WO1997004196A1 - An interengaging modular wall - Google Patents

An interengaging modular wall Download PDF

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Publication number
WO1997004196A1
WO1997004196A1 PCT/AU1996/000458 AU9600458W WO9704196A1 WO 1997004196 A1 WO1997004196 A1 WO 1997004196A1 AU 9600458 W AU9600458 W AU 9600458W WO 9704196 A1 WO9704196 A1 WO 9704196A1
Authority
WO
WIPO (PCT)
Prior art keywords
panel
structural
facing
region
projecting
Prior art date
Application number
PCT/AU1996/000458
Other languages
French (fr)
Inventor
Michael John Cardinal
Original Assignee
Cardinal Drafting, Technical & Secretarial Services Pty. Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Cardinal Drafting, Technical & Secretarial Services Pty. Ltd. filed Critical Cardinal Drafting, Technical & Secretarial Services Pty. Ltd.
Priority to AU64096/96A priority Critical patent/AU705262B2/en
Priority to NZ312626A priority patent/NZ312626A/en
Publication of WO1997004196A1 publication Critical patent/WO1997004196A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/08—Interconnection of layers by mechanical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/292—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and sheet metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
    • B32B2315/06—Concrete
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Definitions

  • This invention relates to a structural wall panel and the like building elements used for the construction of walls, partitions and enclosures, a connecting system and method of forming such panels.
  • Such wall panels often comprise an inner and outer skin surface and a filling between these skin surfaces.
  • the nature of the filling varies depending on the use of the panels.
  • the inner and outer skin surfaces are generally connected together by side edges.
  • Corresponding side edges are provided on each panel to enable adjacent panels to interengage.
  • the most commonly found interengagement between adjacent panels is provided by a tongue and groove joint where one side edge of the adjacent side edges is provided with a tongue element which is received in the groove of the other of the adjacent side edges.
  • An object of the present invention is to provide an improved structural panel construction which is relatively inexpensive to manufacture and overcomes some of the difficulties of earlier structural panels.
  • the invention provides a structural panel formed from two opposed facing sheets, defining a space therebetween each facing sheet including a facing surface, a stepped region extending from said facing sheet offset from the plane of said facing surface, an end region defining an interlocking element which co-operates with a corresponding interlocking element from an adjacent panel and a joining means, said end region having a projecting flange which combines with the joining means of the opposed facing sheet to join said two opposed facing sheets together, said projecting flange and joining means from the opposed facing sheet forming a projecting element which co-operates with the connecting region of the adjacent panel to prevent relative transverse movement of the panels.
  • a connecting region of the panel is defined by the stepped region, projecting element and end region.
  • the projecting element may be received within the stepped region of the adjacent panel or fixture.
  • the stepped region of the connecting region defines one side of the interlocking element and the projecting flange element forms one side of the recess for receiving the corresponding interlocking element of the adjacent panel or fixture.
  • the joining means between the facing sheets may include joining flange providing a U-shaped fold at one end of the facing sheets, the U-shaped fold receiving the projecting flange of the other of the facing sheet in a folded seam to form the projecting element.
  • the stepped region, end region and the joining means are integrally formed in the facing sheets by a pressing operation.
  • the invention provides a structural panel having two facing surfaces and at least one connecting region adapted to connect with a corresponding region of an adjacent panel, the connecting region including a stepped region offset from the plane of the facing surfaces, an end region having an interlocking element and a recess to receive a corresponding interlocking element from the adjacent panel and a projecting element for co-operating with the connecting region of the adjacent panel to prevent movement of the panel in a direction transverse to the plane of the facing surfaces.
  • the stepped region defines one side of the interlocking element and the projecting element may form one side of the recess for receiving the correspondmg interlocking element of the adjacent panel or fixture.
  • the projecting element is capable of being received within the stepped region formed in the connecting region of the adjacent panel or fixture such that the outer surface of the projection is co-planar with the facing surface of the adjacent panel.
  • the progression across the end region from the interlocking element to the recess is gradual.
  • the interlocking element may be defined as an element distinct from the recess.
  • the invention provides a structural wall including a plurality of structural panels, each structural panel having two opposed facing sheets defining a space therebetween, said sheets including a facing surface, a stepped region extending from said facing surface offset from the plane of said facing surface, an end region defining an interlocking element and recess for receiving a corresponding interlocking element of an adjacent panel and a joining means, said end region having a projecting flange which combines with the joining means of the opposed facing sheet to form a projecting element and join said opposed facing sheets together, said projecting element co-operating with the stepped region of the adjacent panel to prevent relative movement of adjacent panels in a direction transverse to the surface of the facing surfaces.
  • the stepped region of the connecting region defines one side of the interlocking element and the projecting element forms one side of the recess for receiving the corresponding interlocking element of the adjacent panel.
  • the invention also provides a structural wall panel having an end connector for engaging with at least one adjacent wall panel to form a structural wall, and a facing surface, said end connector including a stepped region extending from said facing surface and offset from the plane of said facing surface and an end region including an interlocking element and recess for receiving a corresponding interlocking element from the end connector of an adjacent structural panel, the stepped region defining one side of the interlocking element and a projecting member adapted to be received within the stepped region of the adjacent panel defining one side of the recess.
  • It is another aspect of the invention to provide a method of forming a structural wall panel including the steps of pressing the end of a planar facing sheet to define a facing surface, a stepped region extending from the facing surface and offset from the plane of said surface, an interlocking element and a projecting flange, forming a joining means in the end of the facing sheet distal to the stepped region, positioning two facing sheets in opposed positions such that the projecting flange of each facing sheet is adjacent the joining means of the opposed facing sheet joining the joining means and projecting flange of each facing sheet to form projecting members at each end of the structural panel.
  • the joining means may be a joining flange which is folded onto the projecting flange of the opposed facing sheet to form a U-shaped folded seam.
  • a space defined between the two opposed facing sheets is filled with a suitable filler.
  • the abovementioned invention has the advantage of providing a structural panel in which the connecting end of the panel is substantially formed in a single pressing operation.
  • the invention is able to provide an end connector in which the interlocking element and recess to receive the interlocking element of an adjacent panel are formed in the same end thereby enabling the end connecting regions of a single panel to be substantially identically shaped.
  • the construction of walls and enclosures is simplified.
  • Figure 1 is a plan view of the interengagement between three panels in accordance with the invention
  • Figure 2 is a plan view of the facing sheet being formed in a brake press
  • Figure 3 is a plan view of two opposing sheets prior to being joined to form a panel shell
  • Figure 4 is a plan view demonstrating the pressing operation which joins the facing sheets of figure 3.
  • a structural wall panel 1 in accordance with the invention is shown in plan view connected to similar adjacent wall panels 2,3.
  • the structural panels include two facing sheets 4a,4b which define a space therebetween.
  • Each facing sheet is formed to provide a facing surface 5a, 5b an end region 7, a stepped region 8 and joining means.
  • the connecting region 6 of the panel includes the end region 7, stepped region 8 and projecting element 15.
  • the stepped region 8 extends from the facing surface 5 and is offset from the plane of the facing surfaces.
  • the connecting region 6 is adapted to co-operate with a corresponding connecting region 6a of an adjacent panel or fixture and further includes an interlocking element 9 formed in end section 7.
  • the end region 7 is also shaped to receive the interlocking element 9a of the adjacent panel or fixture within a recess 11.
  • the end region 7 of the facing sheets 4a, 4b are provided with a projecting flange 10 which cooperates with a joining means on the end of the opposing facing sheet distal to the connecting region of that facing sheet 4a.
  • the joining means is preferably a joining flange 12 (see Figure 3) which is folded back onto the projecting flange 10 in a U-shaped folded seam to form a projecting member 13.
  • One side of the interlocking element 9 is preferably defined by the stepped region 8 of the connecting region 6 and one side of the recess 11 is defined by the projecting member 13.
  • the progression across the end connecting region from the interlocking element to the recess may be gradual and continuous as shown in Figures 1 to 4 or it may be a discrete step so that the interlocking element and recess are clearly defined.
  • projecting elements 13 on either side of the panels provide further resistance to the relative movement of the panels in a direction transverse to the plane of the facing surfaces.
  • the outer surface of the projecting member 13 is co-planar with the facing surface so that a smooth wall surface can be obtained by simply filling the gaps 14 with a suitable sealer.
  • tek screws can be used to secure the projecting members 13, 13a to the stepped regions 8a, 8 of adjacent panels.
  • One advantage of the present invention is the provision of the interlocking element and recess (male/female components) on each end of the panel providing essentially a universal connection.
  • Each end of a structural panel in accordance with the invention is able to engage with either end of an adjacent panel thereby obviating the need to match corresponding ends of adjacent panels when constructing a wall, enclosure or the like.
  • each panel is substantially identical thereby reducing the number of different sections used to construct a structural panel.
  • Another advantage of the invention is that the construction of a panel requires less manufacturing steps.
  • facing sheets of sheet metal are pressed between two brake press dies 20,21 as shown in Figure 2, to form the connecting region 6 of a panel.
  • the connecting region 6 includes a stepped region 8, and an end region 7 having an interlocking element 9, recess 11 and projecting flange 10.
  • the end of the facing sheet distal from the end connector region 6 preferably has a joining flange 12 formed therein as a joining means between two opposed facing sheets.
  • the opposed facing sheets are joined together by aligning the facing sheets on a press anvil or platen 23 so that the projecting flange is against the back side of the opposed facing sheet, in proximity to the joining flange 12.
  • An actuated ram 22 then folds the joining flange 12 back onto the projecting flange 10 preferably in a folded seam to form projecting member 13.
  • the identical operation is then performed on the diagonally opposite corner of the panel to complete the panel shell.
  • the facing sheets of the structural panel form the outer shell for the panel and may be constructed of any material suitable for the required application and preferably is steel, aluminium or other type of sheet metal.
  • the space defined within the panel shell may be filled with a suitable structural filling material.
  • the nature of the filling material will vary depending on the application of the panel, for example if the panel is to be used on modular security enclosures, the panel shell can be filled with cellular concrete. If a lightweight acoustic panel is required, insulating material such as rockwool may be used. Alternatively, if thermal insulation is required, a foamed thermal insulation material well known to the trade may be used.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Finishing Walls (AREA)
  • Joining Of Building Structures In Genera (AREA)

Abstract

A structural panel (5) and a method of forming the structural panel is disclosed. The structural panel is formed from two opposed facing sheets which are joined together to define a space therebetween. Each facing sheet includes a facing surface (5), and end region (7), a stepped region (8) and a joining means. The end region (7) is shaped to form an interlocking element and recess for receiving a corresponding interlocking element from an adjacent panel and a projecting flange (10). The projecting flange co-operates with the joining means of the opposed facing sheet to join the opposed facing sheets together and form a projecting element. When two panels are engaged, the projecting element (13) co-operates with the stepped region (8) of the adjacent panel to prevent relative transverse movement between the adjacent panels. The panel construction in accordance with the invention enables facing sheets having substantially identical connecting regions to be formed thereby avoiding the need to align male/female connections when constructing a modular wall.

Description

AN INTERENGAGING MODULAR WALL PANEL
This invention relates to a structural wall panel and the like building elements used for the construction of walls, partitions and enclosures, a connecting system and method of forming such panels. Background of the Invention
In the building industry, the construction of walls, panels enclosures and the like using modular wall panels is well known. Such wall panels often comprise an inner and outer skin surface and a filling between these skin surfaces. The nature of the filling varies depending on the use of the panels. The inner and outer skin surfaces are generally connected together by side edges. Corresponding side edges are provided on each panel to enable adjacent panels to interengage. To prevent transverse movement between adjacent panels which have been positioned, the most commonly found interengagement between adjacent panels is provided by a tongue and groove joint where one side edge of the adjacent side edges is provided with a tongue element which is received in the groove of the other of the adjacent side edges.
While such an interengagement system enables structural panels to be securely connected, the need to not only provide two types of side edges but also the additional manufacturing steps of joining the two skin surfaces and the side edges represent a major cost component in the production of such wall panels.
Furthermore, when a number of structural panels are to be joined together, care must be taken to ensure that a male side edge is aligned with the female side edge of the adjacent panel to ensure interengagement between the panels. Disclosure of the Invention An object of the present invention is to provide an improved structural panel construction which is relatively inexpensive to manufacture and overcomes some of the difficulties of earlier structural panels.
Accordingly, the invention provides a structural panel formed from two opposed facing sheets, defining a space therebetween each facing sheet including a facing surface, a stepped region extending from said facing sheet offset from the plane of said facing surface, an end region defining an interlocking element which co-operates with a corresponding interlocking element from an adjacent panel and a joining means, said end region having a projecting flange which combines with the joining means of the opposed facing sheet to join said two opposed facing sheets together, said projecting flange and joining means from the opposed facing sheet forming a projecting element which co-operates with the connecting region of the adjacent panel to prevent relative transverse movement of the panels.
In a preferred form of the invention, a connecting region of the panel is defined by the stepped region, projecting element and end region. The projecting element may be received within the stepped region of the adjacent panel or fixture. Preferably, the stepped region of the connecting region defines one side of the interlocking element and the projecting flange element forms one side of the recess for receiving the corresponding interlocking element of the adjacent panel or fixture.
The joining means between the facing sheets may include joining flange providing a U-shaped fold at one end of the facing sheets, the U-shaped fold receiving the projecting flange of the other of the facing sheet in a folded seam to form the projecting element.
The stepped region, end region and the joining means are integrally formed in the facing sheets by a pressing operation.
In another aspect, the invention provides a structural panel having two facing surfaces and at least one connecting region adapted to connect with a corresponding region of an adjacent panel, the connecting region including a stepped region offset from the plane of the facing surfaces, an end region having an interlocking element and a recess to receive a corresponding interlocking element from the adjacent panel and a projecting element for co-operating with the connecting region of the adjacent panel to prevent movement of the panel in a direction transverse to the plane of the facing surfaces.
It is preferably that the stepped region defines one side of the interlocking element and the projecting element may form one side of the recess for receiving the correspondmg interlocking element of the adjacent panel or fixture. Preferably the projecting element is capable of being received within the stepped region formed in the connecting region of the adjacent panel or fixture such that the outer surface of the projection is co-planar with the facing surface of the adjacent panel.
In a preferred form, the progression across the end region from the interlocking element to the recess is gradual.
Alternatively, the interlocking element may be defined as an element distinct from the recess.
In another aspect the invention provides a structural wall including a plurality of structural panels, each structural panel having two opposed facing sheets defining a space therebetween, said sheets including a facing surface, a stepped region extending from said facing surface offset from the plane of said facing surface, an end region defining an interlocking element and recess for receiving a corresponding interlocking element of an adjacent panel and a joining means, said end region having a projecting flange which combines with the joining means of the opposed facing sheet to form a projecting element and join said opposed facing sheets together, said projecting element co-operating with the stepped region of the adjacent panel to prevent relative movement of adjacent panels in a direction transverse to the surface of the facing surfaces.
Preferably the stepped region of the connecting region defines one side of the interlocking element and the projecting element forms one side of the recess for receiving the corresponding interlocking element of the adjacent panel. The invention also provides a structural wall panel having an end connector for engaging with at least one adjacent wall panel to form a structural wall, and a facing surface, said end connector including a stepped region extending from said facing surface and offset from the plane of said facing surface and an end region including an interlocking element and recess for receiving a corresponding interlocking element from the end connector of an adjacent structural panel, the stepped region defining one side of the interlocking element and a projecting member adapted to be received within the stepped region of the adjacent panel defining one side of the recess.
It is another aspect of the invention to provide a method of forming a structural wall panel including the steps of pressing the end of a planar facing sheet to define a facing surface, a stepped region extending from the facing surface and offset from the plane of said surface, an interlocking element and a projecting flange, forming a joining means in the end of the facing sheet distal to the stepped region, positioning two facing sheets in opposed positions such that the projecting flange of each facing sheet is adjacent the joining means of the opposed facing sheet joining the joining means and projecting flange of each facing sheet to form projecting members at each end of the structural panel.
The joining means may be a joining flange which is folded onto the projecting flange of the opposed facing sheet to form a U-shaped folded seam. Preferably a space defined between the two opposed facing sheets is filled with a suitable filler.
The abovementioned invention has the advantage of providing a structural panel in which the connecting end of the panel is substantially formed in a single pressing operation.
The invention is able to provide an end connector in which the interlocking element and recess to receive the interlocking element of an adjacent panel are formed in the same end thereby enabling the end connecting regions of a single panel to be substantially identically shaped. As a consequence, the construction of walls and enclosures is simplified. Description of the Drawings and Preferred Embodiment The forgoing and other features, objects and advantages of the present invention will become more apparent from the description of the prefeπed embodiment and accompanying drawings, in which:-
Figure 1 is a plan view of the interengagement between three panels in accordance with the invention; Figure 2 is a plan view of the facing sheet being formed in a brake press;
Figure 3 is a plan view of two opposing sheets prior to being joined to form a panel shell;
Figure 4 is a plan view demonstrating the pressing operation which joins the facing sheets of figure 3. Referring to Figure 1, a structural wall panel 1 in accordance with the invention is shown in plan view connected to similar adjacent wall panels 2,3. The structural panels include two facing sheets 4a,4b which define a space therebetween. Each facing sheet is formed to provide a facing surface 5a, 5b an end region 7, a stepped region 8 and joining means.
The connecting region 6 of the panel includes the end region 7, stepped region 8 and projecting element 15. The stepped region 8 extends from the facing surface 5 and is offset from the plane of the facing surfaces. The connecting region 6 is adapted to co-operate with a corresponding connecting region 6a of an adjacent panel or fixture and further includes an interlocking element 9 formed in end section 7. The end region 7 is also shaped to receive the interlocking element 9a of the adjacent panel or fixture within a recess 11.
The end region 7 of the facing sheets 4a, 4b are provided with a projecting flange 10 which cooperates with a joining means on the end of the opposing facing sheet distal to the connecting region of that facing sheet 4a. The joining means is preferably a joining flange 12 (see Figure 3) which is folded back onto the projecting flange 10 in a U-shaped folded seam to form a projecting member 13.
One side of the interlocking element 9 is preferably defined by the stepped region 8 of the connecting region 6 and one side of the recess 11 is defined by the projecting member 13. The progression across the end connecting region from the interlocking element to the recess may be gradual and continuous as shown in Figures 1 to 4 or it may be a discrete step so that the interlocking element and recess are clearly defined.
When the connecting region 6 of one panel interengages with the connecting region 6a of an adjacent panel 2, the interlocking element 9 of end region 7 is received within the recess lla of the end region 7a of the adjacent panel 2, 3. The projecting member 13 is received within the stepped region 8a of the adjacent connecting region.
When adjacent panels are connected together, projecting elements 13 on either side of the panels provide further resistance to the relative movement of the panels in a direction transverse to the plane of the facing surfaces. Preferably the outer surface of the projecting member 13 is co-planar with the facing surface so that a smooth wall surface can be obtained by simply filling the gaps 14 with a suitable sealer. To further secure adjacent panels together, tek screws can be used to secure the projecting members 13, 13a to the stepped regions 8a, 8 of adjacent panels.
One advantage of the present invention is the provision of the interlocking element and recess (male/female components) on each end of the panel providing essentially a universal connection. Each end of a structural panel in accordance with the invention is able to engage with either end of an adjacent panel thereby obviating the need to match corresponding ends of adjacent panels when constructing a wall, enclosure or the like.
Additionally, the opposed facing sheets 5 of each panel are substantially identical thereby reducing the number of different sections used to construct a structural panel. Another advantage of the invention is that the construction of a panel requires less manufacturing steps.
To construct a structural panel in accordance with the invention, facing sheets of sheet metal are pressed between two brake press dies 20,21 as shown in Figure 2, to form the connecting region 6 of a panel. The connecting region 6 includes a stepped region 8, and an end region 7 having an interlocking element 9, recess 11 and projecting flange 10. The end of the facing sheet distal from the end connector region 6 preferably has a joining flange 12 formed therein as a joining means between two opposed facing sheets. The opposed facing sheets are joined together by aligning the facing sheets on a press anvil or platen 23 so that the projecting flange is against the back side of the opposed facing sheet, in proximity to the joining flange 12.
An actuated ram 22 then folds the joining flange 12 back onto the projecting flange 10 preferably in a folded seam to form projecting member 13. The identical operation is then performed on the diagonally opposite corner of the panel to complete the panel shell.
The facing sheets of the structural panel form the outer shell for the panel and may be constructed of any material suitable for the required application and preferably is steel, aluminium or other type of sheet metal. The space defined within the panel shell may be filled with a suitable structural filling material. The nature of the filling material will vary depending on the application of the panel, for example if the panel is to be used on modular security enclosures, the panel shell can be filled with cellular concrete. If a lightweight acoustic panel is required, insulating material such as rockwool may be used. Alternatively, if thermal insulation is required, a foamed thermal insulation material well known to the trade may be used.
It can be seen that by using the end connecting region in accordance with the present invention, a structural panel can be produced which is less expensive to instal. Furthermore, during the manufacture of the panel, less manufacturing steps are required thereby reducing the overall cost of the panel.

Claims

CLAJMS;
1. A structural panel formed from two opposed facing sheets, defining a space therebetween each facing sheet including a facing surface, a stepped region extending from said facing sheet offset from the plane of said facing surface, an end region defining an interlocking element which co-operates with a corresponding interlocking element from an adjacent panel and a joining means, said end region having a projecting flange which combines with the joining means of the opposed facing sheet to join said two opposed facing sheets together, said projecting flange and joining means from the opposed facing sheet forming a projecting element which co-operates with the connecting region of the adjacent panel to prevent relative transverse movement of the panels.
2. The structural panel of claim 1 wherein the projecting element is received within the stepped region of the adjacent panel.
3. The structural panel according to claim 1 wherein the stepped region of said facing sheet defines one side of the interlocking element and the projecting flange element defines a side of the recess for receiving the corresponding interlocking element of the adjacent panel.
4. The structural panel of claim 1 wherein the joining means between the facing sheets includes a joining flange adapted to form a U-shaped fold at one end of the facing sheets, the U-shaped fold receiving the projecting flange of the facing surface of the opposed facing sheet in a folded seam to form the projecting flange element.
5. The structural panel according to claim 4 wherein the stepped region, end region and projecting flange are integrally formed in the facing sheets by a pressing operation.
6. The structural panel according to claim 3 wherein the interlocking element formed in the end region of the facing sheet is substantially the same shape as the interlocking element formed in the opposed facing sheet.
7. The structural panel according to claim 3 wherein the opposed facing sheets are substantially the same shape.
8. The structural panel according to claim 3 wherein the end region, stepped region and projecting element define the connecting region of each panel, the connecting region at each end of the panel being substantially the same shape.
9. The structural panel having two facing surfaces and at least one connecting region adapted to connect with a corresponding region of an adjacent panel, the connecting region including a stepped region offset from the plane of the facing surfaces, an end region having an interlocking element and a recess to receive a corresponding interlocking element from the adjacent panel and a projecting element for co-operating with the connecting region of the adjacent panel to prevent movement of the panel in a direction transverse to the plane of the facing surfaces.
10. The structural panel according to claim 9 wherein the stepped region defines one side of the interlocking element and the projecting element forms one side of the recess for receiving the corresponding interlocking element of the adjacent panel.
11. The structural panel according to claim 10 wherein the projecting element is capable of being received within the stepped region formed in the connecting region of the adjacent panel, such that the outer surface of the projection is coplanar with the facing surface of the adjacent panel.
12. The structural panel according to claim 1 wherein the space between the opposed facing sheets is filled with a structural filler.
13. The structural panel according to claim 12 wherein the structural filler is selected from the group including a sound insulating material, a thermal insulating material, and a lightweight cellular concrete.
14. The structural panel according to claim 9 having two connecting regions, said connecting regions being formed by the joining of two substantially identical facing sheets, each facing sheet including an end region, a facing surface, a stepped region and a joining flange.
15. The modular wall including a plurality of structural panels, each structural panel having two opposed facing sheets defining a space therebetween, said sheets including a facing surface, a stepped region extending from said facing surface offset from the plane of said facing surface, an end region defining an interlocking element and recess for receiving a corresponding interlocking element of an adjacent panel and a joining means, said end region having a projecting flange which combines with the joining means of the opposed facing sheet to form a projecting element and join said opposed facing sheets together, said projecting element co-operating with the stepped region of the adjacent panel to prevent relative movement of adjacent panels in a direction transverse to the surface of the facing surfaces.
16. The modular wall according to claim 15 wherein the stepped region of the opposed facing sheets in each structural panel defines one side of the interlocking element and the projecting element forms one side of the recess for receiving the interlocking element of an adjacent panel.
17. The modular wall according to one of claims 15 or 16 wherein the joining means is a joining flange adapted to form a U-shaped fold at one end of the facing sheets, the U-shaped fold receiving the projecting flange ofthe opposed facing sheet in a folded seam to form the projecting element.
18. The modular wall according to claim 15 wherein the facing sheets for each structural panel are substantially identical.
19. The modular wall according to claim 15 wherein the space formed in the structural panels is filled with a structural filler.
20. The modular wall according to claim 19 wherein the structural panels are filled with a structural filler selected from the group including a sound insulating material, a thermal insulating material and a lightweight cellular concrete.
21. A method of forming a structural wall panel including the steps of pressing the end of a planar facing sheet to define a facing surface, a stepped region extending from the facing surface and offset from the plane of said surface, an interlocking element and a projecting flange, forming a joining means in the end of the facing sheet distal to the stepped region, positioning two facing sheets in opposed positions such that the projecting flange of each facing sheet is adjacent the joining means of the opposed facing sheet joining the joining means and projecting flange of each facing sheet to form projecting members at each end of the structural panel.
22. The method of forming a structural wall panel according to claim 21 wherein the joining means is a joining flange which is folded onto the projecting flange of the opposed facing sheet to form a U-shaped folded seam.
23. The method of forming a structural wall panel according to claim 22 wherein the space defined between the two opposing facing sheets is filled with a structural filler.
24. The method of forming a structural wall panel according to claim 23 wherein the structural filler is selected from the group including a sound insulating material, a thermal insulating material and a cellular lightweight concrete.
25. A structural wall panel having an end connector for engaging with at least one adjacent wall panel to form a structural wall, and a facing surface, said end connector including a stepped region extending from said facing surface and offset from the plane of said facing surface and an end region including an interlocking element and recess for receiving a corresponding interlocking element from the end connector of an adjacent structural panel, the stepped region defining one side of the interlocking element and a projecting member adapted to be received within the stepped region of the adjacent panel defining one side of the recess.
26. The structural wall panel according to claim 25 wherein the interlocking element of the end connector of adjacent panels is substantially identical in shape.
PCT/AU1996/000458 1995-07-20 1996-07-19 An interengaging modular wall WO1997004196A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
AU64096/96A AU705262B2 (en) 1995-07-20 1996-07-19 An interengaging modular wall panel
NZ312626A NZ312626A (en) 1995-07-20 1996-07-19 An interengaging modular wall panel

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AUPN4280A AUPN428095A0 (en) 1995-07-20 1995-07-20 A structural panel
AUPN4280 1995-07-20

Publications (1)

Publication Number Publication Date
WO1997004196A1 true WO1997004196A1 (en) 1997-02-06

Family

ID=3788615

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU1996/000458 WO1997004196A1 (en) 1995-07-20 1996-07-19 An interengaging modular wall

Country Status (3)

Country Link
AU (1) AUPN428095A0 (en)
NZ (1) NZ312626A (en)
WO (1) WO1997004196A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11933226B2 (en) * 2022-05-13 2024-03-19 Rtx Corporation Heat shield and method of installing the same

Citations (6)

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GB2057529A (en) * 1979-09-21 1981-04-01 Vale D Building panels and building constructions
AU4857785A (en) * 1984-10-11 1986-04-17 Hong Sheet Metal Pte Limited. Building panel
GB2168732A (en) * 1984-12-24 1986-06-25 Hoesch Ag Wall or roof elements composed of a foamed core and metallic covering layers with tongue and groove snap joint
AU2095288A (en) * 1987-08-14 1989-02-16 Richard Laurance Lewellin Insulation body
GB2234997A (en) * 1989-08-15 1991-02-20 Presco Int Wall panel edge connexion
EP0568227A1 (en) * 1992-04-23 1993-11-03 Hunter Douglas Industries B.V. Fire resistant sandwich panel

Patent Citations (6)

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Publication number Priority date Publication date Assignee Title
GB2057529A (en) * 1979-09-21 1981-04-01 Vale D Building panels and building constructions
AU4857785A (en) * 1984-10-11 1986-04-17 Hong Sheet Metal Pte Limited. Building panel
GB2168732A (en) * 1984-12-24 1986-06-25 Hoesch Ag Wall or roof elements composed of a foamed core and metallic covering layers with tongue and groove snap joint
AU2095288A (en) * 1987-08-14 1989-02-16 Richard Laurance Lewellin Insulation body
GB2234997A (en) * 1989-08-15 1991-02-20 Presco Int Wall panel edge connexion
EP0568227A1 (en) * 1992-04-23 1993-11-03 Hunter Douglas Industries B.V. Fire resistant sandwich panel

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11933226B2 (en) * 2022-05-13 2024-03-19 Rtx Corporation Heat shield and method of installing the same

Also Published As

Publication number Publication date
AUPN428095A0 (en) 1995-08-10
NZ312626A (en) 1999-04-29

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