WO2010144951A1 - Panneau mural thermique, système de construction et procédés d'utilisation et de construction associés - Google Patents

Panneau mural thermique, système de construction et procédés d'utilisation et de construction associés Download PDF

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Publication number
WO2010144951A1
WO2010144951A1 PCT/AU2010/000735 AU2010000735W WO2010144951A1 WO 2010144951 A1 WO2010144951 A1 WO 2010144951A1 AU 2010000735 W AU2010000735 W AU 2010000735W WO 2010144951 A1 WO2010144951 A1 WO 2010144951A1
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WO
WIPO (PCT)
Prior art keywords
thermal
wall panel
thermal wall
panel
board
Prior art date
Application number
PCT/AU2010/000735
Other languages
English (en)
Inventor
Stephen Tyralik
Original Assignee
Stephen Tyralik
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
Priority claimed from AU2009902751A external-priority patent/AU2009902751A0/en
Application filed by Stephen Tyralik filed Critical Stephen Tyralik
Publication of WO2010144951A1 publication Critical patent/WO2010144951A1/fr

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Classifications

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    • 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
    • E04C2/296—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 non-metallic or unspecified sheet-material
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    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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Definitions

  • the present invention relates to thermal wall panels, building systems and methods of use and construction of such thermal wall panels and building systems, such as for use in constructing low cost walls, housing or buildings.
  • one aspect of the present invention provides a thermal wall panel incorporating a layer of a thermal material sandwiched between first and second layers of board, the first and second layers forming respective inner and outer facings of the panel.
  • the board may be magnesium oxide (MgO) board. Whilst MgO board has been found to be particularly effective, other board materials are considered usable, such as cement based boards.
  • the thermal material may be extruded polystyrene (XPS), preferably high density (HD) XPS, or Expanded polystyrene (EPS), or a combination of both, such as a lamination of both.
  • XPS extruded polystyrene
  • HD high density
  • EPS Expanded polystyrene
  • a third layer of MgO board and a polypropylene honeycomb panel or metal (aluminium) honeycomb panel may be provided between the thermal material and the outer facing layer of MgO board.
  • an additional external coating may be provided on the panel.
  • This may include a spray or paint on coating, such as a paint or sealant, or a render type coating, or combinations of both.
  • a metal or plastic mesh may be applied to the external surface of the outer and/or inner facing, which may be used to assist an exterior or interior use coating or finish to be applied, such as a decorative coating, by providing increased adhesion properties.
  • the MgO board may be bonded to the thermal material by an adhesive.
  • other optional components of the panel such as the preferred polypropylene or metal honeycomb panels may also be bonded with adhesive when forming embodiments of the panel.
  • a thermal wall panel construction system provides a lower track and an upper track, the lower track and upper track arranged to retain therebetween a plurality of thermal wall panels, the lower track arranged to be fastened, in use, to a floor or base of a building, the upper track arrange to form an upper extent of a wall section formed by said thermal wall panels, wherein each said wall panel includes an elongate recess along at least one upright side edge thereof such that adjacent said thermal wall panels form therebetween an upright channel defined by said adjacent upright elongate recesses, and wherein an elongate support member extends through each said upright channel and each said elongate support member is fastened, in use, to said lower and upper tracks.
  • the elongate recesses are 52mmx26mm of rectangular section such that a square channel section is formed when two such recesses are brought together.
  • Double story construction requiring thicker elongate upright supports and therefore requiring wider and/or deeper recesses to accommodate such thicker elongate supports.
  • the thermal wall panels may include one or more of the thermal wall panels according to embodiments of the thermal wall panels of the present invention.
  • the thermal wall panel construction system of at least one form of the present invention provides an efficient walling system that is relatively quick to construct whilst providing required thermal properties.
  • the elongate recess or 'slot' in the side(s) of each panel assist to stabilise the thermal wall panel in the walling system.
  • the upper and/or lower tracks may include one or more apertures therethrough for receiving therethrough an end of a respective elongate support member.
  • the elongate support member may include one or more flanges at one or more ends thereof. Such flanges may be used as fastening flanges for attaching the elongate support member to upper and/or lower side edges of each respective panel, the upper and lower side edges extending, in use, generally horizontally between the upright side edges of each respective thermal wall panel.
  • separate fastening plates may be provided to fasten the elongate support member to the respective track. Screw, bolt and/or rivet fastenings may be used.
  • the flanges or plates may be used to attach the elongate support members to the upper and preferably lower tracks for strength and stability.
  • the upper and/or lower tracks are U channel sections, more preferably with flat bases to the U section for stability in use.
  • the upper and/or lower tracks do not have apertures for receiving the respective elongate support member therethrough
  • welding may be used to attach the elongate support members to the track(s).
  • riveting or other fastening, such as screw fastening, through a side wall of the respective elongate support member and 'leg(s)' of the U section channel(s) may effect attachment one to the other.
  • the thermal wall panels may include one or more reinforcing member apertures therethrough from an upper side face to a lower side face.
  • One or more reinforcing members may pass through a respective said reinforcing member aperture.
  • the reinforcing members may be fastened to the respective upper and/or lower tracks, or the reinforcing members may be fastened one to the other to provide strength and stability to the thermal walling system.
  • the reinforcing members may be reinforcing rods, such as rebar or steel or aluminium rods or bars, or timber members.
  • the reinforcing members may be attached together by welding for strength and structural integrity, eg at 1 metre or so intervals.
  • each reinforcing member may extend beyond the upper track by an amount sufficient to allow attachment between one such member and another, eg 10-50 mm, preferably between 20 and 40mm, and more preferably around 25-30mm.
  • Expanded Polystyrene System is light in weight with high thermal insulation properties, versatility and is environmentally friendly.
  • the use of steel in prefabrication products also ensures strength ratio and load bearing qualities are maintained.
  • the use of metal sheets or honeycomb panels advantageously gives bracing characteristics, such as when sandwiched between outer layers of (expanded) polystyrene of any required thickness.
  • the base or floor is commonly either concrete slab(s) or above the ground construction using posts spaced at intervals with a suspended floor. These posts will vary in thickness depending on design specifications and win be erected at corners and load transfer points as determined.
  • Top and bottom plates may be connected to the posts around the periphery of the house.
  • a building system utilises a track and frame system using channels, such as 'C channels.
  • a lower channel may be fixed in place, such as anchoring to the concrete base or floor or to a timber floor structure. This lower channel may be between the vertical posts to stabilize the thermal wall panel(s) from moving.
  • the thermal wall panel is guided into the lower channel it is affixed to an upper support or 'top plate' using one or more fasteners, such as self tapping screws.
  • This procedure may be limited to forming one or more walls or continued around the building (such as a low cost house).
  • Markings for doorways or window openings may be provided or pre- marked during construction, or alternatively the window and door openings may be formed by or built around by the thermal wall panels.
  • the thermal wall panel walling may be provided in a variety of forms and styles.
  • an enhanced coating system may be provided reinforced with an alkaline mesh for the internal face.
  • a metal (steel) mesh eg 2 inch or 50mm mesh
  • a stand off spacing to allow for utilities such as phone, gas, electrical and other services between the panel outer face and the mesh so they can be installed into the wall with ease.
  • One or more forms of the present invention may utilise an external coating of sprayed concrete or 'shotcrete' or other rendered surface finish.
  • a minimum SO-60mm thick concrete coating may be applied using a process called 'shotcrete'. This concrete coat may be used to bear the main load of the external wall.
  • An alternative thermal wall system of the present invention utilises multiple thermal wall panels of embodiments of the present invention, which may use the same mesh coating system on either side (internal and external faces) which may include different panel thicknesses depending on required thermal qualities or specifications.
  • the panels may be roller pressed or glued between a metal sheet for bracing and/or a honeycomb panel to allow added strength.
  • Forms of the present invention seek to provide a construction system and a thermal wall panel for use therein for use in effecting low cost housing, with the desire of substantially reducing overall construction costs, maintain or improve thermal properties of the wall(s) or building compared to present contemporary building methods.
  • the present proposed residential building system and methods according to forms of the present invention provide an inspirational platform for significant reduction both in building costs and lead-time to building completion, as well as seeking to maintain or improve thermal qualities of the constructed walling.
  • the present invention proposes an alternative to the standard procedures of double-brick and timber and plasterboard stud-wall methods.
  • At least one form of the present invention utilizes a structural insulated sandwich thermal wall panel.
  • a thermal wall panel may include a structural metal plate bonded between a thermal material layer either side of the plate.
  • the thermal material may preferably be expanded or extruded polystyrene, such as EPS or XPS, preferably of high density (HD).
  • the metal plate may be a steel or aluminium plate providing structural support and rigidity to the panel, and may include a textured or open surface for improved adhesion of the thermal material.
  • the thermal wall panel provides an outer wall face and an 'Expanded Polystyrene System' (EPS) which represents the inner-wall face.
  • EPS 'Expanded Polystyrene System'
  • the outer-wall face may include a composition of welded wire frame; vertical posts which is then held together by a layer of S0-60mm thick spray-on 'shotcrete' application to the external outer-wall.
  • the inner wall face may consist of (EPS) panels of predetermined widths with reinforced coating of alkaline mesh.
  • the (EPS) consists of panels joined together, which also provide rigidity for wind bracing capabilities.
  • An alternative arrangement provides panels including expanded polystyrene panels of predetermined widths and thicknesses with a reinforced coating of alkaline mesh on either side fused between a metal (tin) sheet or a honeycomb panel. This acts as the outer shell or single wall system around the light gauged steel construction.
  • the purpose of the (EPS) is to offer an easier and improved construction methodology as opposed to the standard conventional internal wall construction.
  • FIGS 1 and 2 show sectional views through alternative thermal wall panels according to embodiments of the present invention
  • FIGS 3 to 6 show sectional views through alternative thermal wall panels according to further embodiments of the present invention.
  • Figures 7 and 8 show alternative horizontal sections through 90mm and 130mm thick thermal wall panels according to embodiment sof the present invention.
  • FIGS 9a to 9d show various arrangements of the thermal wall panel and fastening arrangements according to embodiments of the present invention.
  • Figure 10 shows an embodiment of the construction system assembled
  • Figure 1 1 shows a thermal wall panel according to an alternative embodiment of the present invention.
  • a thermal wall panel 10 of different overall thicknesses is provided as shown in figures 1 and 2.
  • a thermal material 12 of expanded or extruded (preferably HD) polystyrene is sandwiched between outer MgO boards 14,16.
  • the thickness of the thermal material can be varied to control the overall thickness and thus the thermal properties of the wall panel.
  • a polypropylene or metal honeycomb layer 18 is provided to give additional strength and rigidity to the panel.
  • a further MgO board 20 layer (eg 3mm MgO) is provided in the sandwich. The layers are bonded together by adhesive.
  • Figures 3 to 6 show alternative embodiments of construction of the panel.
  • Figure 3 shows a 90mm overall thickness panel 30 with 50mm of thermal material
  • figure 4 shows a 140mm panel 30 with 101 mm thermal material.
  • Outer boards 32 and 34, of MgO in these embodiments, sandwich therebetween is the XPS or EPS thermal material 36 (preferably between 50-150mm), a third layer of board (MgO) 38, preferably between 2mm and 6mm thickness, and a honeycomb layer 40 (preferably polypropylene honeycomb material) which is preferably between 10mm and 30mm thick.
  • MgO third layer of board
  • honeycomb layer 40 preferably polypropylene honeycomb material
  • FIGS 5 and 6 show similar embodiments to those shown in figures 3 and 4. However, these show markings for a recessed channel to be made down the side edge face of each panel 50.
  • Thermal material (XPS or EPS) 52 is sandwiched between exterior boards (MgO) 54, 56 of 6mm thickness.
  • a honeycomb layer 58 and a further board layer 60 (eg of 3mm MgO) is provided.
  • the vertical dashed lines 62, 64 represent edges of the recess for forming the channel between adjacent panels to receive therebetween the upright elongate support member (not shown) that gets fastened to the upper and lower tracks in the construction system.
  • the recess edges 62,64 are inset 6mm from the board at either side thereof. This retains sufficient integrity in the thermal material.
  • Figures 7 and 8 show general sections through alternative embodiments of 90mm and 130mm thick panels 80.
  • the edge recesses 82,84 define the upright channels when panels are placed side by side with said recesses facing one another.
  • the panel can have hollow core 86 sections, which may provide the apertures for passing reinforcing members therethrough.
  • Figures 9a to 9d reveal embodiments of the construction system.
  • the edges of two adjacent panels 90a,90b have complementary recesses 92,94 facing one another. These recesses form a channel to receive the elongate support member 96, which can be a metal, plastic or timber support, or combinations thereof.
  • the elongate support includes flanges 96a-d to fasten the support 96 to the track 98 at those four respective points.
  • Figure 9b shows an embodiment of the elongate support 96 with the four flanges 96a to 96d.
  • An alternative or additional form of attaching an elongate support member or a reinforcing member (the latter passing through the core of the panel) is to have an upper portion 100 of the respective member 102 extending above a top face of the panel.
  • This protruding portion can be connected to other such members to provide strength and rigidity to the wall. This arrangement can be effected with or without the upper track.
  • Figure 9d shows an embodiment of the panel 1 10 with apertures 1 12 for receiving therethrough the reinforcing members 102 (not shown).
  • Figure 10 shows the system assembled.
  • the construction system includes a lower track 120, an upper track 122 and a thermal wall panel 124 therebetween.
  • the panel 124 includes outer layers of a facing board 126, 128 (preferably MgO board), a layer of thermal material 130, a layer of structural board 132 (preferably 3-6mm MgO board) and a honeycomb layer 134 of preferably polypropylene honeycomb.
  • a support member 136 extends along an upright recess in the side face of the panel and connects the upper and lower tracks 120, 122.
  • the support member is attached by fasteners 138a-d through respective flanges or plates140a-d.
  • a similar connection arrangement can be used for the lower track. Alternatively welded attachment or riveted attachment can be used.
  • the thermal wall panel 150 includes a supporting metal plate 152, such as a steel or aluminium plate, between layers of thermal material 154,156.
  • the metal plate is bonded directly or indirectly to the thermal material layers, such as by adhesive.
  • the metal plate provides rigidity and structural strength to the panel. This arrangement can be used instead of or in combination with the thermal material between boards panel.
  • a mesh 158 can be attached or bonded to one of the layers of thermal material.
  • the mesh can receive a coating, such as a render.
  • the other layer 154 can receive an interior finish coating 160, such as a plasterboard, wet plaster coat or other finishing coat.
  • the thermal wall panel may only include the layers of thermal materials with the metal sheet bonded therebetween.
  • the metal sheet may be textured, have apertures or include a mesh to enhance bonding characteristics.
  • an alternative system of the present invention provides for the reinforcing members to extend through the respective panels between and be fastened to the upper and lower tracks. This arrangement can augment or replace the recess and upright support member embodiments.

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  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Acoustics & Sound (AREA)
  • Building Environments (AREA)

Abstract

La présente invention concerne un panneau mural thermique, un système de construction et des procédés d'utilisation et de construction associés. Le panneau mural thermique comporte un matériau thermique, tels que du polystyrène expansé ou extrudé, qui est pris en sandwich entre deux panneaux. Les panneaux peuvent être des panneaux d'oxyde de magnésium (MgO). Des modes de réalisation préférés comportent une structure en nid d'abeille métallique ou de polypropylène et une couche de panneau de MgO facultative à l'intérieur de la construction en sandwich pour une isolation supplémentaire, la rigidité et l'insonorisation. Les panneaux sont retenus entre des pistes supérieure et inférieure à section en C. Des évidements sur le bas des côtés des panneaux reçoivent des supports verticaux qui sont fixés aux pistes supérieure et/ou inférieure pour la résistance et la stabilité.
PCT/AU2010/000735 2009-06-15 2010-06-15 Panneau mural thermique, système de construction et procédés d'utilisation et de construction associés WO2010144951A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2009902751 2009-06-15
AU2009902751A AU2009902751A0 (en) 2009-06-15 Oceanic Innovations 'proposed building sytem'

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WO2010144951A1 true WO2010144951A1 (fr) 2010-12-23

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH705196A1 (de) * 2011-06-29 2012-12-31 Sager Ag Verfahren zur Herstellung von Dämmplatten.
WO2013010217A1 (fr) * 2011-07-15 2013-01-24 RAFP Pty Ltd Panneau antibruit
AU2012238289B2 (en) * 2012-08-01 2016-05-12 Cycleworld Corporation Sdn. Bhd. Sandwiched panel construction and a method of manufacturing thereof
EP3043991A1 (fr) * 2014-01-28 2016-07-20 Kupferberg, Robert Jeffrey Panneau barrière thermique à haute résistance pour logement d'unité cvca
CN107724596A (zh) * 2017-10-09 2018-02-23 清华大学建筑设计研究院有限公司 部分预制夹心墙板及其墙体结构和建筑
US9909501B2 (en) 2013-07-03 2018-03-06 Pratt & Whitney Canada Corp. Acoustic structure for a gas turbine engine

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JPS63170026A (ja) * 1987-01-08 1988-07-13 旭化成株式会社 アルミニウム製ハニカム複合板
WO2002025034A1 (fr) * 2000-09-19 2002-03-28 James Hardie Research Pty Limited Systeme d'enduction au ciment
US20050064145A1 (en) * 2000-03-22 2005-03-24 Tor Hoie Composite building components
US20070245640A1 (en) * 2003-10-03 2007-10-25 Euretech International Pty Ltd, An Australian Corporation Building Structure and Modular Construction
WO2008100558A1 (fr) * 2007-02-17 2008-08-21 Dan Williams Système de construction utilisant une technologie intégrée avec des âmes en polystyrène expansé moulées
WO2009038786A1 (fr) * 2007-09-21 2009-03-26 Scuderi Group, Llc Système de mur composite
US20090313931A1 (en) * 2008-06-24 2009-12-24 Porter William H Multilayered structural insulated panel

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Publication number Priority date Publication date Assignee Title
JPS63170026A (ja) * 1987-01-08 1988-07-13 旭化成株式会社 アルミニウム製ハニカム複合板
US20050064145A1 (en) * 2000-03-22 2005-03-24 Tor Hoie Composite building components
WO2002025034A1 (fr) * 2000-09-19 2002-03-28 James Hardie Research Pty Limited Systeme d'enduction au ciment
US20070245640A1 (en) * 2003-10-03 2007-10-25 Euretech International Pty Ltd, An Australian Corporation Building Structure and Modular Construction
WO2008100558A1 (fr) * 2007-02-17 2008-08-21 Dan Williams Système de construction utilisant une technologie intégrée avec des âmes en polystyrène expansé moulées
WO2009038786A1 (fr) * 2007-09-21 2009-03-26 Scuderi Group, Llc Système de mur composite
US20090313931A1 (en) * 2008-06-24 2009-12-24 Porter William H Multilayered structural insulated panel

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH705196A1 (de) * 2011-06-29 2012-12-31 Sager Ag Verfahren zur Herstellung von Dämmplatten.
WO2013000837A1 (fr) * 2011-06-29 2013-01-03 Sager Ag Procédé de fabrication de panneaux isolants
WO2013010217A1 (fr) * 2011-07-15 2013-01-24 RAFP Pty Ltd Panneau antibruit
AU2012238289B2 (en) * 2012-08-01 2016-05-12 Cycleworld Corporation Sdn. Bhd. Sandwiched panel construction and a method of manufacturing thereof
US9909501B2 (en) 2013-07-03 2018-03-06 Pratt & Whitney Canada Corp. Acoustic structure for a gas turbine engine
EP3043991A1 (fr) * 2014-01-28 2016-07-20 Kupferberg, Robert Jeffrey Panneau barrière thermique à haute résistance pour logement d'unité cvca
EP3043991A4 (fr) * 2014-01-28 2017-05-03 Kupferberg, Robert Jeffrey Panneau barrière thermique à haute résistance pour logement d'unité cvca
AU2014380921B2 (en) * 2014-01-28 2018-03-22 Robert Jeffrey Kupferberg High strength thermal barrier panel for an H.V.A.C. unit housing
CN107724596A (zh) * 2017-10-09 2018-02-23 清华大学建筑设计研究院有限公司 部分预制夹心墙板及其墙体结构和建筑
CN107724596B (zh) * 2017-10-09 2023-08-29 清华大学建筑设计研究院有限公司 部分预制夹心墙板及其墙体结构和建筑

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