WO2014075147A1

WO2014075147A1 - Concealed panel connections

Info

Publication number: WO2014075147A1
Application number: PCT/AU2013/001323
Authority: WO
Inventors: Damien John DIGNEY
Original assignee: Aqua Harvester Pty Ltd
Priority date: 2012-11-19
Filing date: 2013-11-15
Publication date: 2014-05-22

Abstract

A concealable connecting device for a building system incorporating a prefabricated structure comprising at least a first member and a second member. The concealable connecting device comprising: a plurality of cylindrical fasteners located in a spaced apart relationship on said first member; at least one opening in said second member for receiving an enlarged head portion of the cylindrical fastener; and wherein the first member and the second member are joined in an edge-to-edge relationship by relative sliding movement to engage said enlarged head of the second end of the cylindrical fastener within said at least one opening, said first member and said second member being secured in engagement by permitting length adjustment of the cylindrical fastener within said at least one opening by said adjustable means.

Description

CONCEALED PANEL CONNECTIONS

FIELD OF THE INVENTION

The present invention generally relates to building systems incorporating concealed connection of panels. The invention also relates to buildings and construction systems employing vertical, horizontal and angular panels, with a concealed connection method allowing fast and strong connections while using labour with a low skill level.

The invention particularly relates, but is not necessarily limited to a skeletal steel box section frame or other tensile frame material which is enclosed with facing sheets to both sides of the panel while still enabling connections to be made between panels with facing sheets installed.

■ BACKGROUND OF THE INVENTION

It should be noted that reference to the prior art herein is not to be taken as an acknowledgement that such prior art constitutes common general knowledge in the art.

In prior art as set out below, existing floor to wall systems relate to connection and tie down of a wall panel to slab element or floor panel. There are many methods to connect panel elements in construction. One such typical construction method is detailed in US 2006/0016139 A1 , These methods generally require skilled labour and specialist tools for installation.

An example of wall to floor connection is disclosed in JP20060187544 20060707 in the name of KATO SHIGEYASU "CONNECTION STRUCTURE OF BUILDING UNIT AND FOUNDATION, CONNECTION METHOD OF BUILDING UNIT AND FOUNDATION, AND UNIT BUILDING" which states the "PROBLEM TO BE SOLVED: To provide a connection method of a building unit and a foundation that can positively resist pull-out force generated to a bearing wall and reducing joint work in the construction field."

In another example, JP19990130244 19990511 MORITA MASANORI shows connection rods to join the two elements.

In another example, WO20121 14665 (A1 ) — 2012-08-30 by

"SUGIHARA MASAMI [JP]; SUNAGAWA HITOMI [JPJ; HATAE TOMOYA [JP]; OGAWA MASAYUKI [JP]; KAWAKAMI HIROAKI [JP]; FUJIHASHI KAZUNORI

[JP]." Uses flanges and bolt(s) with oversized washer(s) connections in frames to connect panels.

In another example, AU2010257353 (A1) — 2012-07-05, by ΉΑΤΑΕ TOMOYA; OGAWA MASAYUKI; ICHIKAWA KAZUKI", panel connections employ brackets for connecting panels.

While such inventions have proved successful, they involve specialized tools and skilled labour for installation and generally do not have facing sheets installed.

Unlike prior art, the present invention provides a novel method to connect horizontal, vertical and angular panels together with a simple method of construction with facing sheets installed on the panel.

Clearly it would be advantageous if a building system incorporating the concealed connection of panels could be devised that helped to at least ameliorate some of the shortcomings described above. In particular, it would be beneficial to create a concealed connection method for vertical, horizontal and angular panel elements that may include facing_, sheets installed to both sides of the panel to provide a strong structural connection of panel elements that can be uninstalled using the same method as used for installation which simplifies horizontal, vertical and angular panel connections and Installation while minimizing the requirement for skilled labour and tools.

SUMMARY OF THE INVENTION

The present invention provides horizontal, vertical and angular building panels which can be manufactured in a range of lengths, widths and/or thicknesses from a number of different materials with concealed connections within the panels. A preferred embodiment may also provide such a panel which has a strong skeletal frame with facing sheets attached.

One advantage of the preferred embodiment may provide simplified and concealed connections to horizontal, vertical and angular panels with facing sheets attached to enable fast erection in building systems employing such panels.

In accordance with a first aspect, the present invention provides a concealable connecting device for a prefabricated structure comprising at least a first member and a second member, said concealable connecting device comprising: a plurality of cylindrical fasteners located in a spaced apart relationship on said first member, each said cylindrical fastener comprising; a first end adapted lo be secured into a recess within said first member; and a second end opposing said first end and having an enlarged head portion; at least one opening in said second member for receiving the enlarged head portion of the second end of the cylindrical fastener; a means for adjustably securing the cylindrical fastener within the recess in the first member; and wherein the first member and the second member are joined in an edge-to- edge relationship by relative sliding movement to engage said enlarged head of the second end of the cylindrical fastener within said at least one opening, said first member and said second member being secured in engagement by permitting length adjustment of the cylindrical fastener within said at least one opening by said adjustable means.

Preferably, the cylindrical fastener may be a threaded bolt and may further comprise a washer fixedly mounted in contact with the underside of the enlarged head portion.

Preferably, the first member may comprise a horizontal panel with four sides, a top and a bottom side, wherein the top and bottom sides are spaced apart a distance from each other. The plurality of cylindrical fasteners may be spaced apart in recesses on the top and/or bottom side and are peripherally disposed and adjacent at least one of the four sides of the first member. The recess may comprise a threaded section which is adapted to communicate with a threaded portion of the cylindrical fasteners, such that the cylindrical fasteners are rigidly mounted in the recess with the enlarged head and washer positioned a distance above the top and/or bottom side of the first member such to allow a section of shaft of the cylindrical member to be exposed.

Preferably, the second member may comprise a vertical panel having at least a pair of spaced, vertical studs and top and bottom hollow stringers for securing said studs in horizontally spaced positions, and a covering material such as dry wall sheeting or the like secured to at least one side of said second member. The at least one opening is located in the top or bottom or both stringers.

Alternatively, a plurality of openings may be positioned in the top or bottom or both stringers and each one of the plurality of openings is located in positions suitable for communication with a corresponding one of the plurality of cylindrical fasteners in the first member.

Preferably, the opening may comprise an elongated slotted portion extending inwardly from a bottom side surface of the hollow stringer and an aperture extending perpendicular to the bottom edge and in a side portion of the stringer such that when the enlarged head and washer of the cylindrical fastener is positioned inside the stringer the exposed section of shaft of the cylindrical fastener is positioned in a fixing position by slideably moving the second member so that the exposed section of shaft of the cylindrical member is seated against an end of the elongated slotted portion. The aperture may be sized to allow both the washer and enlarged head of the cylindrical fastener and the adjusting means access within the hollow stringer in order to fix and secure the first member to the second member. Preferably, the aperture may further comprise a lip located at a bottom edge of the aperture to allow the washer and cylindrical fastener to be retained inside the hollow inner section of the stringer.

Alternatively, the opening may comprise a keyhole located in a bottom side of the stringer, the keyhole having a circular portion with a rectangular portion having a width smaller than the diameter of the circular portion projecting from a bottom side of the circular portion, and an aperture located adjacent and within the side portion of the stringer, wherein the circular portion has a sufficient diameter to allow the enlarged head and washer of the cylindrical fastener to be located within the hollow stringer.

Preferably, once the enlarged head and washer of the cylindrical fastener are located within the circular portion of the keyhole the second member may then slideably positioned to place the exposed shaft of the cylindrical fastener in a position located within the rectangular portion of the keyhole to allow_^ the cylindrical fastener to secure the first member to the second member, The aperture may be sized to allow the adjusting means access within the stringer to fix and secure the first member to the second member.

Preferably, the means for adjustably securing the first member to the second member and adjusting the length of the cylindrical fastener to control the spacing of the exposed section of shaft may comprise a spanner. Preferably, a third member may be attached to the top hollow stringer of the second member to form a top substantially horizontal panel with four sides, a top and a bottom side, wherein the top and bottom sides are spaced apart a distance from each other. A plurality of cylindrical fasteners may be spaced apart in recesses on the top and/or bottom side and are peripherally disposed and adjacent at least one of the four sides of the third member.

Preferably, at least one opening may be located in the top stringer of the second member. Alternatively, a plurality of openings may be positioned in the top stringer and each one of the plurality of openings is located in positions suitable for communication with a corresponding one of the plurality of cylindrical fasteners in the third member.

In accordance with a further aspect, the present invention provides a prefabricated building system providing a plurality of first, second and third members to which a covering material such as dry wall sheeting or the like is applied to both an inside and outside surface of the second members and an inside surface of the third members, with a roofing material applied to an outside surface of an external third member with a concealable connecting device as claimed in any one of claims 1 to 19 to securely connect the first, second and third members to form the prefabricated building.

In accordance with a still further aspect, the present invention resides in a horizontal or angular panel incorporating a steel skeletal frame or alternate tensile material for use in building construction that connects to a vertical panel to the top and/or bottom face or side perimeter face of the horizontal or angular panel,

The horizontal or angular panel may have predetermined threaded fixings to the top or bottom face of the panel to accept a bolt(s) with oversized washer(s) to be inserted for top face fixing of vertical panels.

Alternatively, the vertical, horizontal or angular panel may be constructed of concrete or alternate building material. The horizontal or angular panels may have predetermined profile cut-outs at various locations of the panel to accept or attach bolt(s) with oversized washer(s) to be inserted for fixing of vertical panels.

Preferably, the structural frame of the horizontal or angular panel is bonded and/or fastened to facing sheets, to form a fully encapsulated panel with small openings for access to connections. The horizontal or angular panel may be prefabricated and modular in sizes to suit building designs for floors and roof panels.

In a further aspect, the present Invention resides in vertical panels incorporating a steel skeletal frame or alternate tensile material for use in building wall panel construction that connects to horizontal or angular panel to the top and/or bottom lace or side face of the horizontal or angular panel,

The vertical panel preferably has predetermined threaded fixings to accept bolt(s) with oversized washer(s) connection to be inserted for connection to horizontal and angular panels. Preferably, the vertical panel has predetermined profile cut-outs at varying locations of the panel to accept or attach bolt(s) with oversized washer(s) for fixing of horizontal or angular panels.

Alternatively, the vertical panel may be constructed of concrete or alternate building material.

Preferably, the structural frame of the vertical panel is bonded and/or fastened to facing sheets, to form a fully encapsulated panel with small openings for access to connections. Preferably, the vertical panels may be prefabricated and modular in sizes to suit building designs for wall panels.

BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment of the invention is now described by way of example only with reference to the accompanying drawings in which:

Fig. 1 shows a section of a horizontal panel for use in accordance with an embodiment of the present invention including a hole and/or mechanical insert with a bolt and oversized washer;

Fig. 2 shows a horizontal panel with multiple hole(s) and/or mechanical insert(s) and multiple bolt(s) with oversized washer(s) for use in accordance with an embodiment of the present invention;

Fig, 3 shows the horizontal panel of Fig. 2 with the bolts and washers screwed into the horizontal panel so as to leave the head of the bolt at a pre- determined height;

Fig. 4 shows a section of a vertical panel with a cut-out in the bottom plate to accept a bolt and oversized washer of Fig. 3;

Fig. 5 shows a section of a vertical panel of Fig. 4 with a two sided and separated section profile cut-outs in the bottom plate to accept a bolt and oversized washer to allow connection from the underside of the vertical panel in accordance with a further embodiment of the present invention;

Fig. 6 shows a vertical panel skeletal steel box section framing with multiple two sided singular profile cut-outs at top and bottom plates to accept bolts with oversized washers to allow connections to a horizontal and/or angular panels in accordance with an embodiment of the present invention;

Fig. 7 shows a section of the horizontal panel of Fig. 3 aligned and prior to connection with a section of vertical panel of Fig. 6;

Fig. 8 shows a section of the vertical panel of Fig. 6 engaged with a section of the horizontal panel of Fig. 3 wilh a bolt with oversized washer engaged within the recessed cut-out in accordance with an embodiment of the present invention;

Fig, 9 shows spanner entering the cut-out of Fig.8;

Fig. 10 shows the spanner and sections of panels of Fig. 9 in place in the cut-out for securing the bolt and oversized washer to secure the horizontal panel to the vertical panel;

Fig. 11 shows the bolt and oversized washer and panels of Fig.10 with the bolt now secured to connect the vertical panel to horizontal panel;

Fig. 12 shows the two sided and separated profile cut-out of Fig. 5 located over the horizontal panel of Fig.3;

Fig. 13 shows the two sided and separated profile cut-out of Fig. 12 installed over the horizontal panel of Fig. 3;

Fig. 14 shows the two sided and separated profile cut-out of Fig. 12 sliding into fixing position over the horizontal panel of Fig. 3 with the bolt and oversized washer set to engage the vertical panel base plate to the horizontal panel and bolt;

Fig. 15 shows a spanner placed within the two sided and separated profile cut-out of Fig. 12 prior to final tightening of the boll and washer;

Fig. 16 shows a horizontal or angular panel stud with a hole and/or mechanical insert and bolt prior to being connected and a section of vertical panel with two sided singular profile cut-out in accordance with an embodiment of the present invention;

Fig. 17 shows the structure of Fig. 16 with the bolt and oversized washer in place prior to connecting to the vertical panel; Fig. 18 shows a section of the structure of Fig 16 with the horizontal or angular panel connected to the vertical panel;

Fig. 19 shows vertical panel of Fig. 6 prior to installation of facing sheets;

Fig. 20 shows a section of the panel of Fig. 19 with facing sheets installed for a fully enclosed panel;

Fig. 21 shows a vertical panel fully enclosed with facing sheets and bolts and oversized washers installed through one side of the facing sheets prior to connecting to a horizontal panel fully enclosed with facing sheets with two sided singular profile cut-outs to accept vertical panel bolts with oversized washers in accordance with a further embodiment of the present invention;

Fig. 22 shows the panels of Fig. 21 prior to accepting a spanner to secure bolts with oversized washers between horizontal and vertical panels;

Fig. 23 shows a vertical panel fully enclosed with facing sheets and bolts with oversized washers installed through one side of the facing sheets prior to connecting to a horizontal or angular panel fully enclosed with facing sheets with two sided singular profile cut-outs to accept vertical panel bolts and washers;

Fig. 24 shows a section of the panels of Fig. 23 ready to accept the spanner to secure bolts with oversized washers between horizontal or angular panels and vertical panels;

Fig. 25 shows a vertical panel fully enclosed with facing sheets and bolt(s) with oversized washer(s) installed through one side of a vertical stud prior to engaging with an additional vertical panel lully enclosed with facing sheets and two sided singular profile cut-out on the vertical stud; and

Fig. 26 shows the panels of Fig. 25 with the final connection between the vertical panel fully enclosed with facing sheets and bolts with oversized washers installed through one side of the vertical stud and an additional vertical panel fully enclosed with facing sheets and two sided singular profile cut-out on the vertical stud.

DETAILED DESCRIPTION OF THE INVENTION

The building industry traditionally constructs floor, wall and angular roofing panels from steel or timber skeletal frames. These are either prefabricated in a factory environment or manually constructed onsite by skilled tradespersons. Connections of horizontal and/or angular panels to vertical panels generally involve complex connections which may include channels or brackets to provide structural connections. Generally, the horizontal, angular and vertical panels are not fabricated with facing sheets attached until the framed panels are connected together, to enable access through the open frame to complete connections.

The connection methods of horizontal or angular panels to vertical panels in accordance with the present invention will enable panels to incorporate fixed facing sheets with a simplified concealed connection without the requirement of brackets or tie down rod connectors.

Figs 1 to 3 illustrate a horizontal panel 1 used in accordance with an embodiment of the present invention. The horizontal panel 1 includes at least one pre-drilled hole and/or a mechanical insert 2 with an internal thread located within the hole for communication with a bolt with an oversized washer 3. Horizontal panel 1 may be a concrete structure such as a concrete slab constructed onsite or a prefabricated concrete panel. Horizontal panel 1 may be a skeletal frame constructed in steel hollow section or cold rolled formed steel sections or an alternate tensile material for use in building construction. The hole and/or mechanical insert 2 are preferably fabricated to accept various design configurations of bolts with oversized washers 3. The bolt is a type of fastener characterized by a helical ridge, known as an external thread located on one end of the bolt and wrapped around and extending along the cylindrical bolt for a pre-determined distance. The thread on the bolt is designed to mate with a complementary thread, known as an internal thread located within the mechanical insert as described above. A metal or plastic washer forms the bolt washer combination 3 and is used to distribute the load of the bolt when inserted into the mechanical insert 2 to form a rigidly mounted structure when inserted into the insert 2. In order to reduce installation time the oversized washer may be a captive or retained washer which is located under the head of the bolt. Fig 2 illustrates the horizontal panel 1 with multiple holes and/or mechanical inserts 2 and multiple bolts with oversized washers 3. The horizontal panel 1 comprises four sides 21 and a top 20 and bottom 22 surface, with the top and bottom surfaces 20, 22 separated by a standard panel width or in this case floor height. As is illustrated the bolts and washers 3 are distributed around the periphery of the horizontal panel 1 and adjacent at least one of the four sides 21 of the horizontal panel 1. In Figs 2 and 3 the bolts and washers 3 are distributed around three of the four sides 21. As will be appreciated the bolts and washers 3 could be distributed in any pattern around the horizontal panel as well as on both the top 20 and bottom 22 surfaces as required. Fig 3 illustrates the horizontal panel 1 with multiple bolts with oversized washers 3 installed partially Into multiple holes and/or mechanical inserts 2 in locations as required. The bolts and washers 3 are only partially installed in order to allow sufficient clearance between the underside of the washer and the vertical panel so that the head of the bolt and the washer will easily enter the recess or cut- out 5, 7, This is more clearly illustrated in Figs 7 to 1 1 below.

A vertical panel as illustrated in Fig 6 typically comprises bottom plate 4, top plate 8 with vertical studs 6. The vertical panel may be a skeletal frame constructed in steel hollow section or cold rolled formed steel sections or an alternate tensile material for use in building construction. Preferably, bottom plate 4 and top plate 8 are welded to vertical studs 6 at Incremental spacing's. Single or multiple two sided singular profile cut-out(s) 5 or single or multiple two sided and separated profile cut-out(s) 7 are installed to bottom plate 4, vertical stud 6 or top plate 8 at incremental spacing's in a suitable location to enable alignment to horizontal panel 1 or angular panel 1 1 bolts with oversized washers 3.

Vertical panels may also employ single or multiple holes and/or mechanical inserts 2 on vertical studs 6 in locations as required to accept bolts with oversized washers 3 to enable connection of the horizontal panel 1 and/or angular panel 1 1.

Preferably, facing sheets 12 are attached to both faces of vertical panels with cut-outs in facing sheet material to form a clear opening similar in size to the two sided singular profile cut-out 5 or two sided and separated profile cutout 7 to enable spanner 9 access to tighten bolts with oversized washers 3.

Preferably, facing sheets 12 are attached to both faces of vertical panels wilh cut-outs in facing sheet material to form a clear opening similar in size to the holes and/or mechanical inserts 2 in locations as required for bolts with oversized washers 3 to connect through facing sheets 12.

Fig 4 illustrates a typical steel framed hollow section vertical panel with bottom plate 4. A two sided singular profile cut-out 5 is preferably oversized to allow tolerances without affecting the structure of the hollow section profile, This two sided singular profile cut-out 5 is one method to enable the side entry engagement of the vertical panel bottom plate 4 to horizontal panel 1 bolts with oversized washers 3. A first opening 30 is located in a front side of the bottom plate 4 and a second opening 31 is located substantially in the bottom of the bottom plate 4 but opening from a front edge of the bottom plate 4. The two openings 30, 31 form the cut-out 5. The first opening 30 is formed by an elongated slotted portion extending inwardly from a bottom side surface of the bottom plate or hollow stringer 4. A second opening 31 is formed by the aperture extending perpendicular to the bottom edge and in a side portion of the bottom plate or stringer 4, The cut-out 5 is designed such that when the enlarged head and washer of the cylindrical fastener 3 is positioned inside the hollow bottom plate 4 a lip or lips 33 located at a bottom edge where the first and second openings 30, 31 meet allow the washer and cylindrical fastener 3 to be retained inside the hollow inner section of the bottom plate 4. The vertical panel is then slid or guided into position in order for the fastener to then be tightened to secure the horizontal panel to the vertical panel.

An alternate connection method when side entry engagement of the vertical panel cannot be achieved is the two sided and separated profile cut-out 7. Two sides of the hollow section member are separated to both the side face and bottom face of the bottom plate 4. Alternatively, the two sided and separated profile cut-out can be used for vertical stud 6 and top plate 8.

Fig. 5 illustrates the two sided and separated profile cut-out 7. This alternate profile cut-out is to enable connection of panels where a side entry engagement of vertical panels to horizontal panels 1 or angular panels 11 are not achievable. Preferably, facing sheets 12 are attached to both faces of the vertical panel with cut-outs in facing sheet material to form a clear opening similar in size to two sided and separated profile cut-out 7 to enable spanner 9 access to tighten bolts with oversized washers 3,

The two sided and separated cut-out 7 comprises two separate openings, a first opening 40 and a second opening 41. The first opening 40 is in the shape of a keyhole located in the bottom side of the bottom plate 4. The keyhole having a circular portion with a rectangular portion having a width smaller than the diameter of the circular portion, the rectangular portion projects from a bottom side of the circular portion. The second opening 41 , is an aperture located adjacent and within a side portion of the bottom plate 4. The circular portion of the keyhole has been designed such that the circular portion has a diameter to allow the enlarged head and washer of the cylindrical fastener 3 to pass through the circular portion and into the hollow bottom plate 4. Once the enlarged head and washer of the cylindrical fastener 3 are located within the circular portion of the keyhole the vertical panel is then slideably positioned to place the exposed shaft of the cylindrical fastener 3 in a position located within the rectangular portion of the keyhole to allow the cylindrical fastener to secure the vertical panel to the horizontal or angular panel 1 , 10. The second opening 41 is sized to allow the spanner 9 access within the second opening 41 of the bottom plate 4 to fix and secure the vertical panel to the horizontal panel 1.

The various stages of engagement between horizontal panel 1 and the vertical panel are illustrated in Figs 7 to 1 1. Facing sheets 12 have been omitted from the vertical panel for clarity of the connection process. Horizontal panel 1 has multiple bolts with oversized washers 3 installed in holes and/or mechanical inserts 2. Bolts with oversized washers of the fastener 3 are rigidly installed into the insert 2 while leaving the enlarged head and oversized washer a gap or short distance above the top surface of horizontal panel 1 to allow accessible side entry connection of two sided singular profile cut-out 5. This allows a small portion or section of the cylindrical shaft of the fastener 3 to be left exposed above the top surface of the horizontal panel 1 . The vertical panel is then positioned to align profile cut-out 5 on bottom plate 4 with horizontal panel 1 bolts with oversized washers of the fastener 3.

Fig. 8 illustrates a typical vertical panel when it has been shifted sideways to engage profile cut-out 5 through bottom plate 4 to horizontal panel 1 bolts with oversized washers 3.

Preferably, spanner 9 illustrated in Fig. 9 has built in integral ratchet so the spanner can tighten bolts with oversized washers 3 without needing to lift the spanner 9 off top of the bolt 3, to therefore tighten bolt with a side to side action to secure the vertical panel to the horizontal panel 1.

To complete final engagement of bolts with oversized washers 3 to vertical panel bottom plate 4, spanner 9 connects to the bolls with oversized washers 3 via opening 30 provided through the vertical face of the two sided singular profile cut-out 5 as illustrated in Fig' 9. Preferably, the two sided singular profile cut-out 5 is oversized on the underside of bottom plate 4 to enable tolerances for bolts with oversized washers 3 should they be out of alignment.

Fig. 10 illustrates that the opening 30 of the two sided singular profile cut-out 5 on the vertical face of bottom plate 4 is sized to enable spanner 9 to be able to access and tighten bolts with oversized washers 3 to the bottom plate 4. The bolts with oversized washers 3 are then tightened with spanner 9 to the bottom plate 4. The final engagement of bolts with oversized washers 3 to bottom plate 4 is illustrated in Fig. 11.

Figs 12 to 15 illustrate the vertical panel alternate two sided and separated profile cut-out 7 positioned over horizontal panel 1 with the bolts with oversized washers 3 aligned with the keyhole 40 circular opening.in Fig 12 and with the bolts and oversized washer 3 inserted through the circular portion of the keyhole opening 40 in Fig 13. With the bolt and oversized washer 3 inserted through the keyhole opening 40 the vertical panel is now able to be slideably moved in the direction of arrow A.

Fig. 14 and Fig. 15 illustrates the vertical panel engagement to horizontal panel 1 using alternate two sided and separated profile cut-out 7 with vertical panel sliding over horizontal panel 1 with the bolt with oversized washer 3 remaining rigidly in place, The spanner 9 is then used to tighten the bolt with oversized washer 3 to connect vertical panel bottom plate 4 with horizontal panel 1.

The two sided and separated profile cut-out 7 method may also be utilized to connect horizontal or angular panel 11 or angular stud 10 with top plate 8.

Fig. 16 illustrates a typical angular panel stud 10 configuration which includes the hole and mechanical insert 2 and bolt with oversized washer 3 to engage vertical panel top plate 8 through two sided singular profile cut-out 5. Facing sheets 12 have been omitted from all panels for clarity of connection.

Fig. 17 illustrates horizontal or angular stud 10 prior to engagement to vertical panel two sided singular profile cut-out 5 on vertical panel top plate 8. In this position the bolt and oversized washer 3 are aligned with the cut-out 5 of the top plate or stringer 8 of the vertical panel.

Fig. 18 illustrates horizontal or angular panel 11 engaged with the vertical panel. Horizontal or angular panel 11 is preferably installed with facing sheets 12 attached to one of both sides of the panel to enable omission of fixing facing sheets on the construction site at heights. For example when the horizontal or angular panel 10 is utilised as a ceiling and roof panel.

Fig, 19 illustrates a vertical panel prior to installation of facing sheets 12. Preferably, all horizontal, vertical and angular panels have facing sheets attached prior to assembly on the construction site,

Preferably, all horizontal, vertical or angular panels are manufactured in an offsite controlled factory environment prior to delivery to site for installation,

A vertical panel fabricated with skeletal steel frame with facing sheets attached is illustrated in Fig. 20, A cut-out 50 is left in the facing sheet 12 in order for access to the bolt and oversized washer 3 to allow a user to tighten and fix ther vertical panel in place on a horizontal panel 1. Typically the facing sheets 12 are a covering material such as plasterboard sheeting or the like. Plasterboard, wallboard, gypsum board, gyprock or drywall is a panel made of gypsum plaster pressed between two thick sheets of paper and is typically used to make interior walls and ceilings.

Fig. 21 illustrates horizontal panel 1 with facing sheets 12 attached. In this horizontal panel configuration, the two sided singular profile cut-out 5 is located on the top face of horizontal panel 1 to accept connection of vertical panel bolts with oversized washers 3. The orientation of the panels have been reversed to illustrate the versatility of the present invention. It is now the vertical panel which includes the bolts with oversized washers 3 and the horizontal panel which includes the cut-out 5.

Fig. 22 illustrates horizontal panel 1 positioned engaged with the vertical panel. Access to complete connection with spanner 9 is via opening 50 in facing sheet 12 on the top side of horizontal panel 1 through two sided singular profile cut-out 5.

Facing sheets 12 provide separation of the steel frame on the vertical panel from the horizontal panel 1 steel framing. As described above the facing sheet 12 may be constructed from plasterboard. Alternatively, the facing sheet 12 is manufactured from a material with high compression properties, such as magnesium oxide board. Vertical panel in Fig. 22 is structurally supported by horizontal panel 1. Magnesium oxide is a versatile mineral that when used as part of a cement mixture and cast into thin cement panels under proper curing procedures and practices can be used in residential and commercial building construction. Magnesium board Is an environmentally friendly building material and is suitable for a wide range of general building uses and for applications that require fire resistance, mould and mildew control.

In contrast to Fig. 22, the vertical panel structurally supports horizontal panel 1 in Fig. 23. Horizontal panel 1 engages the vertical panel bolts with oversized washers 3. Bolts with oversized washers 3 are typically installed in vertical panel studs 6 for this connection configuration.

Fig. 24 illustrates the horizontal panel with a two sided singular profile cut-out 5 positioned over a vertical panel bolt with oversized washer 3. Horizontal panel 1 is lowered to engage the vertical panel and spanner 9 completes the connection via the opening 50 to underside facing sheet 12 of horizontal panel 1.

Multiple vertical panel connections are illustrated in Fig. 25 and Fig. 26. That is more than one vertical panel can be joined to a corresponding adjacent vertical panel to form a vertical wall section. Likewise, connection between multiple inline horizontal, vertical and angular panels all use a similar connection as shown in Fig. 24 and Fig. 25. Alternatively, two sided and separated profile cut-out 7 may be utilised. Alternatively, both two sided singular profile cut-out 5 and separated two sided profile cut-out 7 can be used to connect multiple inline horizontal, vertical and angular panels.

Preferably, a combination of two sided singular profile cut-out 5, two sided and separated profile cut-out 7 will be used on all horizontal, vertical and angular panels at various locations.

Preferably, multiple holes and/or mechanical inserts 2 and bolts with oversized washers 3 in combination with two sided singular profile cut-out(s) 5, two sided and separated profile cut-out(s) 7 will enable multiple panel configurations to be used on all horizontal, vertical and angular panels.

In order to cover the concealed connections cover strips are provided. Due to the location of the concealed connections at either the base or top of the vertical panel the cover strip could be in the form of a skirting panel which covers the joint between the vertical panel and the horizontal panel at the base or a cornice which covers the joint between the vertical panel and the horizontal or angled panel at the top.

The present invention has been described as a concealed method of connecting two panels, typically a vertical panel and a horizontal panel to form a wall structure. It should be understood that the present invention also allows the easy modification or disassembly of the walls and hence the easy relocation or removal of the wall structure.

While the present invention has been described In relation to single or multiple two sided singular profile cut-out(s) 5 or single or multiple two sided and separated profile cut-out(s) 7 installed in either the bottom plate 4, vertical stud 6 or top plate 8 it would be appreciated by the skilled addressee that other shapes and forms for the recess and cut-outs could be envisaged. For example the bottom plate 4, vertical stud 6 or top plate 8 can all be constructed from roll formed C-channel or box channel and therefore the shape of the cutout could be in the shape of a molded insert which replicates the shape of the channel. This provides a reinforced channel section which is stronger and resists movement during installation of the vertical panel to the horizontal panel or vice versa.

ADVANTAGES

It will be apparent that the connection of panels of the present invention has many advantages over prior art systems. Structural horizontal, vertical and angular panels with attached facing sheets can be prefabricated offsite to enable fast installation avoiding costly specialized tools and skilled labour onsite.

Human error in this construction method is greatly minimized given offsite precision manufacturing of panels which offers substantial cost and time savings during onsite construction.

Unlike alternate panelised systems, panels are connected with concealed and hidden fixings within the pre-lined panels without a requirement for channels, tie down rods or brackets. The majority of connections are at the base or top of vertical panels which are generally overlaid with cover strips. It will be apparent that minimised persons directing a crane operator with only a spanner can install these building panels to construct single and multiple level buildings, deleting the majority of skilled labour requirements onsite. Time and cost savings are substantial.

VARIATIONS

It will be realized that the foregoing has been given by way of illustrative example only and that all other modifications and variations as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as herein set forth. Throughout the description and claims of this specification the words "comprise" and variations of that word such as "comprises" and "comprising" are not intended to exclude other additives, components, integers or steps.

Claims

1. A concealable connecting device for a prefabricated structure comprising at least a first member and a second member, said concealable connecting device comprising:

a plurality of cylindrical fasteners located in a spaced apart relationship on said first member;

at least one opening in said second member for receiving an enlarged head portion of the cylindrical fastener; and

wherein the first member and the second member are joined in an edge-to- edge relationship by relative sliding movement to engage said enlarged head of the cylindrical fastener within said at least one opening, said first member and said second member being secured in engagement by permitting length adjustment of the cylindrical fastener within said at least one opening.

2. The concealable connecting device as claimed in claim 1 , wherein the cylindrical fastener is a threaded bolt and further comprises a washer fixedly mounted in contact with the underside of the enlarged head portion.

3. The concealable connecting device as claimed in claim 1 , wherein the first member comprises a horizontal panel with four sides, a top and a bottom side, wherein the top and bottom sides are spaced apart a distance from each other.

4. The concealable connecting device as claimed in any one of claims 1 to 3, wherein the plurality of cylindrical fasteners are spaced apart in recesses on the top and/or bottom side and are peripherally disposed and adjacent at least one of the four sides of the first member.

5. The concealable connecting device as claimed in any one of the preceding claims, wherein the recess comprise a threaded section which is adapted to communicate with a threaded portion of the cylindrical fasteners, such that the cylindrical fasteners are rigidly mounted In the recess with the enlarged head and washer positioned a distance above the top and/or bottom side of the first member such to allow a section of shaft of the cylindrical member to be exposed.

6. The concealable connecting device as claimed in claim 1 , wherein the second member comprises a vertical panel having at least a pair of spaced, vertical studs and top and bottom hollow stringers for securing said studs in horizontally spaced positions, and a covering material such as dry wall sheeting or the like secured to at least one side of said second member.

7. The concealable connecting device as claimed in claim 6, wherein the at least one opening is located in the top or bottom or both stringers.

8. The concealable connecting device as claimed in claim 6, wherein a plurality of openings are positioned in the top or bottom or both stringers and each one of the plurality of openings is located in positions suitable for communication with a corresponding one of the plurality of cylindrical fasteners in the first member.

9. The concealable connecting device as claimed in claim 7 or claim Θ, wherein the opening comprises an elongated slotted portion extending inwardly from a bottom side surface of the hollow stringer and an aperture extending perpendicular to the bottom edge and in a side portion of the stringer such that when the enlarged head and washer of the cylindrical fastener is positioned inside the stringer the exposed section of shaft of the cylindrical fastener is positioned in a fixing position by slideably moving the second member so that the exposed section of shaft of the cylindrical member is seated against an end of the elongated slotted portion.

10. The concealable connecting device as claimed in claim 9, wherein the aperture is sized to allow both the washer and enlarged head of the cylindrical fastener and an adjusting means access within the hollow stringer in order to fix and secure the first member to the second member.

11. The concealable connecting device as claimed in claim 9 or claim 10, wherein the aperture further comprises a lip located at a bottom edge of the aperture to allow the washer and cylindrical fastener to be retained inside the hollow inner section of the stringer.

12. The concealed connecting device as claimed in claim 7 or claim 8, wherein the opening comprises a keyhole located in a bottom side of the stringer, the keyhole having a circular portion with a rectangular portion having a width smaller than the diameter of the circular portion projecting from a bottom side of the circular portion, and an aperture located adjacent and within the side portion of the stringer, wherein the circular portion has a sufficient diameter to allow the enlarged head and washer of the cylindrical fastener to be located within the hollow stringer.

13. The concealable connecting device as claimed in claim 12, wherein once the enlarged head and washer of the cylindrical fastener are located within the circular portion of the keyhole the second member is then slideably positioned to place the exposed shaft of the cylindrical fastener in a position located within the rectangular portion of the keyhole to allow the cylindrical fastener to secure the first member to the second member.

14. The concealable connecting device as claimed in claim 12 or claim 13, wherein the aperture is sized to allow the adjusting means access within the stringer to fix and secure the first member to the second member.

15. The concealable connecting device as claimed in any one of the preceding claims, wherein the means for adjustably securing the first member to the second member and adjusting the length of the cylindrical fastener to control the spacing of the exposed section of shaft comprises a spanner.

16. The concealable connecting device as claimed in any one of the preceding claims, further comprising a third member attached to the top hollow stringer of the second member to form a top substantially horizontal panel with four sides, a top and a bottom side, wherein the top and bottom sides are spaced apart a distance from each other.

17. The concealable connecting device as claimed in claim 16, wherein a plurality of cylindrical fasteners are spaced apart in recesses on the top and/or bottom side and are peripherally disposed and adjacent at least one of the four sides of the third member.

18. The concealable connecting device as claimed in claim 16 or claim 17, wherein at least one opening is located in the top stringer of the second member.

19. The concealable connecting device as claimed in any one of claims 16 to 18, wherein a plurality of openings are positioned in the top stringer and each one of the plurality of openings is located in positions suitable for communication with a corresponding one of the plurality of cylindrical fasteners in the third member.

20. A prefabricated building system providing a plurality of first, second and third members to which a covering material such as dry wall sheeting or the like is applied to both an Inside and outside surface of the second members and an inside surface of the third members, with a roofing material applied to an outside surface of an external third member with a concealable connecting device as claimed in any one of claims 1 to 19 to securely connect the first, second and third members to form the prefabricated building.