[0001 ] The present invention relates to building panels and a building system using such building panels, such as those used for low cost housing and commercial properties.

BACKGROUND TO THE INVENTION

[0002] There is a need for low cost structures, such as residential and employee housing as well as commercial and industrial properties.

[0003] Traditional brick and concrete blocks are energy intensive to manufacture. Constructing a building using bricks or blocks is also time consuming and labour intensive, requiring brick layers to lay the bricks/blocks using mortar.

[0004] Thermal panels are known and can be used as an alternative form of building construction. Thermal panels are typically used for cold stores because of their high thermal insulation properties, but are also used to clad buildings for the same reason.

[0005] Thermal panels typically have a sandwich construction of outer sheets of timber, gypsum or anti-corrosion coated steel, bonded either side of a sheet of material of low coefficient of thermal conductivity, typically foam, such as expanded polystyrene.

[0006] One benefit of using panels is that they can be packed flat together and transported with minimal loss of space. Fast building construction is achieved by mounting the panels to a metal or wooden skeletal framework to erect the building. That is, the panels are typically used to clad a framework. [0007] Such thermal panels are generally supplied in set sizes. Cutting panels to size on site is achievable if simple square ended butt joints are acceptable. However, such butt joints, especially at corners of walls lack strength and rigidity. An improved concept is required whereby panels can be produced that form improved corners, both for accuracy and rigidity.

[0008] Also, it would be beneficial to tie the top of the panels to the floor for improved structural integrity of the building, particularly in cyclone rated environments.

[0009] With this in mind, it has been found desirable to provide wall panels with improved features to aid construction of a building.

[0010] It is also desirable to provide a wall panel building system with improved structural integrity.

[001 1 ] It is further considered desirable to provide a wall panel arrangement whereby corners of building or walls can be constructed more accurately and with greater rigidity from flat building panels.

SUMMARY OF THE INVENTION

[0012] With the aforementioned in view, an aspect of the present invention provides a wall panel comprising at least one material with dimensions of length, width and thickness defining the panel, the panel having first and second opposed external panel faces, the length and width being substantially greater than the thickness, the wall panel including at least one aperture extending within the material on an axis along the length of the panel from a predetermined position on an end face of the panel determined by said width and thickness. [0013] Preferably the at least one aperture is a single aperture extending through the panel from one end face to an opposite end face defined by the width and thickness.

[0014] The axis preferably extends centrally from the end face(s) i.e. halfway across the thickness and width.

[0015] The at least one aperture may be a rectilinear shape in cross section, preferably square. However, circular or other shapes are envisaged to fall within the scope of the present invention.

[0016] The aperture extending into the material at the end face provides a cutting marker. However, an additional linear or other mark onto or into the surface of the end face(s) may be provided. For example, a (ink) scribed, printed or inscribed mark on the surface as a linear indicator diagonally across the aperture may be provided. Such linear markers may, if imaginarily extended, extend externally away from the opposed faces of the panel.

[0017] First and second panel portions are formed once the panel is cut through along its length following the at least one aperture. With the cut made through the material along the axis at an acute/obtuse angle with respect to the first and second faces, each resulting panel portion has a channel in an oblique edge face thereof formed by the cutting along the length of the panel. With one of the panel portions reversed, the oblique edge faces form a mitred corner with a corner central channel therethrough from one end face to the other.

[0018] A connecting member can be inserted through the corner central channel to tie a top plate and a floor plate of a building system. This connecting member ensures the roof is tied down to the floor, which is particularly useful in high wind/cyclone regions. The connecting member may be a metal rod connected to a top plate and bottom plate member, such as by screw fastening, nut and bolt or welding etc. [0019] A structural member may alternatively or additionally be inserted through the corner central channel to provide structural integrity to the building. Preferably the structural member may include an elongate steel member, preferably of steel (which may be galvanised or stainless steel). The structural member may be between 10mm and 150mm wide by 10mm to 150mm thick and approximately between about 1200mm long to about 3600mm long.

[0020] An internal strengthener may be applied to the mitred corner.

Preferably the internal strengthener is positioned in the recess at the respective exterior or interior angle of the corner between the respective facing sheet and the core. The strengthener may include an elongate angle member, such as 'L' (uneven length arms) or 'V (even length arms) in cross section to cover, protect and strengthen the corner. The strengthener may be bonded to the core and/or facing sheet by an adhesive and/or screw fastener(s).

[0021 ] The panel may include an external channel extending along the length of one or both edges of the panel between the end faces. Each such external channel may be half the cross section of said at least one aperture through the material. This, if one panel is cut along its length through the at least one aperture and perpendicular to the first and second panel faces, the resulting panel portions will have channels with cross section corresponding to the edge channels along the external edges of the panel.

[0022] The first and/or second face of the panel may include a recess adjacent a peripheral edge thereof. For example, a recess of a few millimetres depth into the panel face may be provided long a peripheral edge portion of the respective first or second face such that a corresponding adjacent panel with a similar recess creates a recessed region for a connecting plate. The recess may preferably be between 20 and 50mm wide and between 2mm and 5mm depth. Preferably the recess is between 35 and 40mm wide and between 2.0mm to 5mm deep, and more preferably 37mm wide and 2.0mm deep. [0023] Thus, the connecting plate can cover the join between two adjacent panels and, with the connecting plate a matching thickness to the depth of the adjacent recesses, may create a continuous facing surface across the two adjacent panels.

[0024] At corners, the external facing surfaces of two panels meeting at an angle to one another may have the recesses adjoining such that a corner connecting member creates a continuous exterior surface at the corner.

[0025] The recess may be provided on a face of the panel(s) on an interior of the room/building. Thus, a continuous surface can also be created on the inside of the room/building.

[0026] Internal connecting plates (internal of the panel between the core and facing sheet) may be joined though the thickness of the core.

[0027] A said panel may include one or multiple apertures through the core material from one end edge to the opposite end edge. Thus, one panel can either be cut down along one or both of the apertures to create panel portions, or the single large panel can be used to span a wide wall space. For example, a single panel may be 2400mm, 2700mm or 3000mm high, and 1200mm wide, each with a respective aperture centre at 400mm centres on the end faces and inboard from a respective longitudinal side edge.

[0028] The panel may have a sandwich construction, with a core of a thermal insulation material and external first and second faces formed of sheet material. The insulation material may be a foam material, preferably expanded polystyrene. The panel face material may be of gypsum and/or cement based material.

[0029] The sheet facing material may be bonded to the core by adhesive. The sheet facing material may extend over the peripheral recess around the edges of the face of each sheet of core material. Thus, joiners between adjacent sheets set into the recess across adjoining sheets may be hidden behind the facing sheet material which creates a continuous external surface.

[0030] Multiple building panels may be used to form a doorway or window opening. For example, two of the panels may be provided spaced apart to create a door or window opening width, and one or more similar panels provided extending over the top of the opening to create the doorway or window opening.

[0031 ] The building system according to a further aspect of the present invention may include multiple building panels. The system may include connection means connecting a top plate to a floor structure or floor plate. For example, the aperture channel extending vertically between adjacent panels may have a rod inserted therein, the rod connected to a top fixing and lower fixing. The rod ties the top plate to the floor, which can preferably assist in cyclone proofing the building, especially the roof by assisting in tying the roof through to the floor..

[0032] The floor may include a surround around a concrete base. The surround may be of plastic or metal material. Plastic is beneficial because it is non-corrosive. The surround is known as a perimeter channel and it provides form work for the pouring of the concrete floor (slab). Once the concrete is set, the perimeter channel may not be removable from the concrete floor.

[0033] At 600mm centres, holes are provided in the floor to insert 45 degree 200mm crank bolts which in turn are engulfed by the concrete as it is poured. When the concrete is set, these bolts anchor a coupler bolt and tie down rod at each point around the floor. Thus, the roof is tied to the floor via the tie down rods passing through the panels and bolted into the concrete floor.

[0034] The metal or plastic perimeter channel may include a respective steel or plastic beam structure creating a floor perimeter arrangement. The rod(s) may connect to the beam structure, though preferably are fixed into the concrete floor via anchor bolts set into the concrete.

[0035] When the perimeter channel arrangement is used, a rubber or rubberised seal may be provided between the perimeter channel and the bottom plate. If no perimeter channel is used, the rubber or rubberised seal may be provided between the concrete floor and bottom plate.

[0036] Chemical anchors may be provided in the concrete floor wherever a connection to one of the rods is required. This is preferably either every 600mm or 1200mm into the concrete to hold the tie down rods.

BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Embodiments of the present invention will hereinafter be described with reference to the accompanying drawings, in which:

[0038] Figures 1 a and 1 b show a building panel according to an embodiment of the present invention.

[0039] Figures 2a and 2b show a building panel according to an embodiment of the present invention.

[0040] Figures 3a and 3b show a building panel according to an embodiment of the present invention.

[0041 ] Figures 4a and 4b show a building panel according to an embodiment of the present invention.

[0042] Figures 5a and 5b show a building panel according to an embodiment of the present invention. [0043] Figures 6a and 6b show a building panel according to an embodiment of the present invention.

[0044] Figures 7a and 7b show a building panel according to an embodiment of the present invention.

[0045] Figures 8a and 8b show a kitchen building panel according to an embodiment of the present invention.

[0046] Figure 9 shows a building panel arrangement for a doorway according to an embodiment of the present invention.

[0047] Figures 10 and 1 1 show installation arrangements for a building system incorporating panels according to an embodiment of the present invention.

[0048] Figure 12 shows a corner arrangement with two mitre edge panels forming an aperture channel therebetween and having a strengthener plate over the external corner edge.

[0049] Figure 13 shows an end on view of a panel according to an embodiment of the present invention including a longitudinal recess to receive a lintel, such as over a window, door or garage opening.

[0050] Figures 14 to 16 show top/bottom end views of a panel according to alternative embodiments of the present invention.

DESCRIPTION OF PREFERRED EMBODIMENT

[0051 ] Figures 1 a through 8b show alternative building panels according to embodiments of the present invention. [0052] Figures 1 a and 1 b show a building panel 10 with first 12 and second 14 facing sheets of a compressed, solid cement based material. Other materials, such as a gypsum based material, can be used. The core 16 is of expanded polystyrene. The facing sheets are bonded to the core using an adhesive.

[0053] Figures 1 a and 1 b show the recess 26 formed in the core material such that, when the facing sheets are applied, a narrow channel is created. This channel can hide a connecting panel/plate between adjacent panels.

[0054] A slot 18,20 is provided on the opposed side edges of the panel 10. When these slots abut to corresponding slots on adjacent panels, a channel is formed to receive a support member, such as a steel rod extending the length of the panels. Such a support member can be tied to a floor and a top plate to add structural strength and rigidity to a building system incorporating the panels.

[0055] Figures 2a and 2b show a central channel 22 extending through the interior length of the panel from a top edge 30 to a bottom edge 32. This central channel 22 can also receive a support member as used in the abutted edge slots.

[0056] The edge recess 26 can extend along a central portion 28 of the panel. This is preferably twice the width of the edge recess 26. Thus, when the panel is cut in half, the double width recess forms two recesses of the same width as the edge recesses 26.

[0057] Also, when the panel is cut through along the a central axis, the cut passes centrally through the rectilinear channel 22 to form two slots equivalent to the edge slots 18,20.

[0058] It will be appreciated that the central channel can be of any desired cross sectional shape, though regular shapes are preferred. For example, circular, square or diamond shapes. [0059] Figures 3a and 3b show an alternative embodiment of a building panel of the present invention, with a diamond shaped central channel 24. In such an embodiment, when the panel is cut through at a 45° angle (lines A-A or B-B) with respect to the plane of the building panel, a mitred edge face is formed with a square U cross section slot is formed in each half. Thus, the two panel halves can be used for a mitred 90° corner. With the central recess sufficiently wide, new edge recesses are formed.

[0060] Figures 4a and 4b show an alternative form of the building panel 10 of the present invention. This is a wider panel with two aperture channels 22a,22b running through the core offset from the centreline C-C. However, the concept of being able to cut the full panel down through the channels 22a,22b to form narrower panel sizes and still retain the edge slot feature. Likewise the central recess 28 in figure 3b becomes a pair of offset recesses 28a,28b in this panel. Other iterations using this same concept are envisaged to fall within the scope of the present invention.

[0061 ] Figures 5a and 5b show a building panel 10 with facing sheets 12 and 14 and core 16 as described previously. The central aperture channel 24 is diamond in cross section and extends through the length of the core between the top 30 and bottom 32 end faces.

[0062] When cut diagonally e.g. at 45° to normal to the facing sheets, a pair of mitred sub-panels 10a, 10b are formed. These have the square U shaped slot running along the newly formed side edge of each sub-panel.

[0063] In the alternative, Figures 6a and 6b show a preformed mitred edge panel that does not need cutting to form the mitre. Such a panel can be supplied to site preformed from the factory to meet a planned design rather than needing cutting onsite. It will be appreciated that such a panel can be formed from a larger panel as in Figures 5a,5b, but in the factory to save material. [0064] Figures 7a and 7b show a building panel 10 of the present invention with mitred edges 40, 42 along each side edge. Thus, such a panel can be preformed in the factory and transported to site without the need for cutting onsite.

[0065] The panel in Figures 8a and 8b is designed for kitchens and/or bathrooms, whereby kitchen cabinets or bathroom cabinets respectively can be mounted to the panel. A steel plate 44 can be retained in the recess 46 between the core material 16 and facing sheet 12,14. Thus, cabinets, which are relatively heavy (especially when loaded with items) is supported by fastenings through the panel into the steel plate. Preferably the steel plate is galvanised.

[0066] Figure 9 shows a doorway construction using three panels of the present invention. The doorway has two upright panels 10a, 10b and a header panel 10c extending over them. Window openings can be formed the same way.

[0067] Figure 10 shows a building system arrangement 60 with a square U channel section floor plate 62 bolted to a steel floor beam 64 that surrounds a concrete floor 66. The channel forms a bottom plate and is bolted into the concrete floor using a bolt system 68The upright portions 70 of the bottom channel slot into the recesses 26 behind the facing sheets 12, 14 of the panel 10 to create a smooth continuous surface with hidden connections.

[0068] A tie rod 72 passes through the aperture channel 74 through the panel. The tie rod is fastened to a fixing plate 76 via a fastening nut 78 to attach the tie rod to the top plate 80. The fixing plate also attaches to a roof beam 86. The top plate has elongate side portions similar to the bottom plate portions 70, but these do not need to be concealed in the recesses 26 because they are either hidden behind cornice 82 or are at facia board level externally.

[0069] In an alternative embodiment shown in Figure 1 1 , the building panel 10slots into a top channel 80 and bottom channel 62. The bottom channel is fastened directly into the concrete floor 66. The top channel is fixed directly to the ceiling beam 90.

[0070] Figure 12 shows a mitred corner using two mitred corner panels

10d,1 Oe forming a corner aperture channel 50 for a tie rod strengthener member and having a corner strengthener 48 within the recess 26.

[0071 ] Figures 13 to 16 show alternative forms of panels according to embodiments of the present invention.

[0072] Figure 13 shows a lintel panel 100. The panel 100 includes sheet facings 12 and 14 similar to the embodiments described above. One longitudinal side edge 102 includes a full length recess or channel 104 to receive and cover a lintel (not shown). The recess or channel has a depth E into the panel of preferably 200mm and a width F preferably of 100mm, though other dimensions fall within the scope of the present invention to suit the particular application of the panel. It will be appreciated that the lintel recess arrangement can have a recess of larger dimensions, such as 190mm wide by 90mm deep, or other dimensions to suit a required application. The lintel recess can be within the core bounded on three sides by core material, or can be exposed to the end edge and to one side i.e. bounded by core material on only two sides.

[0073] Figure 14 shows a top/bottom end/edge view of an alternative an embodiment of the panel 200. The panel 200 has an enlarged recess/channel 202 in one side edge. The recess/channel is preferably of 90mm depth G and 90mm width H, though it will be appreciated that other depths and widths can be accommodated depending on the required application.

[0074] The extra width and depth compared with the recess/channel 18,20 previously described allows the panel edge to accommodate larger structural supports, such as 90/90mm steel or timber posts, or allow room for smaller dimensioned posts and electrical and/or plumbing utilities. [0075] Inset from the edge recess 18,20 is at least one passage passing through the core 16 form the top edge to the bottom edge. Preferably this passage is oval in cross-section, though other shapes are permitted. In a preferred form, the cross section is an oval of around 50mm length by 30mm width.

[0076] The passage can accommodate electrical and plumbing utilities. In a preferred arrangement, the passage is inset from the edge of the panel by 150mm, which passage can therefore be utilised close to the edge of the panel, for connection of electric light switches to the electrical cable positioned close to the edge of walls and doors etc., but inset sufficiently from the panel edge to allow for door frames and wall corners and still allow for panel strength at the panel edge.

[0077] Figure 15 shows a version of the panel 200 with two of the larger edge recesses 202, one recess/channel 202a,202b at each opposed edge.

[0078] Figure 16 shows a further preferred embodiment of the panel 200 with oval utility passageways 204 through the core as described in relation to figure 14. These are preferably inset with their respective centres 150mm from the edge of the panel, as indicated at J in Figure 16. These allow the passages to be predictably found for running utilities after the panel system has been erected. A central channel 206 passes through the centre of the core 16.

[0079] Preferably each oval passageway has dimensions 50mm (K) by 30mm (L) as shown in Figure 16, though other dimensions can be selected within the core of the panel as required for a particular application.

It will be appreciated that the oval cross section passageways can be square in cross section or diamond or other regular polygon to suit an application of the panels.