Patent Application
20130139462
The present application claims priority from Australian Provisional Patent Application No. 2010902421, the entire content of which is incorporated herein by reference.
The present disclosure relates to a panel connection assembly, to a building panel and to a building construction method utilising a panel connection assembly.
The panel connection assembly, panel, and building construction method have been developed particularly for use in erecting housing at remote sites, temporary housing and/or low cost housing, and will be described hereinafter with reference to these applications. However, it will be appreciated that the panel connection assembly, panel, and construction method are not limited to these applications and may also be used for erecting other buildings or containers, or for display partitions/panels, internal walls and partitioning (such as office partitioning or internal building walls), fencing, barriers and screens, flooring, ceilings and roofing.
Conventional building techniques, which include brick veneer, double brick, steel frame with external cladding, and timber frame with external cladding, typically require skilled labourers and specialist tools. Moreover, with conventional building techniques, buildings often take several months to construct.
The erection of buildings in remote locations using conventional techniques can therefore be problematic, as skilled labour is often not available locally.
Speed of construction is often highly desirable when constructing buildings in response to natural disasters or other emergencies. Accordingly, erection of buildings in such situations using conventional techniques requires undesirably long construction times.
Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is solely for the purpose of providing a context for the present invention. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”; will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
In a first aspect, there is provided a panel connection assembly for connecting adjoining panels, the panel connection assembly comprising:
an elongate first component adapted for connection to a surface of a first panel;
an elongate second component adapted for connection to a surface of a second panel;
a first locking member removably engageable with the first and second components for restraining the first and second components against shearing movement orthogonal to their longitudinal axes;
at least one second locking member removably engageable with the first and second components for restraining the first and second components against movement away from one another orthogonal to their longitudinal axes.
The first component may comprise one or more pieces extending at least two thirds of the length, and in some embodiments substantially a full length, of said surface of the first panel. The second component may comprise one or more pieces extending at least two thirds of the length, and in some embodiments substantially a full length of said surface of the second panel. The first component may, in use, be sandwiched between the first and second panels. The second component may, in use, be sandwiched between the first and second panels.
The first and second components may be of substantially the same length. The first locking member may comprise one or more pieces having a length, or, in the case of the first locking member being formed from a plurality of pieces, a combined length, that is at least two thirds of the length of the first and second components. In some embodiments, the first locking member may comprise one or more pieces having a length, or, in the case of the first locking member being formed from a plurality of pieces, a combined length, that is substantially equal to the length of the first and second components. The second locking member may comprise one or more pieces having a length, or, in the case of the second locking member being formed from a plurality of pieces, a combined length, that is at least two thirds of the length of the first and second components. In some embodiments, the second locking member may comprise one or more pieces having a length, or, in the case of the second locking member being formed from a plurality of pieces, a combined length, that is substantially equal to the length of the first and second components.
The first component may include an opening extending longitudinally therethrough, the second component may also include an opening extending longitudinally therethrough, the first locking member being slidably engageable in the opening of the first component and the opening of the second component.
The opening of the first component may be defined by a longitudinally extending channel in a surface of the first component. The opening of the second component may be defined by a longitudinally extending channel in a surface of the second component. The openings of the first and second components may align to define a unitary opening in which the first locking member is slidably engageable.
At least one sidewall of the opening of the first component may include at least one groove or projection that is engageable by a corresponding projection or groove on the first locking member to restrain the first locking member in the opening of the first component against movement toward the second component.
At least one sidewall of the opening of the second component may include at least one groove or projection that is engageable by a corresponding projection or groove on the first locking member to restrain the first locking member in the opening of the second component against movement toward the first component.
At least one first anchor may extend from the first component for connecting the first component to the first panel. The of least one first anchor may include a prong for engaging a slot in the first panel. The prong may include a serrated edge.
At least one second anchor may extend from the second component for connecting the second component to the second panel. The at least one second anchor may include a prong for engaging a slot in the second panel. The prong of the second anchor may include a serrated edge.
First projections may extend from opposite sides of the first component, in a direction generally orthogonal to the longitudinal axis of the first component, and corresponding second projections may extend from opposite sides of the second component, in a direction generally orthogonal to the longitudinal axis of the second component to define corresponding pairs of first and second projections on each side of the assembly. Two said second locking members may be provided, each being engageable around one of the corresponding pairs of first and second projections to restrain the first and second components against movement away from one another orthogonal to their longitudinal axes. A fastener, such as a screw fastener, may be engageable between the second locking member and third and fourth components for securing the second locking member to the third and fourth components. The first and second projections may be formed, respectively, on third and fourth elongate components engageable with the first and second components. The anchor(s) may also be formed on the third and fourth components. The second locking member may be snap-lockingly engageable with the third and fourth components.
The at least one second locking member may include a face plate adapted to cover a gap between the first and second panels. The width of the face plate, measured in a direction orthogonal to a plane defined by a contact surface between the first and second components, may be equal to a sum of the widths of the first and second components measured in the same direction, such that the face plate is adapted to be flush with opposing surfaces of the first and second panels.
Materials used in the panel connection assembly may be formed from environmentally sustainable materials. The first and second components, and the first locking member, may be formed from one or more recyclable plastics materials. The core may be formed from a recyclable material, such as a recyclable foam material.
In a second aspect, there is provided a pre-fabricated panel for a building, the panel being generally planar and having a first major side and a second major side, the panel comprising:
a core formed from a thermally insulative material;
a first skin layer extending over the core on the first major side of the panel;
a second skin layer extending over the core on the second major side of the panel;
at least one opening in the panel for receiving an anchor of a panel connection assembly as defined in the first aspect above.
The at least one opening is preferably in the form of a slot.
The core may be formed from a foam material, more preferably phenolic foam. Alternatively, the core may be formed from other insulative materials, such as solid timber or a honeycombed plastics material. The core may be between 30 mm and 150 mm thick, and in some embodiments between 60 mm and 100 mm thick.
The first skin layer may be formed from a pre-finished material. The first skin layer may be formed from fibre cement sheet, preferably of approximately 4.5 mm thickness. Alternatively, the first skin layer may be formed from plywood, plastic laminate, resin sheet material, metal sheet, or plasterboard.
The second skin layer may be formed from a pre-finished material. The second skin layer may be formed from fibre cement sheet, which is in some embodiments has a thickness of approximately 4.5 mm. Alternatively, the second skin layer may be formed from plywood, plastic laminate, resin sheet material, metal sheet, or plasterboard.
A structural frame may extend at least partially around the core. The at least one slot may extend into the structural frame. The frame may be formed from timber frame elements. The timber frame elements may be treated to provide resistance to insect damage. The timber frame elements may be treated to provide resistance to climatic damage. The timber frame elements may have at least one dimension of between 10 mm and 100 mm, in some embodiments of between 20 mm and 70 mm, in some embodiments of between 30 and 60 mm, and in some embodiments of approximately 45 mm, when viewed in transverse cross-section. In alternative embodiments, the frame may be formed from structural elements formed from other materials, such as steel or plastic.
The frame may include at least one opening for receiving at least one anchor of a panel connection assembly for interconnecting adjacent panels.
The first skin layer may completely covers the frame when viewed from the first major side of the panel. The second skin layer may completely covers the frame when viewed from the second major side of the panel.
The panel may have a mass of less than 70 kg. In some embodiments, the panel has a mass of less than 50 kg. In some embodiments, the panel has a mass of approximately 40 kg.
The first skin layer may be connected to the frame, and in some embodiments also to the core, by an adhesive. The second skin layer may be connected to the frame, and in some embodiments also to the core, by an adhesive.
The panel may be adapted for connection to an adjoining panel using a panel connection assembly as defined in the first aspect above. The panel may be connected to an adjoining panel using a panel connection assembly as defined in the first aspect above.
In a third aspect, there is provided a method of constructing a wall of a structure, the method comprising:
providing a plurality of pre-fabricated panels according to the second aspect above;
providing a panel connection assembly in one of the panels;
connecting said one panel to an adjoining one of the panels using the panel connection assembly.
The panel connection assembly may be a panel connection assembly as defined in the first aspect above. However, in other embodiments, the panel connection assembly may include a latch assembly located in the one panel and a catch assembly located in the adjoining one of said panels, the latch assembly being actuable to engage a latch of the latch assembly with a catch of the catch assembly. In such alternative embodiments, the latch assembly may be actuable using a hand-held tool, such as a hex key or screwdriver.
The present disclosure also extends to a barrier, such as a wall, floor, ceiling or roof, constructed in accordance with the method defined in the third aspect above.
An embodiment will now be described, by way of example only, with reference to the accompanying drawings, in which:
Referring to
As best shown in
Sidewalls of the opening of the first component include grooves 28 that are engageable by corresponding projections 62 on the first locking member 60 to restrain the first locking member in the opening 24 of the first component 20 against movement toward the second component 40. Similarly, sidewalls of the opening of the second component 40 include grooves 48 that are engageable by corresponding projections 64 on the first locking member 60 to restrain the first locking member in the opening 44 of the second component 40 against movement toward the first component 20. The projections 62 are angular to increase the amount of force required to disengage the first locking member 60 from the first component 20. However, the projections 64 are rounded to reduce the amount of force required to disengage the first locking member 60 from the second component 40.
A pair of first anchors 92 extends from the first component 20 for connecting the first component 20 to the first panel 200. The first anchors 92 include prongs for engaging a slot 202 in the first panel. The prongs 92 include a serrated edge 94 for increasing friction between the prongs 92 and the slot 202 and/or for dispersing glue, applied to the serrated edge 94, into the slot 202. Similarly, a pair of second anchors 102 extends from the second component 40 for connecting the second component 40 to the second panel 400. The second anchors 102 include prongs for engaging a slot 402 in the second panel. The prongs 102 include a serrated edge 104 for increasing friction between the prongs 102 and the slot 402 and/or for dispersing glue, applied to the serrated edge 104, into the slot 402.
First projections 96 extend from opposite sides of the first component 20, in a direction generally orthogonal to the longitudinal axis 22 of the first component, and corresponding second projections 106 extend from opposite sides of the second component 40, in a direction generally orthogonal to the longitudinal axis 42 of the second component to define corresponding pairs of first and second projections on each side of the assembly 10. A gap 150 is defined between the first and second projections 96, 106. As shown in
It will be appreciated that the width of the first and second components 20, 40 is chosen to suit the thickness of the panels 200, 400 with which the panel connection assembly 10 is to be used. For thicker panels, the first and second components 20, 40 are wider to ensure that the face plates 82 finish flush with the surface of the panels, and vice versa for thinner panels.
Detailed views of the pre-fabricated building panel 200, 400 are shown in
The core 208, 408 is formed from phenolic foam and is approximately 70 mm thick for panels 200, 400 of 80 mm thickness or approximately 90 mm thick for panels of 100 mm thickness.
The first 212, 412 and second 214, 414 skin layers are formed from pre-finished fibre cement sheets of approximately 4.5 mm thickness.
The frame 210, 410 is formed from timber frame elements, including two vertical members that extend along opposite sides of the core and two horizontal members that extend along the top and bottom of the core. The frame members include pairs of slots 202, 402 for receiving the anchors 92, 102 of the panel connection assembly 10. In transverse cross-section, the timber frame elements have one dimension of approximately 45 mm and another dimension matching that of the core 208, 408 thickness (i.e. by 70 mm or 90 mm) The timber frame elements are treated to provide resistance to insect and climatic damage.
Embodiments of the panels 200, 400 having a 90 mm×45 mm timber frame, have a mass of approximately 40 kg, so as to be easily carried by two people.
To construct a wall 500, two of the panels 200, 400 are placed adjacent one another. The panels may be provided with a panel connection assembly 10 as shown in
If the panel connection assembly 10 of
Disassembly of the wall is achieved by reversing the above steps.
A second embodiment of a panel connection assembly 10 and wall 500 using same is shown in
It will be appreciated that the panel connection assembly 10, panels 200, 400 and method described above with reference to the drawings can be used to facilitate joining panels side by side or one on top of another to form structural walls or non-load bearing walls for external or internal application. The panel connection assembly 10, panels 200, 400 and method can also be modified by providing the slots 202, 402 in major surfaces of the panels to facilitate joining panels at right-angles and other angles. It will also be appreciated that the panel connection assembly 10, panels 200, 400 and method can be used by unskilled workers without the need for special tools. The panel connection assembly 10, panels 200, 400 and method also facilitate very fast barrier (eg. wall, ceiling, floor and roof) construction and allow for easy disassembly and re-use.
An advantage of the illustrated panels 200, 400 is that they can be prefinished in the factory. A further advantage is that the panels 200, 400 can generally be recovered for reuse after a building containing the panels is disassembled. However, if the panels are damaged or otherwise unsuitable for reuse, the phenolic foam cores 208, 408 can be recovered and potentially converted into recycled plastic fuel and/or used as solid fuel at steel plants and paper plants. Research into such secondary uses of recycled phenolic foam is currently underway. Depending on the particular materials chosen for the skins and frame, the skins and frame of the panels 200, 400 can also typically be recycled using conventional techniques.
It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the specific embodiments described above with reference to the drawings without departing from the scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. Examples of possible modifications include, but are not limited to:
| Number | Date | Country | Kind |
|---|---|---|---|
| 2010902421 | Jun 2010 | AU | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/AU2011/000695 | 6/2/2011 | WO | 00 | 2/18/2013 |
