"Buildinq Panel and Method of Formation of Building Panel"

Field of the Invention

This relates to lightweight building panels which can be used as the floor and/or wall and/or roof and/or ceiling panels of a building.

Background Art

In the past it has been known to utilise panels in the construction of buildings rather than utilising frames or bricks or conventional arrangements. Such panels have generally comprised monolithic elements which can incorporate within their body a frame support structure which is encased within a matrix such as conventional concrete, lightweight concrete, expanded or foamed plastics material. A difficulty with such panels relates to the deterioration that can occur to the frame structure encased within the concrete over a period of time as a result of moisture entering and seeping into the matrix. The panels can also be heavy and thus difficult to handle Alternative arrangements have utilised lightweight expanded or foamed plastics material which is sandwiched between a pair of hard board panels or the like and which in some cases is associated with a supporting frame located between the hardboard panels. Such panels can present a fire risk or at least can present a danger in the event of fire.

Disclosure of the Invention

Throughout the specification and claim, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

According to one aspect the present invention resides in a building panel comprising a building frame which has sufficient structural integrity to withstand

the anticipated loadings for the panel, the frame having one face overlaid by an outer layer formed of a lightweight concrete which is fixed to the frame, the outer layer being separated from the frame panel by a separation layer, the outer layer being fixed to the frame through fixings which are received through the separation layer.

According to a preferred feature of the invention the other face of the panel is adapted to receive a finishing cladding.

According to a preferred feature of the invention the separation layer is formed of metal sheeting.

According to a preferred feature of the invention the separation panel is formed of a thermal insulating material. According to a preferred feature of the invention the separation panel is formed from an expanded or foamed plastics material.

According to a preferred feature of the invention the separation layer is formed from a membrane formed of a plastics material. According to a preferred feature of the invention the plastics membrane is formed with a plurality of closely adjacent closed spaced, fluid filled cells. According to a preferred feature of the invention the separation layer comprises at least two membranes separated by a plurality of closely adjacent, closed spaced, fluid filled cells.

According to a preferred feature of the invention the outer layer incorporates reinforcing. According to a preferred feature of the invention the reinforcing comprises a mesh. According to a preferred feature of the invention the reinforcing is fixed to the frame by said fixings.

According to a preferred feature of the invention the outer layer comprises a cellular panel which is fixed to the frame said cellular panel being formed of an open cellular matrix which is filled with said lightweight concrete. According to a preferred feature of the invention the open cellular matrix is formed of a plastics

material. According to a preferred feature of the invention the open cellular matrix is formed with closely adjacent cells which are open to at least the outer face of the cellular panel. According to a preferred feature of the invention the open cellular matrix is formed with closely adjacent cells which are open to each other.

According to a preferred feature of the invention the panel is intended in use to be used as a wall and/or ceiling panel.

According to a preferred feature of the invention the panel is intended to be used as a floor panel.

According to a preferred feature of the invention the frame includes a truss like structure.

According to another aspect the invention resides in a method of forming a building panel comprising forming a substantially planar frame which has sufficient structural integrity to withstand the anticipated loadings for the panel; locating the frame substantially horizontal, defining a mould space above the upper face of the frame which has a perimeter substantially corresponding to the perimeter of the frame, locating a separation panel across the base of the moulding space to cover the upper face, introducing a lightweight concrete into the mould, screeding the lightweight concrete to form an outer layer and allowing the concrete to harden, the method including applying fixings between the outer layer and the frame, said fixings being received through the separation layer.

According to a preferred feature of the invention a finishing cladding is applied to the other face of the.

According to a preferred feature of the invention the separation layer is formed of metal sheeting.

According to a preferred feature of the invention the separation layer is formed from a membrane formed of a plastics material. According to a preferred feature of the invention the separation panel is formed of a thermal insulating material. According to a preferred feature of the invention the separation panel is formed from an expanded or foamed plastics material. According to a preferred feature of the invention the plastics membrane is formed with a plurality of closely adjacent closed closely spaced fluid filled cells. According to a preferred feature of the invention the separation layer comprises at least two membranes separated by a plurality of closely adjacent, closed spaced, fluid filled cells.

According to a preferred feature of the invention reinforcing is introduced into the moulding space prior to the introduction of the lightweight concrete.

According to a preferred feature of the invention the reinforcing comprises a mesh. According to a preferred feature of the invention the reinforcing which is fixed to the frame prior to the introduction of the lightweight concrete by said fixings.

According to a preferred feature of the invention the reinforcing is supported in spaced relation from the separation layer within the moulding space. According to a preferred feature of the invention the separation layer is covered by at least one cellular panel which is fixed to the frame prior to the introduction of the lightweight concrete by said fixings, said cellular panel being formed of an open cellular matrix which is to be filled with said lightweight concrete. According to a preferred feature of the invention the open cellular matrix is formed of a plastics material. According to a preferred feature of the invention the open cellular matrix is formed with closely adjacent cells which are open to at least the outer face of the cellular panel. According to a preferred feature of the invention in the open cellular matrix is formed with closely adjacent cells which are open to each other.

According to a preferred feature of the invention wherein the frame includes a truss-like structure.

The description of the invention will be more fully understood in light of the following description of several specific embodiments.

Brief Description of the Drawings

The description is made with reference to the accompanying drawings of which;

Figure 1 is a schematic side elevation of a mould accommodating a frame according to the first embodiment with the separation panel in position;

Figure 2 is a schematic section elevation of the mould of Figure 1 with the open cellular matrix material in position;

Figure 3 is a schematic section elevation of the mould of Figure 2 with the open cellular matrix panel in position;

Figure 4 is a schematic sectional elevation of a panel according to the first embodiment formed from the mould of figures 1 , 2 and 3;

Figure 5 is a part sectional isometric view of the panel according to the first embodiment; and

Figure 6 is a schematic sectional elevation of a panel according to the second embodiment formed from the mould.

Detailed Description of Specific Embodiments

Each of the embodiments relates to building panels which can be utilised in the construction of a building which can be used as a floor panel or a wall panel, or a ceiling panel.

The panel according to the first embodiment as shown in Figures 4 and 5 is intended as a wall or ceiling panel and comprises a frame 11 which comprises a

stud frame similar to those used in frame building constructions and which is formed of an appropriate channel section formed of steel sheet. One face of the frame 11 supports separation panel 13 which is formed of an expanded polystyrene foam. The separation panel is overlaid by a layer 15 of lightweight concrete which accommodates an open cellular plastic matrix panel 17 which is fixed to the frame 11 by fixings 19 which extend between open cellular plastic matrix panel 17 and the frame 11.

The open cellular panel which is formed of a suitable plastics material is one which is used conventionally in water drainage and is formed with an apertured upper and lower face which are held in spaced relation by a set of spaced apertured webs to form a set of cells whereby communication is also open across the panel and between the cells. An example of such material is one marketed under the trade mark VERSICELL

The lightweight concrete which is utilised with the invention comprises concrete intermixed with expanded polystyrene granules and/or beads.

As shown in Figures 1 , 2 and 3 the method of forming the panel comprises initially forming the frame 11 , positioning the frame such that it is horizontal creating a moulding space above a the upper face of the frame by a set of side boards 21 such that the frame defines the base of the moulding space and the sides of the moulding space extend above the frame. The frame is then overlaid by a separation panel 13 as shown at Figure 1. The separation panel comprising a panel formed of an expanded polystyrene foam. The separation panel is then overlaid by a panel or plurality of panels 17 formed of the open cellular matrix which are located in position over the separation panel 13 to fully cover the separation panel 13. The cellular matrix panels 17 are fixed to the frame 11 by suitable fixings 19 whereby the fixings 19 pass through the separation panel as shown at Figure 2.

A lightweight concrete mixture incorporating expanded polystyrene granules is then poured into the mould cover the open cellular matrix and to fill the cells within the open cellular matrix 17. After pouring the concrete the upper face of the concrete can then be screeded and/or textured as desired provide the desired external finish and to define the outer later 15 over the separation layer as shown at Figure 3. The concrete is then allowed to harden and when satisfactorily hardened the composite panel is removed from the mould.

The other face of the building panel can have a cladding 27 of the form marketed under the trade mark GYPROCK applied to it subsequent to the moulding of the other layer or prior to the moulding of the other layer.

The embodiment provides a building panel with the structural capacity of conventional building frame but one which also has the high thermal insulating carrying capacities as a result of the lightweight concrete panel which is fixed to the frame. The presence of the separation panel serves to provide for relative expansion and contraction of the frame relative to the overlying concrete panel without causing cracking and/or the creation of zones of weakness between the frame and the outer layer.

The second embodiment as shown at Figure 5 is intended for use as a floor panel and corresponding components to those of the first embodiment are given the same reference numerals in Figure 5. In the case of the second embodiment the frame 11 incorporates a truss-like structure to be able to take the additional loadings anticipated for a floor panel. In addition the separation panel is formed of metal sheeting which has a similar a profile to that form of sheeting which is used as roof cladding. Finally the layer of light weight concrete 15 incorporates a reinforcing mesh 23 which is supported from the separation panel by suitable chairs 25 before the lightweight concrete is introduced into the mould. The formation of the panel is similar to that of the first embodiment.

The third embodiment of the invention is a variation of the first and second embodiments and involves the replacement of the panel of expanded polystyrene foam as the separation layer by a material in the form of a plastics membrane which incorporates a separated by a plurality of closely adjacent, closed spaced, fluid filled cells. An example of such a material comprises one in which at least two layers of a plastics membrane are separated by a plurality of closely adjacent, closed spaced, fluid filled cells. One such material is marketed under the trade mark AIR-CELL.

In forming the panels they can be preformed to accommodate access ways such as doorways windows ventilation ducts and the like.

It is envisaged that the panels according to the embodiments can be formed of materials which have been recycled and which are mainly recyclable in that steel frame can be formed of a recycled steel, the open cellular matrix material can be formed of a recycled plastics, and the lightweight expanded polystyrene granules and/or beads can be provided by recycling expanded polystyrene materials which have been granulated.

The present invention is not to be limited in scope by any of the specific embodiments described herein. These embodiments are intended for the purpose of exemplification only. Functionally equivalent products, formulations and methods are clearly within the scope of the invention as described herein.