WO2013052997A1 - Panneau de paroi composite - Google Patents

Panneau de paroi composite Download PDF

Info

Publication number
WO2013052997A1
WO2013052997A1 PCT/AU2012/001222 AU2012001222W WO2013052997A1 WO 2013052997 A1 WO2013052997 A1 WO 2013052997A1 AU 2012001222 W AU2012001222 W AU 2012001222W WO 2013052997 A1 WO2013052997 A1 WO 2013052997A1
Authority
WO
WIPO (PCT)
Prior art keywords
frame
mesh
wall panel
composite wall
panel according
Prior art date
Application number
PCT/AU2012/001222
Other languages
English (en)
Inventor
Damien John DIGNEY
Original Assignee
Project Modular Aust 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 AU2011904257A external-priority patent/AU2011904257A0/en
Application filed by Project Modular Aust Pty Ltd filed Critical Project Modular Aust Pty Ltd
Publication of WO2013052997A1 publication Critical patent/WO2013052997A1/fr

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
    • E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
    • E04C2/386—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a frame of unreconstituted or laminated wood

Definitions

  • This invention relates generally to a composite panel system incorporating mesh and structural foam and to al building solution for construction purposes.
  • the invention also relates to buildings and construction systems employing vertical wall panel elements, horizontal floor panel elements, horizontal ceiling panel elements and angular roofing panel elements that use the structural benefits of a composite panel design of the present invention.
  • the invention particularly relates to, but is not necessarily limited to, a steel framed stud panel with attached steel reinforcing mesh adhered to cladding material or a reinforced board with spray foam materials to increase structural strength, bracing of panel, thermal- barrier and acoustic-barrier standards, and to buildings and construction systems employing such panels.
  • Panels fabricated with a structural steel frame have sheet materials generally mechanically fastened to the steel framework. This presents issues in providing a thermal break from exterior cladding material and allowing heat transmission through the cladding and into the steel framed structure. Mechanical fastening in conventional systems is also time consuming and costly.
  • US Patent No. 2008/0115442 A1 (“Chi Wai Cheng”) discloses a composite sandwich wall panel comprising two skins of sheeting material, mesh and polystyrene laminated together to form a composite structural panel.
  • the inherent strength of the panel is attributed to the adhesion of the external cladding material to the inner core, which is strengthened by the mesh reinforcement.
  • This method of manufacture for structural insulated panels (SIP's) with board cladding generally employs machinery to press the components under pressure and heat.
  • US Patent No. 5,526,629 (“Joseph A Caverness”) discloses a composite building panel using a steel frame member to embed into a concrete screed to form the structural panel. This method may be subject to cracking due to lack of reinforcement for the concrete material.
  • a composite wall panel could be devised that helped to at least ameliorate some of the shortcomings described above.
  • One embodiment of the present invention provides a building panel which can be manufactured in a range of heights, widths and/or thicknesses from a minimum number of different components.
  • a preferred embodiment may also provide such a panel which has minimal thermal bridging, for improved thermal- barrier characteristics, whilst still obtaining high bracing and structural properties.
  • the preferred embodiment may provide a building panel which minimises corrosion by separating dissimilar materials.
  • One advantage of the preferred embodiment of the building panels is to provide a reduction of structural studs required for fabrication.
  • the present invention provides a composite wall panel comprising: a fabricated structural frame; a mesh for bracing the structural frame; and a foam for bonding a cladding material to the mesh and frame to create a strong lightweight panel.
  • the composite panel system provides a building structural panel for use in a building construction as a floor panel, or a wall panel or a roof panel.
  • the building panel may comprise a perimeter frame to be bonded and/or fastened to the inner studs at various spacings.
  • the composite panel system may comprise a panel which
  • the structural frame may comprise a steel frame manufactured from thin sheets of galvanized steel formed into steel vertical studs adapted for use with horizontal steel track that are fixed to the floor and ceiling with the vertical studs are arranged spaced apart in the tracks, and fastened at the top and bottom.
  • the steel frame is cold formed rolled section or steel hollow section.
  • the frame may comprise a conventional timber frame of timber components.
  • the frame may comprise a composite stud frame comprising a composite of wood and plastic materials.
  • the frame may comprise one or more multi-frame openings, each multi-frame opening being structured to be converted into an opening of desired size as required.
  • the frame openings may comprise an opening for a window, a door or a sliding door or window.
  • the mesh may comprise a grid profile reinforcing mesh sheet which is attached directly to the structural frame.
  • the mesh sheets are formed of steel wire and welded to the steel frame with mesh fabric attached to the frame.
  • the mesh sheets may be attached to timber studs with mesh fabric attached to the timber frame.
  • the mesh may be a fibreglass or a carbon fibre mesh or any other mesh profile suitable for bracing and reinforcing the composite wall panel.
  • the mesh may be attached to the frame using loop or hoop iron mesh tie and fasteners.
  • the hoop iron can be diagonally or horizontally installed over the mesh to fasten the mesh to the frame.
  • the reinforcing mesh is a spatial mesh manufactured from high tensile steel wire.
  • the reinforcing mesh may be a square mesh manufactured from ribbed wires that are welded together with equal spacing in both directions to form square apertures or may be a rectangular mesh forming rectangular apertures.
  • the reinforcing mesh does not cover the multi- frame openings for a window, a door or a sliding door or window.
  • the mesh aperture size may be varied dependent upon the use of the wall panel. For example, if the panel is to be installed in a house in an area which is prone to cyclone activity then the reinforcing mesh used in the wall panel has a small aperture in order to prevent any projectiles from piercing through the wall and penetrating the building.
  • the mesh can be in small or large grid sizes typically from 20mm x 20mm x 1 mm wire to 200mm x 100mm x 9mm wire.
  • the mesh is attached to the frame on the same side of the frame to which the external cladding is to be attached.
  • the external cladding material is spaced apart from the frame by the mesh, with the mesh facing the cladding material.
  • the external cladding may be bonded to the mesh and frame with a foam. Therefore no mechanical fixings are required for fixing the exterior cladding to the frame, as the foam bonds to the mesh and frame gluing to the exterior cladding.
  • the exterior cladding may comprise a fibre cement siding or fibre cement cladding used to cover the exterior of the composite panel system.
  • the external cladding material may comprise a steel or metal cladding.
  • a coated metal which comes in different styles and colours and may have a corrugated or flat profile.
  • the roof panel, floor panel or the wall panel may comprise a composite wall panel.
  • the foam may be a high density polyurethane foam which may be applied with a spray gun.
  • an interiorcladding may be glued and/or mechanically fixed to the inside of the frame.
  • the thickness formed by the bonding foam between the external cladding and the frame of the composite panel provides a thermal break or thermal barrier which is formed as an element of low thermal conductivity placed in the composite wall panel to reduce or prevent the flow of thermal energy between conductive materials.
  • the bonding foam also provides improved structural acoustic properties.
  • the thermal break is achieved by having a wall in which the thickness of the bonding foam can be varied to achieve different thermal breaks between the conductive materials. That is, the cladding can be spaced off the mesh at 10mm or 50mm to give the wall additional thermal and acoustic properties.
  • the present invention provides a new panel system comprising of vertical wall panel elements, horizontal floor panel elements, horizontal ceiling panel elements and angular roofing panel elements that may use structural benefits of the composite panel design.
  • Fig. 1 shows a front, side and top views of a composite panel in accordance with an embodiment of the present invention
  • FIG. 2 and 3 show an expanded view of a panel, without foam added, Fig. 2 is shown with an exterior flat panel and Fig, 3 with a corrugated exterior panel;
  • Fig. 4 shows the structural wall panel framing attached to mesh reinforcing elements in accordance with the composite panel of Fig. 1 ;
  • Fig. 5 illustrates framing and mesh panel being suspended over extemal cladding material elements and foam being applied through mesh onto the external cladding to create bonding and composite panel structure in accordance with Fig. 1
  • Fig. 6 show exploded sectional views along line B-B through the composite panel of Fig. 2;
  • Fig. 7 show exploded sectional views along line D-D through the composite panel of Fig. 3.
  • the structural capacity and bracing strength of lightweight composite panel systems may vary given construction methods.
  • the construction of a composite panel system 10, 20 inaccordance with the present invention consists of a structural steel frame 12, an internal cladding 15 and an external cladding 11.
  • the external cladding 1 1 being bonded by foam 14 to a steel reinforcing mesh 13 and to the frame 12 as shown in Figs 1 to 3.
  • Figure 1 also illustrates an aperture 16 in the external cladding 11 , the frame 12, the mesh 13 and the internal cladding 15.
  • the aperture 16 or the multi-frame openings allow the composite panel 10, 20 to include openings which are structured to be converted into an opening of desired size as required.
  • the openings 16 are typically an opening in the panel for a window, a door or a sliding door or window.
  • Figs 1 and 2 show the composite panel 10 in which the external cladding is in the form of a flat sheet of fiber cement siding or fibre cement cladding 11 which is used to cover the exterior of a composite panel 10 in both commercial and domestic applications.
  • the fiber cement siding 11 is manufactured in a sheet form and is used not only as external cladding but may also be used as an internal cladding and in particular in bathrooms.
  • the external cladding sheets 11 may be a magnesium oxide board, timber plywood, steel rolled profile roof sheeting, or any material suitable for the intended application.
  • Fig. 3 illustrates a composite panel 20 in which an external cladding 21 is in the form of a corrugated galvanised iron sheet 21 which is used to cover the exterior of a composite panel 20 in both commercial and domestic applications.
  • Corrugated galvanised iron is a building material composed of sheets of hot -dip galvanised mild steel, cold-rolled to produce a linear corrugated pattern in them. The corrugations increase the bending strength of the sheet in the direction perpendicular to the corrugations, but not parallel to them.
  • Figure 4 shows the structural steel frame 12 which may be constructed from timber, steel or any composite framed alternative. To simplify the process only a steel frame 12 will be used throughout the description however it is to be understood that the present invention is not limited to only a steel frame 12.
  • the frame 12 is constructed with a top wall plate 24, a bottom wall plate
  • the aperture 16 in this case for a window also includes two horizontal studs 17.
  • the mesh 13 is attached to the steel frame 12 by any suitable process which will secure the mesh 13 to the frame 12. For example, by welding or by using a loop or hoop iron mesh tie (not shown) and a suitable fastener such as a metal screw, a screw bolt or rivet. When the loop or hoop tie is used the iron is stretched across the diagonal or horizontally across the panel to further provide reinforcement to the composite panel 10, 20.
  • a loop or hoop iron mesh tie (not shown) and a suitable fastener such as a metal screw, a screw bolt or rivet.
  • the mesh 13 shown in Figures 1 to 7 is a grid profile reinforcing mesh which is attached directly to the structural frame 12.
  • the mesh sheets 13 are formed of steel wire and welded to the steel frame 12.
  • a mesh fabric is attached to the frame to allow the mesh 13 to be welded.
  • the mesh 13 can alternatively be manufactured from other materials such as fibreglass or carbon fibre mesh or any other mesh profile suitable for bracing and reinforcing the composite panel system 10, 20.
  • the mesh 13 is a square mesh manufactured from high tensile steel wire.
  • the square mesh 13 is manufactured from ribbed wires that are welded together with equal spacing in both directions to form square apertures.
  • the mesh 13 may be a rectangular mesh forming rectangular apertures or any other shape provided the mesh 13 provides the reinforcement required for the composite panel 10, 20.
  • the mesh aperture size may be varied and is dependent upon the use of the wall panel. For example, if the panel is to be installed in a house in an area which is prone to cyclone activity then the reinforcing mesh used in the wall panel would have a relatively small aperture in order to prevent any projectiles from piercing through the wall and penetrating the building.
  • the mesh 13 can be in small or large grid sizes typically from 20mm x 20mm x 1 mm wire to 200mm x 100mm x 9mm wire.
  • the mesh 13 is attached to the frame 12 on the same side of the frame 12 to which the external cladding 11 is to be attached.
  • a number of cladding material sheets 11 are placed in a jig (not shown) to the desired size of the composite panel 10, 20.
  • the mesh 13 and frame 12 as shown in Figure 4 is then suspended over sheets 11 with the desired spacing.
  • a lightweight structural spray foam product 14 is then applied via a spray gun under pressure through the mesh 13 directly to the rear side of the external cladding material sheets 11.
  • the foam 14 bonds to form a substrate of the external cladding sheets 1 , the mesh 13 and the frame 12.
  • a thermal break and improved structural acoustic properties are created due to the spacing separating the external cladding sheets 11 , the mesh 13 and the frame 12 with foam product 14.
  • the foam 14 is used to fix the external cladding 11 to the frame 12 and mesh 13 no mechanical fixings are required for fixing the exterior cladding 11 to the frame 12, as the foam 14 bonds to the mesh 13 and frame 12 therefore gluing or fixing the exterior cladding 11 .
  • the distance which the external cladding 11 is spaced apart from the mesh 13 and frame 12 is therefore variable to provide the composite panel 10, 20 with a variable thermal break or thermal barrier which is formed as an element of low thermal conductivity placed in the composite wall panel 10, 20 to reduce or prevent the flow of thermal energy between conductive materials.
  • the external cladding 1 1 can be spaced off the mesh 13 with a variable gap or space of between 10mm to 100mm to give the wall additional thermal and acoustic properties.
  • Figures 6 and 7 show an exploded sectional view of the two composite wall panels 10, 20.
  • Figure 6 shows the composite wall panel 10 with the relatively flat external cladding material 11
  • Figure 7 shows the composite wall panel 20 with the corrugated external cladding 21 in accordance with an embodiment of the present invention.
  • ADVANTAGES ADVANTAGES
  • the composite panel system of the present invention has many advantages over prior art systems.
  • the panels are structural, lightweight, high impact and allow for high bracing characteristics due to mesh, foam and cladding material connections.
  • Some advantages of the present invention may include;

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Panels For Use In Building Construction (AREA)

Abstract

L'invention porte sur un système de panneau composite, lequel système comprend un plancher, un panneau de paroi et un panneau de toit qui sont fabriqués avec un cadre structurel; un treillis pour renforcer le cadre structurel; et une mousse pour lier un matériau de gaine au treillis et au cadre afin de créer un panneau de faible poids robuste.
PCT/AU2012/001222 2011-10-10 2012-10-09 Panneau de paroi composite WO2013052997A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2011904257A AU2011904257A0 (en) 2011-10-10 Wall to foundation connection
AU2011904257 2011-10-10

Publications (1)

Publication Number Publication Date
WO2013052997A1 true WO2013052997A1 (fr) 2013-04-18

Family

ID=48081256

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU2012/001222 WO2013052997A1 (fr) 2011-10-10 2012-10-09 Panneau de paroi composite

Country Status (1)

Country Link
WO (1) WO2013052997A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015120502A1 (fr) * 2014-02-12 2015-08-20 Arkistruct Ltd. Système de construction de panneaux préfabriqués
US10011989B2 (en) 2014-07-22 2018-07-03 Wanessa Sue Pence Composite building panel
US10294668B2 (en) 2017-01-04 2019-05-21 Kenneth R. Kreizinger Stiffened foam backed composite framed structure
WO2023015727A1 (fr) * 2021-08-09 2023-02-16 上海恪耐新材料科技有限公司 Paroi composite comprenant une quille en acier léger présentant une structure de section profilée et procédé de construction

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4019297A (en) * 1974-07-29 1977-04-26 David V. Munnis Construction panel
US6099768A (en) * 1998-05-22 2000-08-08 Canam Manac Group, Inc. Modular building panel and method for constructing the same
AU1834301A (en) * 2000-02-07 2001-08-09 Noel Barry Haig Thermal insulation construction
US20040261356A1 (en) * 2003-03-31 2004-12-30 Pn Ii, Inc. Self supportive panel system
US7836663B2 (en) * 2005-08-11 2010-11-23 Platinum Advanced Technologies, Inc. Poly-bonded framed panels

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4019297A (en) * 1974-07-29 1977-04-26 David V. Munnis Construction panel
US6099768A (en) * 1998-05-22 2000-08-08 Canam Manac Group, Inc. Modular building panel and method for constructing the same
AU1834301A (en) * 2000-02-07 2001-08-09 Noel Barry Haig Thermal insulation construction
US20040261356A1 (en) * 2003-03-31 2004-12-30 Pn Ii, Inc. Self supportive panel system
US7836663B2 (en) * 2005-08-11 2010-11-23 Platinum Advanced Technologies, Inc. Poly-bonded framed panels

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015120502A1 (fr) * 2014-02-12 2015-08-20 Arkistruct Ltd. Système de construction de panneaux préfabriqués
AU2014383001A2 (en) * 2014-02-12 2019-02-28 Arkistruct Ltd. A prefabricated panel building system
US10011989B2 (en) 2014-07-22 2018-07-03 Wanessa Sue Pence Composite building panel
US10294668B2 (en) 2017-01-04 2019-05-21 Kenneth R. Kreizinger Stiffened foam backed composite framed structure
WO2023015727A1 (fr) * 2021-08-09 2023-02-16 上海恪耐新材料科技有限公司 Paroi composite comprenant une quille en acier léger présentant une structure de section profilée et procédé de construction

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