GB2618882A

GB2618882A - Structural insulated panel for use in buildings

Info

Publication number: GB2618882A
Application number: GB2303217.0A
Authority: GB
Inventors: Peter Morrish Mark; Morrish John
Original assignee: Individual
Current assignee: Individual
Priority date: 2020-09-21
Filing date: 2021-09-20
Publication date: 2023-11-22
Also published as: GB2600546B; GB2600546A8; GB202014854D0; GB2600546A; GB202303217D0

Abstract

A structurally insulated panel extending in a longitudinal and lateral direction comprising: a first board; a second board, and; an insulation member having a first surface and a second surface and a conduit, the first board adhesively connected to the first surface and the second board connected to the second surface, the insulation member comprises a conduit, the conduit extending in a depth direction from the first surface and extending across the lateral and/or longitudinal direction, the conduit including a utility member carrying portion for transmitting a utility member across the structurally insulated panel, wherein the conduit is arranged to prevent or reduce excess adhesive from said adhesive connection from entering into the utility member carrying portion.

Description

STRUCTURAL INSULATED PANEL FOR USE IN BUILDINGS

TECHNICAL FIELD

The present disclosure relates to structural insulated panels for use in buildings. BACKGROUND Structural insulated panels (SIPs) can be used for walls, roofing and flooring of buildings, and comprise an inner core of an insulation member sandwiched between opposed structural boards. SIPs may have higher insulation performance than conventional building techniques, such as brick formed walls. SIPs may also reduce construction time. It is therefore increasingly desirable to implement SIPs panels in buildings.

CA2081651A1 discloses a SIPs panel with a pre-formed conduit through the insulation member, which is for transmitting electrical wiring through the panel. In use the electrical wiring can connect to an electrical socket arranged on an interior of a building. The conduit is formed by injecting molten insulation material around a PVC pipe that becomes embedded in the set insulation material. A drawback of this method of forming the conduits is that it requires a PVC pipe to be precisely aligned each time a panel is formed in a mould. It is therefore not particularly adaptable to different conduit positions.

Therefore, in spite of the effort already invested in the development of said structural insulated panels further improvements are desirable.

SUMMARY

The present disclosure provides a structurally insulated panel, which extends in a longitudinal and lateral direction, the structurally insulated panel comprising: a first board; a second board, and; an insulation member having a first surface and a second surface, the first board connected to the first surface and the second board connected to the second surface.

As used herein the term "connected to" in respect of the first and/or section board and the insulation member may include a direct connection, e.g. via an adhesive therebetween, or via an indirection connection through an intermediate member. The connection may be by an adhesive connection.

In embodiments, the insulation member comprises a conduit that extends in a depth direction from the first surface (e.g. it has an open cross-section in the insulation member) and extends (e.g. with a major axis thereof) across the lateral and/or longitudinal direction (e.g. depending on an orientation of the structurally insulted panel) for transmitting a utility member across the structurally insulated panel.

By having the conduit extending from the first surface it may be conveniently formed into the insulation member from the first surface. In the example of machining, convenient formation is facilitated from cutting from the first surface. In the example of moulding or extrusion convenient formation is facilitated by a more convenient mould since the part of the mould responsible for forming the conduit does not need to be separated or "floating" from the first surface.

In embodiments, the conduit and may be closed (e.g. such that the section is bounded on all sides) by the first board. By closing the open cross-section of the conduit by the first board, convenient formation and closure of the conduit may be facilitated.

In embodiments, the conduit is machine cut (e.g. it consists of or includes a machine cut portion). By implementing a conduit in the insulation member that is machine cut, the conduit may be precisely formed, (e.g. when compared to a moulded conduit that is formed around a mould that comprises a conduit former around which liquid insulation material is injected). The conduit may be cut to an easily adaptable range of shapes. For example a machining sequence can be programmed on a milling machine (or other suitable machine) that can be executed to form the conduit. Such an implementation may be preferable to a moulded conduit that requires the conduit former of the mould to be retained as part of the structurally insulated panel.

In embodiments, the conduit is formed (e.g. machine cut) before connection of the first board to the insulation member, such that the conduit does not extend into or through the first board or second board. By forming the conduit before connection of the insulation member to the first board, and unsightly channel in the first board is avoided since there is no need to cut through the first board to form the conduit. Moreover, the conduit may be arranged proximal an interior surface of a building, which may mean certain utility members are less likely to be damaged as they are not proximal an exterior surface of the building, and therefore not subject to outdoor weather extremes (e.g. water pipes are less likely to freeze due to exposure to colder temperatures).

In embodiments, the conduit extends from a top surface of the insulation member to a bottom surface. By arranging the conduit to extend continuously (e.g. straight through) from the top to the bottom, the conduit may be conveniently formed by running a machining tool across the entire longitudinal length (e.g. as part of an inline assembly process where the insulation member moves relative a machining tool). The conduit may also be accessible from a top face and a bottom face of the insulation member. Moreover, the conduit may be particularly convenient to access from an exterior of the structurally insulated panel, since any alignment in an aperture in the first board to the lateral position of the conduit automatically connects the conduit to the exterior without further machining of the insulation member (which would be the case if the conduit were formed by a moulding process as the conduit would be fully surrounded by the insulation member).

In embodiments, the conduit includes a utility member carrying portion for transmitting the utility member across the structurally insulated panel. The conduit may be arranged to prevent or reduce excess adhesive from the adhesive connection of the proximal board from entering into the utility member carrying portion.

By implementing conduit to reduce an amount of adhesive seeping from the bond of the first surface and first board, and protruding into the a utility member carrying portion of the conduit, it may be ensured that the utility member is not prevented by any such adhesive from being inserted through the conduit.

In embodiments, to prevent or reduce excess adhesive from protruding into the utility member carrying portion the conduit comprises one or more of the following: an adhesive collecting portion; a closing member, which is arranged to close the utility member carrying portion, and; a restrictor portion arranged to at least partially close the conduit. By implementing any one or more of said arrangements, adhesive can be at least reduced from protruding into the utility member carrying portion.

By implementing the closing member, the conduit can be sealed/closed so that adhesive from the bond between first surface and the first board is less likely to enter the conduit. For example, the adhesive can be sprayed on any region of the first surface (including on the closing member) regardless of the position of the conduit since it is closed by the closing member.

In embodiments, the closing member is includes an adhesive strip to adhesively close the conduit. By implementing an adhesive strip the conduit may be conveniently closed. The adhesive strip may be arranged on a substrate, e.g. for form a tape or other substrate, including a plastic based strip.

In embodiments, the closing member is arranged as a thin strip of 0.1 -2 mm or 0.01 -3 mm in thickness. By implementing a thin strip, the bond between the first surface and the first board may not be interrupted by the closing member arranged therebetween.

In embodiments, the conduit includes a recess to receive the closing member. By implementing a recess, which is complementary in shape to the closing member, the closing member can be conveniently located in the recess and may be arranged to be aligned with the first surface (e.g. flush with the first surface) so that the bond between the first surface and first board may not be interrupted by the closing member arranged therebetween.

In embodiments, the conduit including the closing member also includes the restrictor portion to reduce a portion of the conduit closed by the closing member. By having a smaller portion closed by the closing member, a smaller closing member can be implemented. Moreover, in the instance where the closing member includes an adhesive strip, less adhesive of the closing member may be exposed to the utility member carrying portion the conduit, which would otherwise make insertion of the utility member harder.

In embodiments, the restrictor portion includes a narrowing section relative the utility member carrying portion. By implementing a narrowing section, a portion of the conduit through which the adhesive can enter the utility member carrying portion may be restricted. As used herein the term, "restrictor portion" may refer to any arrangement of cross-section profile of the conduit that is shaped to prevent or reduce flow of adhesive therethrough.

In embodiments, the restrictor portion is arranged between the first surface and the utility member carrying portion. By arranging the restrictor portion above the utility member carrying portion, adhesive attempting to enter the utility member carrying portion has to first pass the restrictor potion, which may reduce transmission of the adhesive.

In embodiments, the collecting portion is arranged to collect flow of adhesive before it can enter the utility member carrying portion. By implementing a dedicated portion of the conduit to collect adhesive, an amount of adhesive remaining that can be transmitted to the utility member carrying portion may be reduced.

In embodiments, the collecting portion is arranged above and/or to the side of the utility member carrying portion. In embodiments, the restrictor portion is arranged between the collecting portion and the utility member carrying portion. By arranging the collecting portion with one of these arrangements it may intercept said flow of adhesive before it can get to the utility member carrying portion.

In embodiments, the collecting portion is comprise a cavity. By implementing the collecting portion as a cavity, the cavity may be preferentially filled with adhesive rather than the utility member carrying portion. As used herein the term "collecting portion" may refer to any geometric arrangement of the conduit that is capable of containing the adhesive, including via a cavity or a surface disposed to collect run off. The cavity may include the restrictor portion at the base.

In embodiments, the first board includes an aligned wall aperture, through which the conduit is accessible. By having an aligned aperture in the first board, when the first board is bonded to the insulation member, the conduit is accessible from the wall aperture, which may facilitate convenient insertion of the utility member into the conduit.

Moreover, the wall aperture may be conveniently formed with the same cutting tool when the first and/or second boards are cut to size.

In embodiments, the conduit and the wall aperture form a recess that is complimentary in shape to an electrical socket housing. By preforming a recess in both the conduit and first board that is sized to accommodate an electrical socket housing, the socket and housing can be conveniently fitted.

In embodiments, the insulation member comprises a plurality of conduits, each extending in the longitudinal direction (and/or a lateral direction depending on the orientation of the structurally insulated panel) at predetermined intervals for transmitting a utility member across the structurally insulated panel. By having a plurality of conduits, an end user/fitter may have the option of selecting which conduit to use according to a specific position in the building.

In embodiments, the plurality of conduits are separated with the same pitch distance P. By having the conduits separated apart by the same distance, an end user/fitter can predictably locate a conduit from in interior of the building when fitting a utility member. The pitch may for example be 200 mm.

In embodiments, an end conduit is arranged with the same pitch distance P to a corresponding end conduit of an adjoining structurally insulated panel. For example, the distance from the end conduit to the adjacent side face of the adjoining structurally insulated panel may be 100 mm, so that when the structurally insulated panel is connected to another at the side face, the pitch between adjacent end conduits is maintained at 200 mm, which is the same pitch between the rest of the conduits. It will be appreciated that the pitch is measured between corresponding positions on a conduit.

In embodiments, an exterior surface of the first board is pre-finished as an interior surface of a room of a building. By pre-finishing the exterior surface of the first board (i.e. an interior exposed surface of a room of the building), finishing on-site of the interior is obviated, which may reduce on-site building construction time. Alternatively the exterior surface of the first board may comprise battens for receiving an interior member, e.g. a plaster board.

In embodiments, an exterior surface of the second board is pre-finished as an exterior surface of a building. By pre-finishing the exterior surface of the second board (i.e. an exterior exposed surface of the building), finishing on-site of the exterior is obviated, which may reduce on-site building construction time. Alternatively the exterior surface of the second board may comprise battens for receiving an exterior member, e.g. a plastic or wood member.

In embodiments, the structurally insulated panel has a lateral dimension of 25 cm to 100 cm or 25 cm to 80 cm or 25 to 60 cm. By implementing a width that is substantially narrower than that of a prior art structurally insulated panel, the structurally insulated panel may be conveniently transported to a construction site and assembled, e.g. manually, as part of a building without complex lifting machinery, including a crane. In embodiments, an entire building is made of panels of this dimension.

It has been found that there is an extreme prejudice for forming panels that are much larger in the industry. This is because the panels are not used on smaller buildings, and also because of the panel construction assembly lines are all arranged for large panel construction. The large panels are then shipped to a building location for assembly.

The present disclosure provides a system comprising a connecting member and a first and second structurally insulated panel of any preceding embodiment or another embodiment disclosed herein. One or both of the structurally insulated panels both comprises one or more conduits in their associated insulation members, wherein the or each conduits including an access aperture arranged in an end surface of the insulation members. The connecting member is arranged to interconnect and align the first and second structurally insulated panel.

In embodiments, the connecting member comprises corresponding access apertures to align with the access apertures of both the first and second structurally insulated panel, with a utility member arrangeable in a conduit accessible via the access aperture in the connecting member.

By having a connecting member with at access apertures aligned to correspond in position to the arness apertures of conduits of the structurally insulating panel, the connecting member may be used as a structural connection for the structurally insulated panels whilst maintaining access therethrough to the conduit for the utility member.

In embodiments, for both of the structurally insulated panels, the first and second boards comprise extensions that extend beyond the insulation members, and the connecting member is arrangeable between (e.g. an in contact with) the extensions and to adjoin (e.g. to contact or be separated from) the insulation member. By having the connecting member sandwichable between the first and second board, the connecting member can locate the structurally insulated panel as well as provide access to the conduits.

In embodiments, the access apertures of the connecting member are arranged such that a utility member can only be inserted into the utility member carrying portion of the conduit. By arranging the access apertures so that the utility member can only be inserted into the utility member carrying portion, e.g. an not a collecting portion or other portion, it may be ensured that the utility member is correctly inserted into the conduit.

In embodiments, the access apertures in the connecting member are arranged as slots that have a major axis in a direction of an elongated axis of the connecting member, and the access apertures of the conduits can be aligned with the access apertures of the conduit with the connecting member in a range of positions. By having the access apertures arranged as slots that extend along the length of the connecting member, precise lengthwise positioning of the connecting member is not required, for example it may be slide between a range of suitable positions along its length axis. This may aid in accounting for adjoining panels which are not precisely positioned, e.g. with a small gap therebetween, or for large manufacturing tolerances in position of the conduits.

In embodiments, the access apertures of the connecting member are interconnected by an interconnection conduit for transmitting the utility member between the access apertures. By implementing an interconnection conduit that extends in a lengthwise direction of the connecting member, the interconnection conduit may conveniently be used to run the utility member between conduits.

In embodiments, the connecting member is arranged to interconnect adjacent edges of the first and second structurally insulated panels and a further connecting member is arranged to interconnect adjoining edges of the first and second structurally insulated panels, with the connecting member to overlap (e.g. as a top of a T-shape extends over a base) the further connecting member. Such a combinatory arrangement of the connecting members may provide a rigid assembly of adjacent structural insulated panels.

In embodiments, exterior surfaces of the adjoining edge of the first board comprises adjoining cutouts to form a channel for receiving an edge member. By sinking an edge member in a cut-out formed between two panels it may aid in concealing the interior joint between structurally insulated panels or may make said joint more aesthetically pleasing.

In embodiments, an exterior member of the first structural insulated panel is arranged to interlock with a corresponding exterior member of the second structurally insulated panel. An interlocking exterior member connection may provide a more rigid and/or weather proof structural connection between two panels. The connection may also be slidable engageable which is consistent with the connection type of the connection members.

The present disclosure provides a kit for assembly into the structurally insulated panel of any preceding embodiment or another embodiment disclosed herein. The kit comprising: a first board; a second board, and; an insulation member. The insulation member may comprise the conduit in suited embodiments.

The present disclosure provides a building comprising one or more of the structurally insulated panel of any preceding embodiment or another embodiment disclosed herein. In embodiments, the or each structurally insulated panel is arranged to form an exterior surface (e.g. an externally visible surface) of the building and/or an intemal surface (e.g. a surface that is visible from an interior room) of the building.

In embodiments, the building includes structurally insulated panels connected by the connecting member. In embodiments, the building consists of structurally insulated panels with a lateral dimension of 25 cm to 110 cm or 40 cm to 80 cm. Said panels may have a longitudinal length that extends from a top to a base of the building, e.g. with no other side panels there between, and may be arranged sequentially for form the sides of the building.

The present disclosure provides a kit for assembling a building comprising one or more of the structurally insulated panel of any preceding embodiment or another embodiment disclosed herein. In embodiments, the kit consist of structurally insulated panels with a lateral dimension of 25 cm to 110 cm or 40 cm to 80 cm. In embodiments, the kit includes structurally insulated panels and a corresponding connecting member.

The present disclosure provides use of the structurally insulated panel of any preceding embodiment or another embodiment disclosed herein for a building. The use may include the structurally insulated panels connected by the connecting member.

The present disclosure provides a method of forming a structurally insulated panel according to any preceding embodiment or another embodiment disclosed herein. The method may comprise adhesively connecting a first board to a first surface of an insulation member, and; connecting a second board to a second surface of the insulation member.

In embodiments, the method comprises forming a conduit with a utility member carrying portion for carrying a utility member across the structurally insulated panel in an insulation member. In embodiments, the conduit is formed to prevent or reduce excess adhesive from protruding into the utility member portion.

In embodiments, the method comprises forming in the insulation member a plurality of conduits in structurally insulated panel, wherein the conduits may be formed concurrently. By forming the conduits at the same time, they may be more conveniently formed and with greater accuracy.

In embodiments, the method comprises machining directly from a first surface of the insulation member the or each conduit. In embodiments the method comprises moving an arrangement of cutting tools relative the insulation member to form the conduits. The cutting tools, with a predefined configuration, may conveniently be moved over the insulation member to form the conduits, e.g. as part of an in-line manufacturing process.

In embodiments, the method comprises forming an insulation member with a conduit for carrying a utility member across the structurally insulated panel by extrusion. With such an implementation the conduit may be conveniently formed at the same time as the insulation member, thus obviating a separate step of conduit formation.

In embodiments, the method comprises connecting a first board to the first surface to conceal (e.g. close) the conduit. In embodiments, the method comprises arranging an adhesive to bond the first board to the first surface of the insulation member at a portion of the first surface distal (i.e. not on) the conduit. The adhesive may be applied (e.g. by spraying) to one or both of the first surface and first board prior to their connection.

The present disclosure provides a method of assembling a building with the structurally insulated panel of any preceding embodiment or another embodiment disclosed herein.

In embodiments, the method comprises: arranging an exterior surface of the second board as an externally visible outer wall of the building; arranging an external surface of the first board as an externally visible inner wall of the building.

In embodiments, the method comprises: manually lifting (e.g. without the assistance of a crane) the structurally insulated panel from a transported position (e.g. from a transport vehicle, including a lorry or van) to an assembly position on the building. The panels according to said method may have a lateral dimension of 25 cm to 110 cm or 40 cm to 80 cm.

In embodiments, the method comprises connecting structurally insulated panels by: interconnecting and aligning adjoining structurally insulated panels with a connecting member; arranging the connecting member with access apertures to correspond with the access apertures of one or more conduits of at least one of the structurally insulated panels. In embodiments, the method comprises: feeding a utility member through a conduit from a wall aperture of the conduit, which is arranged in the first board or an access aperture. The method may comprise feeding the utility member through the access apertures of an connecting member. The method may comprise feeding the utility member through a utility member carrying portion of the conduit.

The methods may implement the features of any preceding embodiment or another embodiment disclosed herein.

The preceding summary is provided for purposes of summarizing some embodiments to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the above-described features are merely examples and should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the above and/or proceeding embodiments may be combined in any suitable combination to provide further embodiments. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following Detailed Description, Figures, and Claims.

BRIEF DESCRIPTION OF THE FIGURES

Aspects, features and advantages of embodiments of the present disclosure will become apparent from the following description of embodiments in reference to the appended drawings in which like numerals denote like elements.

Figure 1 is an exploded perspective view showing of components of an embodiment structurally insulated panel.

Figure 2 is an perspective view showing the assembled structurally insulated panel of figure 1. Figure 3 is a perspective view showing a top face of the structural insulated panel of figure 1.

Figure 4 is a perspective view showing an insulation member of the structural insulated panel of figure 1.

Figures 5A to 5F are a cross-sectional views showing embodiment conduits of the structural insulated panel of figure 1 Figure 6 is a perspective view showing connected structural insulated panels of figure 1 and a corresponding connecting member.

Figure 7 is a close-up view of a connection region of figure 6 Figure 8 is a perspective view showing an embodiment connecting member for use in the connection of figures 6 and 7.

Figures 9 and 10 are perspective views showing an interior edge of connected structural insulated panels of figure 1.

Figure 11 shows a method of assembling structurally insulated panel of figure 1. DETAILED DESCRIPTION OF EMBODIMENTS Before describing several embodiments of the structural insulated panel, it is to be understood that the structural insulated panel is not limited to the details of construction or process steps set forth in the following description. It will be apparent to those skilled in the art having the benefit of the present disclosure that the system is capable of other embodiments and of being practiced or being carried out in various ways.

The present disclosure may be better understood in view of the following explanations: As used herein the term "structurally insulated panel" may refer to a generally planar member that comprises an inner core of insulating material arranged between opposed boards. The structurally insulated panel may have a lateral dimension of 25 cm to 110 cm or 40 cm to 80 cm. The structurally insulated panel may have a longitudinal dimension of 0.5 m to 5 m or 2 m to 3 m. In other examples larger or smaller structurally insulated panels may be provided.

As used herein the term "building" may refer to an outdoor a structure with a roof and walls standing more or less permanently in one place. A building can include commercial or domestic premises, including: a house; factory; shed; office; garage; other building.

As used herein the term "first board" may refer to a generally planar member that provides structural rigidity and protects the insulation member. The first board may be arranged to form an interior surface and/or interior facing surface of the building. The first board may be formed of or based on one or more of: wood, including oriented strand board, plywood, chip board; cement board; plaster board; a plastic based material, including PVC; composite, including glass or composite fibre; metal, including aluminium. The first board may be 6 mm to 18 mm thick. The first board may comprise an outer layer to form an interior surface of a room of the building, which can include or be based on one or more of the following: plaster board; wall paper; paint; other material.

As used herein the term "second board" may refer to a generally planar member that provides structural rigidity and protects the insulation member. The second board may be arranged to form an exterior surface and/or exterior facing surface of the building. The first board may be formed of or based on one or more of: wood, including oriented strand board, plywood, chip board; cement board; plaster board; a plastic based material, including PVC; composite, including glass or composite fibre; metal, including aluminium; other suitable material. The second board may be 6 mm to 18 mm thick. The second board may comprise an outer layer to form an exterior of the building, which can including or be based on one or more of the following: wood battens to receive cladding; metal cladding; wood slats; other material. The material of the second board, including the outer layer, may be impermeable to water.

As used herein the term "insulation member" may refer to a member that is substantially thicker than the first and second board, and that has a lower rate of heat transfer (i.e. a lower thermal conductivity (k)) than the first board and second board. The insulation member may be formed of or based on one or more of: polystyrene, including expanded polystyrene; polyurethane; other suitable material. The insulation member may not be formed of a loose material. The insulation member may be 60 mm to 200 mm thick.

As used herein the term "conduit" or "passageway" may refer to the portion of the insulation member specifically formed to transmit (e.g. to carry/house) a utility member, (e.g. it may or may not exclude a recess in the insulation member to receive an electrical socket housing that the utility member connects to). It may refer to a portion in the insulation member that only carries the utility member.

As used herein the term "utility member" may refer to a cable of conduit for carrying one more of the following utilities: water; gas; electric, including for communications; other utility.

As used herein the term "machine cut" may refer to a process of removing material from a solid material by a complex or simple machine, including: a milling machine; router; chisel; saw; CNC machines; drill; other machine.

As used herein the term "electrical socket housing" may refer to a member to be sunk into a wall for receiving/mounting/formed integrally with an electrical socket.

Referring to figures 1, 2 and 3, a structurally insulated panel 2 comprises a first board 4 a second board 6, and; an insulation member 8. The insulation member 8 has a first surface 10 and a second surface 12. The first board 4 has an interior surface 14 and an exterior surface 16. The second board 6 has an interior surface 18 and an exterior surface 20.

In the assembled configuration (shown in figure 2), the first surface 10 of the insulation member 8 is bonded by an adhesive (not illustrated) to the interior surface 14 of the first board 4. The second surface 12 of the insulation member 8 is bonded by an adhesive to the interior surface 18 of the second board 6. The adhesive may be a polyurethane based adhesive.

The structurally insulated panel 2 is aligned in an in-plane direction, which is defined by a longitudinal direction 100 and a lateral direction 102, which are both orthogonal to a depth direction 104. The structurally insulated panel 2 is assembled in the depth direction 104 as will be discussed.

Referring to figure 3 in particular, the assembled structurally insulated panel 2 has an interior face 22, which is defined by the exterior surface 16 of the first board 4 and an exterior face 24, which is defined by the exterior surface 20 of the second board 6.

The structurally insulated panel 2 has a top face 26, which is defined by a top face of the first panel 4, second panel 6 and insulation member 8. The structurally insulated panel 2 has a bottom face 28, which is defined by a bottom face of the first panel 4, second panel 6 and insulation member 8.

The structurally insulated panel 2 has a first side face 30, which is defined by a side face of the first panel 4, second panel 6 and insulation member 8. The structurally insulated panel 2 has a second side face 32, which is defined by a side face of the first board 4, second board 6 and insulation member 8.

At the top face 26, bottom face 28, first side face 30 and second side face 32, the first board 4 and second board 6 have extensions that extend beyond the insulating material 8 in the respective longitudinal 100 and lateral directions 102. In this way a connecting member or connecting member (as will be discussed) can be inserted between the extensions of the first board 4 an second board 6 and abut the insulation member 8 of adjoining structural insulated panels 2, to facilitate their alignment an interconnection.

Referring to figure 4, the insulation member 8 comprises a conduit 34 (although multiple conduits are present, for convenience only one is discussed initially). The conduit 34 is arranged to carry a utility member (not illustrated). It is configured to carry a utility member, including a pipe, of up to 15 mm or 10 mm in diameter.

The conduit 34 extends from a mouth 36 arranged at the first surface 12 in the depth direction 104 to a base 38. The conduit 34 is elongate and extends with a major axis 40 in the longitudinal direction 100. The major axis 40 is the axis along which a utility member (not illustrated) is inserted through the conduit 34.

In variant embodiments, which are not illustrated: the conduit extends from the second surface of the insulation member; the conduit is elongate and extends with a major axis in the lateral or depth directions; other shapes of conduit are possible, including one with a large recess cut therein for receiving an electrical socket housing.

The conduit 34 is machine cut from the first surface 12 of the insulation member 8 by moving a cutting tool (not illustrated) along the longitudinal direction 100, when the first surface 12 is exposed (i.e. prior to bonding of the first board 4 to the insulation member 8). Accordingly, the conduit 34 initially includes an open cross-section at the mouth 36.

In variant embodiments, which are not illustrated, the conduit is alternatively machined, e.g. by a drill extending in the longitudinal direction; the conduit may be formed by extrusion or moulding, including at the same time as the insulation member is formed; the conduit does not have an open cross section, e.g. the cross-section is fully surrounded by the insulation material.

Referring to figure 2, the cross-section of the conduit 34 is closed (e.g. it is bounded by the interior surface 14 of the first board 4) when the first board 4 is bonded to the insulation member 8. The cross-section of the conduit 34 does not extend into or through the first board 6.

In variant embodiments, which are not illustrated, the conduit extends into or through the first board; the first and second board are alternatively fixed to the insulation member, e.g. by mechanical fixings such as with a bracket or a threaded connection.

Since the conduit 34 extends in the depth direction 104 from the first board 6, when the first board 6 is arranged as an interior surface of a building (not illustrated), the conduit 34 is arranged close to the interior of the building rather than the exterior, which may facilitate more convenient servicing and/or insulating of the utility member.

Referring back to figure 4, the conduit 34 extends from a top surface 42 of the insulation member 8 to a bottom surface 44 along the entire longitudinal length.

In variant embodiments, which are not illustrated, the conduit extends partially along the longitudinal length of the insulation member.

In figures 1 -4, 6, 7 and 11, the conduit 34 is arranged with a rectangular shaped cross-section, with aligned side walls 46 and a flat base 38. It will be understood that the shape of the cross-section can be changed by selecting a different shaped cutting tool.

Referring to figures 5A -5F, the cross-section of the conduit 34 is alternatively arranged and may be combined with any of the other embodiments. In particular, the conduit 34 includes a utility member carrying portion 70, which is dimensioned for carrying the utility member (not illustrated). The conduit is 34 is arranged to prevent or at least reduce (e.g. when compared to a rectangular cross-section conduit) excess adhesive from the adhesive bond between the first board 4 (shown in figure 1) and first surface 10 of the insulation member 8 from entering the entering into the utility member carrying portion 70 by seeping from said bond, which could otherwise impede insertion of the utility member through the a utility member carrying portion 70.

The utility member carrying portion 70 includes side walls 72 and a base 74, which define a cavity to house the utility member. The utility member carrying portion 70 has a rectangular cross section. The utility member carrying portion 70 includes an opening 76, that allows access to the wall apertures 52 (shown in figure 3), and is generally a product of the machining (or other) formation process.

In variant embodiments, the utility member carrying portion is alternatively shaped, e.g. it may be circular, V-shaped or otherwise shaped.

In a first example, referring to figure 5A the conduit 34 includes a restrictor portion 78, which comprises a narrowing portion arranged to prevent or reduce adhesive from entering the opening 76 of the utility member carrying portion 70. The restrictor portion 78 includes extensions 80 that extend from the side walls 72 to partially close the opening 76 and thereby reduce adhesive ingress. The extensions are rectangular in cross-section.

The restrictor portion 78 is arranged to interconnect the first surface 10 of the insulation member 8 and the utility member carrying portion 70.

In variant embodiments, which are not illustrated, the extensions are alternatively shaped, including as semi-circular cross-sectioned.

In a second example, referring to figure 5B, the conduit 34 implements the features of the first example, and additionally includes a closing member 82 to seal the opening 76 of the utility member carrying portion 70. The closing member 82 is arranged as an adhesive tape, and is relatively thin so as not to disrupt the bond between the first surface 10 of the insulation member 8 and the first board 4. In the example, the closing member 82 seals the opening defined by the restrictor portion 78.

In variant embodiments, which are not illustrated, the restrictor portion is omitted; the adhesive on the closing member is omitted and the closing member can be held in place by the two opposed forces of the board and insulation member or by another means.

In a third example, referring to figure 5C, the conduit 34 implements the features of the first example, and includes a recess 84 in the first surface 10 of the insulation member 8 to receive the closing member 82, which is complementary in shape to the recess 84. The closing member 82 once inserted in the recess 84 sits flush with its outer surface aligned in the depth direction to the first surface 10 of the insulation member 8. The closing member 82 and recess 84 both have a rectangular cross section.

In variant embodiments, which are not illustrated, the surfaces may not sit flush; the closing member and recess may have a alternatively shaped cross sections, including with tapered edges; the recess may be located in another portion of the conduit rather than the first surface of the insulation member.

In a fourth example, referring to figure 5D, the conduit 34 includes a collecting portion 86, that collects adhesive from the bond. The collecting portion 86 is arranged as two portions on opposed sides of the utility member carrying portion 70 each of which is arranged to interconnect the associated sidewall 72 of the utility member carrying portion 70 and the first surface 10 of the insulation member 8. Each portion of the collecting portion 86 is arranged as a cavity 88 with a first apex at the junction with the sidewalls 72 and a second apex at the junction with the first surface 10 of the insulation member 8 and a base therebetween. The first apex is offset in the depth direction 104 from the first surface 10. In this way any adhesive on the first board 4 (shown in figure 1) that overlaps the opening 76 can seep to the cavity 88.

In variant embodiments, which are not illustrated, the restrictor portion of the prior embodiments is implemented in the fourth example, such that the cavities are arranged on the extensions.

In a fifth example, referring to figure 5E, the collection portion 86 is similar to that of the fourth example, however each cavity is arranged as first 90 and second cavities 92 disposed adjacent to each other.

In a sixth example, referring to figure 5F, the collection portion 86 is arranged between the utility member carrying portion 70 and the first surface 10 of the insulation member 8. The collection portion 86 comprises a cavity 94 extending from first surface 10 and into the restrictor portion 78, which was discussed for the first, second and third examples. A base of the cavity 94 of the collection portion 86 includes the opening 76 of the restrictor portion 78.

Referring back to figures 2 and 4, the insulation member 8 includes three conduits 34, which all extend parallel to each other in the longitudinal direction 100. The conduits 34 are separated by an equal pitch P, which is measure in the lateral direction 102 from the major axis 40 (or other suitable reference point). Typically P is 100 to 300 mm or 150 to 250 mm or about 200 mm.

The end conduits 34 are arranged with the same pitch distance P to a corresponding end conduit of an adjoining structurally insulated panel (not illustrated). For example, the distance from the end conduit 34 to the outer adjacent edge of the first board 4 or second board 8 is P/2 as illustrated in figure 2.

In variant embodiments, which are not illustrated, the conduits are arranged with a variable pitch; other distances between the end conduit and the outer adjacent edge of the first board or second board can be selected so that on adjoining panels the overall pitch between end conduits is maintained as P, e.g. on one panel the distance from the end conduit to the outer adjacent edge of the first board or second board is P/4 and on the adjoining panel the distance from the end conduit to the outer adjacent edge of the first board or second board is 3.P/4; any number of conduits may be present in the structurally insulated panel, e.g. 2, 3, 4, 5 or more.

Referring to figure 3, the first board 4 includes a though-hole wall aperture 52, through which the conduit 34 is accessible. The wall aperture 52 may be cut at the same time (e.g. with the same cutting tool) as when the first board 4 is cut to size. The wall aperture 52 is cut in a position so that when the first board 4 is bonded to the insulating material 8 it is aligned to the conduit 34.

The conduit 34 and the wall aperture 52 form a recess that is complimentary in shape to an electrical socket housing (not illustrated). In this way an electrical socked can be conveniently inserted into the panel 2 without additional cutting. The panel 2 may be supplied to a customer with the electrical socket installed and the electrical cabling installed in the conduit and connected to the socket.

In variant embodiments, which are not illustrated: the wall aperture is provided in the second board, e.g. to provide electrical connections on the exterior of the building; the wall aperture is alternatively shaped to accommodate other interconnecting members for the utility member; part of the conduit may be specifically cut to interlock with the interconnecting member.

Referring back to figure 3, since the conduit 34 is pre-formed, either or both of the interior face 22 and exterior face 24 of the structural insulated panel 2 can be pre-finished as the respective interior of a room of a building or an exterior of a building because no unsightly cutting of the conduit onsite is required.

Referring to figure 6, a connecting member 54 comprises access apertures 56, which are arranged with a pitch P to correspond in position to access apertures 58 in the top face 42 of the insulation member 8 of adjoining structurally insulated panels 2A, 2B.

The connecting member 54 is rectangular in cross section and extends principally in the lateral direction 102.

The connecting member 54 can be inserted between longitudinally extending extensions 62 of the first board 4 and second board 6 that protrude in the longitudinal direction 100 beyond the top face 42 of the insulation member 8 of the structurally insulated panel 2A, and between corresponding extensions 64 of the adjoining structurally insulated panel 2B. When fully inserted a proximal surface of the connecting member 54 abuts the top face 42 of the insulation member 8. The connecting member 54 can therefore locate and align in the lateral and depth directions adjoining structurally insulated panels 2A, 2B.

The access apertures 56 in the connecting member 54 are arranged to align with the access apertures 58 in the top face 42 of the insulation member 8 of both panels 2A, 2B, such that access is provided to the conduits 34 form the distal surface of the connecting member 54.

The access apertures 56 in the connecting member 54 are arranged such that a utility member (not illustrated) can only be inserted into the utility member carrying portion 70 (shown in figures 5A -5F) of the conduit 34. In particular, the access apertures 56 do not overlap the collecting portion 72 or restrictor portion 78 or other portion shown in the embodiments of figures 5A -5F, so that the utility member (not illustrated) could otherwise erroneously be inserted into these portions.

In variant embodiments, which are not illustrated, the access apertures in the connecting member may be omitted, e.g. for a connection system that does not require conduit access.

Referring to figure 7, the access apertures 56 in the connecting member 54 are arranged as slots that have a major axis in a direction of an elongated axis (which is the example is also the lateral direction 102) of the connection member 56.

With reference to the adjoining structurally insulated panels 2A, 2B in figures 6 and 7, it will be appreciated that the connecting member 54 can be translated in the lateral direction 102 over the length of the slot so that the access apertures 56 in the connecting member 54 are arranged to align with the access apertures 58 in the top face 42 of the insulation member 8 of both panels 2A, 2B, in a range of positions through the slot length. Such an arrangement allows for less precision in positing of the connecting member 56 and can therefore simplify assembly. As for the previous embodiment, the slot can be positioned such that a utility member (not illustrated) can only be inserted into the utility member carrying portion 70 of the conduit 34.

The access apertures 56 of the connecting member 54 are interconnected by an interconnection conduit 80 for transmitting the utility member between the access apertures 56. The interconnection conduit 80 can be cross-sectioned as for the utility member carrying portion 70 of the conduit 34. With such an arrangement, a portion of the utility member can be fed along a top edge of the structurally insulated panel 2A,2B though the interconnection conduit 80 and into one or more of the conduits 34. Typically the edge comprising the connecting member 54 forms a top edge of a side of a building.

Referring to figure 7, a further connecting member 82 is arranged to interconnect adjoining edges of the first and second structurally insulated panels 2A, 2B. In particular, the further connecting member 82 is inserted between laterally extending extensions 84 of the first board 4 and second board 6 that protrude in the lateral direction 102 beyond the side face of the insulation member 8 of the structurally insulated panel 2A, and between corresponding extensions 84 of the adjoining structurally insulated panel 2B. The connecting member 54 therefore extends over, in the lateral direction 102, to overlap the end on the further connection member 82.

Both the connecting member 54 and the further connecting member 82 are fixed in place due to friction between the adjoining extensions 62,82 and adjoining face of the insulation member 8. In variant embodiments, which are not illustrated, they may additionally be fixed in place by mechanical fixings, including a bolt or screws or nails, through the extensions and into the connecting member.

Referring to figure 7, the second board 6 of the first structural insulated panel 2A is arranged to interlock with a corresponding second board 6 of the second structurally insulated panel 2B. In particular, the second board 6 of first structural insulated panel 2A comprises extensions 86, which engage with complimentary cut-outs 88 of the second board 6 member of the second structurally insulated panel 2B.

In variant embodiments, which are not illustrated: the interlocking feature can be provided by any suitable arrangement of extensions and cut-outs; the second board can include an exterior member, such as a plastic or wood, that implements the interlocking.

Referring to figures 9 and 10, the exterior surfaces 16 of the adjoining edge of the first board 4 of the first and second structurally insulated panels 2A, 2B comprise adjoining cut-outs to form a channel 90 for receiving an edge member 92. The edge member 92 may be profiled to sit flush in the channel 90 or protrude therefrom. The edge member 92 therefore conceals the adjoining edge between the first and second structurally insulated panels 2A, 2B.

Although not illustrated, fixing means, e.g. screws or nails, can be inserted through the extensions 62, 64 and into the connecting member 54 to fix the connecting member 54 and structurally insulated panels 2A, 2B together. The extensions 62, 64 may comprise preformed holes (not illustrated) to receive the fixing means so that they are arranged in the correct position to extend into the connecting member 54.

In variant embodiments, which are not illustrated, the connecting member can also locate and provide access to apertures in the bottom face of the insulation member or on the side face; the connecting member can have other shapes, e.g. a more square than rectangular cross-section; the connecting member may extend beyond two structurally insulated panels, such that it can interconnected more than two panels.

Method of assembly Referring to figure 11, a method of forming the structurally insulated panel 2 comprises: Step 1: cut the first board 4 and second board 6 to size, including cut any wall apertures (which are not illustrated in the figure).

Step 2: machine the conduits 34 into the insulation member 8. This may comprise an inline process, wherein the insulation member 8 is displaced along its length in the longitudinal direction relative cutting tools (e.g. a milling machine blade which is profiled to give the desired profile of conduit) of a machining system. Multiple conduits can be formed by a row of cutting tools, at the same time by moving said row though the insulation member 8.

Step 3: connect the second board 6 to the second surface 12 of the insulation member 8 by applying an adhesive (not illustrated) to the interior surface 18 of the second board 6 and pressing the second board 6 and insulation member 8 together. The adhesive can be sprayed on to the interior surface 18 of the second board 6.

Step 4: connect the first board 4 to the first surface 10 of the insulation member 8 by applying an adhesive (not illustrated) to the first surface 10 of the insulation member 8 and pressing the first board 4 and insulation member 8 together.

The adhesive can be sprayed on to the first surface 10 of the insulation member 8. In particular, it can be sprayed on to the portion of the first surface 10 that does not comprise the conduit 34 so that the conduit 34 is not blocked with adhesive. This may comprise an inline process, when the insulation member 8 is displaced along its length in the longitudinal direction (i.e. the same direction that the conduits extend) relative to nozzles of an adhesive spraying system.

It will be appreciated that steps 3 and 4 are executed as part of a bottom up process, i.e. the structurally insulated panel 2 is assembled by adding layers from a bottom layer to a top.

In variant embodiments, which are not illustrated: the wall apertures are not cut at the same time as the first and/or second board; the steps can be executed in any suitable order, e.g. step 2 before step 1 or step 4 before step 3; multiple conduits may be formed sequentially e.g. with a single cutting tool rather than concurrently with multiple cutting tools; in steps 3 or 4 the other surface to the one mentioned may be additionally or alternatively sprayed with adhesive; the closing member 50 as discussed in figure 5B may be implemented before applicafing of adhesive at step 4; at step 2 the conduits in the insulation member may be formed by an alternative process including by extrusion or moulding; in some embodiments without a conduit the conduit can be omitted.

As used in this specification, any formulation used of the style "at least one of A, B or C", and the formulation "at least one of A, B and C" use a disjunctive "or' and a disjunctive "and" such that those formulations comprise any and all joint and several permutations of A, B, C, that is, A alone, B alone, C alone, A and B in any order, A and C in any order, B and C in any order and A, B, C in any order. There may be more or less than three features used in such formulations.

In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word 'comprising' does not exclude the presence of other elements or steps then those listed in a claim. Furthermore, the terms "a" or "an," as used herein, are defined as one or more than one. Also, the use of introductory phrases such as "at least one" and "one or more" in the claims should not be construed to imply that the introduction of another claim element by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim element to inventions containing only one such element, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an." The same holds true for the use of definite articles. Unless stated otherwise, terms such as "first" and "second" are used to arbitrarily distinguish between the elements such terms describe. Thus, these terms are not necessarily intended to indicate temporal or other prioritization of such elements. The mere fact that certain measures are recited in mutually different claims does not indicate that a combination of these measures cannot be used to advantage.

Unless otherwise explicitly stated as incompatible, or the physics or otherwise of the embodiments, example or claims prevent such a combination, the features of the foregoing embodiments and examples, and of the following claims may be integrated together in any suitable arrangement, especially ones where there is a beneficial effect in doing so. This is not limited to only any specified benefit, and instead may arise from an "ex post facto" benefit. This is to say that the combination of features is not limited by the described forms, particularly the form (e.g. numbering) of the example(s), embodiment(s), or dependency of the claim(s). Moreover, this also applies to the phrase "in one embodiment", "according to an embodiment" and the like, which are merely a stylistic form of wording and are not to be construed as limiting the following features to a separate embodiment to all other instances of the same or similar wording. This is to say, a reference to 'an', 'one' or 'some' embodiment(s) may be a reference to any one or more, and/or all embodiments, or combination(s) thereof, disclosed. Also, similarly, the reference to "the" embodiment may not be limited to the immediately preceding embodiment.

As used herein, any machine executable instructions, or compute readable media, may carry out a disclosed method, and may therefore be used synonymously with the term method, or each other.

The foregoing description of one or more implementations provides illustration and description, but is not intended to be exhaustive or to limit the scope of the invention to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practice of various implementations of the present disclosure.

LIST OF REFERENCES

2 Structurally insulated panel 22 Interior face 24 Exterior face 26 Top face 56 Access apertures 28 Bottom face First side face 32 Second side face 4 First board 14 Interior surface 16 Exterior surface 52 Wall aperture 6 Second board 18 Interior surface 20 Exterior surface 8 Insulation member First surface 12 Second surface 42 Top surface 44 Bottom surface 34 Conduit 36 Mouth 38 Base 40 Major axis 46 Side walls 48 Step Closing member 54 Connecting member 56 Access apertures

Claims

CLAIMS1. A structurally insulated panel extending in a longitudinal and lateral direction comprising: a first board; a second board, and; an insulation member having a first surface and a second surface and a conduit, the first board adhesively connected to the first surface and the second board connected to the second surface, the conduit extending in a depth direction from the first surface and extending across the lateral and/or longitudinal direction, the conduit including a utility member carrying portion for transmitting a utility member across the structurally insulated panel, wherein the structurally insulated panel has a lateral dimension of 25 cm to 80 cm.
2 The structurally insulated panel of claim 1, wherein the conduit is configured to prevent or reduce excess adhesive from said adhesive connection from entering into the utility member carrying portion.
3 The structurally insulated panel of claim 2, wherein to prevent or reduce excess adhesive from entering into the utility member carrying portion the conduit comprises one or more of the following: an adhesive collecting portion; a closing member, which is arranged to close the utility member carrying portion, and; a restrictor portion arranged to at least partially close the conduit.
4. The structurally insulated panel of claim 3, wherein the closing member is includes an adhesive strip to adhesively close the conduit.
The structurally insulated panel of either of claims 3 or 4, wherein the closing member is arranged as a thin strip of 0.1 -2 mm in thickness.
6. The structurally insulated panel of any of claims 3 to 5, wherein, the conduit includes a recess to receive the closing member.
7. The structurally insulated panel of any of claims 3 to 6, wherein the conduit includes the restrictor portion to reduce a portion of the conduit closed by the closing member.
8 The structurally insulated panel of claim 1, wherein the restrictor portion includes a narrowing section relative the utility member carrying portion and the restrictor portion is arranged to interconnect the first surface and the utility member portion.
9. The structurally insulated panel of claim 3, wherein the collecting portion is arranged to collect flow of adhesive before it can enter the utility member carrying portion.
10. The structurally insulated panel of claim 8, wherein the collecting portion comprises a cavity.
11. The structurally insulated panel of any of claims 3, 9 or 10, wherein the collecting portion is arranged above and/or to the side of the utility member carrying portion and the restrictor portion is arranged between the collecting portion and the utility member carrying portion.
12. A kit for assembly into the structurally insulated panel of any of claims 1 to 11, the kit comprising: the first board; the second board, and; the insulation member comprising the conduit.
13. A kit for assembling a building comprising one or more of the structurally insulated panels of any of claims 1 toll.
14. A building comprising one or more of the structurally insulated panel of any of claims 1 to 11.
A system comprising a connecting member and a first and second structurally insulated panel of any of claims 1 to 11, the structurally insulated panels one or both comprising one or more conduits in their associated insulation members, wherein the or each conduits including an access aperture arranged in an end surface of the insulation members, wherein the connecting member is arranged to interconnect and align the first and second structurally insulated panel, and comprises corresponding access apertures to align with the access apertures of both the first and second structurally insulated panel, with a utility member arrangeable in a conduit accessible via the access aperture in the connecting member.
16. The system of claim 15, wherein for both of the structurally insulated panels, the first and second boards comprise extensions that extend beyond the insulation members, and the connecting member is arrangeable between the extensions and to adjoin the insulation member.
17. The system of either of claims 15 or 16, wherein the access apertures of the connecting member are arranged such that a utility member can only be inserted into the utility member carrying portion of the conduit
18. The system of any of claims 15 to 17, wherein the access apertures in the connecting member are arranged as slots that have a major axis in a direction of an elongated axis of the connection member, and the access apertures of the conduits can be aligned with the access apertures of the conduit with the connecting member in a range of positions.
19. The system of any of claims 15 to 18, wherein the access apertures of the connecting member are interconnected by an interconnection conduit for transmitting the utility member between the access apertures.
The system of any of claims 15 to 19, wherein the connecting member is arranged to interconnect adjacent edges of the first and second structurally insulated panels and a further connecting member is arranged to interconnect adjoining edges of the first and second structurally insulated panels, with the connecting member to overlap the further connection member.
21. A method of forming a structurally insulated panel comprising: forming a conduit with a utility member carrying portion for carrying a utility member across the structurally insulated panel in an insulation member, wherein the conduit is formed to prevent or reduce excess adhesive from protruding into the utility member portion, adhesively connecting a first board to a first surface of the insulation member, and; connecting a second board to a second surface of the insulation member, wherein the structurally insulated panel has a lateral dimension of 25 cm to 80 cm.
22. The method of claim 21 comprising forming the conduit by extrusion or machining.
23 The method of either of claims 21 or 22 comprising forming in an insulation member a plurality of said conduits, wherein said conduits are formed concurrently.
24 The method of claim 23, wherein an arrangement of cutting tools are moved relative the insulation member to form the conduits concurrently.
25. A method of assembling a building with structurally insulated panels of any of claims 1 -11, the method comprising: manually lifting the structurally insulated panels from a transported position to an assembly position on the building, and; assembling the structurally insulated panels to form the building.