WO2016065389A1 - A construction system - Google Patents

A construction system Download PDF

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Publication number
WO2016065389A1
WO2016065389A1 PCT/AU2015/000589 AU2015000589W WO2016065389A1 WO 2016065389 A1 WO2016065389 A1 WO 2016065389A1 AU 2015000589 W AU2015000589 W AU 2015000589W WO 2016065389 A1 WO2016065389 A1 WO 2016065389A1
Authority
WO
WIPO (PCT)
Prior art keywords
panel
construction system
building construction
beam element
pair
Prior art date
Application number
PCT/AU2015/000589
Other languages
French (fr)
Inventor
Thomas TRAINOR
Mark HUTTON
Original Assignee
Innoglobe 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 AU2014904322A external-priority patent/AU2014904322A0/en
Application filed by Innoglobe Pty Ltd filed Critical Innoglobe Pty Ltd
Publication of WO2016065389A1 publication Critical patent/WO2016065389A1/en

Links

Classifications

    • 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
    • E04B1/02Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/12Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of other material
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building 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
    • E04C2/34Building 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 composed of two or more spaced sheet-like parts
    • E04C2/36Building 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 composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building 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
    • E04C2/38Building 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
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building 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
    • E04C2/40Building 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 composed of a number of smaller components rigidly or movably connected together, e.g. interlocking, hingedly connected of particular shape, e.g. not rectangular of variable shape or size, e.g. flexible or telescopic panels

Definitions

  • the present disclosure relates to a construction system.
  • the present disclosure relates to a building construction system.
  • Prefabricated components such as frames and panels, and even fully prefabricated structures in knockdown form, have been used.
  • the aim of these concepts is to achieve a structure that can be rapidly assembled on site by relatively un-skilled labour.
  • a building construction system comprising a panel assembly, the panel assembly comprising at least one beam element, the or each beam element comprising a section profile comprising an elongate base and a pair of lengthwise extending parallel flanges cooperatively defining a channel, the panel assembly comprising at least one panel element, the or each panel element comprising a pair of ends and a pair of sides, where each end is sized and shaped to locate in the channel defined by the beam element.
  • the beam element comprises a plurality of locators spaced apart along the channel, and the ends of each panel comprises a plurality of locating sockets spaced apart there-along, where these locating sockets are spaced, sized and shaped to receive the locators when the end of the panel is located in the channel defined by the beam element.
  • the panel element can be used in either of a wall or a roof assembly.
  • the panel assembly can be used in either of a wall or a roof assembly.
  • the or each panel element comprises a plurality of internal tubes extending between the ends thereof, each tube comprising one of the locating sockets at opposing ends thereof.
  • the sides of the or each panel element comprise interlocking features for connecting the panel to the side of a further panel element.
  • these interlocking features extend along the side of the or each panel.
  • the features comprise interlocking male and female features.
  • the interlocking features comprise an interlocking tongue and groove arrangement.
  • the sides of the or each panel element comprise sealing features for sealing the panel to the side of a further panel element.
  • the sealing features comprise a sealing element located in the groove of the interlocking tongue and groove arrangement.
  • the sealing element is elastomeric.
  • the interlocking features comprise a shear key and shear key groove arrangement.
  • the interlocking features comprise a sealing tongue and a sealing groove.
  • the interlocking features and sealing features extend the length of each side of each panel.
  • the or each beam element comprises at least one lengthwise extending tubular hollow for receiving a connecting bracket.
  • the or each beam element comprises an inner wall comprising a lengthwise extending slot providing access to a respective lengthwise extending tubular hollow.
  • the or each beam element comprises a substantially parallel pair of the substantially lengthwise extending rectilinear hollows separated by a central channel defined by the pair of the slotted inner walls.
  • services such as pipes or cabling can be routed along the central channel.
  • the building construction system further comprises at least one connecting bracket for connecting beam elements, the or each connecting bracket comprising at least a pair of ends, where at least one end is sized and shaped for insertion into a lengthwise extending tubular hollow of a beam element.
  • the ends of the connecting bracket subtend an angle, so that in use, a pair of beam elements is joined at this angle. In one form, this angle is 90 ° .
  • the building construction system further comprises at least one beam element for use at the top of a first panel element forming a wall, and adapted for supporting a roof fonning panel at an angle with respect to the wall forming panel element.
  • this beam element will be referred to herein as a slope beam.
  • the building construction system further comprises at least one beam element for use at the top of a first panel element fonning a wall, and adapted to stack a further wall fonning panel atop of the first wall forming panel. This is useful for constructing multistorey buildings.
  • the panel stacking beam element comprises oppositely directed locators spaced apart there along.
  • the building construction system further comprises at least one beam element for use at an apex of a roof structure, and adapted to bridge ends of at least a pair of roof panels converging at the apex beam element.
  • this beam element will be referred to herein as an apex beam.
  • the apex beam element comprises locators directed for insertion into locating sockets of each of the converging panels.
  • the section profile of the or each beam element is extruded, and the locators are manufactured separately and then secured to the section profile.
  • the locators are moulded from a plastic material and bolted to the section profile.
  • the or each panel element is extruded endwise.
  • the building construction system further comprises at least one column element, the or each column element comprising a pair of ends, each end comprising a socket sized and shaped to receive a locator of a beam element, and further comprising at least one side with interlocking features for connecting the column element to the side of a panel element.
  • each column element comprises at least a pair of side edges comprising interlocking features for connecting the column element to a side edge of a panel element.
  • the building construction system comprises a plurality of the above described panel assemblies forming a building.
  • the building construction system further comprises at least one column top bracket for forming a structural joint between a column clement and beam elements.
  • kits of parts for the above described building construction system there is provided a kit of parts for the above described building construction system.
  • a method for constructing a building using the above described building construction system comprising the steps as herein described.
  • Figures 1 and 2 are isometric views of a beam element
  • Figure 3 is an end view of the beam element of Figure 1 ;
  • Figure 4 is an isometric view of an end connecting bracket for beam elements
  • Figure 5 is an isometric view of a corner connecting bracket for beam elements
  • Figure 6 is an isometric view of an assembly comprising a beam element and a pair of corner connecting brackets
  • Figure 7 is an isometric view of a frame comer assembly
  • Figure 8 is an isometric view of a panel element
  • Figure 9 is a plan view of the panel element of Figure 8;
  • Figure 10 is an isometric view of a seal ing element for panel elements;
  • Figure 1 1 is a plan view of the sealing element of Figure 10;
  • FIG. 12 is an isometric view of an assembly of panel elements
  • Figure 13 is a detailed view of a connection between a pair of panel elements in the assembly of Figure 12;
  • Figure 14 is an isometric view of a corner column element
  • Figure 15 is a plan view of the corner column element of Figure 14;
  • Figure 16 is an isometric view of a roof supporting beam element
  • Figure 17 is an end view of the roof supporting beam element of Figure 16;
  • Figures 18 through 23 illustrate stages of assembly of a building structure
  • Figure 24 is an isometric view of a portion of a building structure
  • Figure 25 is an isometric view of an apex beam element
  • Figure 26 is an end view of the apex beam element in use
  • Figure 27 is an isometric view of a portion of a roof structure comprising the apex beam element
  • Figure 28 is an isometric view of a portion of a roofed building structure
  • Figure 29 is an exploded isometric view of a corner portion of a building structure
  • Figure 30 is a plan view of a portion of a building structure
  • Figures 31 and 32 are isometric views of a portion of a building structure
  • Figure 33 is an isometric view of a window frame
  • Figure 34 is a front view of the window frame of Figure 33;
  • Figure 35 is an isometric view of a window frame according to a further embodiment;
  • Figure 36 is a front view of the window frame of Figure 35;
  • Figure 37 is an isometric view of a building structure
  • Figure 38 is a side view of the building structure of Figure 37;
  • Figure 39 is a front view of the building structure of Figure 38;
  • Figures 40 and 41 are isometric views of a panel stacking beam
  • Figure 42 is an isometric view of a portion of a multistorey building structure
  • Figure 43 is an isometric view of a portion of a building structure with a panel removed for clarity
  • Figure 44 is a cross-sectional view through the portion of building structure illustrated in Figure 43.
  • Figure 45 is a detailed sectional view of a portion of the section illustrated in Figure 44.
  • the beam element 10 comprises a section 12 comprising an elongate base 14 and a pair of lengthwise extending parallel flanges 16 cooperatively defining a channel, and a plurality of locators 18 spaced apart along the channel.
  • this beam element 10 will be referred to herein as a track beam 10.
  • Each beam element 10 is extruded from aluminium. Threaded holes are formed into a top face thereof to facilitate attachment of the locators 18 thereto.
  • Each locator 18 is made from a plastic such as Acrylonitrile Butadiene Styrene (ABS).
  • ABS Acrylonitrile Butadiene Styrene
  • locators 18 are attached to the section 12 with bolts, although quick clips or spring fastening systems could be employed.
  • the track beam 10 (and other beams - discussed below) will generally be supplied pre-assembled with the locators 18 bolted to the section 12.
  • the locators 1 8 not only simplify installation but also ensure that all panels 20 (see
  • Figures 8 and 9 are rigidly fixed and compensate for differential thermal expansion between the plastic panels 20 and aluminium frame-work.
  • the locators 18 also seal against sockets 22 (i.e. tube ends) to limit convective air movement.
  • the track beam 10 is a versatile component that can be used for a variety of uses including window frames, door frames, panel capping and structural framework.
  • each connecting bracket comprises at least a pair of ends, where at least one end is sized and shaped for insertion into a lengthwise extending hollow section 19 of the beam element 10, as illustrated in Figure 6.
  • each lengthwise extending hollow section 19 comprises an inner wall comprising a lengthwise extending slot 19S.
  • the end connecting bracket 30 of Figure 4 is made from aluminium, and it comprises a plurality of holes H (some of which are threaded) for accepting bolts B.
  • end connecting bracket 30 is used to connect track beams 10 and slope beams 70 (see Figures 16 and 17) to column top brackets 90.
  • the end connecting bracket 30 is inserted into the end of a lengthwise extending hollow section 19 of the beam element and fixed into position with internally fitted bolts B, the shanks (and only the shanks) of which are passed through the lengthwise extending slot 19S and into holes H.
  • the beams can then be attached to the column top brackets 90.
  • the corner connecting bracket 40 of Figure 5 is made from aluminium and is used to fonn 90 degree corners with the track beams 10. It comprises a plurality of holes H (some of which are threaded) for accepting bolts B.
  • FIG. 6 Refening now to Figures 6 and 7, where it can be seen how a pair of beam elements 10 have been connected by a pair of comer connecting brackets 40 (as illustrated in Figure 5) to form a corner of a frame assembly.
  • Each end of the corner connecting bracket 40 is inserted into a lengthwise extending hollow section 19 of the beam element and fixed into position with internally fitted bolts B, the shanks (and only the shanks) of which are passed through the lengthwise extending slot 19S and into holes H.
  • the bolts B will be concealed by the panel elements 20.
  • Each panel element 20 comprises a pair of faces, a pair of ends and a pair of sides.
  • Each end comprises a plurality of sockets 22 spaced apart there along, where these sockets 22 are spaced, sized and shaped to receive the locators 18 of one of the beam elements 10, when the end of the panel 20 is located within the channel defined by the beam element 10.
  • Each panel element 20 is extruded from plastic or composite feedstock and comprises a tube-like internal structure that provides optimal structural strength whilst minimising panel weight.
  • the panels 20 are used to form both walls and roofing and can free span approximately 7 metres.
  • the panels 20 can be extruded in any colour, including clear, and to any practical length.
  • Each panel 20 features an interlocking tongue 24 and groove 26 arrangement along each side that connects with the corresponding tongue and groove of a neighbouring panel or column.
  • a sealing element (or seal) 50 (see Figures 10 and 1 1) is fitted within each groove 26 creating a water tight seal with the tongue 24 of the opposing component.
  • Each panel also features a shear key 27 and shear key groove 28 to assist load flow, and load sharing between panels 20, as well as limiting lateral movement between panels 10 that would place undue pressure on the seal 50.
  • the unique sectional depth of the panels 20 allows them to achieve long unsupported vertical wall spans and roof spans. That is to say a panel 20 can be used as either a wall or a roof panel, and that wall panels and roof panels are identical in section.
  • the sealing element 50 (see Figures 10 and 1 1) is manufactured from an extruded elastomer, such as silicone rubber.
  • the sealing element 50 provides water and weather proofing between panels 20, and between panels 20 and corner columns 60.
  • the sealing element 50 is designed to allow sliding between itself and the tongue 24.
  • a plurality of panels of varying widths i.e. 20a, 20b, 20c and 20d
  • the tongue 24 and groove 26 pairings are first aligned, pressed together, and then the new panel 20 is slid down over the locators 18.
  • a shear key is featured adjacent to each tongue 24.
  • the function of the shear key 27 is to limit lateral movement between panels 20, or between a panel 20 and a column 60, thereby limiting lateral movement of a tongue 24 within the sealing element 50 and the groove 26 in turn.
  • Each corner column 60 is an aluminium extrusion used to form part of the aluminium framework at the corners of a typical structure.
  • Each corner column 60 comprises a tongue and groove arrangement on two faces that connect with the tongue and groove of each of the adjacent panels.
  • the building construction system further comprises T-connector columns 60a, for connecting with panels 20 on three sides, and cross connector columns 60b for connecting with panels 20 on four sides.
  • Each slope beam 70 is structurally similar to the track beam 10, but features a sloped top
  • roof panels 14a (as opposed to a flat base 14) to form a roof gradient, and optionally wings 14b to facilitate attachment of the roof panels to the wall structure.
  • Roof panels 20 can be fastened to the wings 14b if provided, or directly to the upper sloped face.
  • the slope beam 70 forms part of the upper structural framework.
  • the track beam 10 and slope beam 70 profiles allow internal bolting of framework, facilitating a clean and attractive appearance of installations.
  • FIG. 18 through 23 where it is illustrated, how in use, a building is constructed using the building construction system, by first laying down track beams 10 along the perimeter of the structure.
  • the track beams 10 can be secured to the ground by fixing with mechanical fasteners to a concrete floor slab, or staking it directly to the earth for temporary installations.
  • Wall panels 20 are then erected by first erecting a corner column 60 (see Figure 21 ) and then progressively installing panels 20 (see Figure 22) and comer columns 60.
  • a panel 20 is installed by fitting its tongue 24 and groove 26 to its neighbouring component, and then sliding it down over the locators 18 and into position.
  • the sealing elements 50 ensure sealing at each interface, and accommodate for variations in manufacturing tolerances and thermal expansion/contraction of components.
  • the wall panels 20 are then capped with track beams 10 and/or slope beams 70 (see Figure 20).
  • the roof panels 20 are then installed and fixed to either the top surface or the wings 14b of the slope beams 70 (see Figure 23). Finally the edges of the roof panels 20 are enclosed with track beams 10.
  • apex beam element 80 for use at an apex of a roof structure, and adapted to bridge ends of at least a pair of roof panels 20 converging at the apex beam element 80.
  • the apex beam 80 forms a ridge line.
  • the apex beam 80 is a beam section comprising the form of two track beam sections 12 that are each angled downward to form an apex.
  • On each side of the apex beam 80 is a face that is comprised of locators 18 directed for insertion into locating sockets 22 of each of the converging panels 20.
  • FIG. 28 where it is illustrated, how in use, a roof for a building structure is constructed using the apex beam element 80. Roof panels 20 are supported atop of slope beams 70 at one end, and converge at the apex beam 80, which bridges and connects these roof panels 20.
  • the building construction system further comprises column top brackets 90, which are used to form a structural joint between columns (corner columns 60, T-connector columns 60a, cross connector columns 60b, and inline connector columns 60c) and beams (track beams 10 and slope beams 70).
  • column top brackets 90 There are 10 main types of column top brackets 90, these being namely upper right 90a, lower right 90b, upper left 90c, lower left 9()d, upper tee (i.e. 3-way connection) 90e, lower tee 90f, 4-way 90g, left tee 90h, right tee 90i and inline 90j.
  • Column top brackets 90 have a complex geometry designed to neatly join beams 10, 70 via end connecting brackets 30 with concealed bolts.
  • Column top brackets 90 facilitate a fonnation of the roof gradient. They comprise service hol es SH which provide for routing of water and electrical services where required.
  • a column top bracket 90 is first attached to the top of the respective column 60.
  • FIG. 33 and 34 there is illustrated a window frame assembly comprising track beams 10 at its ends, and sections 12 (of track beams 10) at its sides, all of which are joined and bolted together using the corner connecting brackets 40 (as illustrated in Figure 5).
  • the sections 12 which are devoid of locators 18
  • the locators 18 of the track beams 10 will engage with sockets 22 in ends of panels 20.
  • FIG. 35 and 36 there is illustrated a window frame assembly assembled from low profile track beam elements 10a.
  • Low profile track beam elements 10a differ from track beam elements 10 inasmuch as they comprise a section 16a which is deficient of the lengthwise extending hollow sections 19 of section 16.
  • FIG. 37 through 39 where it is illustrated, how in use, a building is constructed using the building construction system.
  • the building comprises window frames, and a frame for a doorway, which are constructed from track beams and sections in the manner described above.
  • the stacking beam element 100 comprises a section comprising the form of two oppositely directed, but aligned (ie not angled) track beam sections 12, and so it comprises locators 18 directed for insertion into locating sockets of each of the panels 20 being stacked.
  • the panel stacking beam element 100 is positioned atop of a first panel element 20 forming a wall, and a further wall forming panel 20 is stacked atop of the stacking beam element 100 and the first wall forming panel 20 in turn.
  • Figures 43 through 45 illustrate how rain water can be collected from roof forming panels
  • FIG. 43 omits, for clarity, a wall forming panel to show the concealed downpipe 1 10.
  • a section in this case an angle is attached to the roof and directs rainwater toward the downpipe.
  • the building construction system disclosed herein allows buildings and structures to be constructed efficiently, drastically reducing construction times compared to conventional building techniques, while at the same time lending itself to use in combination with conventional building techniques. It also greatly reduces the co-ordination effort required to manage numerous trades on a single site.

Abstract

A building construction system is disclosed. In one aspect, the building construction system comprises a panel assembly, the panel assembly comprising at least one beam element, the or each beam element comprising a section comprising an elongate base and a pair of lengthwise extending parallel flanges cooperatively defining a channel, and a plurality of locators spaced apart along the channel, and at least one panel element, the or each panel element comprising a pair of ends and a pair of sides, each end comprising a plurality of sockets spaced apart there along, where these sockets are spaced, sized and shaped to receive the locators when the end of the panel is located in the channel defined by the beam element. A kit of parts, and a method for constructing a building are also disclosed.

Description

A CONSTRUCTION SYSTEM
PRIORITY DOCUMENTS
10001 ] The present application claims priority from Australian Provisional Patent Application
No. 2014904322, filed on 29 October 2014, the content of which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002 ] The present disclosure relates to a construction system. In a particular form the present disclosure relates to a building construction system.
BACKGROUND
100031 The competitive nature of the building industry has led to a need for cost-effective methods of construction. Cost effectiveness is achieved by simplicity and efficiency in construction. A major component of the cost of building is labour.
10004 ] Prefabricated components such as frames and panels, and even fully prefabricated structures in knockdown form, have been used. The aim of these concepts is to achieve a structure that can be rapidly assembled on site by relatively un-skilled labour.
100051 A problem with these concepts in that they are generally incapable of meeting the wide range of requirements such as fast assembly, versatility, recyclability, performance, durability, reduced requirement for support equipment such as cranes, and suitability for various building types, such as, for example, standard residential, high density residential, commercial and industrial.
[0006] It is against this background and the problems and difficulties associated therewith that the present invention has been developed.
10007] Certain objects and advantages of the present invention will become apparent from the following description, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed. SUMMARY
[0008 ] According to a first aspect, there is provided a building construction system comprising a panel assembly, the panel assembly comprising at least one beam element, the or each beam element comprising a section profile comprising an elongate base and a pair of lengthwise extending parallel flanges cooperatively defining a channel, the panel assembly comprising at least one panel element, the or each panel element comprising a pair of ends and a pair of sides, where each end is sized and shaped to locate in the channel defined by the beam element.
[0009 ] In one form, the beam element comprises a plurality of locators spaced apart along the channel, and the ends of each panel comprises a plurality of locating sockets spaced apart there-along, where these locating sockets are spaced, sized and shaped to receive the locators when the end of the panel is located in the channel defined by the beam element.
[0010 ] In one form, the panel element can be used in either of a wall or a roof assembly.
[001 1 1 In one form, the panel assembly can be used in either of a wall or a roof assembly.
[0012] In one form, the or each panel element comprises a plurality of internal tubes extending between the ends thereof, each tube comprising one of the locating sockets at opposing ends thereof.
[ 0013] In one form, the sides of the or each panel element comprise interlocking features for connecting the panel to the side of a further panel element.
[ 0014] In one form, these interlocking features extend along the side of the or each panel.
[0015] In one form, the features comprise interlocking male and female features.
[0016] In one form, the interlocking features comprise an interlocking tongue and groove arrangement.
[ 0017] In one form, the sides of the or each panel element comprise sealing features for sealing the panel to the side of a further panel element.
[ 0018 ] In one form, the sealing features comprise a sealing element located in the groove of the interlocking tongue and groove arrangement. In one form, the sealing element is elastomeric. [0019 ] In one form, the interlocking features comprise a shear key and shear key groove arrangement.
[0020 ] In one form, the interlocking features comprise a sealing tongue and a sealing groove.
[ 0021 ] In one form, the interlocking features and sealing features extend the length of each side of each panel.
[0022] In one form, the or each beam element comprises at least one lengthwise extending tubular hollow for receiving a connecting bracket.
[0023] In one form, the or each beam element comprises an inner wall comprising a lengthwise extending slot providing access to a respective lengthwise extending tubular hollow.
[0024] In one form, the or each beam element comprises a substantially parallel pair of the substantially lengthwise extending rectilinear hollows separated by a central channel defined by the pair of the slotted inner walls.
[0025] In use, services such as pipes or cabling can be routed along the central channel.
[0026] In one form, the building construction system further comprises at least one connecting bracket for connecting beam elements, the or each connecting bracket comprising at least a pair of ends, where at least one end is sized and shaped for insertion into a lengthwise extending tubular hollow of a beam element.
[0027] In one form, the ends of the connecting bracket subtend an angle, so that in use, a pair of beam elements is joined at this angle. In one form, this angle is 90°.
[0028] In one form, the building construction system further comprises at least one beam element for use at the top of a first panel element forming a wall, and adapted for supporting a roof fonning panel at an angle with respect to the wall forming panel element. For clarity, this beam element will be referred to herein as a slope beam.
[0029] In one form, the building construction system further comprises at least one beam element for use at the top of a first panel element fonning a wall, and adapted to stack a further wall fonning panel atop of the first wall forming panel. This is useful for constructing multistorey buildings. [0030 ] In one form, the panel stacking beam element comprises oppositely directed locators spaced apart there along.
[003 1 ] In one form, the building construction system further comprises at least one beam element for use at an apex of a roof structure, and adapted to bridge ends of at least a pair of roof panels converging at the apex beam element. For clarity, this beam element will be referred to herein as an apex beam.
[ 0032 ] In one form, the apex beam element comprises locators directed for insertion into locating sockets of each of the converging panels.
[0033 ] In one form, the section profile of the or each beam element is extruded, and the locators are manufactured separately and then secured to the section profile.
[0034 ] In one form, the locators are moulded from a plastic material and bolted to the section profile.
[ 0035] In one form, the or each panel element is extruded endwise.
[ 0036] In one form, the building construction system further comprises at least one column element, the or each column element comprising a pair of ends, each end comprising a socket sized and shaped to receive a locator of a beam element, and further comprising at least one side with interlocking features for connecting the column element to the side of a panel element.
[ 0037] In one form, each column element comprises at least a pair of side edges comprising interlocking features for connecting the column element to a side edge of a panel element.
[0038] In one form, the building construction system comprises a plurality of the above described panel assemblies forming a building.
[0039] In one form, the building construction system further comprises at least one column top bracket for forming a structural joint between a column clement and beam elements.
[0040] According to a further aspect, there is provided a kit of parts for the above described building construction system. [0041 ] According to a further aspect of the present invention, there is provided a method for constructing a building using the above described building construction system, the method comprising the steps as herein described.
[0042 ] A detailed description of one or more embodiments of the invention is provided below along with accompanying figures that illustrate by way of example the principles of the invention. While the invention is described in connection with such embodiments, it should be understood that the invention is not limited to any embodiment. On the contrary, the scope of the invention is limited only by the appended claims and the invention encompasses numerous alternatives, modifications and equivalents. For the purpose of example, numerous specific details are set forth in the following description in order to provide a thorough understanding of the present invention.
[0043] The present invention may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the present invention is not unnecessarily obscured.
BRIEF DESCRIPTION OF DRAWINGS
[0044] Embodiments of the present invention will be discussed with reference to the accompanying drawings wherein:
[0045 ] Figures 1 and 2 are isometric views of a beam element;
[ 0046] Figure 3 is an end view of the beam element of Figure 1 ;
[0047] Figure 4 is an isometric view of an end connecting bracket for beam elements;
[ 0048] Figure 5 is an isometric view of a corner connecting bracket for beam elements;
[0049] Figure 6 is an isometric view of an assembly comprising a beam element and a pair of corner connecting brackets;
[0050] Figure 7 is an isometric view of a frame comer assembly;
[0051 ] Figure 8 is an isometric view of a panel element;
[0052] Figure 9 is a plan view of the panel element of Figure 8; [0053] Figure 10 is an isometric view of a seal ing element for panel elements;
[0054 ] Figure 1 1 is a plan view of the sealing element of Figure 10;
[0055J Figure 12 is an isometric view of an assembly of panel elements;
[ 0056 ] Figure 13 is a detailed view of a connection between a pair of panel elements in the assembly of Figure 12;
[0057] Figure 14 is an isometric view of a corner column element;
[ 00581 Figure 15 is a plan view of the corner column element of Figure 14;
[0059] Figure 16 is an isometric view of a roof supporting beam element;
[0060] Figure 17 is an end view of the roof supporting beam element of Figure 16;
[0061 ] Figures 18 through 23 illustrate stages of assembly of a building structure;
[0062] Figure 24 is an isometric view of a portion of a building structure;
[0063 ] Figure 25 is an isometric view of an apex beam element;
[ 0064] Figure 26 is an end view of the apex beam element in use;
[0065] Figure 27 is an isometric view of a portion of a roof structure comprising the apex beam element;
[0066] Figure 28 is an isometric view of a portion of a roofed building structure;
[0067] Figure 29 is an exploded isometric view of a corner portion of a building structure;
[0068 ] Figure 30 is a plan view of a portion of a building structure;
[0069] Figures 31 and 32 are isometric views of a portion of a building structure;
[ 0070] Figure 33 is an isometric view of a window frame;
[0071 ] Figure 34 is a front view of the window frame of Figure 33; [0072 ] Figure 35 is an isometric view of a window frame according to a further embodiment;
[0073] Figure 36 is a front view of the window frame of Figure 35;
[ 0074] Figure 37 is an isometric view of a building structure;
[0075] Figure 38 is a side view of the building structure of Figure 37;
[ 0076] Figure 39 is a front view of the building structure of Figure 38;
[0077] Figures 40 and 41 are isometric views of a panel stacking beam;
[ 0078] Figure 42 is an isometric view of a portion of a multistorey building structure;
[0079] Figure 43 is an isometric view of a portion of a building structure with a panel removed for clarity;
[0080] Figure 44 is a cross-sectional view through the portion of building structure illustrated in Figure 43; and
[ 0081 ] Figure 45 is a detailed sectional view of a portion of the section illustrated in Figure 44.
[ 0082] In the following description, like reference characters designate like or corresponding parts throughout the figures.
DESCRIPTION OF EMBODIMENTS
[ 0083] Referring now to Figures 1 through 3, where there is shown a beam element 10 of a building construction system according to an embodiment of the present disclosure. The beam element 10 comprises a section 12 comprising an elongate base 14 and a pair of lengthwise extending parallel flanges 16 cooperatively defining a channel, and a plurality of locators 18 spaced apart along the channel. For clarity (i.e. to avoid confusion), this beam element 10 will be referred to herein as a track beam 10.
[0084] Each beam element 10 is extruded from aluminium. Threaded holes are formed into a top face thereof to facilitate attachment of the locators 18 thereto.
[0085] Each locator 18 is made from a plastic such as Acrylonitrile Butadiene Styrene (ABS).
An injection moulding process is used to manufacture the locators 18. Each locator 18 is attached to the section 12 with bolts, although quick clips or spring fastening systems could be employed. The track beam 10 (and other beams - discussed below) will generally be supplied pre-assembled with the locators 18 bolted to the section 12.
[0086] The locators 1 8 not only simplify installation but also ensure that all panels 20 (see
Figures 8 and 9) are rigidly fixed and compensate for differential thermal expansion between the plastic panels 20 and aluminium frame-work. The locators 18 also seal against sockets 22 (i.e. tube ends) to limit convective air movement.
[0087] The track beam 10 is a versatile component that can be used for a variety of uses including window frames, door frames, panel capping and structural framework.
[ 0088 ] Referring now to Figures 4 and 5, each of which illustrates a connecting bracket for joining the beam elements to other beam elements, and to other system components, to fonn a framework. Each connecting bracket comprises at least a pair of ends, where at least one end is sized and shaped for insertion into a lengthwise extending hollow section 19 of the beam element 10, as illustrated in Figure 6. With reference to Figure 3, it can be seen that each lengthwise extending hollow section 19 comprises an inner wall comprising a lengthwise extending slot 19S.
[0089] The end connecting bracket 30 of Figure 4 is made from aluminium, and it comprises a plurality of holes H (some of which are threaded) for accepting bolts B.
[0090] With reference to Figure 29, it can be seen how end connecting bracket 30 is used to connect track beams 10 and slope beams 70 (see Figures 16 and 17) to column top brackets 90. Once a beam element 10, 70 has been cut to suit, the end connecting bracket 30 is inserted into the end of a lengthwise extending hollow section 19 of the beam element and fixed into position with internally fitted bolts B, the shanks (and only the shanks) of which are passed through the lengthwise extending slot 19S and into holes H. The beams can then be attached to the column top brackets 90.
[ 0091 ] The corner connecting bracket 40 of Figure 5 is made from aluminium and is used to fonn 90 degree corners with the track beams 10. It comprises a plurality of holes H (some of which are threaded) for accepting bolts B.
[ 0092] Refening now to Figures 6 and 7, where it can be seen how a pair of beam elements 10 have been connected by a pair of comer connecting brackets 40 (as illustrated in Figure 5) to form a corner of a frame assembly. Each end of the corner connecting bracket 40 is inserted into a lengthwise extending hollow section 19 of the beam element and fixed into position with internally fitted bolts B, the shanks (and only the shanks) of which are passed through the lengthwise extending slot 19S and into holes H. In use, the bolts B will be concealed by the panel elements 20.
[0093] Referring now to Figures 8 and 9, where there is illustrated a panel element (or panel) 20 of the building construction system. Each panel element 20 comprises a pair of faces, a pair of ends and a pair of sides. Each end comprises a plurality of sockets 22 spaced apart there along, where these sockets 22 are spaced, sized and shaped to receive the locators 18 of one of the beam elements 10, when the end of the panel 20 is located within the channel defined by the beam element 10.
[0094 ] Each panel element 20 is extruded from plastic or composite feedstock and comprises a tube-like internal structure that provides optimal structural strength whilst minimising panel weight. The panels 20 are used to form both walls and roofing and can free span approximately 7 metres. The panels 20 can be extruded in any colour, including clear, and to any practical length.
[0095 ] Each panel 20 features an interlocking tongue 24 and groove 26 arrangement along each side that connects with the corresponding tongue and groove of a neighbouring panel or column. A sealing element (or seal) 50 (see Figures 10 and 1 1) is fitted within each groove 26 creating a water tight seal with the tongue 24 of the opposing component.
10096] Each panel also features a shear key 27 and shear key groove 28 to assist load flow, and load sharing between panels 20, as well as limiting lateral movement between panels 10 that would place undue pressure on the seal 50.
10097] The unique sectional depth of the panels 20 allows them to achieve long unsupported vertical wall spans and roof spans. That is to say a panel 20 can be used as either a wall or a roof panel, and that wall panels and roof panels are identical in section.
10098] The sealing element 50 (see Figures 10 and 1 1) is manufactured from an extruded elastomer, such as silicone rubber. The sealing element 50 provides water and weather proofing between panels 20, and between panels 20 and corner columns 60. The sealing element 50 is designed to allow sliding between itself and the tongue 24.
10099] With reference to Figure 12, it can be seen how a plurality of panels of varying widths (i.e. 20a, 20b, 20c and 20d) can be assembled to form a wall assembly. When a new panel 20 is installed alongside a pre-installed panel 20, the tongue 24 and groove 26 pairings are first aligned, pressed together, and then the new panel 20 is slid down over the locators 18. A shear key is featured adjacent to each tongue 24. The function of the shear key 27 is to limit lateral movement between panels 20, or between a panel 20 and a column 60, thereby limiting lateral movement of a tongue 24 within the sealing element 50 and the groove 26 in turn.
[00100] With reference to Figure 13, it can be seen how the sealing element provides a seal between the connected panels 20.
[00101 ] Referring now to Figures 14 and 15, where there is illustrated a corner column element
60 of the building construction system.
[00102] Each corner column 60 is an aluminium extrusion used to form part of the aluminium framework at the corners of a typical structure. Each corner column 60 comprises a tongue and groove arrangement on two faces that connect with the tongue and groove of each of the adjacent panels.
[00103] With reference to Figure 30, it can be seen that the building construction system further comprises T-connector columns 60a, for connecting with panels 20 on three sides, and cross connector columns 60b for connecting with panels 20 on four sides.
100104] Referring now to Figures 16 and 17, where there is illustrated a roof supporting beam element 70 (the term 'slope beam element' is used interchangeably herein).
100105] Each slope beam 70 is structurally similar to the track beam 10, but features a sloped top
14a (as opposed to a flat base 14) to form a roof gradient, and optionally wings 14b to facilitate attachment of the roof panels to the wall structure. Roof panels 20 can be fastened to the wings 14b if provided, or directly to the upper sloped face. In use, the slope beam 70 forms part of the upper structural framework.
[00106] The track beam 10 and slope beam 70 profiles allow internal bolting of framework, facilitating a clean and attractive appearance of installations.
[00107] Referring now to Figures 18 through 23, where it is illustrated, how in use, a building is constructed using the building construction system, by first laying down track beams 10 along the perimeter of the structure. The track beams 10 can be secured to the ground by fixing with mechanical fasteners to a concrete floor slab, or staking it directly to the earth for temporary installations. Wall panels 20 are then erected by first erecting a corner column 60 (see Figure 21 ) and then progressively installing panels 20 (see Figure 22) and comer columns 60. A panel 20 is installed by fitting its tongue 24 and groove 26 to its neighbouring component, and then sliding it down over the locators 18 and into position. The sealing elements 50 ensure sealing at each interface, and accommodate for variations in manufacturing tolerances and thermal expansion/contraction of components. The wall panels 20 are then capped with track beams 10 and/or slope beams 70 (see Figure 20). The roof panels 20 are then installed and fixed to either the top surface or the wings 14b of the slope beams 70 (see Figure 23). Finally the edges of the roof panels 20 are enclosed with track beams 10.
[00108 ] Referring now to Figures 25 through 27, where there is illustrated an apex beam element
80 for use at an apex of a roof structure, and adapted to bridge ends of at least a pair of roof panels 20 converging at the apex beam element 80.
[00109] With reference to Figure 26, it can be seen that the apex beam 80 forms a ridge line. The apex beam 80 is a beam section comprising the form of two track beam sections 12 that are each angled downward to form an apex. On each side of the apex beam 80 is a face that is comprised of locators 18 directed for insertion into locating sockets 22 of each of the converging panels 20.
[001 10] Referring now to Figure 28, where it is illustrated, how in use, a roof for a building structure is constructed using the apex beam element 80. Roof panels 20 are supported atop of slope beams 70 at one end, and converge at the apex beam 80, which bridges and connects these roof panels 20.
[001 1 1 ] With reference to Figures 31 and 32, it can be seen that the building construction system further comprises column top brackets 90, which are used to form a structural joint between columns (corner columns 60, T-connector columns 60a, cross connector columns 60b, and inline connector columns 60c) and beams (track beams 10 and slope beams 70).
1001 12] There are 10 main types of column top brackets 90, these being namely upper right 90a, lower right 90b, upper left 90c, lower left 9()d, upper tee (i.e. 3-way connection) 90e, lower tee 90f, 4-way 90g, left tee 90h, right tee 90i and inline 90j. Column top brackets 90 have a complex geometry designed to neatly join beams 10, 70 via end connecting brackets 30 with concealed bolts. Column top brackets 90 facilitate a fonnation of the roof gradient. They comprise service hol es SH which provide for routing of water and electrical services where required.
[001 13] In use, a column top bracket 90 is first attached to the top of the respective column 60.
The beam elements 10, 70 are cut to suit and then two end connecting brackets 30 are installed to each end of the beam elements 10, 70 by internal bolting. The beam elements 10, 70 are then placed into position and bolted to the column top bracket. [001 14] Column top brackets 90 are always coupled with a universal plug 92 (see Figure 29), which is used as a substitute for plastic locators 18 in locations where higher strength is required, such as at the top and bottom of columns 60.
[001 15] With reference to Figures 33 to 36, it can be seen how building features such as window frames are constructed using track beams.
[001 16] In Figures 33 and 34 there is illustrated a window frame assembly comprising track beams 10 at its ends, and sections 12 (of track beams 10) at its sides, all of which are joined and bolted together using the corner connecting brackets 40 (as illustrated in Figure 5). In use, the sections 12 (which are devoid of locators 18) will locate against the sides of panels 20, and the locators 18 of the track beams 10 will engage with sockets 22 in ends of panels 20.
[001 17] In Figures 35 and 36 there is illustrated a window frame assembly assembled from low profile track beam elements 10a. Low profile track beam elements 10a differ from track beam elements 10 inasmuch as they comprise a section 16a which is deficient of the lengthwise extending hollow sections 19 of section 16.
[001 18] Referring now to Figures 37 through 39, where it is illustrated, how in use, a building is constructed using the building construction system. The building comprises window frames, and a frame for a doorway, which are constructed from track beams and sections in the manner described above.
[001 19] Referring now to Figure 40, where there is illustrated a panel stacking beam element 100.
The stacking beam element 100 comprises a section comprising the form of two oppositely directed, but aligned (ie not angled) track beam sections 12, and so it comprises locators 18 directed for insertion into locating sockets of each of the panels 20 being stacked.
[00120] In use, the panel stacking beam element 100 is positioned atop of a first panel element 20 forming a wall, and a further wall forming panel 20 is stacked atop of the stacking beam element 100 and the first wall forming panel 20 in turn.
[00121 ] With reference to Figures 41 and 42, it can be seen how a multistorey building is clad using the panel stacking beam element 100.
[00122] Figures 43 through 45 illustrate how rain water can be collected from roof forming panels
20 and directed through a wall forming panel 20 without the need for guttering or an external downpipe. The water collection system is hidden from view from an observer at ground level and facilitates a 'neat' and 'clean' appearance. Figure 43 omits, for clarity, a wall forming panel to show the concealed downpipe 1 10. A section (in this case an angle) is attached to the roof and directs rainwater toward the downpipe.
[00123] It will be apparent from the foregoing, that the building construction system disclosed herein allows buildings and structures to be constructed efficiently, drastically reducing construction times compared to conventional building techniques, while at the same time lending itself to use in combination with conventional building techniques. It also greatly reduces the co-ordination effort required to manage numerous trades on a single site.
[00124] Where materials of construction have been noted for parts, this is for reference only and parts are not limited to these materials.
[00125] Throughout the specification and the claims that follow, unless the context requires otherwise, the words "comprise" and "include" and variations such as "comprising" and "including" will be understood to imply the inclusion of a stated integer or group of integers, but not the exclusion of any other integer or group of integers.
[00126] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement of any form of suggestion that such prior art forms part of the common general knowledge.
[00127] It will be appreciated by those skilled in the art that the invention is not restricted in its use to the particular application described. Neither is the present invention restricted in its preferred embodiment with regard to the particular elements and/or features described or depicted herein. It will be appreciated that the invention is not limited to the embodiment or embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the invention as set forth and defined by the following claims.

Claims

1. A building construction system comprising a panel assembly, the panel assembly comprising at least one beam element, the or each beam element comprising a section profile comprising an elongate base and a pair of lengthwise extending parallel flanges cooperatively defining a channel, the panel assembly comprising at least one panel element, the or each panel element comprising a pair of ends and a pair of sides, where each end is sized and shaped to locate in the channel defined by the beam element.
2. The building construction system of claim 1, wherein the beam element comprises a plurality of locators spaced apart along the channel, and the ends of each panel comprises a plurality of locating sockets spaced apart there along, where these locating sockets are spaced, sized and shaped to receive the locators when the end of the panel is located in the channel defined by the beam element.
3. The building construction system as in either of the preceding claims, wherein the or each panel element comprises a plurality of internal tubes extending between the ends thereof, each tube comprising one of the locating sockets at opposing ends thereof.
4. The building construction system as in any one of the preceding claims, wherein the sides of the or each panel element comprise interlocking features for connecting the panel to the side of at least a further panel element.
5. The building construction system of claim 4, wherein the interlocking features extend along the sides of the or each panel.
6. The building construction system as in any one of the preceding claims, wherein the sides of the or each panel element comprise sealing features for sealing the panel to the side of a further panel element.
7. The building construction system as in any one of the preceding claims, wherein the or each beam element comprises at least one lengthwise extending tubular hollow for receiving a connecting bracket.
8. The building construction system of claim 7, wherein the or each beam element comprises an inner wall comprising a lengthwise extending slot providing access to a respective lengthwise extending tubular hollow.
9. The building construction system of claim 8, wherein the or each beam element comprises a substantially parallel pair of the substantially lengthwise extending rectilinear hollows separated by a central channel defined between a pair of the slotted inner walls and the base.
10. The building construction system as in any one of the preceding claims, further comprising at least one connecting bracket for connecting beam elements, the or each connecting bracket comprising at least one end that is sized and shaped for insertion into a lengthwise extending tubular hollow of a beam element.
1 1. The building construction system as in any one of the preceding claims, further comprising at least one beam element for use at the top of a first panel element forming a wall, and adapted for supporting a roof forming panel at an angle with respect to the wall forming panel element.
12. The building construction system of claim 1 1 , wherein the panel element is employable as either a roof forming panel or a wall forming panel.
13. The building construction system as in any one of the preceding claims, further comprising at least one beam element for use at the top of a first panel element forming a wall, and adapted to stack a further wall forming panel atop of the first wall forming panel.
14. The building construction system of claim 13, wherein the panel stacking beam element comprises oppositely directed locators spaced apart there along.
15. The building construction system as in any one of the preceding claims, further comprising at least one beam element for use at an apex of a roof structure, and adapted to bridge ends of at least a pair of roof panels converging at the apex beam element.
16. The building construction system of claim 15, wherein the apex beam element comprises locators directed for insertion into locating sockets of each of the converging panels.
17. The building construction system as in any one of the preceding claims, wherein the section profile of the or each beam element is extruded, and the locators are manufactured separately and secured to the section profile.
18. The building construction system as in any one of the preceding claims, wherein the locators are moulded from a plastic material and bolted to the beam section profile.
19. The building construction system as in any one of the preceding claims, wherein the or each panel element is extruded endwise.
20. The building construction system as in any one of the preceding claims, further comprising at least one column element, the or each column element comprising a pair of ends, each end comprising a socket sized and shaped to receive a locator of a beam element, and further comprising at least one side comprised of interlocking features for connecting the column element to a side of a panel element.
21. The building construction system of claim 20, wherein each column element comprises four sides, and at least one of these sides comprises interlocking features.
22. The building construction system as in either of claims 20 or 21, wherein the or each column element is extruded endwise.
23. The building construction system as in any one of claims 20 through 22, further comprising at least one column top bracket for forming a structural joint between a column and beam elements.
24. The building construction system as in any one of claims 5 through 23, wherein the interlocking features comprise an interlocking tongue and groove arrangement.
25. The building construction system as in any one of claims 5 through 24, wherein the interlocking features comprise an interlocking shear key and shear key groove arrangement.
26. The building construction system as in any one of claims 5 through 25, wherein the interlocking features comprise an interlocking sealing tongue and groove arrangement.
27. The building construction system as in any one of claims 6 through 26, wherein the sealing features comprise a sealing element.
28. The building construction system of claim 27 when this depends from claim 26, wherein the sealing features comprise a sealing element located in the groove of the interlocking sealing tongue and groove arrangement.
29. The building construction system of claim 14, where a vertical downpipe is run inside a wall fonning panel and penetrates a roof forming panel, such that rainwater run-off can be collected from the roof fonning panel.
30. The building construction system as in any one of the preceding claims, wherein all the bolts of all bolted connections are concealed.
31. A kit of parts for the above building construction system of any one of the preceding claims.
PCT/AU2015/000589 2014-10-29 2015-09-29 A construction system WO2016065389A1 (en)

Applications Claiming Priority (2)

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AU2014904322 2014-10-29
AU2014904322A AU2014904322A0 (en) 2014-10-29 StreamLITE represents a new generation of modular building products that are designed to enable the user to easily build any number of conceivable structures. The system is comprised of four (4) main components, and supplementary brackets, that can be arranged in limitless combinations to create structures, buildings and a myriad of other imaginable installations. The system features a largely integrated exo-skeletal framework with panels that easily slot together. The roof panels are the same as the wall panels. All connections are generally concealed.

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CN114411975A (en) * 2022-02-13 2022-04-29 重庆交通大学 Composite bolt shear key structure
WO2023059206A1 (en) * 2021-10-07 2023-04-13 Eco Building Technology S.A.C. Structureless sustainable dwelling made with self-supporting thermal panels

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WO2023059206A1 (en) * 2021-10-07 2023-04-13 Eco Building Technology S.A.C. Structureless sustainable dwelling made with self-supporting thermal panels
CN114411975A (en) * 2022-02-13 2022-04-29 重庆交通大学 Composite bolt shear key structure
CN114411975B (en) * 2022-02-13 2023-11-07 重庆交通大学 Structure of composite bolting shear key

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AU2015238809A1 (en) 2016-06-09

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