WO1999066147A1

WO1999066147A1 - Webbed elements

Info

Publication number: WO1999066147A1
Application number: PCT/AU1999/000489
Authority: WO
Inventors: Dickory Rudduck
Original assignee: Dickory Rudduck
Priority date: 1998-06-17
Filing date: 1999-06-17
Publication date: 1999-12-23
Also published as: AUPP418298A0

Abstract

The invention provides a webbed element which has a first sheet (12) on which is located a web (13) of substantially zigzag configuration. In a preferred embodiment, a second sheet (11) is separated wholly or partially from the first sheet by the web of substantially zigzag configuration. The webbed element with the first sheet can be used to manufacture stairs, for example. The webbed element with first and second sheets can be used as a building panel, for example.

Description

WEBBED ELEMENTS

Technical Field

This invention relates to webbed elements. In particular, the invention concerns webbed elements such as panels and other elements which are suitable for use in the building industry. Although the invention is not limited to this application, for the sake of convenience the description below will relate to use of the webbed elements in the building industry.

Background Art

Particularly in the building industry, it is desirable to produce panels and other items which are relatively inexpensive while possessing a requisite amount of strength. Thus, panels, for example, are often made from fibre reinforced cement or plasterboard because these can be manufactured relatively inexpensively. Whilst such panels may be suitable for use in lining walls and similar applications, they lack the strength which would be required for use in load- bearing situations. For example, prior art panels would not be suitable for use in the construction of stairs.

It is an object of this invention to provide a panel suitable for use in the building industry, which is made of inexpensive material but which can be load-bearing.

Disclosure of the Invention

Accordingly, this invention provides a webbed element having a first sheet on which is located a web of substantially zigzag configuration. In a preferred embodiment, the webbed element has a second sheet separated wholly or partially from the first sheet by the web of substantially zigzag configuration.

In the preferred embodiment of the element of the invention, the first and second sheets may be made of any suitable material but are preferably fibre reinforced cement. The sheets may be parallel to one another or they may be formed otherwise - for example, one sheet may be planar while the other may form an arch, the ends of which converge with the first sheet. In this case, the web would have a zigzag configuration which has greater height at the highest point of the arch formed by the second sheet.

5 Preferably, the web of the webbed element of the invention, which is of generally zigzag configuration, has a series of first sections, each being inclined at a first angle to a second section, which in turn is inclined at a second angle to an adjoining first section. The first sections may be parallel to each other and the second sections may be parallel to each other. In some cases, the first angle iso the same as the second angle. In a particular webbed element, the first and second sections will generally be of equal size if the first and second sheets are parallel to each other or may vary in size if the ends of the first sheet converge with the second sheet, as described above.

The first and second angles may be relatively small, particularly where thes webbing element of the invention requires greater strength. Conversely, the first and second angles may be relatively large, where the element of the invention requires less strength. It will be appreciate that adjustment of the first and second angles can determine or contribute to the strength of the element of the invention. 0 It is further preferred that the first and/or second sheets has an inner surface which incorporates technology which facilitates location of the web or assists in stability. For example, an inner surface of one or both of the sheets may contain a series of parallel ribs or grooves which can be used to locate the angles of the web. As another example, the inner face of one or both of the sheets may5 contain ribs or grooves in a grid pattern. This can be particularly useful for locating webs which do not extend for the full length of the sheet. A sheet may also be capable of enabling remote location of the web, such as via a fixing system described in International Patent Application No. PCT/AU99/00185, the content of which is incorporated herein by reference. o Although this is not essential to the invention, the web is preferably orientated with regard to the first and second sheets so that the first angles of the web contact the inner surface of one sheet and the second angles contact the inner surface of the other sheet.

The web may be substantially co-extensive with the length and width of the sheets. Alternately, it may be optimised, by using a series of webs unconnected with each other. In addition, in the same element, one web may be orientated as set out above, while a second web, not connected with the first, may be rotated through 90 degrees.

Where the inner surface of a sheet has ribs, grooves, grids or other location means, these can be adapted to accommodate webs of different angles. In the case of a sheet having ribs or grooves extending throughout the length of the sheet, for example, the angles of the web may contact every rib or groove, or every second rib or groove, or every third rib or groove, etc.

Although the material of the web may be different from that of the pair of spaced sheets, it is preferred that the material is the same, particularly when the spaced sheets are made from fibre reinforced cement.

In addition, although this is not essential to the invention, as explained above, it is preferred that the web is orientated so that ducts are formed in the element. Ducts formed in this way can be useful for insulation, for the passage of air, for cabling or for filling with concrete or other material.

As a development of the formation of ducts, the web may form triangular ducts, either by connecting the open ends of some or all of the web, or by connecting the inclined sections of the web to form a series of "A" frames, for example.

While the web may be formed as a rigid zigzag structure, it is greatly preferred that the web is provided to the building site in flat sheets, appropriate scored and provided with hinges so that the web can be formed in situ.

Hinges are conveniently made of paper tape or from polysulphide or silicon. Any other suitable hinge may be used. Several are described below. It will be readily appreciate by one skilled in the art that if the element of the invention can be formed easily on site, after delivery to the site of flat packages comprising the sheets and the web in flat form, transport costs are greatly reduced as are costs connected with manufacture.

5 The web or the flat sheet from which the web is ultimately constructed may contain perforations, which can be used for the insertion of reinforcing through the web.

In another embodiment of this invention, the webbed element comprises a single sheet to which is attached a web of generally zigzag configuration. Thiso embodiment is particularly useful in the construction of stairs and steps.

Preferably, the web is reinforced with, for example, metal bars and appropriate parts of the web are filled with concrete to provide flat stair or step treads.

Brief Description of the Drawings

Figure 1 is an expanded view of a first embodiment of a webbed elements according to the invention;

Figure 2 is a non-expanded version of the embodiment of Figure 1 (on a slightly smaller scale);

Figure 3 is a perspective view of a second embodiment of the element of the invention; o Figure 4 is a perspective view of the inside surface of one sheet of the element having ribs;

Figure 5 is a perspective view of an alternate form of the inside of one sheet of the element, having a grid pattern;

Figure 6 shows yet another form of the inside surface of a sheet in the element of5 the invention, capable of remote location of a web thereon;

Figure 7 is a perspective view of one version of a web; Figure 8 shows in perspective view a series of three webs attached to a sheet;

Figure 9 shows in perspective view a part of a web similar to that in Figure 7 except that a triangle is formed in one part of the web;

Figure 10 shows in perspective view a web similar to that in Figure 9 except that the web includes perforations or apertures through which reinforcing bars can be passed;

Figure 11 shows the formation of ducts in a web, the ducts forming an "A" shape;

Figure 12 is a cross sectional view of the element in Figures 1 and 2;

Figure 13 is a cross sectional view of a further embodiment of the invention, having a different webbing angle from the embodiment in Figure 12;

Figure 14 shows how the web can be delivered in a flat form with paper tape in place;

Figure 15 is an edge view of the flat web of Figure 14;

Figure 16 shows the formation of the web from the panel in Figures 14 and 15;

Figure 17 shows a different version of the web, reinforced by mesh or a metal bar;

Figure 18 illustrates in cross section an embodiment of the element of the invention, the web being fixed using glue for example;

Figures 19 to 27 show various embodiments of hinges for the web;

Figure 28 illustrates in longitudinal sectional view an embodiment of the invention used for the construction of stairs;

Figure 29 is a perspective view of part of an embodiment of the web which has certain advantages in relation to packing, as explained below;

Figure 30 shows pairs of web sections engaged in an interlocking fashion; Figure 31 shows the pairs of web sections of Figure 30 disengaged and moved longitudinally one with respect to the other;

Figure 32 shows the same pair of web sections with one section having been rotated through 180°;

Figure 33 shows an embodiment similar to that in Figure 29 with reinforcing included;

Figure 34 shows an embodiment of the web wherein the slot shape is out of a truncated isosceles triangle;

Figure 35 shows a different slot arrangement; and

Figure 36 shows yet another slot arrangement.

Best Modes of Carrying out the Invention

Referring first to Figures 1 and 2, webbed element 10 has sheets 11 and 12 separated by web 13 which has a zigzag configuration except for returns 14 and 15. Sheet 11 is parallel to sheet 12.

The embodiment in Figure 3 has sheet 11 forming an arch. Web 13 is appropriately shaped. The ends of sheet 11 converge with sheet 12.

In Figure 4, sheet 12 has spaced parallel ribs 16. These could of course take the form of grooves instead of ribs. An angle of web 13 may be located at each of ribs 16, or at some ribs but not others.

Sheet 12 in Figure 5 has a grid pattern of ribs or grooves, some running longitudinally as indicated at 17 and some running transversely as indicated at 18. This permits location of web pieces either longitudinally or transversely, or a mixture of both.

The sheet in Figure 6 has locations, two of which are indicated at 19, which can permit fixing of web 13 to the appropriate sites, through remote fixing technology, such as that described in International Patent Application No. PCT/AU99/00185. As seen in Figure 7, web 13 has a number of first or upper angles 20 and a number of second or lower angles 21. When web 13 is attached to sheets 11 and 12, ducts 22 and 23 are formed for the passage of air, etc.

Figure 8 shows another configuration of web, being in separate sections 13a, 13b and 13c, showing these webs arranged in sheet 12. Gaps or corridors 24 and 25 may be left empty, or filled with reinforcement, or filled with concrete or other material, as desired.

Web 13 in Figure 9 is formed with paper tape or silicon hinges, as described in more detail below.

As shown in Figure 10, web 13 may include apertures 26 for the reception of reinforcement bars or the like.

Web 13 in Figure 11 shows the formation of "A" shaped ducts 61 which can be used to carry wires, for example.

Turning now to Figure 12, in this embodiment web 13 has at upper angles 20 and lower angles 21 an acute webbing angle of about 45°, with the resultant element 10 having considerably more strength than that in Figure 13, where angles 20 and 21 are obtuse. The element of Figure 12 may be suitable for construction of an external wall, whereas the element of Figure 13 may be used for an internal wall which requires less strength.

Referring now to Figures 14 to 16, web 13 can be manufactured and delivered to site in the form of a flat panel having individual sections 30, 31 and 32 (and further sections as desired). Section 30 is joined to section 31 by paper tape 33 and 34, while section 31 is joined to section 32 by paper tape 35 and 36. Alternately, web 13 is delivered to the site in one piece but incorporating perforated lines 37 and 38 (refer Figure 14).

To assemble web 13, sections 30, 31 and 32 may be positioned as shown in Figure 16, for example. This may cause the paper tape on each external edge (34,35) to rip, while the paper tape on the internal edges (33,36) remains intact, to create the necessary hinge. Alternately, it may be desirable to run a knife or blade down the paper tape on web 13 when in the flat form shown in Figures 14 and 15, to weaken or cut the tape before positioning sections 30, 31 and 32.

Referring now to Figure 17, this shows how webs 13 and 13A can be used to join annexed elements 10 and 10A. In the illustration, element 10A has sheets 11A and 12A separated by web 13A. Angle 21 A is positioned by rib 16A on sheet 12A and angle 20A is positioned by rib 16A on sheet 11A.

The second element 10 on the left hand side of the illustration is integrated with the right hand side element 10A by using returns 46A on web 13A and 48 on web 13. Return 46A, which is part of web structure 13A in the right hand element 10A is joined to both sheets 11 and 11 A, leaving an open joint 42. Return 48, which is part of web structure 13 in the left hand element 10, is joined to both sheets 12 and 12A, leaving a joint 44 which is filled with an appropriate material. In this illustration, two different types of hinge have been used - a paper tape type hinge 33A and a polysulphide type hinge 40. A mesh or reinforcing bar 38 can be inserted through holes 26 in web structures 13 and 13A. Alternately, cables or other services can be carried through holes or apertures 26 and 26A.

If desired, angles 21 and 21 A may be further stabilised against ribs 16 and 16A by the use of glue and angles 20 and 20A may similarly be glued to ribs 16 and 16A.

Figure 18 is a simplified version of an embodiment of the webbed element of the invention and emphasises that web 13 may be fixed to sheets 11 and 12 using various types of technology, including glue (which should be chosen as to the water resistance required for the product), "on board technology" such as ribbing or remote fixing.

Turning now to Figures 19 to 23, these illustrate various forms of hinges 50 which may be used to form web 13 which, in some illustrations, is shown as having sections 30 and 31. The full hinge 50 similar to that encountered in Figures 14 to 16 is shown in Figure 22. An "optimised" hinge 50 is shown in Figures 20 and 21. In Figure 19, hinge 50 has tongues 52 and 54. Tongue 54 is received in a corresponding groove in section 30. Tongue 52 can be received in a corresponding groove in Section 31 (not shown).

As shown in Figure 23, hinge 50 can be fixed in various ways to sections 30 and 31. Examples are fixing by glue, nailing or remote fixing at 51.

Note that in the embodiments shown in Figures 20 to 24, hinge 50 can rotate through 270° to accommodate varying angles between web sections.

Further examples of hinges are found in Figures 24 to 27, with the hinge clip 52 in Figure 27 being shown in greater detail in Figure 24. A cross section of the hinge clip 52 of Figures 24 and 27 is shown in Figure 25. Rather than positioning the hinge clips 52 at the top and bottom of sections 30 and 31 , the clips 52 may be positioned at intermediate locations as shown in Figure 26.

Turning now to Figure 28, sheet 12 has web 13 which in this case forms part of a set of stair treads. There is no sheet 11 in this embodiment. Web 13 in its vertical form comprises the riser for each step tread, while the tread itself is formed by back filling angle 21 with concrete 60. Concrete may also be used to fill in the space bound by sheet 12 and angle 20. If desired, reinforcing bar 38 is inserted through apertures 26 as already described, to strengthen the structure.

Figure 29 through to Figure 32 show a form of the web which enables the web 70 and its associated sheets 71 and 72 to be packed, with the dimensions of the web 70 prior to assembly being about the same as the dimensions of the sheets 71 or 72. (Where the web 13 is manufactured with hinges prior to dispatch, the flat width of the web 13 is about 1.4 times the width of the sheets 71 , assuming the web angles are approximately 45°.)

In the Figure 29-32 embodiment, each section 73, 74, 75 etc of the web is manufactured with a square saw-tooth configuration, as shown in Figure 30. By staggering each section, pairs of webs may be engaged together in an interlocking fashion, thereby reducing their combined width. By appropriate choice of 'tooth' depth, the width of the pair may be the same as the web's pitch when assembled. Assembly requires each pair of web sections to be separated and moved longitudinally so that each projecting tooth is opposite another projecting tooth, as in Figure 31. Adjacent portions may be affixed to each other by hinges or other means, as previously described, to form the web of Figure 29. Figure 32 shows an arrangement where section 73 has been rotated so its top is adjacent the bottom of section 74. This enables the assembled web to have all sections terminating at the same top and bottom positions.

A further advantage of this web is that reinforcement material 78 may be laid in the slots 76 so formed, as shown in Figures 32 and 33. The Figure 32 embodiment is provided with a slot 76 having a side wall which, when assembled, is angled downwards, so as to correctly position reinforcement material. If desired, other slot arrangements may be utilised, as shown in Figures 34 and 35. If desired, the slot shape may be a truncated isosceles triangle, so as to allow the Figure 32 configuration.

Figures 35 and 36 illustrate an enlargement of the area circled by 79 in Figure 33. Figure 35 shows in greater detail the angling downwards of the side wall in Figure 33. Figure 36 shows a different embodiment, where a groove is formed to accommodate reinforcement material 78.

Industrial Applicability

It will be readily apparent to one skilled in the art that the webbed elements of the present invention represent a significant advance on present technology used in the building industry. In particular, the elements of the invention have the capacity of maximising the use of fibre reinforced cement in walls and other forms to close to 100%. Assembly on site is simple and relatively "low-tech", requiring no special tools and hence low capital expenditure by builders and tradesmen.

The elements can be made in differing shapes, thicknesses and forms, depending on the geometry of the web. The elements can be left hollow or can be filled with concrete or other material eliminating the potential for corrosion and being an extremely low fire risk.

Particularly when the elements are made from fibre reinforced cement, the elements are made from components which have the same degree of expansion and contraction and which are more easily joined, by connecting "like to like".

The elements of the invention can be used to form the skeleton of many simple or complex shapes. All surfaces can be pre-finished and hence construction and finishing time can be reduced. Complex elements can be created without the need for formwork on or off site. The elements can offer good sound and heat insulation.

In some embodiments, all items can be flatpacked and thus reduce transportation volume, offering a comparatively low-cost solid wall option.

It will also be appreciated by one skilled in the art that the embodiments described are not intended to be limiting on the scope of the invention and that other variations are possible without departing from the spirit of the invention.

In particular, it will be appreciated that the element of the invention can be expanded to form stud sections that continue the benefits of a homogenous wall solution.

Claims

1. A webbed element having a first sheet on which is located a web of substantially zigzag configuration.

5 2. The webbed element of claim 1 , wherein the element has a second sheet separated wholly or partially from the first sheet by the web.

3. The webbed element of claim 2 wherein the first sheet is parallel to the second sheet and the first sheet is wholly separated from the second sheet by the web. o

4. The webbed element of claim 2, wherein the first sheet has ends which converge with the second sheet and the first sheet is partially separated from the second sheet by the web.

5. The webbed element of claim 1 or 2 wherein the web has a plurality of first sections, substantially each of which is inclined at a first angle to a second5 section which is inclined at a second angle to an adjoining first section.

6. The webbed element of claim 3, wherein the web has a plurality of first sections, substantially each of which is inclined at an angle to a second section which is inclined at the same angle to an adjoining first section.

7. The webbed element of claim 3 or 6, wherein at least one of the first ando second sheets has an inner surface which contains means adapted to locate the web.

8. The webbed element of claim 7, wherein the means are chosen from the group consisting of ribs, grooves and a grid pattern.

9. The webbed element of claim 3 or 4, wherein more than one web is located5 between the first and second sheets.

10.The webbed element of claim 5 or 6, wherein the first and second sections have spaces or apertures adapted to receive reinforcement.

11 The webbed element of claim 5 or 6, wherein each first and second section is joined by a third section to form a cavity.

5 12.The webbed element of claim 5 or 6 wherein a first section is annexed to a second section by means of a paper hinge or clip hinge.

13.The webbed element of claim 5 or 6, wherein the first section is annexed to the second section by glue.

14.The webbed element of claiml when used to form a staircase.

╬╣o 1 ╬┤.The webbed element of claim 2 when used to form a panel.

16.The webbed element of claim 1 wherein the first sheet and the web are made of fibre-reinforced cement.

17.The webbed element of claim 2 wherein the first and second sheets and the web are made of fibre-reinforced cement.

is 18.A method of manufacturing a web element as claimed in claim 1 , the method comprising annexing the web of substantially zigzag configuration to the first sheet.

19.A method of manufacturing the webbed element of claim 2, comprising the steps of assembling the web of substantially zigzag configuration from a flat 20 sheet and annexing the web so-formed to the first and second sheets.

20.The method of claim 19, wherein the flat sheet has score lines or perforations to delineate first and second sections of the web.

21 The method of claim 19, wherein the flat sheet comprises individual first and second sections connected by a hinge.

25 22.A webbed element substantially as herein described with reference to Figures 1 and 2 or 3 or 4 or 5 or 6 or 7 or 8 or 9 or 10 or 11 or 12 or 13 or 14, 15 and 16 or 17 or 18 or 19 or 20 and 21 or 22 or 23 or 24, 25 and 27 or 26 or 28 or 29, 30, 31 and 32 or 33 and 35 or 34 or 36 of the accompanying drawings.

23.A web for a webbed element, the web being of substantially zigzag configuration and being adapted to be located on a first sheet to form the webbed element.

24The web of claim 23, wherein the web is also adapted to be located in relation to a second sheet so as to separate the second sheet wholly or partially from the first sheet.