TE C H NICAL FIE L D OF TH E INVE NTION

The present invention relates to building construction.

In particular, though not solely, the present invention is directed to a panel for constructing buildings, and methods for its construction and use. BAC K G R OUND OF T H E INVE NTION

There are many technologies for building residential housing, whether low or high rise a nd commercial buildings.

Residential requirements are different to those of commercial buildings, but both can take advantages in construction efficiencies. The residential building is often built to a higher standard in terms of building performance therma lly a nd acoustically, as well as finishes required. F lexibility must a lso be available in the building technology to allow for low cost building as well as high specification buildings, while not compromising the fundamental building basics and performance. Typically, there are more utility locations, for example power, internet, gas and water, in a residential dwelling than a commercial dwelling, and so therefore there must be a llowance to install these. In open framing systems, for example prefabricated fra ming, where none, or only one side of the frame is covered, this is facilitated by the ability to enclose the framing after utility installation on site. However, in systems where large portions of the building are manufactured offsite in a prefabrication with interior and exterior cladding a pplied then this is more difficult and requires majority of utility placement in place offsite. It would therefore be beneficial to allow utility placement at least to a certain degree on site in prefabricated wa ll panels. This may be useful for last minute cha nges to utility placement on site during building, or after building is completed and a user wishes to add or remove utilities.

A well-known method is framing that is that clad interna lly and externa lly, for example timber of steel framing. Once the framing is up, and typically the externa l cladding in place, then insulation and utilities are run inside the framing cavity. T he interna l cladding is then placed over the cavity to seal it. Interna l and external finishings, such as paint and render, are then applied to therefore finish the walls of the residence. A problem with such a method is that, even if the timber framing is made in large sections, for example sections of walls, and then brought on site, erected and fastened into place, then internal and external claddings, utilities a nd insulation a nd waterproofing must still then be applied. This is costly and adds to the construction time. G enerally, the interna l and externa l claddings are fragile and so cannot be a pplied beforehand. Even if they were, this creates an issue when utilities, such as water, power, gas, telecoms come to be installed.

Internally such framing construction must also have cross members, or nogs, running crosswise between the vertically running studs. Therefore, utilities must be installed prior to either the external, or internal (typically internal), being attached.

Unless there are exacting design specifications made to allow pre-installation of utilities offsite, then this requires installation of utilities onsite before the fina l cladding is applied. Further, such construction makes later fitting of utilities difficult as the nogs prevent access down the framing. Unless access can be gained from above to drill, then the only way to add utilities on the other side of a nog is to remove the internal cladding (or external), add the utility, and then reclad that section.

Further, such framing requires frequent addition of bracing, either with stra ps running diagona lly, or a sheet brace, for example a sheet of plywood or similar. T he internal a nd external cladding itself plays little part in bracing the framing against movement para llel to the plane of the framing. Therefore, again this ca lls for a further different material to be located on the framing, which then must also be covered and finished. It is also then undesirable at a later date to cut into the shear bracing to add utilities, and possibly compromise its performance.

A further disadvantage of frame type construction is that it is typically dependent on being bolted down to the floor slab a nd temporarily braced until all remaining framing is in place. Then the bracing can be removed. This results in additional work, and materials.

Also, timber frame construction must be dried and reach a certain moisture threshold before cladding can be applied. Therefore, unless the entire building floor is covered, for example from above, then the construction is subject to the elements. This causes unexpected delays in construction due to weather, then drying and subsequent scheduling of the various trades required to complete the build.

In this specification where reference has been made to patent specifications, other external documents, or other sources of information, this is generally for the purpose of providing a context for discussing the features of the invention. Unless specifically stated otherwise, reference to such external documents is not to be construed as an admission that such documents, or such sources of information, in any jurisdiction, are prior art, or form part of the common genera l knowledge in the art.

It is therefore an object of the present invention to provide an improved building panel and constructions therefrom, which s peeds up at least the onsite construction time, or which reduces waste, or which reduces the chances of compromising the integrity of the building envelope, or which provides the user more flexibility, or to overcome the above shortcomings or address the above desiderata, or to at least provide the public with a useful choice.

B RIE F DE S C R IPTION OF TH E INVE NTION

In a first aspect the present invention consists in a build ing pa nel for use in constructing a building, comprising or including,

A first skin of plana r form,

A second skin of pla nar form, parallel to and spaced from the first skin,

A top rib, joining between the first and second skins at or toward top portions thereof, the top rib providing at least one access from external of the panel, to an internal volume of the panel,

At least one side rib joining between the first and second skins at or toward side portions thereof,

At least one internal rib joining between the first and second skins on respective internal facing surfaces thereof,

An insulating material in the internal volume at least in part defined by the first skin, second skin, top rib and the at least one side rib, the insulating material having at least one void therein located under the at least one access, the at least one access and at least one void providing an internal conduit within the pa nel for utilities to pass therethrough,

Wherein the building panel can be used to at least in pa rt define a wall of a residential building.

P referably the building is a residential dwelling, whether low or high rise, or a commercial building.

P referably the first a nd second skins, at least one side rib, a nd at least one internal rib are made from a certified building board.

P referably the certified building boa rd is a magnesium oxide or magnesium sulphate. P referably the insulating material is acoustically insulating. P referably the insulating material is thermally insulating.

P referably the insulating material is both acoustic and thermally insulative.

P referably the at least one side rib, at at least one internal rib are joined to the first skin and second skin by adhesive.

P referably there are two or more interna l ribs that act to define the at least one void.

P referably the top rib is made from steel or metal. P referably the top rib includes lifting locations.

P referably the at least one access in the top rib doubles as the lifting location.

P referably the at least one side rib is set into the internal volume to define with the first skin and the second skin a side recess.

P referably the panel has side recesses on each vertical side.

P referably the building pa nel is adapted to sit on a horizontal pad to at least one pa rt define the building.

P referably the side recess at least in pa rt engages over a vertical upright to hold the pa nel at least vertically. P referably the side recesses of a pair of adjacent panels each engage a mutua l upright and cover the upright.

P referably the upright is a post of steel, or is a magnesium oxide or magnesium sulphate post of hollow construction.

P referably the upright is filled with insulating materia l. P referably the vertical upright is hidden from sight at least externally, a nd preferably internally also, by the side recess(es).

P referably there is a variable eave girt that ca n act as a bracing strut, purlin for the roof, girt, strut for panel bracing and utility tray.

P referably the variable eave girt has a variable angle to follow the line of the roof, yet remain vertical for the wall a nd its pa nels. In another aspect the present invention consists in a method of manufactu re of a building comprising or including the steps of

P roviding a building pa nel having

A first skin of planar form,

A second skin of pla nar form, parallel to a nd spaced from the first skin, A top rib, joining between the first and second skins at or towa rd top portions thereof, the top rib providing at least one access from external of the panel, to a n internal volume of the panel,

At least one side rib joining between the first and second skins at or toward side portions thereof,

At least one internal rib joining between the first and second skins on res pective internal facing surfaces thereof,

An insulating material in the interna l volume at least in part defined by the first skin, second skin, top rib and the at least one side rib, the insulating material having at least one void therein located under the at least one access, the at least one access and at least one void providing an internal conduit within the panel for utilities to pass there through,

P roviding a base floor for the building panel to reset on,

P roviding at least one vertica l upright for a side of the building panel to over- engage at least in pa rt, and

Locating the building panel on the at least one upright and securing it thereto, such that at least part of a wall for a residential dwelling is provided.

P referably the building is a residential dwelling, whether low or high rise, or a commercial building.

P referably the first a nd second skins, at least one side rib, a nd at least one internal rib being made from magnesium oxide or magnesium sulphate. P referably the method includes the step of lifting the panel into place via a prime mover utilising the at least one access in the top rib. P referably the method includes the step of locating utilities before or after locating the panel in place.

P referably the method involves the step of installing a variable eave girt over the building panels

In another aspect the present invention consist in a building including,

At least one panel comprising or including,

A first skin of planar form,

A second skin of pla nar form, parallel to a nd spaced from the first skin, A top rib, joining between the first and second skins at or towa rd top portions thereof, the top rib providing at least one access from externa l of the panel, to a n internal volume of the panel,

At least one side rib joining between the first and second skins at or toward side portions thereof,

At least one internal rib joining between the first and second skins on respective interna l facing surfaces thereof,

An insulating material in the internal volume at least in part defined by the first skin, second skin, top rib a nd the at least one side rib, the insulating material having at least one void therein located under the at least one access, the at least one access and at least one void providing an internal conduit within the panel for utilities to pass therethrough,

At least one upright to side engage the at least one panel and hold it vertica lly, A variable eave girt engaged to the top rib, the variable eave girt including at least one access through the varia ble eave girt to the at least one access of the top rib below, the variable eave girt connecting to at least one roofing structure element above.

P referably the building is a residential dwelling, whether low or high rise, or a commercial building. P referably the first a nd second skins, at least one side rib, a nd at least one internal rib being made from magnesium oxide or magnesium sulphate. P referably the at least one pa nel is ma nufactured off site.

P referably the at least one pa nel is placed in location on the building by a prime mover. In another aspect the present invention consists in a va ria ble eave girt, comprising or including,

A lower panel connecting portion, including at least one access as an a perture from above the lower panel connecting portion to a llow utility connection through to a panel below, the lower panel ada pted to connect to a top rib of the lower panel,

An upper angled connecting portion for connecting to a roof structure, wherein an angle of the upper a ngled connecting portion is varia ble to accommodate varying roof angles,

A connecting portion between the lower pa nel connecting portion, and the upper angled connecting portion,

Wherein the variable eave girt can connect one or more lower wall panels, to one or more roof structure elements, and provide access for utilities from external of the pa nel to internal of the pa nel through the variable eave girt.

P referably the lower panel connecting portion is tray s haped when seen from above and acts as a utility tray for utilities.

P referably the variable eave girt includes fastener a pertures to engage the one or more lower wa ll panels. P referably the variable eave girt includes fastener a pertures to engage the one of more roof structure elements.

P referably the variable eave girt is availa ble in indefinite length. P referably the variable eave girt is made from a resilient material, such as steel or similar.

In yet another aspect the present invention consists in a kit of parts for at least part of a building, comprising or including,

A lower wa ll panel, comprising,

A first skin of planar form,

A second skin of pla nar form, parallel to a nd spaced from the first skin, A top rib, joining between the first and second skins at or towa rd top portions thereof, the top rib providing at least one access from externa l of the panel, to a n internal volume of the panel,

At least one side rib joining between the first and second skins at or toward side portions thereof,

At least one internal rib joining between the first and second skins on respective interna l facing surfaces thereof,

An insulating material in the internal volume at least in part defined by the first skin, second skin, top rib a nd the at least one side rib, the insulating material having at least one void therein located under the at least one access, the at least one access and at least one void providing an internal conduit within the panel for utilities to pass therethrough,

At least one vertical upright to engage a floor or roof element which also engages the lower wall panel from a side,

A variable eave girt, to connect one or more lower wall panels to one or more roof structure elements,

Fastenings to engage the variable eave girt to the lower wall pa nel, a nd to the one or more roof elements,

Wherein the lower wall panel can be engaged to the at least one vertical upright to form at least part of a wa ll for a residential dwelling, and the variable eave girt ca n engage to the top of the lower wall panel, and is then ready to accept one or more roofing elements.

P referably the building is a residential dwelling, whether low or high rise, or a commercial building.

P referably the first a nd second skins, at least one side rib, a nd at least one internal rib being made from magnesium oxide or magnesium sulphate.

In another aspect the present invention consists in a building pa nel, as described herein with reference to any one or more of the accompanying drawings.

In another aspect the present invention consists in a method of manufactu re of a building, as described herein with reference to any one or more of the accompanying drawings.

In another aspect the present invention consists in a va ria ble eave girt, as described herein with reference to any one or more of the accompa nying drawings. In another aspect the present invention consists in a kit of parts, as described herein with reference to any one or more of the accompanying drawings. As used herein the term and/or. means and. or or., or both.

As used herein ^' (s) . following a noun means the plural and/or singular forms of the noun.

The term comprising _, as used in this specification means consisting at least in part of.. When interpreting statements in this specification which include that term, the features, prefaced by that term in each statement, all need to be present, but other features can also be present. Related terms such as comprise . and comprised. are to be interpreted in the same manner. It is intended that reference to a range of numbers disclosed herein (for example, 1 to 10) also incorporates reference to a ll rationa l numbers within that range (for example, 1 , 1.1 , 2, 3, 3.9, 4, 5, 6, 6.5, 7, 8, 9 and 10) and also a ny range of rational numbers within that range (for example, 2 to 8, 1.5 to 5.5 a nd 3.1 to 4.7). The entire disclosures of all applications, patents and publications, cited above and below, if any, are hereby incorporated by reference.

To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments a nd application of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.

Other aspects of the invention may become apparent from the following description which is given by way of example only and with reference to the accompanying drawings.

B RIE F D E S C R IPTION OF TH E D RAWING S

P referred forms of the present invention will now be described with reference to the accompanying drawings in which;

Figu re 1 S hows an exploded schematic of a building utilising the pa nel a nd building method of the present invention, Figure 2 Shows an isometric cutaway upperviewof a panel of the present invention, Figure 3 Shows a close up top view of the top rib with utility access and lifting hole visible,

Figure 4 Shows an isometric close up view of the top region of the panel showing the variable eave girt, and support by the wall structural post,

Figure 5 S hows a similar view to that of Figure 4, with the exception the wall

structural post is replaced by a post made of the same or similar material as the panel skin, with insulation in the post, Figure 6 Shows an isometric close up view of the connection between the panel, variable eave girt (providing a utility tray), and a roof, and

Figure 7 Shows in side elevation a cutaway view of a building panel on a foundation slab.

DETAILED DESCRIPTION OF THE INVENTION

Preferred embodiments will now be described with reference to Figures 1 through 7.

Shown in Figure 2 is a building panel 1, which consists of a firstskin 2, and a parallel to, and spaced from it, is a second skin 3. Between these two is formed an internal void 7. On side portions 9 are side ribs 8. The side ribs 8 are inset into the internal volume 7 to form a side recess 16 on each side, the use of which will be described below. The recess 16 is shown with an even length of first and second skin forming the recess, however, in otherforms one skin may be longer than the other, for example the first skin extending further than the second, or the second skin extending further than the first.

At a top portion 5 of the panel there is a top rib 4. In some embodiments, there is a bottom rib towards the bottom of the panel 1 also. Within the internal volume 7 there are internal ribs 10, as stringers, running between the firstskin 2 and second skin 3 and these run in the preferred form from at or near the top rib 4 to the bottom, or bottom rib 30 (as seen in Figure 7) if present. These ribs add stiffness and strength to the sandwich building panel 1. In one embodiment the first skin 2, second skin 3, side ribs 8, internal rib 10 and optional bottom rib are made from a certified building board, such as magnesium sulphate, MgS 04, or magnesium oxide, MgO. However, other materials with comparable properties as needed may be used, for example plywood or other engineered timber, or other magnesium, or simila r material boards may be used.

In the preferred form, this is cut from sheet, or may be moulded in the desired shape. T he top rib 4 is made from steel, or a similar resilient material. In the preferred form, the top rib 4 is made from rolled steel, preferably galva nised, but may be made from other forming techniques a lso. In the form shown the top rib 4 is channel shaped with the opening 31 of the cha nnel facing downwards as s hown in F igure 2, but other forms are a lso envisaged. P resent in the top rib 4 is at least one access 6, and preferably there are many accesses 6 evenly, or not, spread along the top, as shown in F igures 3 through 5. The access is through the thickness of the top rib 4 as a hole. P refera bly there are no rough edges a nd the access 6 is smooth. P resent a lso, though not shown in Figure 2, are fastener apertures 24 to allow for connection to the variable eave girt 19 described below, or other structures.

Within the internal volume 7 there is insulating material 11 that performs either thermal insulation, or acoustic insulation, or that performs both these functions. In one form, this insulation is that sold under, or known as R OC KWOOLu insulation, but could be any form of suitable insulation, such as polyisocyanurate (PIR). The insulation a lso has preferably the added property of water resista nce, fungal resistance, a nd fire resistance. The interna l ribs 10 are preferably located evenly throughout the internal volume 7. T he internal voids 12 are preferably located directly under, a nd are accessible from above, through the access 6 in the top rib 4. In the preferred form, these voids 12 form conduits 13 a nd allow for running utilities, such as, but not limited to, electricity, water, gas, telecommunications, or others as needed. The smooth internal form of the conduit 13 formed by the void allows for easy running of utilities as needed and prevents snags if utilities are later insta lled. In the preferred form, the voids 12 a re formed by a pair of internal ribs 7 located either side of the access 6. In the void 7 so formed there is no insulation to allow for easy location of utilities. In other less preferred forms the voids may be formed by other structures, such as, but not limited to, pipes, reduction in internal insulation or similar. In the preferred form, the panel 1 is laminated from one skin 2 through to the other skin 3. For example, the first skin 2 is laid down, then top rib 4, side ribs 8, and optional bottom rib located and glued into place against the first skin 2. Internal ribs 10 are then located and glued into place using adhesive 14, for example to form the voids 12 described. In one form, the interna l ribs 10 are rebated at their top region to account for the thickness of the cha nnel walls of the top rib 4, to a llow them to s lide all the way in, if needed, into the cha nnel of the top rib 4. Insulation material 1 1 is then located in the pa rtially formed internal volume 7. At this stage utilities from the top rib, down through the access 6, into the conduits 13, may be added a nd partially terminated. F inally, the other skin, for example the second skin 3, is then located a nd glued into place against the top rib 4, side ribs 8, interna l ribs 10 and optional bottom rib. Apertures (not s hown) may be present in which ever of the first or second skins is the building internal facing skin to allow for further fixing a nd termination of utilities, for example power points, gas connection points, telecommunication junctions, water, waste water a nd simila r.

P ressure may then be applied perpendicularly to the major plan of the first and second skins to ensure the correct connection of all the components, for example by adhesive 14, though other systems may be used such as small pins, screws or similar, as well as geometrical requirements. If necessary to cure the glue or adhesive 14, then heat or other conditions may be applied also. In the preferred form, the glue or adhesive 14 is a high-strength fire-rated bonding agent to form the composite structural building pa nel 1 .

A va riable eave girt 19, in keeping with the present invention is shown in F igures 4 through 6, including its usage with the panel 1. T he variable eave girt 19 consists of a lower connecting portion 27, connecting portion 29 and upper angled connecting portion 28. The lower connecting portion 27 in the embodiment shown is substantially flat on its lower outer surface, and its inner surface forms a channel with the connecting portion 29 as shown in Figure 6. T his forms a utility tray 23 which helps control utilities for the pa nels 1 located below. The lower connecting portion 27 in the preferred form has at least one access 6 also, and preferably has multiple accesses 6 along its length. In the preferred form, these are arranged to coincide with the access 6 in the top rib 4 below of the panel 1 the girt 19 connects to. This allows ease of connection of utilities 21. The upper angled connecting portion 28 provides a purlin structure that is at the correct angle to follow the pitch of the roof 26, while the connecting portion 29 a nd lower panel connecting portion 27 remain para llel, and perpendicular respectively to the plane of the panel 1 below. The girt 19 connects to the rafter system of the roof 26, which connects to the apex connection at the top of the roof. P resent also in each of the lower connecting portion 27 and upper connecting portion 28 are fastener apertures 24 as seen in Figure 4. These in one form line up with like apertures in the top rib 4 below, and roofing elements 26 above, to a llow fasteners 25 to connect the pa nel 1 to the girt 19, and the roofing elements 26 to the girt 19.

The variable eave girt 19 performs the following functions:

I Bracing strut

I P urlin for affixing roof 26

i G irt for affixing panels 1 and transiting loads to post a nd rafter frames

I S trut for in pla ne bracing connection

I Locking pa nels down in place prior to roof 26 insta llation.

The top rib 4 has as described, accesses 6. Once assembled into a panel 1 the access serves a further vital function as a lifting location 1 5 for a prime mover 20 to lift the panel 1 into place. T herefore, the top rib 4 and access 6 must be resilient enough to carry this load, in one form the access 6 is swaged into the top rib 4.

In use to form a residential dwelling 22 it is preferred that a horizontal pad 17 as a base or floor is formed, for example a concrete or similar sla b. As part of forming the slab, or separate thereto, vertical uprights 18 as stringers are placed at the correct intervals to receive a panel 1 , as shown in F igure 1 ^" the side recesses 16 of the panel covering all or part of the upright 18. T he upright interval is defined as the dista nce between the outer facing surfaces of the side ribs 8 of a single pa nel ^" that is the distance across the panel between the inner surfaces of the side recesses 16. Thus, the uprights 18 will be recessed into, preferably, the pa nel side recesses 16 a nd therefore at least in part covered by either or both of the first and second skins 2, 3. The vertical uprights may for example be a steel or metal post as shown in Figure 4, or may be made from a similar materia l, for example, but not limited to certified building boa rd, or magnesium based, to the pa nels 1 , as shown in Figure 5, and both may be filled with insulation material 1 1. When the upright 18 is steel or meta l then it can form a dew point and collect

condensation. T he recesses are therefore sealed from the internal volume 7 of the panel to prevent moisture getting inside the pa nel. This way the side recesses and upright ca n breathe from interna l to the external environment. This allows condensation a nd other gases to escape from the interior of the building to the exterior. Optionally a bottom post 33 may also be located into place on the slab 17, and this will sit within the bottom recess 32, as seen in F igure 7. T he panels 1 a re located into place by lifting locations 15 by a prime mover 20, a nd lowered into place from a bove between the two uprights 17. If a bottom post 33 is present, then an optiona l bottom recess 32 in the panel may fit over the bottom post 33. Once the panel or pa nels 1 is/are located in place then the girt 19 can be located and fastened in place to the panel 1 using fasteners 25. In the preferred form, the girt 19 a lso fastens down onto the vertical post 18 to lock the panels 1 and girt 19 down, and thus also the roof 26. The upper angled connecting portion 28 may be at the correct angle for the roof pitch, or may be varied on site as needed. T he roofing elements 26 can then be located in place.

The s kins of the panels may a lso be textured as desired, for example they may have an embossed pattern to resemble wood or pa nelling or similar. The foregoing description of the invention includes preferred forms thereof. Modifications may be made thereto without departing from the scope of the invention.