IE86668B1

IE86668B1 - Structural panel and a building structure formed therefrom

Info

Publication number: IE86668B1
Application number: IE20110183A
Authority: IE
Inventors: Mccrea Brendan
Original assignee: Mccrea Brendan
Priority date: 2010-04-14
Filing date: 2011-04-14
Publication date: 2016-07-27
Also published as: GB201006176D0; GB2479649A; GB2479649B; GB201106330D0; IE20110183A1

Abstract

A structural panel for constructing a building, said panel comprising a core made from a thermally insulating material, said core being sandwiched between laod bearing outer coverings or facings to enable the panel to be used as a load bearing member is a building structure and a building structure comprising a plurality of structural panels, each panel comprising a core made from a thermally insulating material, said core being sandwiched between load bearing outer coverings or facings.

Description

Structural Panel and a Building Structure formed therefrom The present invention relates to a structural panel for constructing a building and to a building structure formed therefrom and in particular to a structural panel providing enhanced thermal insulating properties when compared to traditional building materials and to a building structure formed from such structural panels.

Due to increasing fuel costs and concerns regarding the emission of green house gases due to the burning of fossil fuels there is increasing demand for alternative building construction methods and materials to reduce the energy usage associated with heating a building. Legislation requires ever increasing levels of thermal insulation and thermal performance of buildings that are increasingly difficult to meet using traditional building practices.

It is known to provide thermally insulating materials to clad the interior of buildings or to infill cavity walls of buildings built using a traditional brick built construction to reduce heat loss in buildings. Materials such as expanded polystyrene (EPS) provide excellent thermal insulation properties when compared to more traditional constructions materials, such as bricks or concrete. However, one problem apparent with these prior art insulating materials is that they do not have strength necessary for a suitable load bearing wall structure, and therefore must normally be used in combination with more traditional building materials, such as bricks and concrete.

It is therefore highly desirable to provide structural panels that can be used to construct a building structure having greatly improved thermal insulation properties with the requisite strength for load bearing walls and roofs and the endurance necessary to withstand the rigors of weather.

According to the present invention there is provided a building structure a claimed in claim 1.

Preferably said reinforcement means comprises an arrangement of metal wires or rods, preferably in the form of a welded mesh. In one embodiment said reinforcement means may comprise stainless steel or mild steel wire mesh. Said reinforcement means may be attached to the core by ties, preferably formed from a non-metallic and/or thermally insulating material. Said ties may extend through the core of the panel to interlink said reinforcement means on either side of the core.

Preferably said ties are formed from a thermally insulating material, such as a non-metallic or ceramic material.

The truss members may be formed from metal wires or rods.

The reinforcement means on each side of the panel may be arranged to be interconnected to the corresponding reinforcement means of an adjacent panel by suitable fastening means to enable adjacent panels to be interconnected to define at least a portion of a building structure.

The thickness of the core may be selected to provide the desired thermal properties. In one embodiment the core may be between 100 and 500mm thick, although any other thickness may be provided depending upon the required thermal properties of the panel and the thermal performance of the insulating material used to form the core of the panel.

Preferably said core is made from expanded polystyrene or any other suitable lightweight thermally insulating material. In one embodiment said core is formed from expanded polystyrene beads. In one embodiment said beads may be provided with a coating, such as a silver coating, to enhance their insulating properties.

The panel may be provided with cut outs or openings for doorways and/or windows. Windows or doors may be prefitted into said cut outs or openings.

The panel may be shaped, for example L shaped or T shaped, to define a shaped portion, such as a corner section of adjoining wall section, of a building structure.

Conduits or pipes may be secured to the reinforcement means on at least one side of the panel for the passage of a heat transfer medium. Such conduits or pipes may be used for solar heating where the panel defines a portion of an outer wall of a building structure. Such conduits or pipes may be arranged to become embedded within a layer of concrete applied to the reinforcement means.

Conduits or ducts may be provided through and/or within the core of the panel for the passage of wiring or pipework and/or for ventilation passages.

Preferably said panels are assembled before uncured concrete is applied to the reinforcement means such that the layer of concrete forms a substantially continuous facing on each side of the assembled panels.

Preferably said reinforcement means comprises an arrangement of metal wires or rods, preferably in the form of a welded mesh, In one embodiment said reinforcement means may comprise stainless steel or mild steel wire mesh.

Preferably said structural panels comprise at least one or more walls of said building structure, preferably the outer walls of the building. All of the walls of the building structure may be formed from such structural panels. The structural panels may also define or be incorporated into the floors of the building structure. The roof of the building structure may also be formed from said structural panels. Preferably substantially all load bearing walls, floors and roof panels of the building structure are formed from said structural panels.

Preferably the reinforcement means of adjacent panels are connected together by suitable fastening means to enable the panels to be assembled to define a building structure before uncured concrete is applied to the panels such that the reinforcement means of the panels become embedded in the concrete.

Preferably the panels are arranged to define channels between adjacent panels into which concrete may be applied to define supporting beams, such as one or more ring beams, through the building structure, for example between adjacent floors of the building structure. Such beams may be formed in place within the building structure such that the panels are integrated into the beams.

One of more of said plurality of structural panels may be shaped to form preformed sections of the building structure and may have door and/or window openings formed therein. Specially shaped panels, such as L shaped corner panels and/or T shaped panels, may be provided for linking the planar panels together to define a three dimensional building structure.

Due to the close fitting arrangement of the panels a substantially airtight structure may be formed. One or more ventilation openings may be provided in one or more of the panels, preferably within the core of said one or more panels. Such ventilation opening may be formed adjacent lower regions of the building structure, and/or in the roof of the building structure, for example in the form of a 5 chimney. The or each ventilation opening may be associated with a heat exchanger to reduce the loss of heat through the or each ventilation opening.

One or more of the panels, preferably said panels defining a roof and/or a south facing wall or eaves region of the building structure, are provided with a plurality of ducts for conveying a heat exchange 10 medium therethrough, such as air or water. Preferably said ducts are arranged to be embedded within the layer of concrete formed on a respective side of said one or more panels. Said ducts may be formed in the core of the panel, adjacent the covering or facing of said panel defining an outer surface of the building structure. Alternatively said ducts may be mounted on an outer face of the panel.

An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:- Figure 1 is a perspective view of a structural panel according to an embodiment of the present 5 invention of a first thickness for use, for example, in an external wall of a building structure; Figure 2 is a perspective view of a structural panel according to an embodiment of the present invention of a second thickness for use, for example, in an internal wall or floor of a building structure; Figure 3 is a front view of the panel of Figure 1 or Figure 2; Figure 4 is a front view of a modified panel having a door opening therein; Figure 5 is a front view of a modified panel having a window opening therein; Figure 6 is a front view of a further modified panel having a smaller window opening therein; Figure 7 is a front view of a domestic dwelling formed from the structural panels of Figures 1 to 6; Figures 7a and 7b are schematic views of the floor layout of the dwelling of Figure 7; Figure 8 is a sectional view of the dwelling of Figure 7; Figure 9 is a detailed sectional view of region A of Figure 8; Figure 10 is a detailed sectional view of region B of Figure 8; Figure 11 is a detailed sectional view of region C of Figure 8; Figure 12 is a detailed sectional view of region D of Figure 8; Figure 13 is a detailed sectional view of region E of Figure 8; Figure 14 is a detailed sectional view of region F of Figure 8; Figure 15 is a detailed sectional view of region G of Figure 8; Figure 16 is a detailed sectional view of region H of Figure 8; Figure 17 is a detailed sectional view of the dwelling of Figure 8 showing the interconnection between adjacent panels; and Figure 18 is a sectional view of the floor of the dwelling of Figure 8.

A structural panel 10 according to an embodiment of the present invention is illustrated in Figures 1 to 6. The panel 10 comprises a thermally insulating core 12 of expanded polystyrene, preferably in the form of beads bonded together into a block, encased within facings 14,16 formed from welded steel mesh for supporting and reinforcing layers of concrete which may be applied to the faces of the panel, as will be described below, to define a structural panel 10 capable of forming a load bearing wall, floor or roof member of a building structure.

The thermally insulating core of the panel 10 may be formed by injecting expanded polystyrene beads into a cage formed from apertures sheet stainless steel or mild steel. Alternatively a solid block of expanded polystyrene may be used to form the core 12, in which case the cage may not be required.

Panels of welded stainless steel or mild steel mesh are attached to the front and rear faces of the polystyrene core 12 and stainless steel or mild steel wire trusses 18 are attached between the stainless steel or mild steel mesh panels around the peripheral edge of the core. The mesh panels are interlinked by ties extending through the core 12. Preferably the ties are formed from a nonmetallic thermally insulating material.

In use, the panels are assembled to define a building structure and wet uncured concrete is applied to the faces of the panels 10 such that the mesh panels become embedded in the concrete to define load bearing facings on either side of the insulating core 12.

The steel reinforcement and the concrete facings of the panel provide great structural load bearing strength while the expanded polystyrene core endows the panel with excellent thermal properties for reducing heat loss through the panels when assembled to form a building structure.

Different core thicknesses may be used depending upon the level of thermal insulation required. In the panel shown in Figure 1 a core thickness of between 200mm and 500mm may be used. Such panels may be suitable for outer walls of a building structure. In the panel shown in Figure 2 a core thickness of between 100mm and 150mm may be used. Such panels may be suitable for inner walls, floors and ceilings of a building structure.

As shown in Figure 3, some panels 10a may be simple planar members for use in the construction of walls, floors, ceilings and the roof of a house. Other panels 10b, 10c, 10d may have door or window openings cut therein, as shown in Figures 4 to 6. Doors and windows may be pre-mounted in such openings to provide preassembled panels.

In the embodiment illustrated the panels may have a uniform size, typically having a length of 2800mm and a width of 1200mm.

Such structural panels 10 may be used to construct a domestic dwelling as shown in Figures 7,7a,7b and 8. However, it is envisaged that such panels 10 may be used in the construction of a wide variety of domestic and commercial building structures.

As shown in Figure 7, the structural panels 10 may be used to construct a traditionally styled two storey semi-detached domestic dwelling 100. However, the excellent thermally insulating properties of the panels enable the dwelling to comply with the highest standards for thermal efficiency and enable the dwelling, when used with solar heating and air handling devices, to achieve zero-carbon status, requiring no additional heating from fossil fuel sources.

As illustrated in Figure 8, the structural panels 10 in accordance with Figures 1 to 6 are used to form the floors, walls and roof of the house.

In order to construct a building structure, the panels 10 are assembled and adjacent panels are tied together by clips or suitable fastening means to interlink the welded mesh panels or adjacent panels 10 before wet uncured concrete is applied to cover the mesh panels and to fill any voids between adjacent panels and to form a unitary load bearing structure. Specially shaped L and T shaped panels may be provided to form the corners and intersecting portions of the building structure.

Figures 9 to 18 illustrate sections through the dwelling 100 shown in Figure 8 to illustrate the way in which the panels 10 are used to construct the dwelling 100.

Figure 9 illustrates a lower corner of the dwelling 100. 150mm thick panels are located within a concrete subfloor 104, as shown in Figure 18. The wall panels 10 are assembled to overlap the sides of the floor panels. A waterproof membrane may be placed over the subfloor 104 to extend under the bottom edges of the wall panels to form a damp proof course. The waterproof membrane may be covered in a screed 106 to define the floors of the dwelling 100, as in conventional in house building. The outer wall panels comprise 250mm thick panels while the floor panels comprise 150mm thick panels. The outer faces of the wall panels may be coated in a screed 101 whereby the finished dwelling looks no different than conventionally built concrete brick buildings.

Figure 10 illustrates the interface between an inner wall of the dwelling 100. The inner walls are preferably formed from 150mm thick panels 10.

Figure 11 illustrates the interface between the upper floor of the dwelling and the outer wall. The floors may be supported by reinforced concrete beams 102 which are formed on site by pouring uncured concrete into channels defined between overlapping panels 10, particularly between panels arranged perpendicular to each other adjacent floors of the building structure. In Figure 11 the beams 102 are located between vertically adjacent wall panels 10.1,10.2.

Figure 12 illustrates a section of the upper floor of the dwelling showing the use of reinforced concrete beams 102 to interconnect the panels 10. The beams comprise 150mm wide poured concrete beams defined by channels formed between the ends of adjacent panels. The beams may be reinforced with steel bars and may include steel ties whereby the beams may be connected to the mesh reinforcing panels of adjacent panels 10. Shuttering may be formed around the panels to allow uncured concrete to be poured into such channels to form said beams.

Figure 13 illustrates a section of a window panel 10d having an opening for receiving a window 110. A window may be mounted within the opening offsite such that the panels may be supplied complete with windows and/or doors already mounted therein.

Figure 14 illustrates the interface between an inner wall of the dwelling and the attic floor. The attic floor is constructed similarly to the upper floor of the dwelling, comprising panels 10 linked and supported by a continuous concrete ring beam defined by channels formed between adjacent panels. The ring beam may be reinforced by steel rods and may incorporating steel ties linking the panels together. At least one of the attic panels may be formed with an aperture to provide access to the roof space.

Figure 15 illustrates an eaves section of the dwelling showing the intersection between the panels 10.3 forming the attic floor, the panels 10.4 forming the outer walls and the roof panels 10.5. The attic floor panel 10.3 overlaps the wall panel 10.4 to about half the thickness of the wall panel and the remaining gap is filled with concrete, which may be reinforced with steel rods and/or steel ties linking the panels together. Tiles 112 or similar roof coverings may be applied to the outer face of the roof panels 10.5 and a gutter 114 is connected to the lower edge of the roof panels 10.5.

Figure 16 illustrates the apex of the roof assembly, formed by the intersection of angled roof panels 10.5 and a central wall panel 10.6.

Figure 17 shows a further illustration of the interconnection between the various panels forming the floor, walls and ceiling of a portion of the dwelling, in particular the relationship between the subfloor panels 10.6, the outer wall panels 10.2,10.1, the inner wall panels 10.8 and the upper floor panels 10.7. As can be seen from Figure 17, the panels form a gap free enclosure around each room of the dwelling, providing optimum thermal insulation with substantially no voids or gaps through which heat may be lost. Any gaps between the panels are filled by concrete, which may be poured and/or sprayed onto the panels.

The dwelling is thus designed as a zero carbon home, meaning that no fossil fuels need to be burned to heat the dwelling. The enhanced thermal insulation of the panels from which the dwelling is formed and the substantially airtight fit between the panels minimises any heat loss from the dwelling, obviating the need for traditional central heating systems.

Instead the dwelling is provided with solar panels 120 on the south facing side of the roof or wall of the dwelling 100, as shown in Figure 8, for heating water in a storage tank 122 and an air management system for ventilating the dwelling while minimising heat loss.

Ducts for conveying a heat transfer medium of the solar panels 120 may be attached to the roof or wall panels before the uncured concrete is applied thereto such that the ducts are embedded within the concrete applied onto the panels to hide and protect the ducts and to enhance the efficiency of the solar panels.

The air management system comprises a central vertical duct 130 running through the house from the ground floor and extending through the roof in the manner of a chimney, the duct defining an inlet passage 132 for drawing air into the duct from outside of the dwelling and a parallel outlet duct 134 for removing stale air from the dwelling. The outlet duct 134 is connected to a heat exchange unit 136 for extracting heat from the outgoing air before it is vented to the environment to further minimise heat loss. Air flow ducts of the air management system may be defined within the thermally 5 insulating core 12 of specific panels.

A water tank 140 is located beneath the subfloor 104 of the dwelling for collecting rainwater from the gutters and drainpipes 142 of the dwelling. The water tank 140 is provided with an overflow outlet 144 to drain excess rainwater. Water from the water tank 140 can be used to service toilets and for 10 washing.

The invention is not limited to the embodiment(s) described herein but can be amended or modified without departing from the scope of the present invention.

Claims

1. A building structure comprising a plurality of structural panels, each panel comprising a core made from a thermally insulating material, said core being sandwiched between load bearing outer coverings or facings to enable the panel to be used as a load bearing member in a building structure, wherein one or more of the panels includes a plurality of ducts for conveying a heat exchange medium therethrough, said load bearing outer coverings or facings of each panel each comprising a reinforcement means to which uncured concrete is applied whereby the reinforcement means becomes embedded in a layer of concrete to attach said layer of concrete to the respective side of the panel and to define load bearing facings on either side of the thermally insulating core, said reinforcement means comprising an arrangement of metal wires or rods, wherein truss members extend between the reinforcement means to interlink said reinforcement means on either side of the core thereof, said truss members extending around a peripheral edge of the core of each panel, wherein said truss members extend at an acute angle between the facings or coverings of each panel to define a triangulated reinforcing structure around the peripheral edge of each panel.

2. A building structure as claimed in claim 1, wherein said reinforcement means is in the form of a welded mesh.

3. A building structure as claimed in any preceding claim, wherein said reinforcement means is attached to the core of each panel by ties.

4. A building structure as claimed in claim 3, wherein said ties are formed from a non-metallic and/or thermally insulating material.

5. A building structure as claimed in claim 3 or claim 4, wherein said ties extend through the core of each panel to interlink said reinforcement means on either side of the core.

6. A building structure as claimed in any preceding claim, wherein the reinforcement means on each side of each panel is arranged to be interconnected to the corresponding reinforcement means of an adjacent panel by suitable fastening means to enable adjacent panels to be interconnected to define said building structure.

7. A building structure as claimed in any preceding claim, wherein said core of each panel is made from expanded polystyrene.

8. A building structure as claimed in any preceding claim, wherein said core of each panel is formed from expanded polystyrene beads.

9. A building structure as claimed in claim 8, wherein said beads are provided with a silver coloured coating to enhance their insulating properties.

10. A building structure as claimed in any preceding claim, wherein at least one of said panels is provided with cut outs or openings for doorways and/or windows.

11. A building structure as claimed in any preceding claim, wherein said structural panels comprise at least one or more walls of said building structure.

12. A building structure as claimed in claim 11, wherein said structural panels comprise the outer walls of the building.

13. A building structure as claimed in claim 12, wherein all of the walls of the building structure are formed from such structural panels.

14. A building structure as claimed in any preceding claim, wherein said structural panels define, or are incorporated into, the floors of the building structure.

15. A building structure as claimed in any preceding claim, wherein the roof of the building structure is formed from said structural panels.

16. A building structure as claimed in any preceding claim, wherein substantially all load bearing walls, floors and roof panels of the building structure are formed from said structural panels.

17. A building structure as claimed in any preceding claim, wherein the reinforcement means of adjacent panels are connected together by suitable fastening means to enable the panels to be assembled to define a building structure before uncured concrete is applied to the panels such that the reinforcement means of the panels become embedded in the concrete.

18. A building structure as claimed in any preceding claim, wherein the panels are arranged to define channels between adjacent panels into which concrete may be applied to define supporting beams through the building structure.

19. A building structure as claimed in claim 18, wherein said supporting beams comprise one or more ring beams.

20. A building structure as claimed in claim 18 or 19, wherein such beams are formed in place within the building structure such that the panels are integrated into the beams.

21. A building structure as claimed in any preceding claim, wherein one or more of said plurality of structural panels is shaped to form preformed sections of the building structure.

22. A building structure as claimed in any preceding claim, wherein specially shaped panels are provided for linking the planar panels together to define a three dimensional building structure.

23. A building structure as claimed in claim 22, wherein said specially shaped panels comprise L shaped corner panels and/or T shaped panels,

24. A building structure as claimed in any preceding claim, wherein said one or more panels define a roof and/or a south facing wall or eaves region of the building structure.

25. A building structure as claimed in any preceding claim, wherein said ducts are arranged to be embedded within the layer of concrete formed on a respective side of said one or more panels.

26. A building structure as claimed in any of claims 1 to 24, wherein said ducts are formed in the core of the panel, adjacent the covering or facing of said panel defining an outer surface of the building structure.

27. A building structure as claimed in any of claims 1 to 24, wherein said ducts are mounted on an outer face of the panel.

28. A building structure substantially as herein described with reference to the accompanying drawings.