spacer arranged such that the spacers are not in contact with said boards.
21. 21. A wall panel according to Claim 20, wherein there is a clearance between the spacer and each board, preferably between 0.5mm and 5mm, more preferably between 1mm and 3mm, yet more preferably between 1.5mm and 2.5mm.
22. 22. A wall panel according to any of Claims 16 to 21, said studs comprising channel sections, preferably steel channels.
23. 23. A wall panel according to Claim 22, wherein a first arm of the channel of each stud provides the first or second outer side surface respectively to which the respective board is attached.
24. 24. A wall panel according to Claim 23, wherein said channel is asymmetric, with the second arm, interior to the panel, being shorter than the first arm.
25. 25. A wall panel according to any of Claims 9 to 24, comprising a strengthening member provided on the first surface of the studding spanning the first and second portions thereof
26. 26. A wall panel according to Claim 25, wherein the strengthening member extends substantially along the height of the panel and substantially along the width of the first surface of the studding.
27. 27. A wall panel according to Claim 25 or 26, wherein the strengthening member comprises a board, said board preferably being attached to said studding by means of fixings, preferably screws.
28. 28. A wall panel according to any of the preceding claims, further comprising insulation adjacent at least one of said first and second boards.
29. 29. A wall panel according to any of the preceding claims, further comprising a channel extending along a lower edge thereof for attachment to a floor rail.
30. 30. A wall panel according to Claim 29, wherein the boards each extend below the studding to form the channel.
31. 31. A wall panel according to Claim 29 or 30, further comprising a resilient member, such as a spring member, in said channel for engaging the floor rail.
32. 32. A method of manufacturing a wall panel comprising: providing at least two pairs of elongate edge studs, attaching the studs of each pair to at least one spacer such that the studs of each pair are spaced apart from each other by a predetermined distance; attaching a board to an outer face of each one of the studs of each pair, such that each pair of studs extends between the boards adjacent an edge of the panel, a side edge of one of the boards protruding beyond the corresponding edge of the other board at least one of the edges of the panel.
33. 33. A method according to Claim 32, comprising attaching the boards in offset relation to each other, with one edge of each board protruding beyond the pair of studs at the corresponding edge of the panel, and the other edge of each board being attached along the respective outer face of the pair of studs at the other edge of the panel.
34. 34. A system for constructing a wall of a building, the system comprising: a plurality of wall panels; and a floor rail arranged to be attached to the floor, in which the floor rail and the lower edges of the panels are correspondingly shaped to engage with each other.
35. 35. A system according to Claim 34, comprising a plurality of wall panels according to any of Claims ito 31.
36. 36. A system according to Claim 34 or 35, said floor rail being tapered inwardly towards an upper edge thereof
37. 37. A system according to Claim 36, said floor rail having a trapezoidal cross-section.
38. 38. A system according to Claim 36 or 37, said wall panels having a corresponding channel in a lower edge thereof.
39. 39. A system according to any of Claims 34 to 38, further comprising a king stud, arranged to be positioned between the edge studding of adjacent wall panels.
40. 40. A system according to Claim 39, said king stud being adapted to engage with said floor rail.
41. 41. A system according to any of Claims 34 to 40, further comprising a side connection rail arranged for attachment to a boundary wall of a building in which the wall is to be fitted.
42. 42. A system according to Claim 41, the width of said side connection rail being arranged to fit closely within the depth of the panels, between the boards.
43. 43. A system according to any of Claims 34 to 42, further comprising a filler board having a width substantially equal to the distance from the first edge of the board attached to the respective edge studding of a panel, and the corresponding second edge of the opposing board of the panel.
44. 44. A system according to any of Claims 34 to 43, further comprising: a top rail for securing to the ceiling of a building into which the wall is to be fitted; and a pair of pelmets arranged to be attached to the top rail on either side thereof and to depend therefrom.
45. 45. A system according to Claim 44, the top rail having a width substantially equal to the width of the wall panels.
46. 46. A studding for a wall panel, comprising: at least one elongate channel section having a base section, and first and second arms dependent therefrom; wherein said first arm is adapted to mount the side edges of two boards each from a respective wall panel along the length thereof, when the said edges are abutted together.
47. 47. A studding according to Claim 46, wherein the first arm extends further from said base than the second arm.
48. 48. A studding according to Claim 46 or 47, wherein said first arm comprises pre-formed holes for accepting fixings to attach said boards.
49. 49. A studding according to any of Claims 46 to 48, wherein said second arm comprises an inwardly projecting angle piece at a free edge thereof
50. 50. A studding according to any of Claims 46 to 49, further comprising a second such elongate channel section, and a spacer, wherein said spacer is attached to the base sections of said first and second channels to space them apart, and wherein the channels are oriented with the first arms thereof on the outer sides of the studding.
51. 51. A studding according to Claim 50, wherein said first arms of each channel section are to the exterior of said studding.
52. 52. A studding according to any of Claims 46 to 51, further comprising a strengthening member attached to the first arm and adapted to be mounted between the first arm and said side edges of the two boards.
53. 53. A studding according to Claim 52, wherein the strengthening member extends substantially along the width of the first arm and the height of the stud.
54. 54. A studding according to Claim 52 or 53, wherein the strengthening member comprises a board, said board preferably being attached to said studding by means of fixings, preferably screws.
55. 55. A wall panel for forming a wall comprising: first and second boards for forming the opposing surfaces of the wall; elongate studding extending between the boards, each studding providing first and second faces which are attached each to a respective one of the boards, the studdings each comprising a pair of studs aligned across the depth of the wall panel, which each provide a respective one of the first and second surfaces; and at least one spacer extending across the depth of the panel between the pair of studs, and being fixed to each stud of a pair; wherein the at least one spacer is arranged such that the spacers are not in contact with said boards.
56. 56. A wall panel according to Claim 55, wherein each board is attached along the second edge thereof to a first portion of the first face of one of the studdings, a second portion of the face of the studding being arranged for attachment to a board of an adjacent panel.
57. 57. A wall panel according to Claim 55 or 56, the at least one spacer comprising a board.
58. 58. A wall panel according to Claim 55, 56 or 57, the at least one spacer extending substantially along the height of the panel.
59. 59. A wall panel according to any of Claims 55 to 58, wherein there is a clearance between the spacer and each board, preferably between 0.5mm and 5mm, more preferably between 1mm and 3mm, yet more preferably between 1.5mm and 2.5mm.
60. 60. A wall panel according to any of Claims 55 to 59 wherein the studding comprises a strengthening member provided on the first face of the studding.
61. 61. A wall panel according to Claim 60, wherein the strengthening member extends substantially along the height of the studding and substantially along the width of the first surface of the studding.
62. 62. A wall panel according to Claim 60 or 61, wherein the strengthening member comprises a board, said board preferably being attached to said studding by means of fixings, preferably screws.
63. 63. A composite wall panel comprising first and second wall panels according to any of Claims 1 to 31 or 55 to 62, the wall panels forming the opposing surfaces of the composite wall panel.
64. 64. A composite wall panel as claimed in claim 63 in which the first and second wall panels are spaced apart.
65. 65. A composite wall panel according to Claim 64, further comprising a spacing member arranged to provide a gap between the first and second wall panels.
66. 66. A composite wall panel according to Claim 65, wherein the gap is between 5 and 40 mm, and preferably between 10 and 30mm, and yet more preferably approximately 20 mm.
67. 67. A wall comprising a panel according to any of Claims ito 31 or 55 to 66.
68. 68. A building comprising a wall according to Claims 67.
69. 69. A wall panel for forming a wall substantially as herein described with reference to the accompanying figures.
70. 70. A method of manufacturing a wall panel substantially as herein described with reference to the accompanying figures.
71. 71. A system for constructing a wall of a building substantially as herein described with reference to the accompanying figures.
72. 72. A studding for a wall panel substantially as herein described with reference to Figures 4, 7, 10,11, 12 and 15.