WO2020033996A1 - A flashing connector - Google Patents

A flashing connector Download PDF

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Publication number
WO2020033996A1
WO2020033996A1 PCT/AU2019/050842 AU2019050842W WO2020033996A1 WO 2020033996 A1 WO2020033996 A1 WO 2020033996A1 AU 2019050842 W AU2019050842 W AU 2019050842W WO 2020033996 A1 WO2020033996 A1 WO 2020033996A1
Authority
WO
WIPO (PCT)
Prior art keywords
panel
building panel
side walls
flashing
connector
Prior art date
Application number
PCT/AU2019/050842
Other languages
French (fr)
Inventor
John Hammond
Gregory Irvine
Original Assignee
Building IP Holdings 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 AU2018902944A external-priority patent/AU2018902944A0/en
Application filed by Building IP Holdings Pty Ltd filed Critical Building IP Holdings Pty Ltd
Priority to US17/268,351 priority Critical patent/US20210214933A1/en
Priority to AU2019321869A priority patent/AU2019321869A1/en
Publication of WO2020033996A1 publication Critical patent/WO2020033996A1/en

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/66—Sealings
    • E04B1/68—Sealings of joints, e.g. expansion joints
    • E04B1/6803—Joint covers
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/14—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements being composed of two or more materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/66—Sealings
    • E04B1/665—Sheets or foils impervious to water and water vapor
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2/28—Walls having cavities between, but not in, the elements; Walls of elements each consisting of two or more parts kept in distance by means of spacers, all parts being solid
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
    • E04B2/562—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with fillings between the load-bearing elongated members
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
    • E04B2/58—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of metal
    • E04B2/60—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of metal characterised by special cross-section of the elongated members
    • E04B2/62—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of metal characterised by special cross-section of the elongated members the members being formed of two or more elements in side-by-side relationship
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
    • E04C2/46—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose specially adapted for making walls
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/64—Insulation or other protection; Elements or use of specified material therefor for making damp-proof; Protection against corrosion
    • E04B1/644—Damp-proof courses
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/388—Separate connecting elements
    • E04B2001/389—Brackets
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2002/0202—Details of connections
    • E04B2002/0243—Separate connectors or inserts, e.g. pegs, pins or keys
    • E04B2002/0247—Strips or bars
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2002/001—Mechanical features of panels
    • E04C2002/004—Panels with profiled edges, e.g. stepped, serrated
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F19/00—Other details of constructional parts for finishing work on buildings
    • E04F19/02—Borders; Finishing strips, e.g. beadings; Light coves

Definitions

  • This invention relates generally to building construction, and deals more particularly with a flashing connector used in a building system using modular components that allow quick and economical construction of buildings.
  • the invention provides an elongate connector for inter-connecting a first building panel below a second building panel, the connector comprising: a hollow and elongate recess defined by two spaced apart side walls separated by a top wall, said side walls and top wall having a length extending between two ends of elongate connector, the recess being arranged to receive a load bearing member positioned above the first building panel and wherein the top wall and side walls are arranged to be received into a channel of the second building panel thereby positioning and inter-connecting the second building panel above the first building panel; a flashing portion extending along the length of one of the side walls, said flashing portion depending downwardly from one of said side walls to lap over a top edge portion of said one of the building panels.
  • the elongate connector further comprises a joining portion extending transversely relative to said one of the side walls and wherein the flashing portion depends downwardly relative to the joining portion.
  • the joining portion extends substantially along the length of the elongate connector.
  • the joining portion is angled to be substantially perpendicular relative to the said side wall and/or flashing portion.
  • each of said spaced apart side walls are substantially parallel to each other.
  • the top wall is transversely oriented relative to said side walls to define said recess.
  • the top wall is substantially perpendicular to one or both of said side walls.
  • a plane of the flashing portion is sufficiently spaced away from a plane of the said side wall to accommodate the top edge portion of one of the building panels positioned thereunder.
  • spacing between the side walls is substantially less than the length of the connector.
  • the side walls, top wall and the flashing portion are integrally formed from sheet metal.
  • the joining portion is integrally formed with the side wall and the flashing portion.
  • the invention provides a method of construction for inter connecting a first building panel below a second building panel in a multi-storey building, at least the first building panel having two spaced apart sheets; an insulating core portion positioned between said spaced apart sheets, wherein edge portions of the spaced apart sheets define a hollow cavity, the cavity extending along peripheral portions of the panel wherein the panel comprises a length (h) and a height (h2) wherein top and bottom channel members face outwardly and extend along the length (h) of the panel and are positioned in respective hollow cavities along in-use top and bottom peripheral portions of the panel respectively; and wherein first and second opposite side channels face outwardly and extend along the height (hi) of the panel and are positioned in respective hollow cavities along each of the lateral peripheral portions of the panel respectively, the method comprising the steps of: positioning a load bearing member into the top channel of the first building panel to support the second building panel to be positioned above the first building panel; positioning a flashing connector above an upper portion of the load bearing member
  • the second building panel positioned above the first building panel also comprises two spaced apart sheets; an insulating core portion positioned between said spaced apart sheets, wherein edge portions of the spaced apart sheets define a hollow cavity, the cavity extending along peripheral portions of the panel wherein the second panel comprises a length (I2) and a height (h2) wherein top and bottom channel members face outwardly and extend along the length (I2) of the panel and are positioned in respective hollow cavities along in-use top and bottom peripheral portions of the panel respectively; and wherein first and second opposite side channels face outwardly and extend along the height (h2) of the panel and are positioned in respective hollow cavities along each of the lateral peripheral portions of the panel respectively.
  • the method comprising the step of: positioning the bottom channel of the second building panel to receive the top wall and an upper portion of the side walls of the flashing connector thereby inter-connecting the second building panel above the first building panel.
  • the invention provides a method of bending sheet metal to form an elongate flashing connector, the method comprising the steps of: bending sheet metal to form two opposing wide walls separated by a top wall such that at least one of the side walls has a greater height than the other of said side wall to define a recess to receive a load bearing member positioned above a first building panel and wherein the top wall and side walls are arranged to be received into a channel of a second building panel thereby positioning and inter-connecting the second building panel above the first building panel; and
  • Figure 1 is a perspective in-use view of the flashing connector 100.
  • Figure 1 a is a perspective view of a panel 1000 which is suitable for use as the top panel TP or the bottom panel BP.
  • Figure 2 is an isolated view of the flashing connector 100 and the load bearing top plate 500.
  • Figure 3A is an exploded sectional view of the flashing connector 100 shown in an in- use configuration for inter-connecting a top panel TP and a bottom panel BP.
  • Figure 3B is a sectional in-use view of the flashing connector 100 shown in an in-use configuration for inter-connecting a top panel TP and a bottom panel BP.
  • Figure 3C is an enlarged view of the flashing portion 140 extending along a side wall 120 of the flashing connector 100 shown in an in-use configuration.
  • Figure 4 shows another exploded sectional view of the flashing connector 100 shown in an in-use configuration for inter-connecting a top panel TP and a bottom panel BP whereby fasteners F have been used to fasten the top panel TP and bottom panel BP to the flashing connector 100 and the load bearing top plate 500.
  • FIG. 1 illustrates a flashing connector 100 for a modular building system.
  • the panel assembly 10 includes a rectangular building panel 100 with four channel elements 200, 205, 210 and 215 that are positioned along respective edge portions of the panel 1000.
  • the panel assembly 10 includes a top channel element 200, a bottom channel element 205 and two opposed side channel elements 210 and 215.
  • a typical panel 1000 comprises a core of fire resistant expanded polystyrene that is sandwiched between two sheets.
  • the sheets may be made from any known construction material that is preferably lightweight, fire-resistant and provides insulation.
  • the panel may be provided in a range of sizes.
  • the width of the panel may be about 300mm-1100mm and the height of panel may be 2400mm, 2700mm or 3000mm.
  • the panel 1000 is an internal wall panel which is symmetrical about a vertical axis such that any panel can be turned upside down or back to front.
  • channel elements 200, 205, 210 and 215 extend along perpendicular edges of the panel 1000.
  • Each channel element 200 has a substantially c-shaped cross section and is typically glued to the core (not shown) and the sheets 105, 1 10 of the panel 1000 providing increased structural integrity of the panel 1000.
  • Each flashing connector 100 comprises a hollow and elongate recess 150 defined by two spaced apart side walls 110 and 120 that are separated by a top wall 130. Referring to Figures 3A, 3B it is clearly shown that the top wall 130 and the spaced apart side walls 1 10 and 120 define the C-shaped recess 150.
  • a load bearing member in the form of a load bearing top plate 500 is arranged into the top channel 200 of the one or more bottom panels BP (BP1 , BP2 and BP3 shown in Figure 1).
  • the top plate 500 supports the construction of an additional floor and allows the top building panels TP (TP1 , TP2 and TP3; shown in Figure 1) in the multi-level building.
  • the dimensions and shape of the top plate 500 may vary in accordance with the load bearing requirements of the building.
  • the height and width of the top plate 500 may be varied in accordance with the load bearing requirements of the building.
  • the shape of the top plate 500 is shown to be square or rectangular, the shape of the load bearing is not limiting. Consequently, the shape of the recess defined by the side walls 110, 120 and the top wall 130 may also be varied without departing from the spirit and scope of the invention.
  • the flashing connector 100 is positioned above the top plate 500 such that at least an upper portion of the top plate 500 is received into the recess 150 of the flashing connector 100.
  • the next step involves positioning the top panel TP above the bottom panel BP. Specifically, the top wall 130 of the flashing connector 100 and a substantial part of the side walls 1 10 and 120 are received into the bottom channel 205 of the top panel TP.
  • Figure 3A illustrates an exploded view
  • Figure 3B illustrates a sectional view of the flashing connector 100 shown in an in-use configuration.
  • the preferred embodiment illustrates the use of building panels BP and TP having identical structural features, such a limitation is not limiting. By way of example, the one or both the top and building panels may have slightly different structural dimensions to suit specific building requirements.
  • the enlarged view of the flashing connector 100 illustrates a flashing portion 140 extending along the length of second side wall 120.
  • the flashing connector 100 includes a joining portion 1 15 that extends transversely and outwardly relative to side wall 120 with a the downwardly dependent flashing portion 140 depending downwardly from an outwardly extending end of the joining portion 1 15 to lap around a top edge portion of an external sheet S of the bottom panel BP (See Figure 3C).
  • the width of the joining portion 115 needs to be slightly greater than the thickness of the sheet S to enable the flashing portion 140 to lap over the top edge of the sheet S. Once again, exact dimensions for the width of the joining portion 115 may vary to suit specific dimensions of the sheet S used in the lower building panel BP.
  • the flashing portion 140 extends along the entire length of the second side wall 120 and prevents rain water from entering the exposed region between the top panel TP and the bottom panel BP thereby preventing rot or other damage to internal wall framing of the building.
  • fasteners such as screws F may be used for fastening each of the top panel TP and the bottom panel BP onto the flashing connector 100.
  • a first set of fasteners may be used to fasten the top panel TP onto the side walls of 110 and 120 and the top plate 500.
  • a drill may be used to drill the screws through the outer sheets of the top panel TP and through the side walls 1 10 and 120 into the top plate 500.
  • a second set of fasteners may be used for fastening the outer sheets of the bottom panel BP with the top plate 500.
  • the flashing connector 100 may be formed from sheet metal such that each of the side walls 110, 120, top wall 130, the joining portion 115 and the flashing portion 140 are integrally formed by bending sheet metal.
  • Sheet metal is a commonly used material for a multitude of applications including housings and casings, interior and exterior structures, and various covers and supports.
  • Stock sheet metal may be supplied a manufacturer in the form of flat sheets or rolls of flat stock. The manufacturer may uses the stock metal sheet and cut the metal sheet by initially cutting the metal sheet to have a width and a length such that the length is substantially greater than the width to form a rectangular piece of sheet metal.
  • the rectangular piece of sheet metal may be initially bent along its length to form the two opposing wide walls 110 and 12 separated by a top wall 130 such that the side walls 110 and 120 depend downwardly from the top wall 130.
  • side wall 120 has a greater height than the other of said side wall 110 to define the recess 150 that can receive a load bearing member 500 positioned above a first building panel BP as has been previously described.
  • the next step would involve bending a lower portion of side wall 120 to extend transversely relative to the side wall 120 to form the joining portion 115 and further form a downwardly dependent flashing portion 140 to lap over a top edge portion of said one of the building panels.
  • the bending steps for bending the sheet metal may be accomplished using either hand tools and/or forms, or bending machines including press and box brakes, and roll embossing machines, depending on the type of bend being performed and the desired results.
  • Computers may also be used to control the metal-forming and metal cutting machines quickly and accurately.
  • One such computer-controlled machine is a laser cutter wherein a laser beam of high energy is controlled by a computer and guided along one surface of metal sheet. The laser energy quickly and accurately cuts or etches the metal sheet, as controlled by the computer and as prescribed by software.
  • Another type of cutting and etching machine uses a powerful stream of water, usually including an abrasive. The resulting water-jet is carefully controlled to abrade through metal sheet. The water-jet system allows for accurate cut lines or etched lines having a prescribed depth.
  • Another software-driven technique may involves scribing or milling the metal with a hard cutting tool driven by a computer.

Abstract

An elongate connector for connecting a first building panel and second building panel, the connector comprising: a hollow and elongate recess defined by two spaced apart side walls separated by a top wall, the recess being arranged to receive a load bearing member positioned above the first building panel and wherein the top wall and side walls are arranged to be received into a channel of the second building panel thereby positioning and inter-connecting the second building panel above the first building panel; a flashing portion extending along the length of one of the side walls, said flashing portion depending downwardly from one of said side walls to lap over an edge portion of said one of the building panels.

Description

A FLASHING CONNECTOR
TECHNICAL FIELD
[001]This invention relates generally to building construction, and deals more particularly with a flashing connector used in a building system using modular components that allow quick and economical construction of buildings.
BACKGROUND
[002]Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge.
[003]lt is often necessary to fix building panels during construction of multi-level buildings. This presents a problem in that the point of contact between two building panels may provide an area where rainwater is able to enter the building and, over time, cause rot or other damage to internal wall framing, etc. It is accordingly desirable to address this problem, or to provide the public with a useful choice.
SUMMARY OF INVENTION
[004] In one aspect, the invention provides an elongate connector for inter-connecting a first building panel below a second building panel, the connector comprising: a hollow and elongate recess defined by two spaced apart side walls separated by a top wall, said side walls and top wall having a length extending between two ends of elongate connector, the recess being arranged to receive a load bearing member positioned above the first building panel and wherein the top wall and side walls are arranged to be received into a channel of the second building panel thereby positioning and inter-connecting the second building panel above the first building panel; a flashing portion extending along the length of one of the side walls, said flashing portion depending downwardly from one of said side walls to lap over a top edge portion of said one of the building panels.
[005] In an embodiment, the elongate connector further comprises a joining portion extending transversely relative to said one of the side walls and wherein the flashing portion depends downwardly relative to the joining portion.
[006] In an embodiment, the joining portion extends substantially along the length of the elongate connector.
[007] In an embodiment, the joining portion is angled to be substantially perpendicular relative to the said side wall and/or flashing portion.
[008] In an embodiment, each of said spaced apart side walls are substantially parallel to each other. [009] In an embodiment, the top wall is transversely oriented relative to said side walls to define said recess.
[010] In an embodiment, the top wall is substantially perpendicular to one or both of said side walls.
[01 1] In an embodiment, a plane of the flashing portion is sufficiently spaced away from a plane of the said side wall to accommodate the top edge portion of one of the building panels positioned thereunder.
[012] In an embodiment, spacing between the side walls is substantially less than the length of the connector.
[013] In an embodiment, the side walls, top wall and the flashing portion are integrally formed from sheet metal.
[014] In an embodiment, the joining portion is integrally formed with the side wall and the flashing portion.
[015] In another aspect, the invention provides a method of construction for inter connecting a first building panel below a second building panel in a multi-storey building, at least the first building panel having two spaced apart sheets; an insulating core portion positioned between said spaced apart sheets, wherein edge portions of the spaced apart sheets define a hollow cavity, the cavity extending along peripheral portions of the panel wherein the panel comprises a length (h) and a height (h2) wherein top and bottom channel members face outwardly and extend along the length (h) of the panel and are positioned in respective hollow cavities along in-use top and bottom peripheral portions of the panel respectively; and wherein first and second opposite side channels face outwardly and extend along the height (hi) of the panel and are positioned in respective hollow cavities along each of the lateral peripheral portions of the panel respectively, the method comprising the steps of: positioning a load bearing member into the top channel of the first building panel to support the second building panel to be positioned above the first building panel; positioning a flashing connector above an upper portion of the load bearing member wherein the flashing connector comprises: a hollow and elongate recess defined by two spaced apart side walls separated by a top wall, said side walls and top wall having a length extending between two ends of elongate connector, and a flashing portion depending downwardly from one of said side walls; arranging the recess of said flashing connector to receive the upper portion of the load bearing member positioned above the first building panel and simultaneously position the flashing portion to lap over a top edge portion of the first building panel; and positioning the second building panel above the top wall of the flashing connector thereby interconnecting the first and second building panels. [016] In an embodiment, the method of construction further comprises the step of positioning the flashing portion over a top edge of one of said spaced apart sheets of the first building panel positioned thereunder.
[017] In an embodiment, the second building panel positioned above the first building panel also comprises two spaced apart sheets; an insulating core portion positioned between said spaced apart sheets, wherein edge portions of the spaced apart sheets define a hollow cavity, the cavity extending along peripheral portions of the panel wherein the second panel comprises a length (I2) and a height (h2) wherein top and bottom channel members face outwardly and extend along the length (I2) of the panel and are positioned in respective hollow cavities along in-use top and bottom peripheral portions of the panel respectively; and wherein first and second opposite side channels face outwardly and extend along the height (h2) of the panel and are positioned in respective hollow cavities along each of the lateral peripheral portions of the panel respectively.
[018] In an embodiment, the method comprising the step of: positioning the bottom channel of the second building panel to receive the top wall and an upper portion of the side walls of the flashing connector thereby inter-connecting the second building panel above the first building panel.
[019] In yet another aspect, the invention provides a method of bending sheet metal to form an elongate flashing connector, the method comprising the steps of: bending sheet metal to form two opposing wide walls separated by a top wall such that at least one of the side walls has a greater height than the other of said side wall to define a recess to receive a load bearing member positioned above a first building panel and wherein the top wall and side walls are arranged to be received into a channel of a second building panel thereby positioning and inter-connecting the second building panel above the first building panel; and
bending a lower portion of said at least one side wall with the greater height to extend transversely relative to the side wall and further form a downwardly dependent flashing portion depending downwardly from one of said side walls to lap over a top edge portion of said one of the building panels.
BRIEF DESCRIPTION OF THE DRAWINGS
[020] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:
Figure 1 is a perspective in-use view of the flashing connector 100.
Figure 1 a is a perspective view of a panel 1000 which is suitable for use as the top panel TP or the bottom panel BP. Figure 2 is an isolated view of the flashing connector 100 and the load bearing top plate 500.
Figure 3A is an exploded sectional view of the flashing connector 100 shown in an in- use configuration for inter-connecting a top panel TP and a bottom panel BP.
Figure 3B is a sectional in-use view of the flashing connector 100 shown in an in-use configuration for inter-connecting a top panel TP and a bottom panel BP.
Figure 3C is an enlarged view of the flashing portion 140 extending along a side wall 120 of the flashing connector 100 shown in an in-use configuration.
Figure 4 shows another exploded sectional view of the flashing connector 100 shown in an in-use configuration for inter-connecting a top panel TP and a bottom panel BP whereby fasteners F have been used to fasten the top panel TP and bottom panel BP to the flashing connector 100 and the load bearing top plate 500.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[021] Referring to Figures 1 to 4, a flashing connector 100 is illustrated. The flashing connector 100 (as shown in Figures 1 and 3 to 4) is used for interconnecting a top building panel TP and a bottom building panel BP. Each of the top panel and the bottom panel may be in the form of a panel 1000 shown in Figure 1a. [022] Figure 1 a illustrates a panel assembly 10 for a modular building system. The panel assembly 10 includes a rectangular building panel 100 with four channel elements 200, 205, 210 and 215 that are positioned along respective edge portions of the panel 1000. Specifically, the panel assembly 10 includes a top channel element 200, a bottom channel element 205 and two opposed side channel elements 210 and 215.
[023] A typical panel 1000 comprises a core of fire resistant expanded polystyrene that is sandwiched between two sheets. The sheets may be made from any known construction material that is preferably lightweight, fire-resistant and provides insulation.
[024] The panel may be provided in a range of sizes. By way of example, the width of the panel may be about 300mm-1100mm and the height of panel may be 2400mm, 2700mm or 3000mm. The panel 1000 is an internal wall panel which is symmetrical about a vertical axis such that any panel can be turned upside down or back to front. As previously discussed, channel elements 200, 205, 210 and 215 extend along perpendicular edges of the panel 1000. Each channel element 200 has a substantially c-shaped cross section and is typically glued to the core (not shown) and the sheets 105, 1 10 of the panel 1000 providing increased structural integrity of the panel 1000.
[025] Each flashing connector 100 comprises a hollow and elongate recess 150 defined by two spaced apart side walls 110 and 120 that are separated by a top wall 130. Referring to Figures 3A, 3B it is clearly shown that the top wall 130 and the spaced apart side walls 1 10 and 120 define the C-shaped recess 150. During construction of multi-level buildings, a load bearing member in the form of a load bearing top plate 500 is arranged into the top channel 200 of the one or more bottom panels BP (BP1 , BP2 and BP3 shown in Figure 1). The top plate 500 supports the construction of an additional floor and allows the top building panels TP (TP1 , TP2 and TP3; shown in Figure 1) in the multi-level building.
[026] It is important to note that the dimensions and shape of the top plate 500 may vary in accordance with the load bearing requirements of the building. By way of example, the height and width of the top plate 500 may be varied in accordance with the load bearing requirements of the building. Whilst, the shape of the top plate 500 is shown to be square or rectangular, the shape of the load bearing is not limiting. Consequently, the shape of the recess defined by the side walls 110, 120 and the top wall 130 may also be varied without departing from the spirit and scope of the invention.
[027] Once the top plate 500 has been positioned into the top channel 200, the flashing connector 100 is positioned above the top plate 500 such that at least an upper portion of the top plate 500 is received into the recess 150 of the flashing connector 100. Once the flashing connector 100 has been positioned above the top plate 500, the next step involves positioning the top panel TP above the bottom panel BP. Specifically, the top wall 130 of the flashing connector 100 and a substantial part of the side walls 1 10 and 120 are received into the bottom channel 205 of the top panel TP. Figure 3A illustrates an exploded view and Figure 3B illustrates a sectional view of the flashing connector 100 shown in an in-use configuration. [028] Whilst the preferred embodiment illustrates the use of building panels BP and TP having identical structural features, such a limitation is not limiting. By way of example, the one or both the top and building panels may have slightly different structural dimensions to suit specific building requirements.
[029] Referring to Figure 3C, the enlarged view of the flashing connector 100 illustrates a flashing portion 140 extending along the length of second side wall 120. The flashing connector 100 includes a joining portion 1 15 that extends transversely and outwardly relative to side wall 120 with a the downwardly dependent flashing portion 140 depending downwardly from an outwardly extending end of the joining portion 1 15 to lap around a top edge portion of an external sheet S of the bottom panel BP (See Figure 3C). The width of the joining portion 115 needs to be slightly greater than the thickness of the sheet S to enable the flashing portion 140 to lap over the top edge of the sheet S. Once again, exact dimensions for the width of the joining portion 115 may vary to suit specific dimensions of the sheet S used in the lower building panel BP.
[030] The flashing portion 140 extends along the entire length of the second side wall 120 and prevents rain water from entering the exposed region between the top panel TP and the bottom panel BP thereby preventing rot or other damage to internal wall framing of the building. Referring to Figure 4, during construction, fasteners such as screws F may be used for fastening each of the top panel TP and the bottom panel BP onto the flashing connector 100. A first set of fasteners may be used to fasten the top panel TP onto the side walls of 110 and 120 and the top plate 500. Specifically, a drill may be used to drill the screws through the outer sheets of the top panel TP and through the side walls 1 10 and 120 into the top plate 500. A second set of fasteners may be used for fastening the outer sheets of the bottom panel BP with the top plate 500.
[031] The flashing connector 100 may be formed from sheet metal such that each of the side walls 110, 120, top wall 130, the joining portion 115 and the flashing portion 140 are integrally formed by bending sheet metal. Sheet metal is a commonly used material for a multitude of applications including housings and casings, interior and exterior structures, and various covers and supports. Stock sheet metal may be supplied a manufacturer in the form of flat sheets or rolls of flat stock. The manufacturer may uses the stock metal sheet and cut the metal sheet by initially cutting the metal sheet to have a width and a length such that the length is substantially greater than the width to form a rectangular piece of sheet metal. The rectangular piece of sheet metal may be initially bent along its length to form the two opposing wide walls 110 and 12 separated by a top wall 130 such that the side walls 110 and 120 depend downwardly from the top wall 130. After the initial bending step, side wall 120 has a greater height than the other of said side wall 110 to define the recess 150 that can receive a load bearing member 500 positioned above a first building panel BP as has been previously described. The next step would involve bending a lower portion of side wall 120 to extend transversely relative to the side wall 120 to form the joining portion 115 and further form a downwardly dependent flashing portion 140 to lap over a top edge portion of said one of the building panels.
[032] The bending steps for bending the sheet metal may be accomplished using either hand tools and/or forms, or bending machines including press and box brakes, and roll embossing machines, depending on the type of bend being performed and the desired results. Computers may also be used to control the metal-forming and metal cutting machines quickly and accurately. One such computer-controlled machine is a laser cutter wherein a laser beam of high energy is controlled by a computer and guided along one surface of metal sheet. The laser energy quickly and accurately cuts or etches the metal sheet, as controlled by the computer and as prescribed by software. Another type of cutting and etching machine uses a powerful stream of water, usually including an abrasive. The resulting water-jet is carefully controlled to abrade through metal sheet. The water-jet system allows for accurate cut lines or etched lines having a prescribed depth. Another software-driven technique may involves scribing or milling the metal with a hard cutting tool driven by a computer.
[033] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term“comprises” and its variations, such as “comprising” and “comprised of” is used throughout in an inclusive sense and not to the exclusion of any additional features.
[034] It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect.
[035] The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

Claims

1. An elongate connector for inter-connecting a first building panel below a second building panel, the connector comprising: a hollow and elongate recess defined by two spaced apart side walls separated by a top wall, said side walls and top wall having a length extending between two ends of elongate connector, the recess being arranged to receive a load bearing member positioned above the first building panel and wherein the top wall and side walls are arranged to be received into a channel of the second building panel thereby positioning and inter-connecting the second building panel above the first building panel; a flashing portion extending along the length of one of the side walls, said flashing portion depending downwardly from one of said side walls to lap over a top edge portion of said one of the building panels.
2. An elongate connector in accordance with claim 1 further comprises a joining portion extending transversely relative to said one of the side walls and wherein the flashing portion depends downwardly relative to the joining portion.
3. An elongate connector in accordance with claim 2 wherein the joining portion extends substantially along the length of the elongate connector.
4. An elongate connector in accordance with claims 2 or 3 wherein the joining portion is angled to be substantially perpendicular relative to the said side wall and/or flashing portion.
5. An elongate connector in accordance with any one of the preceding claims wherein each of said spaced apart side walls are substantially parallel to each other.
6. An elongate connector in accordance with any one of the preceding claims wherein the top wall is transversely oriented relative to said side walls to define said recess.
7. An elongate connector in accordance with claim 6 wherein the top wall is substantially perpendicular to one or both of said side walls.
8. An elongate connector in accordance with any one of the preceding claims wherein a plane of the flashing portion is sufficiently spaced away from a plane of the said side wall to accommodate the top edge portion of one of the building panels positioned thereunder.
9. An elongate connector in accordance with any one of the preceding claims wherein spacing between the side walls is substantially less than the length of the connector.
10. An elongate connector in accordance with any one of the preceding claims wherein the side walls, top wall and the flashing portion are integrally formed from sheet metal.
11. An elongate connector in accordance with claim 10 when dependent upon claim 2 wherein the joining portion is integrally formed with the side wall and the flashing portion.
12. A method of construction for inter-connecting a first building panel below a second building panel in a multi-storey building, at least the first building panel having two spaced apart sheets; an insulating core portion positioned between said spaced apart sheets, wherein edge portions of the spaced apart sheets define a hollow cavity, the cavity extending along peripheral portions of the panel wherein the panel comprises a length (li) and a height (h2) wherein top and bottom channel members face outwardly and extend along the length (h) of the panel and are positioned in respective hollow cavities along in-use top and bottom peripheral portions of the panel respectively; and wherein first and second opposite side channels face outwardly and extend along the height (hi) of the panel and are positioned in respective hollow cavities along each of the lateral peripheral portions of the panel respectively, the method comprising the steps of: positioning a load bearing member into the top channel of the first building panel to support the second building panel to be positioned above the first building panel; positioning a flashing connector above an upper portion of the load bearing member wherein the flashing connector comprises: a hollow and elongate recess defined by two spaced apart side walls separated by a top wall, said side walls and top wall having a length extending between two ends of elongate connector, and a flashing portion depending downwardly from one of said side walls; arranging the recess of said flashing connector to receive the upper portion of the load bearing member positioned above the first building panel and simultaneously position the flashing portion to lap over a top edge portion of the first building panel; and positioning the second building panel above the top wall of the flashing connector thereby interconnecting the first and second building panels.
13. A method of construction in accordance with claim 12 further comprising the step of positioning the flashing portion over a top edge of one of said spaced apart sheets of the first building panel positioned thereunder.
14. A method of construction in accordance with claim 12 or claim 13 wherein the second building panel positioned above the first building panel also comprises two spaced apart sheets; an insulating core portion positioned between said spaced apart sheets, wherein edge portions of the spaced apart sheets define a hollow cavity, the cavity extending along peripheral portions of the panel wherein the second panel comprises a length (I2) and a height (h2) wherein top and bottom channel members face outwardly and extend along the length (I2) of the panel and are positioned in respective hollow cavities along in-use top and bottom peripheral portions of the panel respectively; and wherein first and second opposite side channels face outwardly and extend along the height (h2) of the panel and are positioned in respective hollow cavities along each of the lateral peripheral portions of the panel respectively, the method comprising the step of: positioning the bottom channel of the second building panel to receive the top wall and an upper portion of the side walls of the flashing connector thereby inter-connecting the second building panel above the first building panel.
15. A method of bending sheet metal to form an elongate flashing connector, the method comprising the steps of: bending sheet metal to form two opposing wide walls separated by a top wall such that at least one of the side walls has a greater height than the other of said side wall to define a recess to receive a load bearing member positioned above a first building panel and wherein the top wall and side walls are arranged to be received into a channel of a second building panel thereby positioning and inter-connecting the second building panel above the first building panel; and bending a lower portion of said at least one side wall with the greater height to extend transversely relative to the side wall and further form a downwardly dependent flashing portion depending downwardly from one of said side walls to lap over a top edge portion of said one of the building panels.
PCT/AU2019/050842 2018-08-13 2019-08-13 A flashing connector WO2020033996A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US17/268,351 US20210214933A1 (en) 2018-08-13 2019-08-13 A Flashing Connector
AU2019321869A AU2019321869A1 (en) 2018-08-13 2019-08-13 A flashing connector

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Application Number Priority Date Filing Date Title
AU2018902944A AU2018902944A0 (en) 2018-08-13 A flashing connector
AU2018902944 2018-08-13

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WO2020033996A1 true WO2020033996A1 (en) 2020-02-20

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AU (1) AU2019321869A1 (en)
WO (1) WO2020033996A1 (en)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA3191465A1 (en) * 2020-08-13 2022-02-17 Nexii Building Solutions Inc. Systems and methods for constructing a multi-storey building

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4176504A (en) * 1978-08-21 1979-12-04 Huggins Jack G Weather proof sandwich panel floor attachment device
US4686803A (en) * 1983-02-28 1987-08-18 Elf Isolation Cladding element for outer facades, and application thereof
JP2013231344A (en) * 2012-04-02 2013-11-14 Nippon Steel & Sumikin Coated Sheet Corp Drainage structure of panel side end
GB2502810A (en) * 2012-06-07 2013-12-11 Dale Robert Woodward Plasterboard support clips for temporary suspension of boards during installation to a ceiling

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4176504A (en) * 1978-08-21 1979-12-04 Huggins Jack G Weather proof sandwich panel floor attachment device
US4686803A (en) * 1983-02-28 1987-08-18 Elf Isolation Cladding element for outer facades, and application thereof
JP2013231344A (en) * 2012-04-02 2013-11-14 Nippon Steel & Sumikin Coated Sheet Corp Drainage structure of panel side end
GB2502810A (en) * 2012-06-07 2013-12-11 Dale Robert Woodward Plasterboard support clips for temporary suspension of boards during installation to a ceiling

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US20210214933A1 (en) 2021-07-15

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