AU2016100196A4 - A bracket assembly - Google Patents

Abstract

A bracket assembly is provided for joining a pair of panels, the bracket assembly comprising an elongate inner 5 member; and an elongate outer member. In use, the members can come together to form channels, each channel being for receiving one of the pair of panels respectively. The members can be connectable to one another by a fastener system which is adapted to allow the spacing in the 10 channels to be adjusted as required. 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16 CYa) -1~ Q00 r-14

Description

- 1 A BRACKET ASSEMBLY FIELD OF THE INVENTION The present invention is directed to device for 5 joining panels. In some embodiments, the panels to be joined are arranged to form corners. BACKGROUND Materials have been developed that allow for the 10 formation of panels for the use in the construction of articles that require inherent strength. These articles include for examples, floors in buildings or vehicles, walls in buildings and/or doors or access points in structures, buildings or vehicles. The panels can comprise 15 internal structured articles that give the panel strength. One type of panel which can be used to form structures comprises a honeycomb composite structure, the manufacture of which is described in PCT/AU2013/001353 entitled Method and Apparatus of Composite Articles. Other panels that can 20 be used to form structures are made from e.g. aluminium. Buildings can have one or more panels arranged so as to form walls and even sometimes ceilings and floors. When the panels form walls sometimes smaller panels are connected to one another to form a desired size of wall 25 structure. For example one wall may be comprised of multiple panels. Where the corners of a structure are required the panels must be joined to one another in a strong and robust way so as to form the corner. Known ways of joining panels at corners include 30 right-angled aluminium fixed sections which accommodate the panels into recesses in order to hold them firmly in place. Typically the metal fixed section is secured as a frame and the panel is slotted in by the builder. In order to retain the panel in the joiner, glue can be added 35 to hold it firmly. It is desirable to provide improved means of joining panels. 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16 - 2 SUMMARY OF THE INVENTION According to a first aspect of the invention there is provided a bracket assembly for joining a pair of panels, 5 the bracket assembly comprising an elongate inner member and an elongate outer member which, in use, come together form channels each channel being for receiving one of the pair of panels respectively, wherein the members are connectable to one another by a fastener system which is 10 adapted to allow the spacing in the channels to be adjusted as required. In one embodiment of the invention there is provided a corner bracket assembly for joining a pair of panels at a corner, the corner bracket assembly comprising an 15 elongate inner right-angled member and an elongate outer right-angled member which, in use, together form channels each channel being for receiving one of the pair of panels respectively, wherein the right-angled members are connectable to one another by a fastener system which is 20 adapted to allow the spacing in the channels to be adjusted as required. An advantage of the bracket assembly is that it can accommodate panels of different thicknesses because the spacing in the channels is determined by the thicknesses 25 of the panels themselves rather than by the inherent bracket dimensions. The elongate inner member and the elongate outer member are designed to be used together. The inner and outer members can be referred to as first and second 30 sections respectively. By "inner" it is meant that the member is on a first side of the pair of panels which may form the inner side of a room or chamber. By "outer" it is meant that the member is on a second side of the pair of panels which may form the outer side of a room or chamber. 35 The inner side (or first side) is opposite to the outer side (or second side). The elongate inner member can be of any length. The 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16 - 3 elongate inner member can be made or cut to the desired length which may correspond to the longitudinal length of a panel or panels which it will receive. The elongate inner member is formed by two walls (a first wall and a 5 second wall) disposed relative to one another. The first and second walls can be integral. The length of the first wall can be any length that allows a wall of a channel to be formed. The length of the second wall can be any length that allows a wall of a channel to be formed. The first 10 and second walls can have different lengths. The length of the first and/or second walls can be at most 30, 50, 70, 100 mm. The elongate inner member can be made of a rigid material. By rigid it is meant that it can hold its shape and form a template. The rigid material can be deformable 15 under pressure. In an embodiment the rigid material is a metal. In an embodiment the metal is an aluminium or steel. The thickness of the walls can be at most 0.2, 0.4, 0.6 mm. Likewise, the elongate outer member can be of any 20 length. The elongate outer member can be made or cut to the desired length which may correspond to the longitudinal length of a panel or panels which it will receive. The elongate inner member is formed by two walls (a third wall and a fourth wall) disposed relative to one 25 another. The third and fourth walls can be integral. The length of the third wall can be any length that allows a wall of a channel to be formed. The channel is formed between the first wall of the elongate inner member and the third wall of the elongate outer member. The length of 30 the fourth wall can be any length that allows a wall of a channel to be formed. The channel is formed between the second wall of the elongate inner member and the fourth wall of the elongate outer member. The third and fourth walls can have different lengths. The length of the third 35 and/or fourth walls can be at most 30, 50, 70, 100 mm. Optionally, the walls forming the channels are co terminal. The elongate inner member can be made of a rigid 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16 - 4 material. The material can be the same or different to the material of the elongate outer member. By rigid it is meant that it can hold its shape and form a template. The rigid material can be deformable under pressure. In an 5 embodiment the rigid material is a metal. In an embodiment the metal is an aluminium or steel. The thickness of the walls can be at most 2, 4, 6 mm. As described above, the inner and outer elongate members are adapted to be brought together form channels 10 between them. There are two channels formed by the members, each for receiving a separate panel. Each channel has an axis of elongation which extends through its midline. The axis of elongation is substantially co-planar with the walls of at least one of the elongate members. It 15 should be understood that the walls of the elongate members can be flexible and bend slightly to deviate from their intended plane. The axis of elongation is the angle of the channel. The channels can be oriented at any angle relative to one another. In one embodiment, the angle 20 between the channels is 180 degrees, which results in the panels being joined at 180 degrees with respect to one another. In this embodiment, the panels are therefore in line with one another so that they are co-planar and form a flat wall. The angle formed between the channels can be 25 between 45 to 180 degrees. Smaller angles are not excluded, but are functionally difficult to prepare depending upon the thickness of the panels to be joined. In one embodiment, the angle between the channels is substantially 90 degrees. Slight deviations from 90 30 degrees can be tolerated. The channels formed between the elongate members are typically of the same width to accommodate panels of the same thickness. If the panels to be joined have different thicknesses, then one of the walls of the elongate members 35 may be stepped so as to allow for a wider channel on one side. The panel can be slotted into the channels by the 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16 - 5 builder. The channels can be tightened to be a snug fit around the panels. Each elongate member can be pushed into position thereby taking up the shape of the panels, possibly as the panels sit at right angles to one another. 5 In some embodiments it is preferred that the walls of the elongate members are held rigidly at e.g. 90 degrees from one another in order that the bracket itself can act as a template for panels which are to be joined to it. Each panel can be attached to the walls of the inner 10 member and/or outer member once in position in the respective channels. The attachment of each panel to the wall(s) of each member can be by an adhesive. The adhesive can be glue. The glue can be applied to the inside surfaces of the or each wall of the inner and/or outer 15 members. The glue can be applied to the outside surface(s) of the panels. The glue can be applied as beading prior to insertion of the panels into the channels. The glue can take up to 20 minutes to cure. The glue can be applied so as to result in up to 40 or 50 mm in thickness. 20 The inside surfaces of the walls of the inner member and the outer member can be flat. The walls can be roughened or smooth. Alternatively, the inside surfaces of the walls of the inner member and the outer member can comprise one or more protrusions which can space the panel 25 from the wall. The protrusions can be discreet or elongate. The protrusions can be a series of dimples or a any other protruded shape including straight, circular, zig-zag. The protrusions can be at most 1, 2, 3, 4, 5 mm from the surface of the member. The protrusions can define 30 flat space between. Any number of protrusions can be provided to buffer the wall from the surface of the member. In one embodiment, the protrusions are provided on the panels themselves to achieve the same effect. The space formed between the elongate member and the panel can 35 accommodate excess adhesive. Excess adhesive can also be squeezed into the space where the fastener system is located. The protrusions can grip the panel as the 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16 - 6 fastener system is tightened and cause each panel to be held by frictional forces. The elongate inner member and the elongate outer member are connectable to one another by a fastener 5 system. By connectable, it is meant that they can be joined to each other and cannot be moved apart except upon the application of force. The connection allows the spacing in the channels which form to be adjusted as required. The "as required" is in relation to the 10 thickness of the panels which will be received in the channels. A thicker panel will require a larger spacing, while a thinner panel will require a thinner spacing. The channel size can be changed to substantially match the panel thickness. The panels can be at most 10, 20, 30, 40, 15 50, 60, 70, 80, 90 or 100 mm in thickness. The panels can be gripped between the elongate members. The fastener system can comprise a series of fastening elements. The fastening elements can be screws (or bolts) and nuts which pass through the elongate 20 members. Whilst bolts and nuts are described it should be understood that mechanical equivalents are within the scope and spirit of the invention. When the elongate members are brought together to form the channels, holes in the fastener system can align to allow for the passage 25 of bolts. The fastener system can be located between the channels where there is space in the device to accommodate the bolts. There can be a number of bolts joining the elongate members. The number of bolts will depend on the length of the members and the required resultant 30 structural integrity of the join. In one embodiment the bolts are positioned at least about 100, 200, 250, 300, 400, 500, 600 or 700 mm apart from one another. In some embodiments, there are only a couple of bolts, with the main adhering effected by the adhesive applied to the 35 panels and members. All or some of the bolts can be inserted into a hole in the elongate inner member and a nut can be applied to 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16 - 7 the end of each bolt as it protrudes from the elongate outer member. Alternatively, all or some of the bolts can be inserted into a hole in the elongate outer member and a nut can be applied to the end of each bolt as it protrudes 5 from the elongate inner member. It can be desirable to hide the bolt heads from view in the finished product. In some embodiments a cover can be provided which can be placed over the bolt heads in the finished product. The cover can be one large piece 10 covering all the bolt heads. The cover can be small pieces which cover individual bolt heads. In an embodiment, the bolt heads can be disposed within the bracket assembly itself, so they are not exposed to the outside surface. In this embodiment, a passageway or space can be formed in 15 the elongate inner member or the elongate outer member and the bolt can be received into the passageway so that the head is captured by the screw-threaded body extends outwardly. The bolt can slide down the passageway until it meets a location at which the mating of the other of the 20 elongate members is possible. In this embodiment, the specific positioning of the bolt requires some pre determination because there are not apertures and instead a single passageway in which the bolt can stop at any position. In order to control the location of each bolt 25 there can be marks on the passageway. The bolts can be held in place by a spring washer which secures it to the elongate member at a predetermined position. In order to control the location of each bolt, a number of bolts could be spaced from one another. The spacing of the bolts could 30 be by locating them on a ribbon or tape at predetermined intervals. When the other of the elongate members is brought together with the elongate member housing the bolts, the bolt bodies should line up with holes in that member and nuts can be applied to each bolt to hold it 35 into position. The head of the bolt can be shaped so that it cannot rotate once in position. This makes it easier for the nut 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16 - 8 to be applied to the bolt in position. The head of the bolt can be square-shaped so it cannot rotate within a passageway in which it is located. It can be desirable to hide from view the nuts 5 applied to the bolts in the finished product. In some embodiments a cover can be provided which can be placed over the nuts in the finished product. The cover can be one large piece covering all the nuts. The cover can be small pieces which cover individual nuts. The nuts can be 10 received into a recess in the bracket assembly. The recess can be adapted to be covered by the cover. A joining system according to the present invention can be used between every panel and/or at every corner of adjoining panels. 15 The joining system can be supplied partially preassembled with the elongate members loosely held together by the nuts and bolts. The bolts can then be provided at their pre-determined locations. In order to use the joining system the panels can be inserted and the 20 nuts tightened onto the bolts to grip the pieces together. According to another aspect of the invention there is provided a method of joining a pair of panels, the method comprising the steps of: arranging the panels relative to one another; 25 positioning an elongate outer member so that it can be disposed along the outside surfaces of the panels; positioning an elongate inner member so that it can be disposed along the inside surfaces of the panels; connecting the elongate outer member to the elongate 30 inner member using a fastener system; wherein the panels are gripped in channels formed between the members. These steps can be performed in any order. According to another aspect of the invention there is 35 provided a method of joining a pair of panels at a corner, the method comprising the steps of: arranging the panels relative to one another; 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16 - 9 positioning an elongate inner right-angled member so that it can be disposed along the inside surfaces of the panels; positioning an elongate outer right-angled member so 5 that it can be disposed along the outside surfaces of the panels; connecting the right-angled member to one another using a fastener system, wherein the panels are gripped in channels formed between the members. 10 These steps can be performed in any order. The step of positioning the elongate outer member so that it can be disposed along the outside surface of the panels can include allowing the panels to lay against the walls of the member without attachment. The step of 15 positioning the elongate inner member so that it can be disposed along the inside surface of the panels can include allowing the panels to lay against the walls of the member without attachment. In one embodiment, the elongate members (right angled 20 or otherwise) are not arranged around the panels, and instead are loosely connected to one another first so as to form channels into which the panels can then be received. In this embodiment, the elongate members are positioned so that they can be disposed along the surfaces 25 of the panels. In order to fasten the members to one another the method can include the step of passing bolts through complementary holes provided in the members. The bolts can be held in position on one of the elongate members. The 30 method can further include the step of applying a nut to the end of each bolt. Optionally, the method can include a step of covering the fasteners. The covering can be of the fastener heads or the nuts. The step of connecting the elongate members can be 35 undertaken before or after the panels are inserted into the channels. If the connection is done around the panels, the channels can be formed tightly around the panels. If 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16 - 10 the connection is done before it may occur in two stages; the first stage being a loose connection so that the panels can slide into the channels and then a second stage where the fasteners are tightened. 5 The method can further include the step of applying an adhesive to adhere the panels in the channels. The step of applying adhesive can include applying to the elongate inner and/or outer members and/or to the surfaces of the panels themselves. The adhesive can be as described above 10 in relation to other embodiments of the invention. The glue can be applied before or after insertion of the panels into the channels. The glue can be applied from the top of the system and allowed to seep downwards. 15 BRIEF DESCRIPION OF THE FIGURES The present bracket assembly will now be described by way of non-limiting example only, with reference to the accompanying drawings, in which: Figure 1 shows an embodiment of an elongate outer 20 right-angled member; Figure 2 shows an embodiment of an elongate outer member; Figure 3 shows an elongate right-angled inner member and an elongate right-angled outer member arranged 25 relative to one another; Figure 4 shows an elongate inner member and an elongate outer member arranged relative to one another; Figure 5 shows an elongate right-angled inner member connected to an elongate right-angled outer member with 30 panels in the channels formed; Figure 6 is a close-up view of the nut being applied to a bolt; Figure 7 shows an elongate inner member connected to an elongate outer member with panels in the channels 35 formed. 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16 - 11 DESCRPTION OF EMBODIMENTS OF THE INVENTION Embodiments of the assembly are shown in the following drawings which are not drawn to scale and are for the purposes of illustration only. 5 In Figure 1, an elongate right-angled outer member 10 is shown in perspective view and as a top view. From the top view, it is possible to see the cross-sectional features of the member 10. The first wall 12 and second wall 14 are shown at right-angles to one another. The ends 10 of each wall 12 and 14 are shown as slightly bevelled for gripping. Each wall 12 and 14 has a number of elongate protrusions 16 which can be seen in the perspective view as dotted lines. First and second walls 12 and 14 are integral with 15 one another. Disposed between them is a part of fastener system 18. In this embodiment, the fastener system includes an elongate space defined by two flanges 20 which run the length of the member 10 and define a space 22 into which a bolt head can be passed. The bolt in place is 20 shown in Figure 5. The bolt head is hidden from view by the outside surface 24 of the bracket assembly. The bolts 26 themselves are shown mounted on the other part of the fastener system 28. Each bolt 26 is mounted on tape or ribbon 30 which is designed to thread through space 22. 25 Once mounted, each bolt takes up a pre-determined position. The distance between the bolts can be equidistant or any distance as desired. In Figure 1, the walls 12 and 14 are shown at right angles to one another. Figure 2 is an alternative 30 embodiment in which the elongate outer member 110 has a continuous substantially straight assembly with the walls 112 and 114 disposed at substantial 180 degrees from one another. There is shown one elongate protrusion 116 per wall. In perspective view this can be seen running the 35 entire length of the member 110. It should be understood that the protrusion can be of any shape and can run over only a part of the wall surface. 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16 - 12 The elongate outer member 110 has a elongate space 122 defined by flanges 120. This elongate space can accommodate bolts (not shown). In figure 3, the elongate right-angled outer member 5 10 is shown relative to elongate right-angled inner member 210. The elongate right-angled inner member 210 comprises two walls 212 and 214 which are complementary to walls 12 and 14. The two members together define channels 232 and 234. The channels are at 90 degrees to one another. The 10 channels are each for accommodating a panel. The elongate right-angled inner member 210 comprises a elongate space 236 which includes a number of holes 238. In the embodiment shown in Figure 3 there are shown 5 holes disposed equidistant from one another. Each hole 238 15 is adapted to receive the body of a bolt 226. The bolt bodies 226' protrude through holes 238 and a nut can be applied (not shown). The nut is accommodated in elongate space 236. In order to shield the nuts from view, a cover can be mounted in recess 240. 20 In Figure 4, the arrangement as described in relation to Figure 3 is shown, except now the channels are disposed at 180 degrees relative to one another. The elongate inner member 310 is shown relative to the elongate outer member 110. The channels 332 and 334 are shown as defined by the 25 respective wall portions. In this embodiment, there are three bolts 326 ready to be passed into elongate space 122 in order that the bolt bodies can be aligned with holes 338. Once in place, the bolts will each have nuts applied (not shown). The nuts will be accommodated in space 336. A 30 cover can be placed in recess 340. In Figure 5, the corner bracket assembly 400 is shown in perspective view and in cross-sectional view. Bolt 426 is shown in place in elongate space 422. Nut 442 is shown screwed onto bolt 426 and is disposed in elongate space 35 436. Cover 444 has been slid into the recess defined by flanges 440. In perspective view all that can be seen is cover 444 (bolt and nut is shielded from view). Panel 446 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16 - 13 and panel 448 are each shown disposed in bracket 400. The ends of panels 446 and 448 are shown as flat ends perpendicular to the side walls) however, the ends could be cut to extend into the space preceding bolt 426 as 5 shown by the example dotted line. The panels could be 2.4 m x 1.2 m aluminium panels of about 30 mm thickness. Protrusions 416 are shown engaging each panel. The engagement can be simply touching or spacing or digging in. The protrusions provide space for a glue. The panels 10 can be further held into position using an adhesive such as PVC glue (not shown). The available space in the bracket into which excess adhesive can flow should be clear from the cross-sectional schematic. In Figure 6, the squared head 427 of bolt 426 can be 15 seen. The squared head 427 means that bolt 426 is prevented from spinning in space 422. This means that as nut 442 is brought into place in socket 443 the tool can be used to readily apply the nut and then removed. In Figure 7, panel 546 and panel 548 are shown 20 disposed in the channels formed between inner member 510 and outer member 510'. Bolts 526 extends from the outer member 510 through a hole in inner member 510'. A nut 542 has been applied to hold the bolt into position. A cover 544 has been applied to shield the nut and bolt from view. 25 In some embodiments, the cover can be bevelled to accommodate a longer bolt body. When the cover 544 is bevelled it is held in place by recess 540. In order to form assembly 500, the panels 546 and/or 548 could be rested against outer member 510. Bolts 536 30 can then be passed down elongate space 522. Member 510' can then be brought into close proximity with member 510 in order that holes 538 align with bolt bodies 536. As the holes align the inner member 510' can be pressed against the panels 546 and 548. The two members 510 and 510' are 35 then connected to one another by applying the nuts 542 to the bolts thereby wedging the panels between the members 510 and 510'. Optionally, glue can be applied before the 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16 - 14 members are joined. In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary 5 implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention. 10 It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country. 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16

Claims (14)

1. A bracket assembly for joining a pair of panels, the bracket assembly comprising: 5 an elongate inner member; and an elongate outer member which, in use, come together to form channels each channel being for receiving one of the pair of panels respectively, 10 wherein the members are connectable to one another by a fastener system which is adapted to allow the spacing in the channels to be adjusted as required. 15

2. The bracket assembly of claim 1, wherein elongate inner member is an elongate inner right-angled member and the elongate outer member is an elongate outer right-angled member and wherein the right-angled members are connectable to one another by the 20 fastener system to join panels at a corner.

3. The bracket assembly of claim 1 or 2, wherein the walls of the elongate inner member and/or the walls of the elongate outer member each comprise at least 25 one protrusion for contact with the panels.

4. The bracket assembly according to any one of the preceding claims, wherein the fastener system comprises a plurality of nuts and bolts. 30

5. The bracket assembly according to claim 4, wherein the elongate outer member comprises an elongate space which houses heads of the bolts. 35

6. The bracket assembly according to claim 5, wherein the bolts are spaced from one another by suspension on a tape or ribbon. 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16 - 16

7. A method of joining a pair of panels, the method comprising the steps of: arranging the panels relative to one another; positioning an elongate outer member so that it 5 can be disposed along the outside surfaces of the panels; positioning an elongate inner member so that it can be disposed along the inside surfaces of the panels; 10 connecting the elongate outer member to the elongate inner member using a fastener system; wherein the panels are gripped in channels formed between the members. 15

8. The method according to claim 7, wherein the steps of positioning and connecting the elongate inner and outer members comprises providing the elongate inner and outer members loosely pre connected; and 20 the step of arranging the panels comprises inserting the panels into channels formed between the elongate inner and outer members.

9. The method according to claim 7 or 8, wherein the 25 method further comprises the step of tightening the elongate inner and outer members around the pair of panels.

10. The method according to any one of claims 7 to 9, 30 wherein the method further comprises the step of applying adhesive to the surface(s) of the elongate inner and/or outer members and/or the panels.

11. The method according to claim 10, wherein the 35 adhesive is a glue applied before the step of tightening the elongate inner and outer members around the pair of panels. 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16 - 17

12. A bracket assembly system for joining a pair of panels, the bracket assembly system comprising: an elongate inner member joined to an elongate outer member by a fastener system so as together to 5 form channels each for receiving one of the pair of panels respectively, the fastener system comprising a series of fastening elements wherein each fastening element passes through the elongate inner member and through 10 the elongate outer member to join the members together.

13. A structure comprising panels when joined by the method according to any one of claims 7 to 11. 15

14. A structure comprising panels joined by the bracket assembly of any one of claim 1 to 6. 74495181 (GHMatters) P99371.AU.1 DENISET 23/02/16