WO2012024742A1 - Wall structure - Google Patents

Wall structure Download PDF

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Publication number
WO2012024742A1
WO2012024742A1 PCT/AU2011/001109 AU2011001109W WO2012024742A1 WO 2012024742 A1 WO2012024742 A1 WO 2012024742A1 AU 2011001109 W AU2011001109 W AU 2011001109W WO 2012024742 A1 WO2012024742 A1 WO 2012024742A1
Authority
WO
WIPO (PCT)
Prior art keywords
panels
panel
space
inter
wall structure
Prior art date
Application number
PCT/AU2011/001109
Other languages
French (fr)
Other versions
WO2012024742A8 (en
Inventor
Tommy Vassos
Emanuel Papastamatis
Gary Stephen Gale
Original Assignee
Procutech Targeted Supply Chain Solutions Co., Limited
Ammoveo 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
Priority claimed from AU2010903848A external-priority patent/AU2010903848A0/en
Application filed by Procutech Targeted Supply Chain Solutions Co., Limited, Ammoveo Pty Ltd filed Critical Procutech Targeted Supply Chain Solutions Co., Limited
Publication of WO2012024742A1 publication Critical patent/WO2012024742A1/en
Publication of WO2012024742A8 publication Critical patent/WO2012024742A8/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/56Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
    • E04B2/58Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of metal
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/74Removable non-load-bearing partitions; Partitions with a free upper edge
    • E04B2/7407Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts
    • E04B2/7448Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts with separate framed panels without intermediary posts, extending from floor to ceiling
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B2001/2481Details of wall panels
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/74Removable non-load-bearing partitions; Partitions with a free upper edge
    • E04B2002/7488Details of wiring

Definitions

  • This invention relates to a wall structure and to a wall panel.
  • the invention provides a wall structure formed from a line of side by side panels fitted into a space defined between first and second spaced side members:
  • the panels being interlocked by pairs of inter-engaging first and second interlocking formations, one said first formation being on the first side member and one said second formation being on the second side member, each said panel having a said second and a said first formation at a respective second and. first side edge portion thereof, said inter- engaging pairs of formations inhibiting relative movement between the side members and the panels in the direction normal to the directions of said line and the direction of extent of the side edge portions of the panels, the first and second formations of at least one said pair being formed such that they are movable one relative to the other in the direction of said line to permit the panels to assume respective contracted and expanded states at which the side to side dimension presented by the side by side panels is respectively relatively lesser and relatively greater;
  • said formations permitting assembly of the wall structure by successively moving of each panel into said space- in the direction towards said first side member to position thcm in the space in said line with said pairs of locking formations engaged, the last said panel away from said first member being so positionable, prior to engagement of the first formation thereof with the second formation on the second member, under said contracted state of the panels, whereby those formations are in sidewards alignment for engagement, after which they are brought into engagement by placing the panels in said expanded state.
  • the invention also provides a method of assembling the wall structure as above described wherein the panels are successively inserted into said space and conditioned to said contracted state, and thereafter moved to said expanded condition to complete the wall structure.
  • the invention also provides a prefabricated wall panel for assembly into a frame to form part of a wall, the panel having incorporated therein ducting for provision of services to service fittings securable to the panel.
  • the invention also provides a prefabricated wall panel for assembly into a frame to form part of a wall, the panel having incorporated therein electrical wiring and fittings for provision of services to service fittings securable to the panel.
  • the invention also provides a wall structure having two panels positioned side by side in a side to side extending space in a frame of the wall structure, the space being defined between spaced transverse members of the frame, movement of the panels out of said space by movement in a first direction transverse to the transverse members and the sides of the panels being confined by inter-cngagemcnt between the transverse members and respective adjacent end edge portions of the panels; said inter-engagements between one said transverse member and each said end edge portion permitting movement of the panels in a second direction towards one said transverse member from the other said transverse member to release the inter-engagement between the other transverse member and the respective adjacent end edge portions; movement of the panels one relative to the other in said first direction being confined by a coupling having respective inter-engaging formations on respective adjacent side edge portions of the of the panels, said coupling being releasable, so that said relative movement is permitted, by moving the panels apart, each panel being removable from said space by moving the panels apart to release sad coupling, moving that panel towards the one
  • the invention also provides a method of forming a wall structure having two panels positioned side-side in a side to side extending space in a frame of the wall structure, the space being defined between spaced first and second transverse members of the frame, including: entering one end portion of each said panel into said space by movement thereof to inter- engage the one end portion thereof with one said transverse member, moving each panel to position it in the space with an opposite end portion thereof adjacent to the other said transverse member and moving each anel towards the one transverse member to inter- engage said opposite end portion of each panel with the first transverse member, while maintaining the inter-engagement of each one end portion and the one transverse member, and effecting relative side to side movement between the panels to couple the panels at adjacent side edge portions thereof to limit relative movement between the panels in a first direction transverse to the side to side direction of extent of the space and the end to end direction of the panels, said inter-engagements limiting movement, in said first direction, between the panels and the transverse members.
  • Figure 1 is a front view of an upright wall structure formed in accordance with the invention
  • Figure 2 is a cross-section on the line 2-2 in Figure 1
  • Figure 3 is a cross-section on the line 3-3 in Figure 1
  • Figure 3A is a scrap view like Figure 3 but showing components separated
  • Figures 4 to 6 are vertical sections of the wall structure of Figure 1, illustrating initial steps in fitting a panel of the wall structure into upper and lower members of a frame of the wall structure
  • Figure 7 is a cross-section on the line 7-7 in Figure 1
  • Figure 8 is a cross-section on the line 8-8 in Figure 1
  • Figure 9 is a cross-section on the line 9-9 in Figure 1, illustrating adjoining panels more widely spaced apart
  • Figure 10 is a view like Figure 9, but showing the adjoining panels in more closely spaced positions:
  • Figure 11 is a perspective view illustrating bow a final wall panel is fitted;
  • Figure 12 is a cross
  • FIG. 1 illustrates a wall structure 10 formed in accordance with the invention. It has opposed spaced first and second spaced parallel side members 12, 14, and opposed spaced first and second parallel transverse members 16, 18. Ends of transverse member 16 are connected to respective corresponding first ends of the side members 12, 14 and ends of transverse member 18 are connected to opposite corresponding second ends of side members 12, 14. Thus the members 12, 14, 16 and 18 form a rectangular frame 20 which encloses a central rectangular space 22. Space 22 is occupied by a line 25 of four coplanar side by side adjacent wall panels 27, 29, 31 and 33. The panels are interlocked with each other at adjacent side edge portions 50, 52, and with the members 12, 14 at outer side edges of the panels 27, 33 adjacent respective side members 12, 14. Opposite end edge portions 41, 45 of each panel are also interlocked with respective transverse members 16, 18.
  • the wall structure is illustrated as being in a vertical position, transverse member 18 being horizontal and lowermost, transverse member 16 being horizontal and uppermost and side members 12, 14 extending vertically, such as in use of the wall structure e.g. form part of the upright wall of a building.
  • positional terms such as "upper” and “lower” are to be taken as referring to the wall structure in that condition, although it is not to be taken that the wall structures of the invention must necessarily be in such condition.
  • wall structures of the invention may be utilised to form a ceilings of buildings.
  • first transverse member 16 is, as shown in the cross-section of Figure 2, of channel section, open inwardly to space 22, downwardly as depicted. It has a transverse part 30, with spaced depending flanges 32, 34 so as to define a downwardly open space 36 which extends along the length of member 16.
  • Lower transverse member 18, as shown in Figures 3 and 3A is of composite construction, having a lower channel shaped member 38 open to the front of the panel structure and, affixed to the upper part of section 36, a lengthwise extending retaining element 40 having an upwardly extending and lengthwise extending tongue 42.
  • Tongue 42 is of trapezoidal transverse section, such that it is wider at its base than at its tip, having opposed side faces 47, 49 (Figure 3A) that converge from the base to the tip (i.e., they are upwardly convergent).
  • Panels 27-33 are of like form each having the side edge portions 50, 52 and also having upper and lower end edge portions 41, 45 ( Figure 8). They are each generally planar and rectangular.
  • each edge member 44 which defines a lengthwise extending groove 46.
  • Groove 46 is of complementary cross-sectional form to that of tongue 42 on lower transverse member 18, the groove being trapezoidal in cross section with inwardly divergent side faces 43, 45. Tongues 42 can neatly intcrfit into respective grooves 46.
  • edge member 70 which defines a respective outstanding tongue 72, extending along the length of that edge portion.
  • edge member 74 which defines a respective groove 76.
  • the tongues 72 and grooves 76 are of complementary form so that a tongue 72 can neatly inter-fit with a groove 76.
  • these tongues 72 and grooves 76 are of similar form to the tongues and grooves 42, 46 previously described.
  • the tongues 72 arc in cross-section somewhat trapezoidal, wider at the base than at the tip, with opposed side faces 82, 84 on each tongue that converge from the base to the tip (i.e. they are outwardly convergent).
  • the groove 76 has inwardly convergent side faces 86, 88.
  • Side member 12 ( Figure 7) is of composite form having an upstanding member 90 of hollow rectangular section and, affixed to the inner face thereof a section 92 of similar cross-section to edge members 44 and 74, also defining a lengthwise extending groove 76 of complementary form to tongues 72, and having inwardly extending convergent sides.
  • Side member 14 ( Figure 8) is of composite form having an upstanding member 94 of hollow rectangular section and, affixed to the inner face thereof a section 96 of similar cross-section to edge members 70 and, also defining respective lengthwise extending tongues 72 of complementary form to grooves 76, and having outwardly convergent sides.
  • the frame 20 and panels 27-33 may be first separately prefabricated, the panels 27-33 then fitted into the space 22 of the frame.
  • the panels are positioned on the transverse member 18 with the tongue 42 of member 40 fitted into the grooves 46 of each panel, and the upper edge portions 41 of the panels accommodated in the space 36 within member 30, In this condition the panels are interlocked with each other, and with the side members 12, 14 by accommodation of the tongues 72 on the panels and on side member 14 within grooves 76 on adjacent panels and on side member 12. This is illustrated particularly in Figure 13. In this condition, the panels cannot move significantly in the direction transverse to line 25 and transverse to the edge portions of the panels (i.e. in the front to rear direction as illustrated) because such movement is precluded by the described engagement of tongues and grooves, and the accommodation of the upper edge portions 41 of the panels in member 16.
  • panels 27-31 can be moved into the space 22 and positioned on member 18 to extend upwardly into member 16 by the method illustrated in figures 4-6, which shows insertion of one panel 31.
  • the panel is aligned with its upper edge portion 41 parallel to and immediately below the transverse member 16, the panel depending downwardly therefrom and slightly outwardly so the lower edge portion 41 is adjacent to and slightly below the upper edge of the tongue 42 of member 18, and the panel at the lower end being outwardly disposed relative to transverse member 18.
  • the panel is moved upwardly to enter the upper edge portion 41 of the panel into the space 36 of member 16 until the lower edge portion 45 of the panel is above the level of tongue 42.
  • the panel is swung inwardly into space 22 until the groove 46 of the pane] is aligned with and slightly above the tongue 42. After this the panel is lowered to fit the tongue 42 into the groove 46.
  • This fitting is permitted by selecting the height of the panels to be such that, when the panels rest on member 18 with tongue 42 and grooves 46 engaged, the upper edge portions 41 of these panels are accommodated within space 36 of member 16, and constrained against substantial outwards movement from the space by engagement with the depending flanges 32, 34 of member 16. Also to permit this, the spacing between flanges 32. 34 may be made slightly wider than the thickness of the panels, to accommodate entry of the panels at an angle thereto.
  • these panels are slid on member 18 to the left as viewed in Figure 1, so that the tongues and grooves on the adjacent side edges and on side member 12 are inter-engaged as previously described.
  • the movement of the panel 33 into space 22 may be essentially linear and in the end to end direction of extent of the panel 33, as illustrated in Figures 4 - 6, including some rotation from the condition in Figure 4 to that of figure 5, in any event with the upper edge portion 41 generally parallel to the upper transverse member 16. However it may be swung into position by movement including rotation about an axis 165 angularly disposed to the general plane of frame 20 as shown in Figure 12. Each other panel may be insured by either method. As illustrated in Figures 9 and 10, it is possible to relatively move each panel in the direction of the line 25 with respect to an adjacent panel or member 12, such that the spacing between adjacent panels and that between panel 27 and side member 12 can be varied slightly.
  • Length L1 is such that the panels are engaged with each other and engaged with the side members as described, and length L2 is less, being sufficient to enable completion of the line 25 between the side members.
  • Figures 9 and 1 1 illustrate a method of introducing the last panel 33 into space 22 which differs slightly from the method described.
  • the panel is rotated in direction "A" shown in Figure 11 and moved upwardly to enter the panel into the member 16 as shown by arrow "B” in Figure 11, while bringing the tongue 72 on panel 33 into engagement with groove 76 on panel 31.
  • panel 33 is brought into alignment with the other panels and slid to engage the groove 76 thereof with the tongue 72 of the side member 14. This action may be made possible by making the distance between flanges 32, 34 of member 16 sufficiently greater than the thickness of the panel 33.
  • elongate resilient elements 109 are disposed adjacent either side of each tongue and groove of each coupling 105 presented by a cooperating tongue 72 and groove 76. These may be inserted between each co-operating tongue and groove as the assembly of the panels progresses, such that these ordinarily bias the couplings 105 such that the length of the line 25 of panels 31 to 33 assumes the distance L1 described, but which can be resiliently compressed under sliding movement of the panels to enable the length to be reduced to distance L2.
  • the natural resilience of the elements 109 moves the panels to assume the line length L1.
  • the resilient elements 109 can be introduced after assembly of the panels to the frame, or they may be attached to one of the panels before assembly, or they may be attached to the panels before assembly.
  • the resilient elements 109 may be formed of rubber, ncoprcne or foam rubber for example and may be of any suitable cross section such as circular and/or tubular in the uncompressed condition. These resilient elements are generally formed as discrete elements.
  • the described movement of the panels to enter the upper edge portions of these into transverse member 16 may be described herein as movement in a second direction from one transverse member, member 18, to the other transverse member, member 16. Also, the described movement of the panels to enter these into the upper transverse member 16 may be described as movement in a second direction towards one transverse member, member 16 from the other transverse member, member 18.
  • the assembly may be completed by securing the upper ends of each panel to the member 16, such as by use of screws 1 11 though openings in one of the flanges 32, 34 into the panel as illustrated in Figure 2. While, for convenience of explanation, assembly has been described as proceeding by installing panels 27- 31 first, and finally positioning panel 33, it would of course be possible to install any of the panels last, although for ease of assembly, installing either panel 27 or panel 33 last may be best.
  • the described trapezoidal configurations of the groves 76 and tongues 72 is advantageous in facilitating entry of these when the panels are not completely aligned in a single plane, such as when installing the last panel in the method of assembly described with reference to Figures 9 and 11.
  • the described couplings 105 are formed by inter engaging co-operable formations 158, 160. ( Figures 8 and 9) on the respective couplings parts, these being formed by the described tongues 72 and grooves 76.
  • couplings 1 17 are formed by inter engaging co-operable formations 162, 164 in the form of grooves 46 and tongues 42. While this is advantageous, these formations may be of other form, Figures 14 and 16 illustrates a particular form of panel useful in the invention.
  • This panel 120 is of rectangular form, having an internal frame 122 with facing material 124 at least at one face.
  • the frame interstices may be filled with, e.g. insulation material, and facing may also be provided at the opposite face of the panel.
  • the lower edge portion 45 of the panel is provided with a groove 46 and the side edge portions 152 with tongues 72 and grooves 76, as with the described panels 27-33, so that the panel 120 can be used in forming a wall structure 10, in the same way as the panels 27-33.
  • This panel 120 is provided with ducting 128 running e.g. parallel to and midway between the side edge portions of the panel. This ducting communicates with internal connection boxes 130 to which external electrical fittings 134, such as switches, power outlets and light fittings may be mounted.
  • the ducting is open at the upper end of the panel, such that, when the panel is installed in a wall structure 20, with the upper edge portion 41 retained in upper transverse member 16, electrical wiring 132 may be run from the member 16 down the ducting to the fittings, as shown in Figure 16.
  • the panel 140 shown in Figure 15 is simitar in form to panel 120 except that it has internal ducts in the form of pipes 142 which connect to external fittings 144, able to receive external plumbing fittings 145 such as water control taps, or shower heads.
  • This panel can likewise be used in forming a wall structure 20.
  • lower ends 148 of the pipes 142 projecting below the lower edge portion of the panel 140, extend through apertures in the channel shaped member 38 of member 18 downwardly into the channel shaped member 38 so that water supply and/or return pipes 150, 152 within the channel shaped member can be coupled to these, e.g. by the Illustrated elbow finings 154, 156.
  • the described construction has been advanced merely by way of example and many modifications and variations may be made without departing from the spirit and scope of the invention, which includes every novel feature and combination of features herein disclosed.

Abstract

A wall structure (10) having aligned side by side wall panels (27 to 33) accommodated between opposed side members (12, 14). Couplings (10S) provided between the panels and the side members limit relative movement of the panels and side members, out of alignment. The couplings (105) permit limited movement between panels and the side members to permit the panels to be positioned between the side members such that the couplings are engaged.

Description

WALL STRUCTURE FIELD OF THE INVENTION
This invention relates to a wall structure and to a wall panel. BACKGROUND OF THE INVENTION
So-called "kit buildings" which a customer, such as a home builder, purchases as a kit of parts from which a building can be assembled should preferably be easy for a relatively unskilled person to assemble, with minimum assistance from tradesmen, The fixing of walls and ceilings, and the running of services, particularly electricity and water services, may present particular problems for an unskilled person. SUMMARY OF THE INVENTION In one aspect, the invention provides a wall structure formed from a line of side by side panels fitted into a space defined between first and second spaced side members:
the panels being interlocked by pairs of inter-engaging first and second interlocking formations, one said first formation being on the first side member and one said second formation being on the second side member, each said panel having a said second and a said first formation at a respective second and. first side edge portion thereof, said inter- engaging pairs of formations inhibiting relative movement between the side members and the panels in the direction normal to the directions of said line and the direction of extent of the side edge portions of the panels, the first and second formations of at least one said pair being formed such that they are movable one relative to the other in the direction of said line to permit the panels to assume respective contracted and expanded states at which the side to side dimension presented by the side by side panels is respectively relatively lesser and relatively greater;
said formations permitting assembly of the wall structure by successively moving of each panel into said space- in the direction towards said first side member to position thcm in the space in said line with said pairs of locking formations engaged, the last said panel away from said first member being so positionable, prior to engagement of the first formation thereof with the second formation on the second member, under said contracted state of the panels, whereby those formations are in sidewards alignment for engagement, after which they are brought into engagement by placing the panels in said expanded state.
The invention also provides a method of assembling the wall structure as above described wherein the panels are successively inserted into said space and conditioned to said contracted state, and thereafter moved to said expanded condition to complete the wall structure.
The invention also provides a prefabricated wall panel for assembly into a frame to form part of a wall, the panel having incorporated therein ducting for provision of services to service fittings securable to the panel.
The invention also provides a prefabricated wall panel for assembly into a frame to form part of a wall, the panel having incorporated therein electrical wiring and fittings for provision of services to service fittings securable to the panel.
The invention also provides a wall structure having two panels positioned side by side in a side to side extending space in a frame of the wall structure, the space being defined between spaced transverse members of the frame, movement of the panels out of said space by movement in a first direction transverse to the transverse members and the sides of the panels being confined by inter-cngagemcnt between the transverse members and respective adjacent end edge portions of the panels; said inter-engagements between one said transverse member and each said end edge portion permitting movement of the panels in a second direction towards one said transverse member from the other said transverse member to release the inter-engagement between the other transverse member and the respective adjacent end edge portions; movement of the panels one relative to the other in said first direction being confined by a coupling having respective inter-engaging formations on respective adjacent side edge portions of the of the panels, said coupling being releasable, so that said relative movement is permitted, by moving the panels apart, each panel being removable from said space by moving the panels apart to release sad coupling, moving that panel towards the one transverse member to release the inter- engagement between the other transverse member and respective adjacent end edge portion of that panel, moving the respective adjacent respective end edge portion of that pane) out of said space and moving that panel away from the one transverse member to release the inter-engagement between the one transverse member and the respective adjacent end edge portion of that panel.
The invention also provides a method of forming a wall structure having two panels positioned side-side in a side to side extending space in a frame of the wall structure, the space being defined between spaced first and second transverse members of the frame, including: entering one end portion of each said panel into said space by movement thereof to inter- engage the one end portion thereof with one said transverse member, moving each panel to position it in the space with an opposite end portion thereof adjacent to the other said transverse member and moving each anel towards the one transverse member to inter- engage said opposite end portion of each panel with the first transverse member, while maintaining the inter-engagement of each one end portion and the one transverse member, and effecting relative side to side movement between the panels to couple the panels at adjacent side edge portions thereof to limit relative movement between the panels in a first direction transverse to the side to side direction of extent of the space and the end to end direction of the panels, said inter-engagements limiting movement, in said first direction, between the panels and the transverse members.
The invention is further described by way of example only with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a front view of an upright wall structure formed in accordance with the invention; Figure 2 is a cross-section on the line 2-2 in Figure 1 ; Figure 3 is a cross-section on the line 3-3 in Figure 1 ; Figure 3A is a scrap view like Figure 3 but showing components separated; Figures 4 to 6 are vertical sections of the wall structure of Figure 1, illustrating initial steps in fitting a panel of the wall structure into upper and lower members of a frame of the wall structure; Figure 7 is a cross-section on the line 7-7 in Figure 1 ; Figure 8 is a cross-section on the line 8-8 in Figure 1 : Figure 9 is a cross-section on the line 9-9 in Figure 1, illustrating adjoining panels more widely spaced apart; Figure 10 is a view like Figure 9, but showing the adjoining panels in more closely spaced positions: Figure 11 is a perspective view illustrating bow a final wall panel is fitted; Figure 12 is a cross section on the line 12-12 of Figure 1, illustrating the fitting of the final wall panel; Figure 13 is cross-section corresponding to Figure 12; but showing the final panel fitted; Figure 14 is a partly sectioned front view of an alternative panel useful in forming the wall structure of Figure 1 ; Figure 15 is a partly sectioned front view of a another alternative panel useful in forming the wall structure of Figure 1 ; Figure 16 is a scrap front sectional view of an upper part of the panel of figure 14 illustrating how electrical wiring is run to the panel, when the panel is incorporated into a wall like the wall structure of Figure 1 ; and Figure 17 is a cross-section of the panel of Figure 15 illustrating how plumbing is run to the panel when the panel is incorporated into a wall like the wall structure of Figure 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Figure 1 illustrates a wall structure 10 formed in accordance with the invention. It has opposed spaced first and second spaced parallel side members 12, 14, and opposed spaced first and second parallel transverse members 16, 18. Ends of transverse member 16 are connected to respective corresponding first ends of the side members 12, 14 and ends of transverse member 18 are connected to opposite corresponding second ends of side members 12, 14. Thus the members 12, 14, 16 and 18 form a rectangular frame 20 which encloses a central rectangular space 22. Space 22 is occupied by a line 25 of four coplanar side by side adjacent wall panels 27, 29, 31 and 33. The panels are interlocked with each other at adjacent side edge portions 50, 52, and with the members 12, 14 at outer side edges of the panels 27, 33 adjacent respective side members 12, 14. Opposite end edge portions 41, 45 of each panel are also interlocked with respective transverse members 16, 18.
The wall structure is illustrated as being in a vertical position, transverse member 18 being horizontal and lowermost, transverse member 16 being horizontal and uppermost and side members 12, 14 extending vertically, such as in use of the wall structure e.g. form part of the upright wall of a building. In the following description, positional terms such as "upper" and "lower" are to be taken as referring to the wall structure in that condition, although it is not to be taken that the wall structures of the invention must necessarily be in such condition. For example, wall structures of the invention may be utilised to form a ceilings of buildings. Also, terms such as "front" and "rear" used herein refer to a panel in such orientation, with Figures 1 and depicting the "front" and for example the right hand side of the wall structure as viewed in Figures 2-6 being to the "front" and the left hand side as viewed in these Figures as representing the "rear" of the panel structure. Again, this is not to be taken that those sides of the panel structure are necessarily so oriented. Upper first transverse member 16 is, as shown in the cross-section of Figure 2, of channel section, open inwardly to space 22, downwardly as depicted. It has a transverse part 30, with spaced depending flanges 32, 34 so as to define a downwardly open space 36 which extends along the length of member 16. Lower transverse member 18, as shown in Figures 3 and 3A is of composite construction, having a lower channel shaped member 38 open to the front of the panel structure and, affixed to the upper part of section 36, a lengthwise extending retaining element 40 having an upwardly extending and lengthwise extending tongue 42. Tongue 42 is of trapezoidal transverse section, such that it is wider at its base than at its tip, having opposed side faces 47, 49 (Figure 3A) that converge from the base to the tip (i.e., they are upwardly convergent). Panels 27-33 are of like form each having the side edge portions 50, 52 and also having upper and lower end edge portions 41, 45 (Figure 8). They are each generally planar and rectangular. At the lower edge portions 45, they each have an edge member 44 which defines a lengthwise extending groove 46. Groove 46 is of complementary cross-sectional form to that of tongue 42 on lower transverse member 18, the groove being trapezoidal in cross section with inwardly divergent side faces 43, 45. Tongues 42 can neatly intcrfit into respective grooves 46. Referring to Figures 7 to 10, at one side edge portion 50 of each panel (to the left, and vertical, in Figure 1) there is an edge member 70 which defines a respective outstanding tongue 72, extending along the length of that edge portion. At the opposed edge portion 52 of each panel, (to the right and vertical, in Figure 1) there is an edge member 74 which defines a respective groove 76. The tongues 72 and grooves 76 are of complementary form so that a tongue 72 can neatly inter-fit with a groove 76. In cross-section, these tongues 72 and grooves 76 are of similar form to the tongues and grooves 42, 46 previously described. Particularly, as shown in Figures 9 and 10, the tongues 72 arc in cross-section somewhat trapezoidal, wider at the base than at the tip, with opposed side faces 82, 84 on each tongue that converge from the base to the tip (i.e. they are outwardly convergent). The groove 76 has inwardly convergent side faces 86, 88.
Side member 12 (Figure 7) is of composite form having an upstanding member 90 of hollow rectangular section and, affixed to the inner face thereof a section 92 of similar cross-section to edge members 44 and 74, also defining a lengthwise extending groove 76 of complementary form to tongues 72, and having inwardly extending convergent sides.
Side member 14 (Figure 8) is of composite form having an upstanding member 94 of hollow rectangular section and, affixed to the inner face thereof a section 96 of similar cross-section to edge members 70 and, also defining respective lengthwise extending tongues 72 of complementary form to grooves 76, and having outwardly convergent sides. In manufacture, the frame 20 and panels 27-33 may be first separately prefabricated, the panels 27-33 then fitted into the space 22 of the frame. In the assembled wall structure 10 the panels are positioned on the transverse member 18 with the tongue 42 of member 40 fitted into the grooves 46 of each panel, and the upper edge portions 41 of the panels accommodated in the space 36 within member 30, In this condition the panels are interlocked with each other, and with the side members 12, 14 by accommodation of the tongues 72 on the panels and on side member 14 within grooves 76 on adjacent panels and on side member 12. This is illustrated particularly in Figure 13. In this condition, the panels cannot move significantly in the direction transverse to line 25 and transverse to the edge portions of the panels (i.e. in the front to rear direction as illustrated) because such movement is precluded by the described engagement of tongues and grooves, and the accommodation of the upper edge portions 41 of the panels in member 16.
The manner of assembly of panels 27-33 in the frame 20 is now described. First, panels 27-31 can be moved into the space 22 and positioned on member 18 to extend upwardly into member 16 by the method illustrated in figures 4-6, which shows insertion of one panel 31. First the panel is aligned with its upper edge portion 41 parallel to and immediately below the transverse member 16, the panel depending downwardly therefrom and slightly outwardly so the lower edge portion 41 is adjacent to and slightly below the upper edge of the tongue 42 of member 18, and the panel at the lower end being outwardly disposed relative to transverse member 18. Then, as shown in Figure 4, the panel is moved upwardly to enter the upper edge portion 41 of the panel into the space 36 of member 16 until the lower edge portion 45 of the panel is above the level of tongue 42. Then, as shown in Figure 5, the panel is swung inwardly into space 22 until the groove 46 of the pane] is aligned with and slightly above the tongue 42. After this the panel is lowered to fit the tongue 42 into the groove 46. This fitting is permitted by selecting the height of the panels to be such that, when the panels rest on member 18 with tongue 42 and grooves 46 engaged, the upper edge portions 41 of these panels are accommodated within space 36 of member 16, and constrained against substantial outwards movement from the space by engagement with the depending flanges 32, 34 of member 16. Also to permit this, the spacing between flanges 32. 34 may be made slightly wider than the thickness of the panels, to accommodate entry of the panels at an angle thereto. Next, after the first three panels 27-31 are positioned in space 22, these panels are slid on member 18 to the left as viewed in Figure 1, so that the tongues and grooves on the adjacent side edges and on side member 12 are inter-engaged as previously described.
The movement of the panel 33 into space 22 may be essentially linear and in the end to end direction of extent of the panel 33, as illustrated in Figures 4 - 6, including some rotation from the condition in Figure 4 to that of figure 5, in any event with the upper edge portion 41 generally parallel to the upper transverse member 16. However it may be swung into position by movement including rotation about an axis 165 angularly disposed to the general plane of frame 20 as shown in Figure 12. Each other panel may be insured by either method. As illustrated in Figures 9 and 10, it is possible to relatively move each panel in the direction of the line 25 with respect to an adjacent panel or member 12, such that the spacing between adjacent panels and that between panel 27 and side member 12 can be varied slightly. When this spacing is olosest, the part of the space 22 between the panel 31 and side member 14 is sufficient to enable the last panel 33 to be inserted into that part of space 22, so as to complete the line of panels, leaving the groove 76 of panel 33 in alignment with tongue 72 of member 14, after which the panels may each be moved to slightly increase the gaps between them and the member 12. By this, groove 76 of panel 33 is moved so that this is engaged with the tongue 72 of member 14, in the same manner as the other tongues and grooves. In effect, this inter-fitting can arise because the effective length of the line 25 of panels can be varied from a maximum length L1, prevailing in an expanded state of the line 25, as shown in Figure 13, to a lesser length L2 also marked in this Figure and prevailing in a contracted state of the line 25. Length L1 is such that the panels are engaged with each other and engaged with the side members as described, and length L2 is less, being sufficient to enable completion of the line 25 between the side members. Figures 9 and 1 1 illustrate a method of introducing the last panel 33 into space 22 which differs slightly from the method described. Here, with the lower edge portion 45 of the panel 33 (not shown) somewhat outwardly disposed with respect to the lower transverse member 18, and the upper left hand corner of the panel adjacent and just below the upper transverse member 16 and adjacent panel 31 , and side edges of the panel 33 angled as shown, the panel is rotated in direction "A" shown in Figure 11 and moved upwardly to enter the panel into the member 16 as shown by arrow "B" in Figure 11, while bringing the tongue 72 on panel 33 into engagement with groove 76 on panel 31. After this, panel 33 is brought into alignment with the other panels and slid to engage the groove 76 thereof with the tongue 72 of the side member 14. This action may be made possible by making the distance between flanges 32, 34 of member 16 sufficiently greater than the thickness of the panel 33. In this case, possibly a lesser width of the space between panel 31 and member 14 may be sufficient to enable entry of panel 33. As shown in, for example, Figures 7-10, elongate resilient elements 109 are disposed adjacent either side of each tongue and groove of each coupling 105 presented by a cooperating tongue 72 and groove 76. These may be inserted between each co-operating tongue and groove as the assembly of the panels progresses, such that these ordinarily bias the couplings 105 such that the length of the line 25 of panels 31 to 33 assumes the distance L1 described, but which can be resiliently compressed under sliding movement of the panels to enable the length to be reduced to distance L2. By this, after panel 33 is installed to complete the assembly, the natural resilience of the elements 109 moves the panels to assume the line length L1. Alternatively the resilient elements 109 can be introduced after assembly of the panels to the frame, or they may be attached to one of the panels before assembly, or they may be attached to the panels before assembly. The resilient elements 109 may be formed of rubber, ncoprcne or foam rubber for example and may be of any suitable cross section such as circular and/or tubular in the uncompressed condition. These resilient elements are generally formed as discrete elements. In the assembled wall structure, outwards movement of the lower edge portions 45 of the panels, from space 22, in the mentioned first direction which is transverse to the transverse members 16, 18 and the side members 14, 16 is inhibited by inter engagement of the lower edge portions 45 of the panels with the transverse member 18, this being effected by couplings 119 (Figure 3) formed by the tongue 42 on member 44 and the groove 46 on each panel. Likewise, in the assembled wall structure 10, outwards movement of the upper edge portions 41 of the panels from space 22 in the mentioned first direction is inhibited by couplings 115 (Figure 2) formed by the upper edge portions 41 of the panels, and the flanges 32, 34 on the upper transverse member 16.
The described movement of the panels to enter the upper edge portions of these into transverse member 16 may be described herein as movement in a second direction from one transverse member, member 18, to the other transverse member, member 16. Also, the described movement of the panels to enter these into the upper transverse member 16 may be described as movement in a second direction towards one transverse member, member 16 from the other transverse member, member 18.
The assembly may be completed by securing the upper ends of each panel to the member 16, such as by use of screws 1 11 though openings in one of the flanges 32, 34 into the panel as illustrated in Figure 2. While, for convenience of explanation, assembly has been described as proceeding by installing panels 27- 31 first, and finally positioning panel 33, it would of course be possible to install any of the panels last, although for ease of assembly, installing either panel 27 or panel 33 last may be best.
The described trapezoidal configurations of the groves 76 and tongues 72 is advantageous in facilitating entry of these when the panels are not completely aligned in a single plane, such as when installing the last panel in the method of assembly described with reference to Figures 9 and 11. The described couplings 105 are formed by inter engaging co-operable formations 158, 160. (Figures 8 and 9) on the respective couplings parts, these being formed by the described tongues 72 and grooves 76. Similarly, couplings 1 17 are formed by inter engaging co-operable formations 162, 164 in the form of grooves 46 and tongues 42.While this is advantageous, these formations may be of other form, Figures 14 and 16 illustrates a particular form of panel useful in the invention. This panel 120 is of rectangular form, having an internal frame 122 with facing material 124 at least at one face. The frame interstices may be filled with, e.g. insulation material, and facing may also be provided at the opposite face of the panel. The lower edge portion 45 of the panel is provided with a groove 46 and the side edge portions 152 with tongues 72 and grooves 76, as with the described panels 27-33, so that the panel 120 can be used in forming a wall structure 10, in the same way as the panels 27-33. This panel 120 is provided with ducting 128 running e.g. parallel to and midway between the side edge portions of the panel. This ducting communicates with internal connection boxes 130 to which external electrical fittings 134, such as switches, power outlets and light fittings may be mounted. The ducting is open at the upper end of the panel, such that, when the panel is installed in a wall structure 20, with the upper edge portion 41 retained in upper transverse member 16, electrical wiring 132 may be run from the member 16 down the ducting to the fittings, as shown in Figure 16.
The panel 140 shown in Figure 15 is simitar in form to panel 120 except that it has internal ducts in the form of pipes 142 which connect to external fittings 144, able to receive external plumbing fittings 145 such as water control taps, or shower heads. This panel can likewise be used in forming a wall structure 20. In this case, lower ends 148 of the pipes 142, projecting below the lower edge portion of the panel 140, extend through apertures in the channel shaped member 38 of member 18 downwardly into the channel shaped member 38 so that water supply and/or return pipes 150, 152 within the channel shaped member can be coupled to these, e.g. by the Illustrated elbow finings 154, 156. This is illustrated in Figure 17. The described construction has been advanced merely by way of example and many modifications and variations may be made without departing from the spirit and scope of the invention, which includes every novel feature and combination of features herein disclosed.
Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms pan of the common general knowledge.

Claims

THE CLAIMS: 1. A wall structure formed from a line of side by side panels fitted into a space defined between first and second spaced side members:
the panels being interlocked by pairs of inter-engaging first and second interlocking formations, one said first formation being on the first side member and one said second formation being on the second side member, each said panel having a said second and a said first formation at a respective second and first side edge portion thereof, said inter- engaging pairs of formations inhibiting relative movement between the side members and the panels in the direction normal to the directions of said, line and the direction of extent of the side edge portions of the panels, the first and second formations of at least one said pair being formed such that they are movable one relative to the other in the direction of said line to permit the panels to assume respective contracted and expanded states at which the side to side dimension presented by the side by side panels is respectively relatively lesser and relatively greater;
said formations permitting assembly of the wall structure by successively moving of each panel into said space in the direction towards said first side member to position them in the space in said line with said pairs of locking formations engaged, the last said panel away from said first member being so positionable, prior to engagement of the first formation thereof with the second formation on the second member, under said contracted state of the panels, whereby those formations are in sidewards alignment for engagement, after which they are brought into engagement by placing the panels in said expanded state.
2. A wall structure as claimed in claim 1, including resilient means resiliently biasing said panels to said expanded state.
3. A wall structure as claimed in claim 2 wherein said resilient means includes at least one resilient elongate element disposed between adjacent panels and/or between at least one said side member and the adjacent panel, the panels being able to be brought to said contracted state under resilient compression of the or each resilient element.
4. A wall structure as claimed in claim 3 wherein there is at least one resilient element between each adjacent pair of panels and between each side member and the panel adjacent thereto.
5. A wall structure as claimed in any preceding claim wherein said formations include a groove on one side edge portion of each panel, and one said side member, and inter- fitting tongues formed on opposite side edge portions of the panels and on the other said side member.
6. A wall structure as claimed in any preceding claim, having opposed transverse members and further couplings between one said transverse member and one end edge portion of a panel to limit movement of the panels out of alignment in said normal direction, and opposite transverse edge portions of the panels being accommodated in ion inwardly open space in the other said transverse member, said space being of sufficient depth to permit disengagement between said further couplings by movement of the panels inwardly of said space.
7. A wall structure as claimed in claim 6, wherein said opposed transverse members extend between the side members to form a frame defining said space.
8. A wall structure having aligned side by side wall panels accommodated between opposed side members and couplings between the panels and the side members limiting relative movement of the panels and side members out of alignment, the couplings permitting limited movement between panels and the side members to permit the panels to be positioned between the side members such that the couplings are engaged.
9. A method of assembling the wall structure of any one of claims 1 to 8 wherein the panels are successively inserted into said space and conditioned to said contracted state, and thereafter moved to said expanded condition to complete the wall structure.
10. A prefabricated wall panel for assembly into a frame to form part of a wall, the panel having incorporated therein ducting for provision of services to service fittings securable to the panel.
11. A prefabricated wall panel for assembly into a frame to form part of a wall, the panel having incorporated therein electrical wiring and fittings for provision of services to service fittings securable to the panel.
12. A wall structure having two panels positioned side by side in a side to side extending space in a frame of the wall structure, the space being defined between spaced transverse members of the frame, movement of the panels out of said space by movement in a first direction transverse to the transverse members and the sides of the panels being confined by inter-engagement between the transverse members and respective adjacent end edge portions of the panels; said inter-engagements between one said transverse member and each said end edge portion permitting movement of the panels in a second direction towards one said transverse member from the other said transverse member to release the inter-engagement between the other transverse member and the respective adjacent end edge portions; movement of the panels one relative to the other in said first direction being confined by a coupling having respective inter-engaging formations on respective adjacent side edge portions of the of the panels, said coupling being releasable, so that said relative movement is permitted, by moving the panels apart, each panel being removable from said space by moving the panels apart to release said coupling, moving that panel towards the one transverse member to release the inter- engagement between the other transverse member and respective adjacent end edge portion of that panel, moving that respective adjacent end edge portion of that panel out of said space and moving that panel away from the one transverse member to release the inter- engagement between the one transverse member and the respective adjacent end edge portion of that panel.
13. A wall structure as claimed in claim 12, having resilient means biasing said panels to assume relative positions at which said formations are inter-engaged, and against which biasing the panels are relatively movable apart to release said coupling by releasing inter- engagement between the formations.
14. A wall structure as claimed in claim 13, wherein the panels are two of a line of side by said panels in said space, said line including at least one further panel.
15. A method of forming a wall structure having two panels positioned side-side in a side to side extending space in a frame of the wall structure, the space being defined between spaced first and second transverse members of the frame, the method including: entering one end portion of each said panel into said space by movement thereof to inter- engage the one end portion thereof with one said transverse member, moving each panel to position it in the space with an opposite end portion thereof adjacent to the other said transverse member and moving each panel towards the one transverse member to inter- engage said opposite end portion of each panel with the first transverse member, while maintaining the inter-engagement of each one end portion and the one transverse member, and effecting relative side to side movement between the panels towards each other to couple the panels at adjacent side edge portions thereof to limit relative movement between the panels in a first direction transverse to the side to side direction of extent of the space and the end to end direction of the panels, said inter-engagements limiting movement, in said first direction, between the panels and the transverse members.
16. A method as claimed in claim 15 including providing resilient means to resiliently bias to resiliently bias the panels away from each other to a position at which said coupling is released to permit relative movement between the panels in said first direction, the coupling between the panels being maintained by limiting relative movement of the panels away from each other under said resilient bias.
17. A method as claimed in claim 15 or claim 16, wherein after positioning a first of said panels in said space with said end portions thereof inter-engaged with the transverse members, the one end portion of a second of said panels is entered into the space, so as to be inter-engaged with the one transverse member, by movement thereof in the end to end direction thereof.
18. A method as claimed in claim 15 or claim 16, wherein after positioning a first of said panels in said space with said end portions thereof inter-engaged with the transverse members, the one end portion of a second of said panel is entered into the space, so as to be inter-engaged with the one transverse member, by movement in the end to end direction thereof and rotational movement of the panel substantially about a corner of the second panel positioned adjacent the first panel and the second transverse member.
19. A method as claimed in claim 19 wherein said corner is, during said rotational movement, positioned adjacent the first panel and the one transverse member.
20. A wall structure having two panels positioned side-side in a side to side extending space in a frame of the wall structure by the method of any one of claims 15 to 19.
PCT/AU2011/001109 2010-08-27 2011-08-26 Wall structure WO2012024742A1 (en)

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3002561A1 (en) * 2013-02-26 2014-08-29 Neolife Partition assembly for partitioning interior space of building, has connectors comprising connection strip encased in connection groove and fitment portions encased in longitudinal fitment portion and in one of peripheral grooves of panels
WO2022269579A1 (en) 2021-06-25 2022-12-29 Eekowall Limited Wall panel
WO2022269581A1 (en) * 2021-06-25 2022-12-29 Eekowall Limited Wall panel
WO2022269580A1 (en) 2021-06-25 2022-12-29 Eekowall Limited Wall panel
WO2023012541A1 (en) * 2021-08-02 2023-02-09 Eekowall Limited Wall panel
GB2612401A (en) * 2021-06-25 2023-05-03 Eekowall Ltd Wall panel

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4422226A1 (en) * 1994-06-24 1996-01-04 Weichenrieder Erich Sen Wall structure erected from positively coupled wall elements
ES2162528A1 (en) * 1998-05-14 2001-12-16 Mari Victor Ibanez Lightened dovetailed panel with pipes for electrical cabling and plumbing for the formation of internal partitions and external enclosures.

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4422226A1 (en) * 1994-06-24 1996-01-04 Weichenrieder Erich Sen Wall structure erected from positively coupled wall elements
ES2162528A1 (en) * 1998-05-14 2001-12-16 Mari Victor Ibanez Lightened dovetailed panel with pipes for electrical cabling and plumbing for the formation of internal partitions and external enclosures.

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3002561A1 (en) * 2013-02-26 2014-08-29 Neolife Partition assembly for partitioning interior space of building, has connectors comprising connection strip encased in connection groove and fitment portions encased in longitudinal fitment portion and in one of peripheral grooves of panels
WO2022269579A1 (en) 2021-06-25 2022-12-29 Eekowall Limited Wall panel
WO2022269581A1 (en) * 2021-06-25 2022-12-29 Eekowall Limited Wall panel
WO2022269580A1 (en) 2021-06-25 2022-12-29 Eekowall Limited Wall panel
GB2612401A (en) * 2021-06-25 2023-05-03 Eekowall Ltd Wall panel
GB2612403A (en) * 2021-06-25 2023-05-03 Eekowall Ltd Wall panel
GB2612402A (en) * 2021-06-25 2023-05-03 Eekowall Ltd Wall panel
GB2612403B (en) * 2021-06-25 2024-01-03 Eekowall Ltd Wall panel
GB2612402B (en) * 2021-06-25 2024-01-03 Eekowall Ltd Wall panel
GB2612401B (en) * 2021-06-25 2024-01-03 Eekowall Ltd Wall panel
GB2612400B (en) * 2021-06-25 2024-01-10 Eekowall Ltd Wall panel
WO2023012541A1 (en) * 2021-08-02 2023-02-09 Eekowall Limited Wall panel

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