IE20170074A1 - A building component - Google Patents

A building component Download PDF

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Publication number
IE20170074A1
IE20170074A1 IE20170074A IE20170074A IE20170074A1 IE 20170074 A1 IE20170074 A1 IE 20170074A1 IE 20170074 A IE20170074 A IE 20170074A IE 20170074 A IE20170074 A IE 20170074A IE 20170074 A1 IE20170074 A1 IE 20170074A1
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IE
Ireland
Prior art keywords
building component
structural support
component
building
outer covering
Prior art date
Application number
IE20170074A
Original Assignee
Ig Elements Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ig Elements Ltd filed Critical Ig Elements Ltd
Publication of IE20170074A1 publication Critical patent/IE20170074A1/en

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F17/00—Vertical ducts; Channels, e.g. for drainage
    • E04F17/02—Vertical ducts; Channels, e.g. for drainage for carrying away waste gases, e.g. flue gases; Building elements specially designed therefor, e.g. shaped bricks or sets thereof
    • E04F17/026—Exterior cladding, e.g. of chimney parts extending above the roof; Rain covers for chimney tops without draught-inducing aspects
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B7/00—Roofs; Roof construction with regard to insulation
    • E04B7/18—Special structures in or on roofs, e.g. dormer windows
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/10—Forming by pressure difference, e.g. vacuum
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
    • E04D13/14—Junctions of roof sheathings to chimneys or other parts extending above the roof
    • E04D13/147—Junctions of roof sheathings to chimneys or other parts extending above the roof specially adapted for inclined roofs
    • E04D13/1473—Junctions of roof sheathings to chimneys or other parts extending above the roof specially adapted for inclined roofs specially adapted to the cross-section of the parts extending above the roof
    • E04D13/1475—Junctions of roof sheathings to chimneys or other parts extending above the roof specially adapted for inclined roofs specially adapted to the cross-section of the parts extending above the roof wherein the parts extending above the roof have a generally rectangular cross-section
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
    • E04D13/15—Trimming strips; Edge strips; Fascias; Expansion joints for roofs
    • E04D13/158—Trimming strips; Edge strips; Fascias; Expansion joints for roofs covering the overhang at the eave side, e.g. soffits, or the verge of saddle roofs
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F17/00—Vertical ducts; Channels, e.g. for drainage
    • E04F17/02—Vertical ducts; Channels, e.g. for drainage for carrying away waste gases, e.g. flue gases; Building elements specially designed therefor, e.g. shaped bricks or sets thereof
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00—Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/04—Frames for doors, windows, or the like to be fixed in openings
    • E06B1/32—Frames composed of parts made of different materials
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00—Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/04—Frames for doors, windows, or the like to be fixed in openings
    • E06B1/34—Coverings, e.g. protecting against weather, for decorative purposes
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00—Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/04—Frames for doors, windows, or the like to be fixed in openings
    • E06B1/36—Frames uniquely adapted for windows
    • E06B1/363—Bay windows
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00—Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/04—Frames for doors, windows, or the like to be fixed in openings
    • E06B1/52—Frames specially adapted for doors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/10—Building elements, e.g. bricks, blocks, tiles, panels, posts, beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/10—Building elements, e.g. bricks, blocks, tiles, panels, posts, beams
    • B29L2031/108—Roofs

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Mechanical Engineering (AREA)
  • Building Environments (AREA)
  • Laminated Bodies (AREA)

Abstract

A building component 1 comprising a structural support framework 2, and outer covering component 3 for covering all or part of the structural support framework 2. the outer covering component 3 comprising a prefabricated a plastic preformed/prefabricated shell 3 providing a rigid covering member 3. <Figure 1>

Description

The present invention relates to a building component and in particular to an architectural building component to be mounted onto a new building wall or roof or to be retrofitted to an existing wall or roof of a building.
GRP building units such as door canopies, dormer units, chimney stacks, bay window roof units as well as door and roof preformed surrounds are well known structures in buildings located on and protruding from the relevant part of the building such as the sloping surface of a building’s pitched roof or around the door window or on top of the bay windows.
They are designed to reduce the amount of manual labour on building sites and to enhance any one of or any combination of the aesthetic appearance of the relevant part of the building, the life expectancy of the components, the weathering capabilities and thermal performance of the buildings. The conventional GRP building unit is typically made up in a mould which requires a release agent to be applied manually to the mold. A gelcoat is then applied manually with a brush roller or sprayed before the layers of fibreglass and resin are layed up on the mold. In the laying up process a layer of fibre glass mat is applied manually and the resin coating is applied with an operative manually rolling the resin to remove air bubbles. The component is then separated from the mold using wedges, compressed air or both.
Generally, a large amount of manual touching up of the outside surface of the molded building unit GRP component requires a large amount of man hours. A lot of the manual labour is highly skilled and so operatives require significant experience and training to gain the required levels of skill to produce high quality end product. As a result of the manual aspect of the manufacturing process a significant amount of wasted GRP and other materials used in the process are also wasted which must be disposed to landfill adding significantly to the overall manufacturing process.
It is an object of the present invention to mitigate the problem of manual labour involved in the manufacture of traditional GRP building units.
Accordingly, the present invention provides a building component for a building, the building component comprising an outer covering means for covering all or part of the building component, the outer covering means comprising a plastic preformed/prefabricated shell providing a rigid covering member.
Ideally, the plastic prefabricated shell is manufactured from a thermoplastic material.
Preferably, the plastic prefabricated shell is manufactured from an amorphous thermoplastic material.
Preferably, the plastic prefabricated shell is manufactured from polystyrene.
Ideally, the plastic prefabricated shell is manufactured from high impact polystyrene sheeting.
Preferably, the plastic prefabricated shell is manufactured from any one of acrylic, acrylonitrile butadiene styrene (ABS), polystyrene, co-polyester, polycarbonate, polypropylene, polyethylene and polyvinylchloride.
Preferably, the building component comprising a structural support framework.
Ideally, the outer rigid covering member is mountable on the structural support framework.
Preferably an insulation layer is disposed on or proximal to the internal surface of the 20 outer rigid covering member.
Ideally, the building component of a building is any one of a dormer component, door canopy, chimney stack, bay window roof component as well as door and roof preformed surrounds.
Ideally, the dormer component comprising a structural support framework for 25 supporting a roof, two lateral walls and a front wall defining an opening for a window.
Preferably, the dormer unit comprising the outer covering means for covering all or part of at least the two lateral walls.
Ideally, the front wall which defines an opening for a window for the building component also comprises the outer covering means for all or part of the front wall.
Ideally the building component is prefabricated prior to on-site installation.
Preferably, the outer covering means of the building component is formed as a single piece.
Ideally, the outer covering means is thermoformed.
Preferably, the outer covering means is vacuum formed.
Advantageously, having an outer covering means formed as a single piece providing at least both lateral walls of the outer covering means of the dormer unit allows a quicker and simpler installation process when on-site beyond that of the conventional prior art. The outer covering means provides a shell like structure to enclose the structural framework of the building component. This requires that the outer covering means is secured onto the structural framework.
Alternatively, the outer covering means of the building component is a modular unit capable of being connectable together.
Preferably, the outer rigid covering member is formed from a sheet.
Preferably, the outer covering means is mechanically coupled to the structural support framework along at least part of its length.
Most preferably, the outer rigid covering member is strapped, clipped, slotted, riveted, bonded, adhesively bonded, adhered, glued or welded to the at least part of the structural support framework or coupled to the at least part of the structural support framework using any combination of these fasteners or fixing methods.
It will be appreciated that this list of coupling means/methods is in no way limiting and the invention covers any form of coupling suitable to provide sufficient rigidity and strength to retain the mechanical joint between the outer covering means and the structural support framework to withstand the range of forces acting on a building component such as a dormer window unit.
Preferably, the outer covering means comprises a reinforcing means.
Ideally, the reinforcing means of the outer covering means is locatable along at least part of the span of the outer covering means.
Most ideally, the reinforcing means of the outer covering means is locatable along all or a substantial part of the span of the outer covering means.
Preferably, the reinforcing means of the outer covering means extends along all or at 10 least part of the height wise span of the outer covering member. In the in-use orientation of the building component the reinforcing means extends from the base of the building component to the roof of the building component.
Most preferably, the reinforcing means of the outer covering means extends along all or part of the lateral span of the outer covering member. In use, this is substantially perpendicular to the height wise span.
Ideally, the reinforcing means of the outer covering means is connectable to the outer rigid covering member.
Preferably, the reinforcing means of the outer covering means is integral to the outer rigid covering member.
Preferably, the insulation means comprises a foam such as a polyisocyanurate foam material or a phenolic foam material.
Most preferably, the insulation means is formed of polyurethane.
Ideally, the insulation means is pumped into the outer rigid covering member.
Alternatively, the insulation means is a foam sheet.
Ideally, the thermal conductivity of the outer covering means is less than 3 W/m2K.
Ideally, the thermal conductivity of the outer covering means is less than 1 W/m2K.
Preferably, the thermal conductivity of the outer covering means is less than 0.5 W/m2K.
Most preferably, the thermal conductivity of the outer covering means is 0.2 W/m2K.
Preferably, the outer rigid covering member has a wall thickness in the range of 1.5mm to 4.5mm.
Ideally, the outer rigid covering member has a wall thickness in the range of 2mm to 4mm.
Most ideally, the outer rigid covering member has a wall thickness of 3mm.
Preferably, the insulation means has a wall thickness in the range of 15mm to 35mm.
Ideally, the insulation means has a wall thickness in the range of 20mm to 30mm.
Most ideally, the insulation means has a wail thickness of 25mm.
Ideally, the structural support framework comprises of a plurality of structural support members.
Preferably, the structural support members of the structural support framework are formed of an orthotropic material.
Ideally, the structural support members of the structural support framework are formed of timber.
Preferably, the structural support members comprise an auxiliary structural support means.
Ideally, the auxiliary structural support means are connectable to the structural support member.
Most ideally, the auxiliary structural support means are integral to the structural 25 support member.
Preferably, the auxiliary structural support means is formed of a channel located within the individual structural support members.
Alternatively, the auxiliary structural support means is formed of a plurality of channels located within the individual structural support members.
Preferably, at least some of the structural support members are hollow.
Accordingly, the present invention provides a method of manufacturing a building component comprising the method of vacuum forming a sheet of plastic material into a prefabricated plastic architectural building component.
Ideally, the method further comprising thermoforming a sheet of plastic material into a 10 prefabricated plastic building component.
Preferably, the method further comprising the steps of manufacturing an external building component.
Ideally, the method further comprising the steps of building a structural support frame work for the prefabricated plastic building component.
Preferably, the method further comprising coupling the structural support frame work and the prefabricated plastic building component together.
Ideally, the method further comprising forming the plastic prefabricated shell from a thermoplastic material.
Preferably, the method further comprising forming the plastic prefabricated shell from 20 an amorphous thermoplastic material.
Preferably, the method further comprising forming the plastic prefabricated shell from polystyrene.
Ideally, the method further comprising forming the plastic prefabricated shell from high impact polystyrene sheeting.
Preferably, the method further comprising forming the plastic prefabricated shell from any one of acrylic, acrylonitrile butadiene styrene (ABS), polystyrene, co-polyester, polycarbonate, polypropylene, polyethylene and polyvinylchloride.
Preferably, the method further comprising providing an insulation layer on or proximal 5 to the internal surface of the outer rigid covering member.
Ideally, the method further comprising forming the plastic prefabricated shell of a dormer component, door canopy, chimney stack, bay window roof component as well as door and roof preformed surrounds.
Ideally, the method further comprising forming the plastic prefabricated shell of the 10 dormer component comprising a structural support framework for supporting a roof, two lateral walls and a front wall defining an opening for a window.
Preferably, the method further comprising mechanically or otherwise coupling the outer covering means to the structural support framework along at least part of its length.
Most preferably, the method further comprising strapping, clipping, slotting, riveting, bonding, adhesively bonding, adhering, gluing or welding the outer rigid covering member to the at least part of the structural support framework or coupling the outer rigid covering member to the at least part of the structural support framework using any combination of these fasteners or fixing methods.
It will be appreciated that this method of coupling means/methods is in no way limiting 20 and the invention covers any form of coupling suitable to provide sufficient rigidity and strength to retain the mechanical joint between the outer covering means and the structural support framework to withstand the range of forces acting on a building component such as a dormer window unit.
The invention will now be described with reference to the accompanying drawings which show by way of example only four embodiments of a building component in accordance with the invention.
Figure 1 is a perspective view of the building component in the form of a dormer window unit; Figure 2 is a perspective view of the building component in the form of a chimney stack unit; Figure 3 is a vertical cross sectional view of the building component in the form of a door canopy; Figure 4 is a second vertical cross sectional view of the building component showing the structural support framework for the door canopy; Figure 5 is a vertical cross sectional view of the building component in the form of a door surround.
In the drawings, there is shown at least part of a building component indicated generally by the reference numeral 1 comprising a structural support framework 2, an outer covering component 3 for covering all or part of the structural support framework 2. The outer covering component 3 comprising a prefabricated a plastic preformed/prefabricated shell 3 providing a rigid covering member 3. The plastic prefabricated shell 3 is manufactured from a thermoplastic material. The plastic prefabricated shell 3 is manufactured from an amorphous thermoplastic material. The plastic prefabricated shell 3 is manufactured from polystyrene. The plastic prefabricated shell 3 is manufactured from high impact polystyrene sheeting. The plastic prefabricated shell 3 is manufactured from any one of acrylic, acrylonitrile butadiene styrene (ABS), polystyrene, co-polyester, polycarbonate, polypropylene, polyethylene and polyvinylchloride. An insulation member 7 is provided on or proximal to the outer rigid covering member 3.
Referring more particularly to Figure 1, the building component 1 for a roof of a building is a dormer window unit and comprises a structural support framework 2 for supporting a roof 8, two lateral walls 9 and a front wall 10 defining an opening 11 for a window. The building component 1 further comprising an outer covering component 3 for covering all or part of at least the two lateral walls 9. The front wall 10 which defines the opening for a window 11 also comprises an outer covering member 12 for all or part of the front wall 10.
The building component 1 is prefabricated prior to on-site installation. The outer covering member 3 of the building component is formed as a single piece by for example vacuum forming or thermoforming techniques. Having an outer covering component 3 which is a single piece provides at least both lateral walls 9 of the building component 1 with a quicker and simpler installation process when on-site beyond that of the conventional prior art. The outer covering component 3 provides a shell like structure to enclose the structural framework 2 of the building component 1. This requires that the outer covering component 2 is secured once placed onto the structural framework 2. In an alternative embodiment, the outer covering component 3 of the building component 1 is a modular unit capable of being connectable together.
Advantageously, the outer rigid covering member 3 provides a rigid surface mountable to the structural support framework 2. Furthermore, the rigid homogenous structure of the outer covering component 3 enhances the structural properties of the outer covering component 3 further improving the overall durability and strength of the building component 1.
The outer rigid covering member 3 form a uniform homogeneous one piece component produced by vacuum forming or thermoforming techniques. This homogeneous one piece component defines a seat for the insulation member 7.
Alternatively, the outer rigid covering members 3 are provided as connectable modular components.
The outer rigid covering member 3 is strapped, clipped, slotted, riveted, bonded, adhesively bonded, adhered, glued or welded to the at least part of the structural support framework 2 or coupled to the at least part of the structural support framework 2 using any combination of these fasteners or fixing methods.
It will be appreciated that this list of coupling methods is in no way limiting and the invention covers any form of coupling suitable to provide sufficient rigidity and strength to retain the mechanical joint between the outer covering component 3 and the structural support framework 2 to withstand the range of forces acting on a building component such as a dormer window unit 1, a chimney stack component 2, a door canopy 31 and a door surround 41.
The outer covering component 3 comprises a reinforcing member. The insulation member 7 comprises an insulation layer covering all or part of the outer rigid covering members 3. The insulation member 7 comprises a foam such as a polyisocyanurate foam material or a phenolic foam material which is pumped or set onto the outer rigid covering members 3. The insulation member 7 is a foam sheet.
The outer rigid covering member 5 has a wall thickness of approximately 3mm. The insulation member 7 has a wall thickness of approximately 25mm.
The structural support framework 2 for supporting a roof comprises of a plurality of structural support members 17. The structural support members 17 are formed of an orthotropic material; most ideally timber. These structural support members 17 comprise an integral auxiliary structural support members (not shown). The auxiliary structural support members (not shown) are one or more hollow forming channel(s) (not shown) located within the individual structural support members 17. The one or more channel(s) (not shown) which form the auxiliary structural support members (not shown) of the structural support member 17 provide the structural support framework 2 of the building component with a lightweight structural material formed of a minimal density whilst maintaining and/or increasing the relative high out-of-plane compressional properties and out-of-plane shear properties of the material. Further, these one or more channels (not shown) reduce thermal bridging between the internal and the external surface of the building component 1; thus further increasing the thermal efficiency of the entire building component 1. A layer of foam 22 fills out the space between the outer covering component 3 and the skeletal support frame work 2.
The channel and/or channels forming the auxiliary structural support member (not shown) comprise an auxiliary insulation member (not shown) for the building component in the form of cavity insulation (not shown). Alternatively, the plurality of channels forming the auxiliary structural support member (not shown) are filled with an auxiliary thermal insulation component (not shown). This provides the building component 1 with further thermal io efficiency beyond that of simple cavity insulation. The auxiliary insulation component (not shown) within the plurality of channels (not shown) of the structural support members 17 is formed of an insulating material that is different from that of the insulation member 7 sandwiched within the outer covering component 3. Alternatively, these insulating materials are identical.
In relation to the detailed description of the different embodiments of the invention, it will be understood that one or more technical features of one embodiment can be used in combination with one or more technical features of any other embodiment where the transferred use of the one or more technical features would be immediately apparent to a person of ordinary skill in the art to carry out a similar function in a similar way on the other embodiment.
In the preceding discussion of the invention, unless stated to the contrary, the disclosure of alternative values for the upper or lower limit of the permitted range of a parameter, coupled with an indication that one of the said values is more highly preferred than the other, is to be construed as an implied statement that each intermediate value of said parameter, lying between the more preferred and the less preferred of said alternatives is itself preferred to said less preferred value and also to each value lying between said less preferred value and said intermediate value.
The features disclosed in the foregoing description or the following drawings, expressed in their specific forms or in terms of a means for performing a disclosed function, or a method or a process of attaining the disclosed result, as appropriate, may separately, or in any combination of such features be utilised for realising the invention in diverse forms thereof.

Claims (46)

1. A building component for a building comprising an outer covering means for covering all or part of the building component, wherein the outer covering means comprises a 5 plastic prefabricated shell providing a rigid covering member.
2. A building component as claimed in claim 1, wherein the plastic prefabricated shell of the outer covering means is manufactured from a thermoplastic material.
3. A building component as claimed in claim 2, wherein the thermoplastic material is an amorphous thermoplastic material. io
4. A building component as claimed in any one of the preceding claims, wherein the building component comprises a structural support framework.
5. A building component as claimed in claim 4, wherein the outer rigid covering member is mountable on the structural support framework.
6. A building component as claimed in any one of the preceding claims, wherein an 15 insulation layer is disposed on or proximal to the internal surface of the outer rigid covering member.
7. A building component as claimed in any one of the preceding claims, wherein the outer covering means of the building component is formed as a single piece.
8. A building component as claimed in any one of the preceding claims, wherein the 20 outer covering means is thermoformed.
9. A building component as claimed in any one of claims 1 to 7, wherein the outer covering means is vacuum formed.
10. A building component as claimed any one of claims 1 to 6 or claims 8 to 9 when dependent on any one of claims 1 to 6 wherein, the outer covering means of the 25 building component is a modular unit capable of being connectable together.
11. A building component as claimed in any one of the preceding claims, wherein the outer rigid covering member is formed from a sheet.
12. A building component as claimed in any one of claims 4 to 11, wherein the outer covering means is coupled to the structural support framework along at least part of 5 its length.
13. A building component as claimed in claim 12, wherein the outer rigid covering member is strapped, clipped, slotted, riveted, bonded, adhesively bonded, adhered, glued or welded to the at least part of the structural support framework or coupled to the at least part of the structural support framework using any combination of these 10 fasteners or fixing methods.
14. A building component as claimed in any one of the preceding claims, wherein the outer covering means comprises a reinforcing means.
15. A building component as claimed in claim 14, wherein the reinforcing means of the outer covering means is locatable along at least part of the span of the outer covering 15 means.
16. A building component as claimed in any one of claims 14 or 15, wherein the reinforcing means of the outer covering means is connectable to the outer rigid covering member.
17. A building component as claimed in any one of claims 14 or 15, wherein the 20 reinforcing means of the outer covering means is integral to the outer rigid covering member.
18. A building component as claimed in any one of the preceding claims, wherein the insulation means comprises a foam such as a polyisocyanurate foam material or a phenolic foam material. 25
19. A building component as claimed in claim 18, wherein the insulation means is pumped into the outer rigid covering member.
20. A building component as claimed in claim 18, wherein the insulation means is a foam sheet.
21. A building component as claimed in claims 4 to 20, wherein the structural support framework comprises of a plurality of structural support members. 5
22. A building component as claimed in claim 21, wherein the structural support members of the structural support framework are formed of an orthotropic material.
23. A building component as claimed in any one of claims 21 to 22, wherein the structural support members of the structural support framework are formed of timber.
24. A building component as claimed in any one of claims 21 to 23, wherein the structural io support members comprise an auxiliary structural support means.
25. A building component as claimed in claim 24, wherein the auxiliary structural support means are connectable to the structural support member.
26. A building component as claimed in claim 24, wherein the auxiliary structural support means are integral to the structural support member. 15
27. A building component as claimed in claim 26, wherein the auxiliary structural support means is formed of a channel located within the individual structural support members.
28. A building component as claimed in claim 26, wherein the auxiliary structural support means is formed of a plurality of channels located within the individual structural 20 support members.
29. A building component as claimed in any one of claims 21 to 28, wherein at least some of the structural support members are hollow.
30. A building component as claimed in any one of the preceding claims, wherein the building component is prefabricated prior to on-site installation. 25
31. A building component as claimed in any one of the preceding claims, wherein the building component of a building is any one of a dormer component, door canopy, chimney stack, bay window roof component as well as door and roof preformed surrounds.
32. A building component as claimed in any one of the preceding claims, wherein the thermal conductivity of the outer covering means is less than 3 W/m 2 K. 5
33. A building component as claimed in any one of claims 1 to 31, wherein the thermal conductivity of the outer covering means is less than 1 W/m 2 K.
34. A building component as claimed in any one of claims 1 to 31, wherein the thermal conductivity of the outer covering means is less than 0.5 W/m 2 K.
35. A building component as claimed in any one of claims 1 to 31, wherein the thermal 10 conductivity of the outer covering means is 0.2 W/m 2 K.
36. A method of manufacturing a building component comprising the method of vacuum forming a sheet of plastic material into a prefabricated plastic architectural building component.
37. A method of manufacturing a building component as claimed in claim 36, wherein the 15 method further comprises thermoforming a sheet of plastic material into a prefabricated plastic building component.
38. A method of manufacturing a building component as claimed in any one of claims 36 to 37, wherein the method further comprises the steps of manufacturing an external building component. 20
39. A method of manufacturing a building component as claimed in any one of claims 36 to 38, wherein the method further comprises the steps of building a structural support frame work for the prefabricated plastic building component.
40. A method of manufacturing a building component as claimed in claim 39, wherein the method further comprises coupling the structural support frame work and the 25 prefabricated plastic building component together.
41. A method of manufacturing a building component as claimed in any one of claims 36 to 40, wherein the method further comprises forming the plastic prefabricated shell from a thermoplastic material.
42. A method of manufacturing a building component as claimed in any one of claims 36 5 to 41, wherein the method further comprises forming the plastic prefabricated shell from an amorphous thermoplastic material.
43. A method of manufacturing a building component as claimed in any one of claims 36 to 42, wherein, the method further comprises providing an insulation layer on or proximal to the internal surface of the outer rigid covering member. 10
44. A method of manufacturing a building component as claimed in any one of claims 36 to 43, wherein the method further comprises forming the plastic prefabricated shell of a dormer component, door canopy, chimney stack, bay window roof component as well as door and roof preformed surrounds.
45. A method of manufacturing a building component as claimed in claim 44, wherein the 15 method further comprises forming the plastic prefabricated shell of the dormer component comprising a structural support framework for supporting a roof, two lateral walls and a front wall defining an opening for a window.
46. A method of manufacturing a building component as claimed in any one of claims 36 to 45, wherein the method further comprises coupling the outer covering means to the 20 structural support framework along at least part of its length.
IE20170074A 2016-04-07 2017-04-07 A building component IE20170074A1 (en)

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EP4190989A1 (en) 2021-12-03 2023-06-07 Martinus Gijsbertus Carolus Maria Kemenade van Prefab building part, in particular a prefab chimney, as well as method for manufacturing the prefab building part

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