JP2003531986A - Building panels - Google Patents

Abstract

Abstract: An architectural or insulated panel (30) comprising a collapsible frame in a generally square or rectangular configuration that can be folded between a substantially flat condition and an assembled condition when installed. . The frame includes overlying top and bottom sheets (31, 32) that are substantially parallel and spaced in the assembled state of the frame by two webs (33, 36), the two webs comprising: , Extending in a substantially parallel relationship along the length of the frame at opposite sides of the frame. The webs (33, 36) extend substantially perpendicular to the top and bottom sheets (31, 32) in the assembled state and to the top and bottom sheets (31, 32) in the collapsed state. And are arranged substantially parallel. The panel further includes reinforcing means (37) inserted between the top sheet (31) and the bottom sheet (32) when the frame is in the assembled state to reinforce and fold the panel (30). prevent. The thermal insulation panel may have an intermediate sheet disposed between the top and bottom sheets that is adhesively connected to each of the top and bottom sheets. The intermediate sheet is formed as a corrugated sheet, and at least one of the top and bottom sheets and the intermediate sheet is formed from a reflective insulating foil to create a reflective air space.

Description

Detailed Description of the Invention

This invention relates to building panels and methods and configurations for installing building panels. This invention was developed with respect to an insulating bat, and in particular, but not exclusively, with respect to the structure and installation of an insulating bat formed from a self-supporting sheet of reflective insulation. Therefore, although it is convenient to describe the present invention with respect to this style of insulating bat, the present invention is directed to non-insulating panels and insulating bats formed differently from those described above, or alternatives to those described above. It should be understood that it can be applied to insulating bats formed from various materials.

Australian Patent Nos. 511853 and 647948 disclose a thermal insulation bat having a substantially flat, self-supporting sheet of reflective insulation secured in a substantially parallel and overlying relationship. The sheets of these bats are secured to each other by a parallel web of sheet material that allows the bats to be adjusted between the folded and assembled states. Advantageously, these bats have a very small volume when folded and can be stored and shipped in that state, but are generally assembled in the field during installation on the roof of a building.

Installing insulating bats of the type described above is not always easy, especially for commercial buildings such as warehouses and factories. Until recently, suitable methods for such installations have been found in these buildings, where it is preferable to fit an insulating bat between adjacent purlins, which is easy and efficient in terms of the insulation provided. There wasn't.

According to the present invention, there is provided a building panel including a foldable frame of a generally square or rectangular configuration that can be folded between a substantially flat state and an assembled state at installation. The frame includes a top sheet and a bottom sheet which are substantially parallel and which are spaced apart by two webs in the assembled state of the frame, the two webs being spaced apart on opposite sides of the frame. Extends along the region in a generally parallel relationship along the length. The web extends substantially perpendicular to the top and bottom sheets in the assembled state,
In the folded state, they are arranged substantially parallel to the top and bottom sheets. The panel further includes reinforcing means for being inserted between the top sheet and the bottom sheet to reinforce the panel from folding when the frame is in the assembled state.

The present invention further provides a method for installing a building panel having a foldable frame of a generally rectangular or rectangular configuration that can be folded between a generally flat condition and an assembled condition. The frame includes a top sheet and a bottom sheet that are substantially parallel and that are spaced apart by two webs in the assembled state of the frame, the two webs being spaced apart on opposite sides of the frame. Along the region of, extending substantially parallel to the lengthwise direction. The web extends substantially perpendicular to the top and bottom sheets in the assembled state and is arranged substantially parallel to the top and bottom sheets in the folded state. The method comprises transporting the frame to the installation site in the folded state, unfolding the frame to the assembled state, and reinforcing means to the top layer and the bottom layer of the frame. And then placing the panel in place.

The stiffening means may be in the form of a sheet that may be folded between a substantially flat condition for shipping and an assembled condition for installing the insulating bat, or
It may be formed as a member ready for assembly in a frame in a nestable state, where a plurality of reinforcing means may be nested together for transport to the installation site. In each case, the advantages of the invention are realized by the compact nature of the reinforcement means for transportation and manufacturing and the simple nature of the assembly process. In either case, the reinforcing means can be inserted in their assembled condition into the space of the assembled frame, after which the insulating bat can be installed.

The present invention advantageously includes a foldable frame and a foldable,
Or nestable reinforcement means, each of which is handled in a substantially reduced volume compared to the assembled state of the panel or bat,
It consists of a foldable frame that can be transported to the installation site and foldable or nestable reinforcement means. Thus, the components of the insulating bat are easy to handle, transport at minimal cost, and easy to assemble and subsequently install. This withstands comparison with alternative bat constructions that are bulky and more difficult to install.

The stiffening means includes continuous, oppositely directed cusps extending in contact with each of the top and bottom sheets of the frame to support the sheets in a spaced arrangement. Can be in the form of a sheet of. The corrugated portion may be a curved configuration that takes a cross-sectional shape similar to a sine wave, or is arranged at opposite slanted angles to define a series of adjacent cusps and troughs. It may also consist of a plurality of substantially planar segments, and even have a concertina-like or sawtooth shape, with each apex and trough apex engaging either the top or bottom sheet of the frame. Good. The strength of the panel or bat when assembled depends in part on the frictional contact between the reinforcing means and the top and bottom sheets of the frame. Therefore, the sinusoidal configuration provides greater strength than the sawtooth shape. This is because the former has a larger surface area contact than the latter edge contact. An advantage of the invention is that the reinforcing means do not have to be fixed in the frame by glue or the like, but simply have to be placed in or inserted into the frame. This provides for the simple assembly that characterizes the present invention.

The required web spacing depends on the grade of paper normally used for the construction of panels or insulating bats. Therefore, by using a heavy paper grade, the need for additional webs between the side edge webs may be reduced. Both the reinforcing means and the web contribute to the stiffness of the panel or bat,
The choice of one material can influence the choice of the other material.

It will be appreciated that the above examples show that the reinforcing means can take various forms. Therefore, the shape of the reinforcement means is not always important, but the important thing is that
The reinforcing means can be nested or, alternatively, foldable and can be transported to the location of insulation either in nested form or in a substantially flat form, in the same transport and handling as the frame. It has an advantage.

In one configuration, the frame includes three or more webs that extend between the top and bottom sheets of the frame to divide the space between the top and bottom sheets into two or more smaller space segments. To divide. Thus, the frame of this configuration comprises a pair of webs which are arranged towards the edge regions on both sides of the frame and at least one further web which is arranged in the middle or in the middle of the two edge webs. In a particularly preferred configuration, a pair of webs are arranged between the side edge webs.

In the arrangements described above, the reinforcing means are arranged to extend between adjacent webs.
Thus, in configurations where three webs are located between the top and bottom sheets, the stiffening means consists of two separate stiffening members or components. The shapes of these members can be the same or different if desired. Alternatively, 1
In a configuration where the pair of intermediate webs are located between the side edge webs, three stiffening members are located between the top and bottom sheets of the frame.

In an alternative configuration, the stiffening means may be arranged only in one of the space segments between adjacent frame webs. That is, in an arrangement in which two intermediate webs are arranged between the side edge webs and thus three space segments are defined, each of these space segments may house a reinforcing means, or alternatively. Only one or two of the space segments may accommodate such stiffening means. The requirements of the reinforcing means depend on the required rigidity of the insulating bat.

For example, in the above configuration where three space segments are formed, the insulation properties of the insulation bat may only require stiffening means in only one of the space segments, which results in an insulation bat. The overall cost of is reduced. Alternatively, if the length or width dimensions of the insulating bat require that each of the space segments accommodate a reinforcing means, such means can easily be included. Therefore, the insulation bat of the present invention is flexible with respect to the requirements of insulation means, depending on the required insulation properties and structural requirements.

Bats of the type described above offer general advantages for storage and transportation. Because it can be stored and transported in a folded form. It also offers manufacturing advantages. Because it is very easy to manufacture, assemble and even install. The panels of the present invention are particularly suitable for ceiling installations, especially so-called suspended T-bar ceilings commonly found in commercial office spaces. The panel can replace the acoustical tile or plasterboard tiles currently in use at a much lower cost. In addition, the panel may be formed as a heat insulating bat, which further enhances its use as a ceiling panel.

The use of a reflective insulating foil provides certain advantages of the present invention in that the reflective foil is waterproof compared to currently used sound absorbing panels and plasterboard panels. Thus, water leaks on the ceiling or walls do not necessarily destroy or affect the performance of the panel, as may occur with non-waterproof panels including the sound absorbing and plasterboards described above. This advantage of the invention also applies to installation sites in high humidity areas, and panels of the present invention formed wholly or partially from reflective insulation foils may be preferred in such areas.

According to the invention, an insulating bat further comprising a top sheet, a bottom sheet, and an intermediate sheet disposed between the top sheet and the bottom sheet and adhesively connected to each of these sheets. Provided. The intermediate sheet is formed as a corrugated sheet, at least one of the top and bottom sheets and the intermediate sheet being from a reflective insulation foil to create a reflective air space.

The thermal insulation bat described above applies a corrugated intermediate sheet to bond one of the top and bottom sheets, and then bonds the other of the top and bottom sheets to the intermediate sheet. It can be manufactured by applying as follows. Like the bat described above, this bat is easy to manufacture and install, and it is recognized that it has industrially acceptable thermal insulation properties with an overall thickness of about 25 mm, so it can be stored and shipped. , And will be attractive regarding installation.

The insulating bat according to the present invention is suitable for insulating various structures such as wall and roof structures. The insulating bat of the present invention may be installed in a gradual manner by installing an insulating bat between adjacent purlins and pushing it with the next bat along the length of the purlin. The bat according to the present invention may be secured to the purlin in any suitable manner, or may simply be secured to its own weight in a slack by using stiffening means.

The accompanying figures illustrate exemplary embodiments of the invention as described above. The details of these figures and the accompanying description do not supersede the broad description of the invention described above.

[0021]

[Detailed description]

FIG. 1 shows an insulating bat 30 that includes a frame that is generally rectangular and further has a top layer 31 and a bottom layer 32 arranged in parallel and overlying relationship. The top and bottom layers can be made from a double-sided foil laminate that is relatively flexible in its planar form, but the invention is not limited to such materials and alternative materials may be used. Good. Australian Patents 511833 and 6479
Materials such as those described in No. 48 are suitable for use in constructing the insulating bat 30.

The frame of the insulating bat 30 further includes a plurality of webs 33 to 36 that extend substantially perpendicular to the top layer 31 and the bottom layer 32 and along the length of the bat 30. Is located in. The webs 33 to 36 are rotated relative to the top layer 31 and the bottom layer 32 so that the web is substantially parallel to the layers 31 and 32 from the assembled state shown in FIG. In turn, it may be possible for the bat 30 to be folded. Therefore, the web is connected to the top layer 31 and the bottom layer 32 in such a way as to allow such pivotal movement, such an arrangement or structure being disclosed in the above mentioned Australian patent. Therefore, the structure may be used in an insulating bat according to the invention, or an alternative structure may be used that allows the same foldable movement.

The insulating bat 30 of FIG. 1 includes four webs as shown. However, the present invention only needs to include webs 33 and 36 that are located along the side edges of the frame of bat 30. Intermediate webs 34 and 35 may be provided as needed to match the required structural properties of bat 30.

Between each of the webs shown in FIG. 1 are reinforcement means 37 to 39 in the form of corrugated insulation sheet reinforcement components. Each of the members 37-39 is formed of a plurality of sloping flats, as shown, which abut, in opposite, opposite directions to contact the inner surfaces of the top and bottom sheets 31 and 32, respectively. The facing vertices are formed. Reinforcing members 37-39 also extend in contact with webs 33-36.
The reinforcing members 37 to 39 support the frame of the heat insulating bat 30 in the lengthwise direction and prevent slack. Therefore, the bat 30 has great rigidity in the longitudinal direction L, and
Can be configured over a greater distance than would be possible without members 37-39. In addition, the use of thermal insulation sheets as the media for the reinforcing members 37-39 promotes better thermal insulation performance than without these sheets. Therefore, the corrugated heat insulating reinforcement members 37 to 39 have a dual function.

The insulating bat 30 can be advantageously folded by removing the corrugated stiffening members 37 to 39, after which the frame of the bat 30 can be folded to a flat condition. The members 37 to 39 can also be nested together. Therefore, it is easy to assemble the frame of the bat 30 and insert the reinforcing members 37 to 39 into the space segments 40 to 42 between the top layer 31 and the bottom layer 32 at the installation site, after which the bat Is ready for installation.

FIG. 2 shows an alternative insulating bat 50 having some of the properties of the insulating bat 30 of FIG. 1, so like parts have the same reference numbers plus 100.
However, the bat 50 differs from the bat 30 in the following points. That is, the bat 50
Differs in that a second layer has been added to include bottom layer 132, middle layer 51 and top layer 52. Such bats may be manufactured according to the methods disclosed in Australian Patent Nos. 511853 and 647948. Accordingly, bat 50 includes webs 53-56 extending between middle layer 51 and top layer 52. Webs 53 and 56 may be extensions of Webs 133-136, but Web 5
Manufacturing limits may require that 4 and 55 be formed separately from webs 134 and 135.

In the configuration shown in FIG. 2, stiffening members 137, 138, and 139 are disposed within space segments 140, 141, and 142. No reinforcing members are placed in the spaces 56 to 58, but reinforcing members can be inserted in these spaces if desired. Thus, the insulation bat 50 exhibits the flexibility provided by the present invention. For example, if additional reinforcement is needed,
Reinforcing members may also be included in only one of the space segments 56-58, or in two of the space segments, or in each of them. Thus, if the thermal insulation properties of bat 50 are required to be higher than that achievable with the configuration shown in FIG. 2, then one or more of space segments 56, 57, and 58 may be These requirements may be achieved by adding additional corrugated stiffeners that are placed.

FIG. 2 illustrates the flexibility that can be provided by the present invention. Therefore, the present invention can be applied to, for example, a four-layer insulating bat. The reinforcing members may be applied to each of the space segments in the bat, or to any of them as appropriate. The reinforcing member may be constructed of any suitable material. If the requirement of the stiffening member is to provide only rigidity with little insulation properties, the stiffening member may be composed of cardboard or board, for example. However, in a preferred configuration, the stiffening member is constructed of the same material as the frame of the insulating bat to enhance the insulating capacity of each bat.

Modifications, variations, and / or additions to the invention described herein are possible other than as specifically described, and the invention is thus within the spirit and scope of the above description. It should be understood to include all such changes, variations, and / or additions.

─────────────────────────────────────────────────── ─── Continued front page    (81) Designated countries EP (AT, BE, CH, CY, DE, DK, ES, FI, FR, GB, GR, IE, I T, LU, MC, NL, PT, SE, TR), OA (BF , BJ, CF, CG, CI, CM, GA, GN, GW, ML, MR, NE, SN, TD, TG), AP (GH, G M, KE, LS, MW, MZ, SD, SL, SZ, TZ , UG, ZW), EA (AM, AZ, BY, KG, KZ, MD, RU, TJ, TM), AE, AG, AL, AM, AT, AU, AZ, BA, BB, BG, BR, BY, B Z, CA, CH, CN, CR, CU, CZ, DE, DK , DM, DZ, EE, ES, FI, GB, GD, GE, GH, GM, HR, HU, ID, IL, IN, IS, J P, KE, KG, KP, KR, KZ, LC, LK, LR , LS, LT, LU, LV, MA, MD, MG, MK, MN, MW, MX, MZ, NO, NZ, PL, PT, R O, RU, SD, SE, SG, SI, SK, SL, TJ , TM, TR, TT, TZ, UA, UG, US, UZ, VN, YU, ZA, ZW (72) Inventor Bostrom, Michel             Australia, 2099 New South             Wales, Dee Why, Monash             Parade, 4 F-term (reference) 2E001 DD01 GA12 GA22 GA24 GA25                       GA47 GA48 GA87 HC07 HF11                 2E162 CC06 CE00 GA00 GA03 GB01                       GB05 [Continued summary] The intermediate sheet is formed as a corrugated sheet and has an upper sheet. Less of the bottom and bottom seats and intermediate seats One of them is made of reflective insulation foil, Is made.

Claims (22)

[Claims] 1. A building panel comprising a foldable frame in a generally rectangular or rectangular configuration that is foldable between a substantially flat state and an assembled state at installation, the frame comprising: Spaced and substantially parallel in the assembled state of the frame by two webs that are spaced apart and extend in a generally parallel longitudinal relationship along regions on either side of the frame; An overlapping top sheet and a bottom sheet, the web extending substantially perpendicular to the top sheet and the bottom sheet in the assembled state, and the top sheet and the bottom portion in the folded state. Disposed substantially parallel to the seat, the panel further comprising: when the frame is in the assembled state,
A building panel that includes a reinforcing member inserted between the top sheet and the bottom sheet to reinforce the panel and prevent folding. 2. The stiffening member is in the form of a sheet and is foldable between a substantially flat condition and an assembled condition, the stiffening member being formed in the assembled condition. The panel according to claim 1, wherein the panel is inserted between the top sheet and the bottom sheet of the frame. 3. The reinforcing member is formed as a member having a shape ready to be inserted between the top sheet and the bottom sheet of the frame, and the shape of the reinforcing member is a plurality of the shapes. The panel of claim 1, which is such as to allow nesting between the reinforcing members. 4. The reinforcing member has a corrugated shape for insertion into the frame, the corrugated shape extending continuously to contact the top sheet and the bottom sheet of the frame, respectively. A panel according to any one of claims 1 to 3, which defines sharp oppositely directed cusps. 5. The panel of claim 4, wherein the corrugated shape is a generally curved shape. 6. The panel of claim 4, wherein the corrugated shape comprises a substantially serrated shape. 7. A panel according to any one of claims 4 to 6, wherein the stiffening means is adapted to engage the web. 8. The panel is disposed between the webs in the regions on opposite sides of the frame, and extends substantially parallel to them, and in the assembled state of the frame, the upper sheet and the panel. Including at least one further web extending substantially perpendicular to the bottom sheet and further arranged in the folded state of the frame substantially parallel to the top sheet and the bottom sheet. The panel of any of claims 1-7, wherein the reinforcing means is provided between at least one pair of adjacent webs. 9. The panel of claim 8 including a single additional web. 10. The panel of claim 9, wherein the additional web is disposed substantially midway of the web in the side regions. 11. The panel of claim 8 including a pair of additional webs. 12. The frame includes an intermediate sheet disposed between and substantially parallel to the top and bottom layers, and further having substantially the same planar dimensions as them. , The web is configured to support the top sheet and the bottom sheet and the intermediate sheet in a spaced relationship.
The panel according to any one of claims 1 to 11. 13. The panel of any of claims 1-12, wherein the top sheet and bottom sheet and the web are formed from a cardboard or cardboard-like material. 14. The panel according to claim 1, wherein the panel is formed as a heat insulating bat and the top layer and the bottom layer are formed of a reflective heat insulating material. 15. The reinforcing member is formed of a reflective heat insulating material.
The panel described in. 16. A thermal insulation bat having a top sheet, a bottom sheet, and an intermediate sheet disposed between the top sheet and the bottom sheet and adhesively connected to each of the top sheet and the bottom sheet. And the intermediate sheet is
An insulating bat formed as a corrugated sheet, at least one of the top and bottom sheets and the intermediate sheet being formed from a reflective insulating foil to create a reflective air space. 17. A method for assembling a building panel having a foldable frame in a generally square or rectangular configuration, which is foldable between a substantially flat condition and an assembled condition, the frame comprising: , Spaced apart and substantially parallel in the assembled state of the frame by two webs that are spaced apart and extend in a generally parallel longitudinal relationship along opposite regions of the frame; A top sheet and a bottom sheet that overlap with each other, the web extending substantially perpendicular to the top sheet and the bottom sheet in the assembled state, and the web in the folded state and the top sheet and the bottom sheet. Disposed substantially parallel to the bottom sheet, the method comprising: spreading the frame to the assembled state; Inserting stiffening means between the top layer and the bottom layer of the frame. 18. A method for installing a building panel having a foldable frame in a generally square or rectangular configuration, which is foldable between a substantially flat state and an assembled state, the frame comprising: Are spaced apart and substantially parallel in the assembled state of the frame by two webs that are spaced apart and extend in a generally parallel longitudinal relationship along regions on either side of the frame, A top sheet and a bottom sheet overlying the web, the web extending substantially perpendicular to the top sheet and the bottom sheet in the assembled state and the top sheet in the folded state. Arranged substantially parallel to the bottom sheet, the method comprises, as a first step, a step of transporting the frame to an installation site. Or expanding the frame to the assembled state and inserting stiffening means between the top layer and the bottom layer of the frame, the method further comprising: Performing the other of the steps, and then placing the panel in a mounting position.
Method. 19. The transporting step is the first step performed.
19. The method of claim 18, wherein in the step, the frame is shipped in the folded state. 20. The reinforcing means can be folded between a substantially flat state and an assembled state, the method comprising transporting the reinforcing means in the flat state to the installation site. 20. Thereafter, spreading the stiffening means to the assembled state and inserting it into the frame. 21. The reinforcement means is formed as a member that can be nested with other reinforcement members, and the method includes the step of transporting a plurality of the reinforcement members in a nested state to the installation site. The method according to 18 or 19. 22. The method of any of claims 18-21, wherein the panel is an insulating bat.