NZ742082A - Structural panels and methods of making and using such panels - Google Patents

Abstract

The present invention relates to a building panel (also known as a structural insulated panel), and methods of using and manufacturing such panels. More specifically, the invention relates to a load bearing structural insulated building panel having an internal frame, to be used in the construction of buildings, for example, for constructing interior walls, exterior walls, floors, and roofs of a building structure including multilevel building structures. of buildings, for example, for constructing interior walls, exterior walls, floors, and roofs of a building structure including multilevel building structures.

Description

James & Wells ref: 306040/108 STRUCTURAL PANELS AND METHODS OF MAKING AND USING SUCH PANELS STATEMENT OF CORRESPONDING APPLICATIONS This application is based on Australian the provisional specification filed in relation to Australian Patent Application Number 2017901543, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD The present invention relates generally to a structural insulated panel. More specifically, the present invention relates to a load bearing structural insulated building panel used in the construction of buildings, for example, for constructing interior walls, exterior walls, floors, and roofs of a building structure including multilevel building structures.

BACKGROUND OF THE INVENTION A building panel, also referred to as a structural insulated panel (SIP), is a composite building material generally comprising an insulating material – frequently of rigid polymer foam – sandwiched between at least two layers of structural board. Any of a wide variety of structural boards can be used, and selection will generally depend on the targeted application for the SIP.

Commonly used structural boards include materials such as sheet metal, plywood, particle board, fibreglass, and composites. The insulating layer usually comprises or consists of a rigid polymer foam, such as expanded polystyrene foam, extruded polystyrene foam, polyisocyanurate foam, or polyurethane foam.

SIPs are suitable for use in many different construction applications, including exterior walls, interior walls, roofs, floors, and foundation systems, as the SIPs can be configured to provide one or more functionalities of traditional building components, such as studs, joists, insulation, vapour barriers, moisture barriers, and air barriers.

A disadvantage of existing SIPs relates to a lack of structural integrity – either as a load bearing element overall, or of the various constitutive components. For example, conventional SIPs may suffer from panel creep or deformation where one or more of the structural boards move with respect to the insulating material or one of the other panel components over time, generally because of loading or adverse environmental conditions. A resultant risk of structural failure of the building structure thus exists. In other examples, SIPs are suitable for cladding and enclosing a James & Wells ref: 306040/108 building structure, but are affixed to separate load bearing elements, where the SIPs themselves do not contribute to load bearing. This can add time, cost and complexity to the building process.

It is therefore an object of the present invention to go some way to overcoming these deficiencies, for example to provide a SIP having improved load bearing, while maintaining the impact resistance, fire resistance, and insulating characteristics expected of conventional SIPs, or to at least provide the public with a choice.

SUMMARY OF THE INVENTION Embodiments of SIPs, also referred to herein as building panels, and methods and systems for making and using building panels, are described herein.

Accordingly, in one aspect, the invention relates to a building panel comprising: a first casing material, a second casing material, one or more bulk materials disposed between the first and second casing materials, a frame disposed substantially within the first and second casing materials, and optionally one or more locking elements, wherein the one or more locking elements is disposed at or towards the periphery of the building panel to allow engagement with a locking element of an adjacently positioned building panel.

In one embodiment, the frame is substantially embedded in and/or coupled to the one or more bulk materials.

In one embodiment, at least a part of the frame is coupled to one or more of the casing materials.

In one embodiment, the frame comprises two or more frame members.

In one embodiment, the two or more frame members are two or more load bearing framing studs; and optionally one or more rails extending between and coupled to the at least two load bearing framing studs.

In one embodiment, the first casing material, the second casing material, or both the first and the second casing materials are secured to one or more of the frame members.

In one embodiment, the first casing material, the second casing material, or both the first and the second casing materials are secured to the bulk material.

James & Wells ref: 306040/108 In one embodiment, the coupling of one or more of the rails to one or more of the framing studs is by a coupling portion of the rail, the coupling portion shaped to engage with the cross-sectional profile of the framing stud to which it is coupled.

In one embodiment, the coupling portion of the one or more rails comprises one or more lugs or extensions engaging with one or more recesses or perforations in the framing stud.

In one embodiment, the coupling of one or more of the rails to one or more of the framing studs is by a coupling portion of the rail, the coupling portion having a recessed portion and a first extension portion adjacent the recessed portion, wherein the first extension portion engages with a receiving portion or profile of the framing stud to which the coupling portion is coupled.

In one embodiment, the coupling portion of the rail has a second extension portion on the opposite side of the recessed portion from the first extension portion; wherein the second extension portion engages with a receiving portion or profile of the framing stud to which the coupling portion is coupled.

In one embodiment, the building panel comprises one or more passages extending from one edge of the building panel to another edge of the building panel through one or more of the one or more bulk materials.

For example, the one or more passages extend between opposing edges of the building panel.

In one embodiment, the one or more passages comprises a conduit element.

In one embodiment, one or more of the framing studs has a cross-sectional profile configured to receive and/or engage a conduit element.

In one embodiment, one or more of the framing studs comprises two flanges joined to and separated by a web.

In one embodiment, in cross-sectional profile the flanges are substantially parallel, and wherein in cross-sectional profile the flanges are substantially perpendicular to the web.

In one embodiment, at least one flange of at least one stud is coupled to one of the casing materials.

In one embodiment, one flange of at least one stud is coupled to a first casing material, and the other flange of the at least one stud is coupled to a second casing material on the opposing face of the building panel.

James & Wells ref: 306040/108 In one embodiment, the framing stud has a cross-sectional profile configured to provide an acoustic break.

In one embodiment, the framing stud comprises a web having a cross-sectional profile comprising a bend or fold or defining a substantially ‘V’ shape.

In various embodiments, one or more of the frame members is a steel frame member, for example, is made from steel having a cross-sectional thickness of from about 0.5mm to about 3mm.

In one embodiment, the conduit runs along the panel exterior face of the framing stud.

In one embodiment, the one or more passages extend from the top edge of the panel to the bottom edge of the panel, and are located within the frame defined by the one or more framing studs and the rails, wherein each of the rails has one or more recesses, perforations, or openings through which the one or more passages passes.

In one embodiment, a conduit runs along the panel interior face of the framing stud, and wherein the coupling portion of a rail coupled to said framing stud has a recess, perforation, or opening through which the conduit passes.

In one embodiment, at least one of the one or more passages are or the conduit element is configured to receive cables, wires, or plumbing lines.

In one embodiment, at least one of the first and second casing materials is substantially waterproof.

In one embodiment, at least one of the first and second casing materials is formed of cement fibre board material.

In one embodiment, one or more of the one or more bulk materials comprises a polymer material.

For example, the polymer material is or comprises one of: polyurethane (PU) foam material; and, polyisocyanurate (PIR).

In one embodiment, the bulk material is fire rated.

In one embodiment, the bulk material is disposed between the first and second casing materials in a continuous process.

In one embodiment, one or more of the bulk materials is or comprises a load bearing material.

In one embodiment, the load bearing material is disposed within the space defined by the first casing material, the second casing material, and the at least two load bearing framing studs.

James & Wells ref: 306040/108 In another aspect, the invention relates to a method of making a building panel, the building panel comprising a first and a second casing material, one or more bulk materials disposed between the first and second casing material, a frame comprising one or more frame members, and one or more locking elements; the method comprising the steps of: positioning a first length of a casing material; positioning at least a portion of one or more of the frame members in contact with the casing material; optionally positioning one or more additional frame members either by engagement with another frame member or in contact with the casing material; securing one or more of the one or more locking elements to the length of casing material; optionally securing one or more bulk materials to the first length of casing material or to at least a portion of one or more of the frame members, or contacting the first length of casing material and/or at least a portion of one or more of the frame members with a precursor of a bulk material; positioning a second length of a casing material to enclose at least a portion of the one or more frame members and when present the one or more bulk materials or precursors thereof; optionally introducing into the one or more cavities defined by the first casing material, the second casing material, and the one or more frame members, one or more bulk materials or precursors thereof; thereby to provide a building panel precursor, and cutting the building panel precursor to a defined length to provide a building panel.

In one embodiment, the positioning of two or more of the frame members is a positioning of two or more load bearing framing studs substantially longitudinally along at least a part of the length of the casing material.

James & Wells ref: 306040/108 In one embodiment, the positioning of one or more of the two or more frame members or of the one or more additional frame members is a positioning of a rail substantially transversely across a length of the casing material.

In one embodiment, the method additionally comprises the step of positioning one or more conduits in contact with the first length of casing material, in contact with one or more of the frame members, in contact with a bulk material, or in contact with any combination of two or more of the casing material, the one or more frame members, and a bulk material.

For example, the one or more conduits is positioned substantially longitudinally along at least a part of the length of the casing material.

In another aspect, the invention relates to a building system comprising: a plurality of building panels as claimed in any one of the preceding claims; wherein for at least one of the plurality of building panels a top surface of the first and second casing materials, a top surface of any additional casing materials present, a top surface of the one or more bulk materials, or a top surface of a frame member are planar; and wherein for at least one of the plurality of building panels a bottom surface of the first and second casing materials, a bottom surface of any additional casing materials present, a bottom surface of the one or more bulk materials, or a bottom surface of a frame member are planar; optionally one or more locking elements engageable with one or more of the building panels; optionally one or more channels configured to engage along a top surface of one or more building panels; optionally one or more channels configured to engage along a bottom surface of one or more building panels.

In one embodiment, the one or more channels configured to engage along a bottom surface of one or more building panels engages with the foundation of the building onto which the one or more building panels is to be placed.

In one embodiment, for at least one of the plurality of building panels, one or more of the load bearing framing studs is planar with a top surface of the building panel or with a top surface of at least one of the other components of the building panel, is planar with a bottom surface of the James & Wells ref: 306040/108 building panel or with a bottom surface of at least one of the other components of the building panel, or is planar with both a top surface and a bottom surface of the building panel or with both a top surface and a bottom surface of at least one of the other components of the building panel.

In one embodiment, for at least one of the plurality of building panels, one or more of the load bearing framing studs is recessed relative to a top surface of the building panel or to a top surface of at least one of the other components of the building panel, is recessed relative to a bottom surface of the building panel or to a bottom surface of at least one of the other components of the building panel, or is recessed relative to both a top surface and a bottom surface of the building panel or to both a top surface and a bottom surface of at least one of the other components of the building panel.

In one embodiment, the building system additionally comprises a framing member engageable with a load bearing framing stud of a first building panel and engageable with a load bearing framing stud of a second vertically adjacently positioned building panel.

In another aspect, the invention relates to a method of constructing a building, the method comprising: providing a plurality of building panels as claimed in any preceding claim; placing a layer of a water proof material on at least that portion of the foundation of the building onto which one or more of the building panels is to be affixed; optionally placing over the water proof material, a channel configured to engage along a bottom surface of one or more of the building panels; fixing one or more of the building panels to the slab over the waterproof layer; engaging the one or more locking elements of one building panel with one or more adjacent building panels, thereby to secure two or more building panels one to the other.

In one embodiment, the method comprises optionally trimming a first building panel or one or more of the components of the first building panel to engage with the panel interior face of the distal face of a second building panel; and forming a corner of the building by standing the first and second panels upright and abutting the panels together in respective intersecting planes to form a first angle between the two panels.

James & Wells ref: 306040/108 In one embodiment, the method comprises engaging one upright edge of a first building panel that is to form a corner of the building in a channel configured to receive said building panel and to provide at least one rigid surface against which a second building panel is configured to engage; and optionally trimming a second building panel to abut the first building panel via engagement with the channel, engaging the channel with each of the two panels; and coupling the channel with each of the two panels to form the corner of the building.

In one embodiment, the method comprises providing a corner joint member having a joint corner defining a joint angle, the corner joint member configured to engage one of the first or second sides of the two panels forming the building corner, the corner joint member optionally further arranged to allow distortion of the corner joint member to vary the joint angle to conform with the first angle; engaging the corner joint member with each of the two panels; and coupling the corner joint member with each of the two panels to form the corner of the building.

In one embodiment, the method comprises arranging a first plurality of building panels to construct walls to form a course of building panels or a story of a building, coupling a second plurality of further panels to the uppermost surface of the first plurality of panels to construct a second course of panels or a wall of a second story.

In one embodiment, prior to arranging, one or more of the building panels comprises a void in the space defined by the first casing material, the second casing material, and the at least two load bearing framing studs, into which is introduced a load bearing material after the panel is arranged.

In one embodiment, two or more vertically adjacent building panels each comprise, prior to arrangement, a void in the space defined by the first casing material, the second casing material, and the at least two load bearing framing studs, wherein on arrangement a contiguous void is formed into which the load bearing material is introduced.

In one embodiment, the building panel comprises an insulating member, such as a polymeric block, casing members secured to opposing surfaces of the insulating member, and an internal frame comprising substantially vertical framing studs and substantially horizontal rails, which in certain James & Wells ref: 306040/108 examples is at least partially embedded in or to the insulating member. The building panel also comprises one or more locking elements disposed at or towards the periphery of the panel so that the panel can be engaged to one or more adjacent panels.

In another aspect, the present invention relates to a system for manufacturing composite building elements, including a feed station configured to position a length of a casing material, a feed station configured to position one or more frame members wherein at least a portion of said frame member is in contact with the first length of casing material, a filler station configured to secure a bulk material to the length of casing material, an insert station that is configured to secure locking elements to the length of casing material, and a cutting station comprising a cutting element configured to cut the casing material to a desired length.

In another aspect of the present invention, a building panel manufactured using the method as substantially described above is provided.

In one embodiment, a method of constructing a building includes providing two or more building panels as described herein, wherein one or more of the frame members, such as one or more of the framing studs, are aligned with and optionally engage with a frame member of an adjacently positioned building panel, and wherein the one or more locking elements disposed at or toward the periphery of the building panel is engaged with at least one locking element of the adjacently positioned building panel.

BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are incorporated into and form a part of the specification, illustrate one or more embodiments of the present invention and, together with the description, serve to explain the principles of the invention. The drawings illustrate certain embodiments of the invention and are not to be construed as limiting the invention.

In the drawings: Figure 1A depicts an isometric view of one embodiment of a building panel, while Figure 1B presents an exploded view of the building panel depicted in Figure Figure 2 presents a transverse cross-section of the building panel Figure 3A shows a transverse cross-section showing the engagement two adjacently positioned building panels. Figures 3B and 3C show magnified views of James & Wells ref: 306040/108 locking elements, and internal framing members, shown in Figure 3A, respectively.

Figure 4 presents an isometric view of various components of an embodiment of a building panel comprising an additional insulative casing material.

Figure 5A and 5B each depict an isometric view of embodiments of load-bearing framing studs.

Figure 6 presents two isometric views of a framing rail.

Figure 7 shows an isometric view depicting the engagement of a framing rail 40 with a framing stud in one embodiment of a building panel.

Figure 8 presents a further embodiment of a building panel particularly suited for use in single level or low-rise buildings. Figure 8A presents a cutaway isometric view of the panel, while Figure 8B presents a cross section of the panel.

Figure 9 presents an embodiment of a building panel configured for high load- bearing applications and particularly suited for use in multi-level or high-rise buildings. Figure 9A shows an isometric cutaway view, while Figure 9B shows a cross-section view of the building panel of Figure 9A.

Figure 10A and 10B each present a cross-sectional view of an approach for positioning a building panel at the perimeter of a concrete slab building foundation.

Figure 11 presents a cross-section view of one embodiment of a building panel configured to engage with a roof substructure 150.

Figure 12 presents various depictions of one embodiment of a building corner comprising two abutting building panels. A cutaway isometric view of the building corner is presented in Figure 12A, and a plan view cross-section of the corner depicted in Figure 12A is shown in Figure 12B. Cross section views of a corner channel 170 and an exterior corner flashing 180 are shown in Figures 12C and 12D, respectively.

All references, including any patents or patent applications cited in this specification are hereby incorporated by reference. No admission is made that any reference constitutes prior art. The discussion of the references states what their authors assert, and the applicants reserve the right to James & Wells ref: 306040/108 challenge the accuracy and pertinency of the cited documents. It will be clearly understood that, although a number of prior art publications are referred to herein, this reference does not constitute an admission that any of these documents form part of the common general knowledge in the art, in New Zealand or in any other country.

Throughout this specification, the word "comprise", or variations thereof such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

Further aspects and advantages of the present invention will become apparent from the ensuing description which is given by way of example only.

DISCLOSURE OF THE INVENTION The invention relates to building panels comprising an integral frame, and methods for their production and use. The building panels described herein comprise a first and a second casing material, and optionally may comprise one or more additional casing materials such as insulative panels, one or more bulk materials disposed between the first and second casing material, and a frame disposed substantially within the first and second casing material. In various embodiments, the frame is substantially or entirely embedded within one or more of the one or more bulk materials.

In certain contemplated embodiments, the building panels described herein are manufactured using continuous processes (methods) and systems to manufacture composite building elements. In these embodiments, the methods and systems produce composite building panels of configurable length, wherein the panels are continually output from the filling and/or moulding station and can be cut to a desired length, where that length need not be predetermined prior to filling and/or moulding. In these continuous processes, the panel can be subsequently cut to produce composite building elements having a desired length (“a cut panel”).

Therefore, the present specification will describe the present inventions with reference to them being “continuous”.

Throughout the present specification reference to the term “continuous” should be understood as referring to a process in which materials are constantly fed into one or more of the components of the system. For instance, a length of casing material is fed into the system without being cut. That is, a roll of the casing material constantly feeds the material into at least one component of the James & Wells ref: 306040/108 system. One or more additional casing materials, one or more frame members, and/or one or more locking elements, for example, are positioned on the casing material, and this process is iterated along the length of the casing material. In certain embodiments, the length of casing material is cut only after all of the components of the building panel have been emplaced, such that cutting the casing material forms the final, cut panel.

Throughout the present specification, reference to the term “bulk material” should be understood as referring to a material which can fill the gap between two sections of casing materials.

In a particularly described embodiment, the bulk material is an insulative material which prevents or reduces transfer of heat through the building panel. In another particularly described embodiment, the bulk material is an insulative material which prevents or reduces transfer of sound through the building panel.

An example of a suitable insulative material is a polyurethane foam or a polyisocyanurate.

Alternative or additional bulk material are envisaged, including polystyrene or other materials.

Throughout the present specification reference to the term “casing material” should be understood as meaning a material which encases the bulk material and/or frame, and which in certain embodiments provides an outer layer of a building panel.

It will be appreciated that building panels comprising one casing material on one face, and a different casing material on the opposing face, are contemplated. For example, building panels intended for use at the exterior of a building will typically comprise on the exterior face a weather- resistant and/or environmentally stable casing material, or a casing material to which a weather resistant and/or environmentally-stable coating can readily be applied, while the interior face is of a casing material suitable for interior finishing or decoration, and may thus have different properties as required.

It will also be appreciated that more than one casing material may be employed on a given face of the building panel. For example, in one embodiment a building panel, such as a building panel intended for use at the exterior of a building, comprises two or more casing materials on the exterior face, the first casing material providing one functionality, for example insulation, the second providing a second functionality, for example weatherproofing. By combining casing materials having different properties, building panels having desired functional performance can thus be prepared.

James & Wells ref: 306040/108 In specifically contemplated examples, such as that depicted in Figure 1, a building panel comprises two casing materials on a particular panel face, such as the building panel face intended to be placed to the exterior of a building. The exterior most casing material comprises an environmentally-stable material such as fibre cement board, while the panel interior casing material provides additional functionality such as improved waterproofing – and in this embodiment is an aluminium zinc sheet. In other particularly contemplated examples, such as that depicted in Figure 4, a building panel comprises more than two casing materials on a particular panel face, where the panel exterior-most face comprises an environmentally-stable material such as cement fibre board, inside which is positioned a further casing material such as an aluminium zinc sheet, inside which is disposed over at least part of the bulk material a further casing material – in this example an insulating material. As will be appreciated by a person skilled in the art on reading this specification, many arrangements comprising different casing materials are possible, where the selection of the various casing materials is informed by the desired characteristics and targeted performance for the panel.

In one embodiment, the casing materials are provided in the forms of elongate sheets.

In a particularly contemplated embodiment wherein the manufacture of the building panel is a continuous process, the lengths of casing materials are in a roll or coil. The casing material can be mounted on a feed station and fed into components to facilitate forming of a building panel via such continuous processes, for example using the methods and apparatuses described in PCT international application , published as WO2013154442, incorporated by reference herein in its entirety.

Examples of the materials from which sheets 10, 20, 80 may be made include, but are not limited to, fibre cement board, wood sheets for example pine or cedar sheets; plaster board, metal sheets such as aluminium sheet or aluminium zinc sheet, MGL (magnesium oxide) board, and composite materials. Further, in various embodiments, different materials may be used for respective sheets , 20 and 80 in any given panel 1.

Generally, since one outer casing material 10 is intended to face outwardly of a building and may as a consequence become exposed to ambient moisture, outer casing material 10 is typically configured so as to be waterproof. In certain embodiments, the building exterior outer casing material 10 is thicker than for example the outermost casing material on the building interior panel face.

James & Wells ref: 306040/108 In certain embodiments, a casing material may be made from, or coated with, a food grade material. This is beneficial for certain applications as it enables the building panels to be used in applications requiring this type of lining without subsequent modification or post-manufacture alteration.

Having the casing material pre-coated with, or made from, a food grade material is a cost-effective way to produce these building panels. If the casing material is not pre-coated or made from food grade material, then such a coating/lining would need to be applied after manufacture of panels prepared for these types of applications, doing so would significantly increase the cost of manufacturing these building panels.

Similarly, casing materials can be chosen to provide building panels having other attributes required of buildings designed for a particular use, to prevent a need for post manufacture or on-site application of coatings, linings, or other surface modifications. The properties of the casing material and their selection should be understood by one skilled in the art.

As used herein, to be "embedded" in or to another panel component or element means at least partially contained within, or at least partially surrounded by, the panel component or element. In one example, a frame member, such as a framing stud, is embedded in a bulk material, such as a polymeric block or a polymer material, if the framing member is inserted, pressed, or dropped into a pre-cut slot or channel in the bulk material. In another example, a frame member such as a framing stud may be embedded by expanding a bulk material, such as a loose foam material or a bulk material precursor, around the frame member. In certain embodiments, there may be clearance between the surfaces (for example, a gap between the surfaces of a framing stud and the adjacent surfaces of one or more bulk materials).

In certain embodiments, the frame is coupled to one or more of the casing materials. In one example, one or more of the framing studs is coupled to one or more of the casing materials, for example one or more flanges of the framing stud is coupled to one or more of the casing materials, and substantially the remainder of the framing stud is embedded in the bulk material.

In certain embodiments, the frame is embedded entirely within one on more of the bulk materials.

In one example, the panel comprises one or more voids extending from the end of one or more of the framing studs to the perimeter of the panel, such that an additional frame member may engage with or abut against the framing stud. In certain embodiments, the additional frame member engages with a framing stud from a first panel and a framing stud from a vertically adjacent second panel, for example to place the two framing studs in load bearing alignment.

James & Wells ref: 306040/108 As used herein the term “feed station” should be understood as referring to one or more components of a manufacturing system or process that are configured to feed the lengths of casing material to facilitate manufacture of a building panel.

In one embodiment, the feed station includes a plurality of decoilers or uncoilers. The term de-coiler or un-coiler is as should be understood by one skilled in the art, referring to a device which can support and unwind a coil of casing material. Reference will be made herein to decoilers.

In this embodiment, each of the decoilers includes a mounting to receive and support a coil of sheet metal, and a drive means configured to rotate the mounting. Rotation of the mounting facilitates feeding of the sheet metal.

In other embodiments, one or more feed stations may employ other decoilers, for instance those which do not include drive means.

As used herein, "frame member" means a member that can be coupled with one or more other members to form a frame. Generally, one or more frame members, for example one or more of the framing studs, will be metal. The building panels described herein can conveniently be manufactured to suit particular applications by, for example, appropriate selection of frame members having desired characteristics. For example, heavy duty frame members are in certain embodiments manufactured from thicker steel or other structural metals, for example 3mm steel or greater, while lighter frames will in certain embodiments comprises thinner metal elements, down to 0.5mm thick or even less. It will be appreciated that by appropriate selection of framing strengths, thicknesses, and compositions, panels suitable for heavy structural loading right through to very light structural loads can be manufactured.

In certain embodiments, and in particular for those frame members in direct contact with one or more casing materials, the frame members comprise one or features configured to provide an acoustic break, and/or one or more features to provide a thermal break, thereby preventing or reducing acoustic transmission and/or heat transfer from one face of the building panel to the other. Specifically contemplated thermal breaks include one or more perforations in the framing member, and/or the incorporation of an insulating material in the framing member.

As used herein, "framing stud", or "stud", means a primarily vertical member that can bear a downward load. In certain embodiments, such as those where the framing stud is coupled to one or more casing materials, framing studs useful herein will have a substantially ‘U’ shaped cross section, where two flanges are separated by a substantially perpendicular web. Usefully, the flanges allow positioning adjacent and coupling to the one or more casing materials, while the web provides James & Wells ref: 306040/108 spacing between the casing materials as well as load bearing. In certain embodiments, the web comprises a bend or fold, such as a substantially ‘V’-shaped bend, to provide an acoustic break and reduce acoustic transmission across the framing stud. In certain embodiments, at least a part of one or more of the flanges, and more usually at least a part of the web, will comprise one or more perforations to reduce thermal transmission across the framing stud.

As used herein, the term “filling station” should be understood as meaning components configured to secure a bulk material to at least one length of casing material, such as by positioning one or more bulk material precursors with one or more cavities formed by the casing materials, and optionally by one or more of the frame members. The functionality and components of the filling station are selected according to the properties of the bulk material to be used.

In a particularly contemplated embodiment, the filling station is a reservoir of liquid(s), and a fluid delivery system. For example, the filling station is configured to provide a liquid foam precursor to the space between the casing materials, such that the foam thus produced in situ fills part or all of the space.

However, the forgoing should not be considered limiting. It is also envisaged that the bulk material may be inserted into a gap between two sheets of material in a non-liquid form such as polystyrene sheets. In this embodiment, the filling station may be provided by automated arms or manual loading mechanisms.

As used herein, the term “insert station” should be understood as meaning components configured to secure locking elements to a section of casing material.

In one embodiment, the insert station comprises a plurality of automatic arms. The arms are configured to engage one or more locking elements and position these with respect to sheets of casing material.

In one example, the insert station is configured to position a locking element so that the foot of the locking element extends into a connection cavity in the length of casing material. This assists in securing, and in certain embodiments is sufficient to secure, the locking element to the length of casing material.

In a particularly contemplated embodiment, the insert station is configured to apply pressure to the length of casing material to thereby clamp the foot of the locking element within the cavity.

Clamping may be achieved using robotic arms and/or hydraulic presses.

James & Wells ref: 306040/108 In other embodiments, the locking elements are secured to the sheet of casing material using other mechanisms such as welding, adhesives, engagement with a recess within the casing material, or similar.

In various embodiments, the insert station is configured to secure the one or more locking elements to a length of casing material prior to the bulk material being positioned on or secured to the casing material. This significantly simplifies the implementation of a continuous process to manufacture building panels, as described herein.

Furthermore, this feature facilitates for the casing material being continuously fed into and through a filling station, and in certain embodiments subsequently pass into a station configured to shaping the building panel and/or trim excess bulk material to provide a length of building panel suitable for cutting. Therefore, in these particularly contemplated embodiments, it is not necessary to cure the bulk material to secure the locking elements before further handling, and the sheet of casing material with locking elements so positioned can be fed through the other components of the manufacturing system.

Securing the one or more locking elements to a length of casing material thus enables the panels to continue through the manufacturing process in a continuous feed into, and through, filling and moulding stations. Accordingly, it is also possible to use the feed rate of casing material to control parameters of the building panels produced as described herein.

Throughout the present specification reference to the term “locking element” should be understood as referring to a component that secures, or assists in securing, adjacent building panels together.

In a particularly contemplated embodiment, locking elements according to the present invention are pairs of locking element halves. In use, each of locking element half engages with a corresponding element half to secure adjacent sandwich panels together.

In a particularly contemplated embodiment, the locking element halves are cam-locks. In this embodiment, the cam-locks are each one of a pair of male and female components that can selectively engage with each other. The male element has a member which can be rotated to a position it engage a corresponding female element. Rotation is achieved using a key or other component.

However, the forgoing should not be seen as limiting and alternatives are envisaged. Those alternatives include locking elements in the form of spring loaded detents and overlapping flange fasteners.

James & Wells ref: 306040/108 In a particularly contemplated embodiment, the locking elements have feet with a portion configured to fit within a corresponding cavity in a section of a casing material forming part of the composite building element.

In a contemplated embodiment, the locking portions include a web.

As used herein the term “web” should be understood as meaning an open lattice.

The web is useful as a bulk material such as polyurethane foam can expand into and completely surround the web. This assists in securing the locking element in position within a building panel according to the present invention. It also assists in holding the locking elements in position so that they are better able to engage with corresponding locking elements on adjacent sandwich panels.

As used herein the term “securing the locking element to one of the sections of casing material” should be understood as meaning attaching to the material at a specific position. In one embodiment, securing is achieved through interaction of the locking element with a corresponding cavity in a length of casing material.

However, the forgoing should not be seen as limiting on the scope of the present invention. It is also envisaged that securing of the locking element to a length of casing material could be achieved using other techniques. For instance, the locking element could be secured using welding, adhesives, or temporary fasteners in the form of clamps.

Securing the locking element to the length of casing material is important in certain embodiments to achieving a continuous method of manufacturing a composite building panel as described herein.

This is because the locking element is fixed in a defined position relative to the length of casing material. This feature in turn enables a continuous feed of casing material, into and through, a moulding station. There is no need to cut lengths of casing materials. Furthermore, the continuous feed of casing materials means that panels are not “batch made” and as such, the manufacturing time is reduced.

These advantages should become clearer from the following description.

In a particularly contemplated embodiment, the step of securing a locking element to a sheet of casing material occurs prior to securing a bulk material to the length of casing material, for example occurs prior to introducing one or more bulk material precursors into the cavity formed by the first and second casing materials.

James & Wells ref: 306040/108 This is beneficial as it enables the sections of casing material with the locking elements secured thereto to be continuously feed into, and through, a moulding station. This in turn facilities the continuous manufacture of composite building panels of configurable length.

As used herein, a "polymeric material" means a material that is made at least primarily of one or more polymers. As used herein, a "polymer" means a naturally occurring or synthetic compound consisting of large molecules made up of a linked series of repeated simple monomers. Examples of polymers include polyolefins (such as polyethylene and polypropylene), polyurethanes, polyvinylchloride, polyesters, poly ethylene vinyl alcohol, polyvinyl alcohol, polycaprolactone, polylactic acid and foamed starch. A polymeric material may be expanded foam, such as expanded polystyrene. In some embodiments, the polymeric material is fire retardant, for example PIR.

As used herein, "polymeric block" means a block that is at least primarily made of a polymeric material.

Turning now to Figure 1, an isometric view of one embodiment of a building panel is shown. Figure 1A shows a number of the components of the building panel in their final arrangement, while Figure 1B presents an exploded view of the embodiment shown in Figure 1A.

Building panel 1 includes casing material 10, for example cement fibreboard, additional casing material 20, for example aluminium zinc sheeting, two load-bearing framing studs 30, two rails 40 extending between the load-bearing framing studs, and conduit 50 positioned towards the panel interior face of the framing studs. Locking elements 70 are shown positioned toward the perimeter of the panel to allow for engagement with an adjacently-positioned panel. In this embodiment, the load bearing framing studs 30 are substantially vertical, and the rails 40 are substantially horizontal, when the building panel 1 is deployed in the construction a building structure.

Figure 2 presents a transverse cross-section of the building panel 1 depicting certain of the components shown in Figure 1. Here, bulk material 60 is disposed within the first and second casing materials 10, and within which the frame comprising two load bearing framing studs 30, one or more rails 40, and conduit 50 is embedded. The framing studs are located inwards from a longitudinal edge of the panel. The frame is located substantially centrally in a width direction of the panel, i.e. centrally in a horizontal direction when the panel is arranged vertically. The frame is located centrally and approximately spans about 50% of the width of the panel. The engagement of locking element 70 with the additional casing material 20, and the embedding of the locking element 70 within the bulk material 60 is also shown.

James & Wells ref: 306040/108 The engagement of a locking element 70 of a first building panel with a locking element 70 of an adjacently positioned building panel is shown in Figures 3A and 3B. Figure 3A shows a transverse cross-section of two adjacently positioned building panels. The frame is located centrally and approximately spans about 50% of the width of the panel. Each stud is located about midway between a longitudinal edge of the panel and a longitudinal centreline of the panel. A distance between the framing studs in the panel 1 is the same as or similar to a distance between the framing stud of one panel and framing stud of an adjacent panel with the adjacent panels joined together along longitudinal edges, as shown in Figure 3A. Figure 3B shows a magnified view of the junction between the first and second building panels identified in region 3B, in which the engagement of the locking elements 70, in this example cam locks, couples the two panels together.

Figure 3C shows a magnified view of representative frame members positioned between the first and second casing materials 10 and at least partially embedded in the bulk material 60. The coupling of the rail 40 with the framing stud 30 via a first extension portion 41 and a second extension portion 42 is also depicted. The positioning of conduit 50 at the panel-interior face of the framing stud 30. Conduit 50 passes through recessed portion 100 of the rail 40.

Figure 4 presents an isometric view of various components of an embodiment of a building panel described herein. In this embodiment, additional casing material comprising an insulated board 80 and additional casing material 20, in this example aluminium zinc sheet, are positioned with panel- exterior first casing material 10. Conduit 50 is positioned on the panel-exterior face of framing studs 30. In this embodiment, the end of conduit 50 is coplanar with the edge of first casing material 10, while the end of framing stud 30 is recessed relative to the edge of first casing material 10. Locating tags 81 engage with framing stud 30 to locate and retain additional casing material 80.

Two embodiments of load-bearing framing studs 30 are shown in Figure 5. Figure 5A shows an isometric view of a section of framing stud 30, wherein the cross-sectional profile is configured to receive conduit (not shown) and to enhance acoustic performance. Perforations 31 enhance thermal performance. Figure 5B depicts an isometric view of another embodiment of a load-bearing framing stud 30 with additional perforations. In the framing studs of both Figure 5A and Figure 5B the acoustic break provided by the ‘V’-shaped bend in the web separating the two substantially parallel flanges can clearly be seen.

One embodiment of a rail 40 is depicted in Figure 6. Figure 6A presents a top isometric view, showing the recessed portion 100 at the end of the rail. Figure 6B is a further isometric view in which the rail has been rotated through 90° relative to its position shown in Figure 6A, and shows James & Wells ref: 306040/108 first extension portion 41 and second extension portion 42 configured to engage with a framing stud The engagement of a framing rail 40 with a framing stud 30 is shown in Figure 7. In this embodiment conduit 50 passes through the recessed portion 100 of rail 40. Recessed portion 100 and this embodiment allows the conduit 50 to be placed within the frame, in this example at the panel- interior face of framing stud 30.

Figure 8 presents a further embodiment of a building panel particularly suited for use in single level or low-rise buildings, such as residential buildings. Figure 8A shows an isometric cutaway view, while Figure 8B shows a cross-section view of the building panel of Figure 8A. A rendered finish 110 is applied to the building exterior surface of casing material 10 to provide additional waterproofing and a desired aesthetic finish. Internal additional casing material 20, in this case aluminium zinc sheet is incorporated for enhanced thermal, acoustic and environmental performance. The internal frame comprising framing studs 30 and rails 40 are embedded within bulk material 60. The framing studs 30 are located inwards from a longitudinal edge of the panel. Conduit 50, in this embodiment 40 mm PVC piping, is positioned on the panel-interior face of each framing stud 30.

Figure 9 presents a still further embodiment of a building panel, in this example a panel configured for high load-bearing applications and particularly suited for use in multi-level or high-rise buildings, such as commercial buildings. Figure 9A shows an isometric cutaway view, while Figure 9B shows a cross-section view of the building panel of Figure 9A. Again, a rendered finish 110 is applied to the building exterior surface of casing material 10 to provide additional waterproofing and a desired aesthetic finish. Internal additional casing material 20, in this case aluminium zinc sheet is incorporated for enhanced thermal, acoustic and environmental performance. The internal frame comprising framing studs 30 and rails 40 are embedded within an enhanced load-bearing bulk material 90, in this instance concrete which can be incorporated during manufacture or poured on site. The enhanced load-bearing bulk material 90 is provided between the framing studs 30, between panel-interior faces of the framing studs. Insulative bulk material 60, in this instance high density carbon black PIR, is positioned from the panel exterior face of the framing studs 30 out to the edge of the building panel. Conduit 50, in this embodiment 40 mm PVC piping, is positioned on the panel-interior face of each framing stud 30.

Two approaches for positioning a building panel at the perimeter of a concrete slab building foundation are shown in the cross-sectional views depicted in Figure 10. In Figure 10A, a cast in metal channel 120 is positioned at the perimeter of the slab during the pouring of the concrete James & Wells ref: 306040/108 foundation. The channel comprises one or more upright sections 121 extending from a horizontal member 122 and positioned to receive the building panel 1. The cast in channel in some embodiments incorporates one or more horizontally extending members 125 extending into the concrete slab to provide additional load-bearing and prevent rotation of the channel particularly around its longitudinal axis. In certain embodiments, such as that shown in Figure 10A, a region 135 of exterior cladding comprising a casing material 10 extends below the channel to provide improved waterproofing. In a second embodiment shown in Figure 10B, a metal channel 120 is positioned at the perimeter of the slab during or after the pouring of the concrete foundation. In this embodiment, the channel lies substantially on the top surface of the concrete slab. The channel comprises one or more upright sections 131 extending from a horizontal member 132 and positioned to receive the building panel 1. In certain embodiments, such as that shown in Figure 10B, a region 135 of exterior cladding comprising a casing material 10 extends below the channel to provide improved waterproofing at the perimeter of the concrete slab. It will be appreciated that building panels comprising interior walls or positioned other than at the perimeter of the concrete slab can likewise be located within similarly configured channels as those depicted in Figure 10, but will typically exclude the extending portion 135 of the casing material 10. In other embodiments of interior walls or building panels positioned other than at the perimeter of the concrete slab, the channel 120, 130 is configured to receive the entire cross section of the building panel 1, whereby the exterior -most casing material 10 on both faces of the building panel are within the channel uprights 121, 131.

Figure 11 presents a cross-section view of one embodiment of a building panel configured to engage with a roof substructure 150. In this embodiment, a top plate 140 such as a length of 90 mm x 45 mm timber is positioned on a top cap 160 positioned over and along the upper edge of the building panel 1.

Figure 12 presents various depictions of one embodiment of a building corner comprising two abutting building panels. A cutaway isometric view of the building corner is presented in Figure 12A, and a plan view cross-section of the corner depicted in Figure 12A is shown in Figure 12B. Here, the edge of a first building panel 1 engages with corner channel 170. Components of a second building panel 2, including the building interior casing material 21 and the bulk material 61 are trimmed to engage with the proximal face of the corner channel, whereby the building exterior casing material extends along the adjacent face of the channel to provide a contiguous unbroken exterior surface. A corner flashing 180 is positioned over the building exterior corner. Top channels 160 are optionally positioned over and along the upper edge of building panels 1, 2. Figure 12 B additionally James & Wells ref: 306040/108 shows internal corner angle flashing 190 affixed to the building interior surfaces of panels 1, 2.

Cross sections of representative corner channel 170 and exterior corner flashing 180 are shown in Figures 12C, and 12D, respectively.

Methods and systems for the production of a building panel as described herein are also provided.

In one embodiment, a system for manufacturing composite building elements, includes a feed station configured to position a length of a casing material, a feed station configured to position one or more frame members wherein at least a portion of said frame member is in contact with the first length of casing material, a filler station configured to secure a bulk material to the length of casing material, an insert station that is configured to secure one or more locking elements to a length of casing material, and a cutting station comprising a cutting element configured to cut the casing material to a desired length.

In certain embodiments, the system includes one or more further feed stations configured to position one or more casing materials, optionally before the filler station.

In certain embodiments, the filler station is configured to provide one or more bulk material precursors to the length of casing material, for example, to one or more cavities formed by the casing materials, and or the frame.

It will be appreciated that the properties of the panels produced by the system and method can be controlled by varying the configuration of or operation of one or more components of the system.

Representative properties include panel dimensions, in particular panel length and/or panel thickness; the total number of locking elements required per panel; the separation (e.g., centre spacing) of locking elements; the positioning of the frame and/or one or more frame members; the creation or maintenance of one or more voids in the building panel, for example, a cavity within the frame or within a space defined at least in part by a frame member; the amount, composition, density, or positioning of one or more bulk materials; fire safety rating for panels; or the insulative (heat transfer) properties for the panel.

Various methods for controlling manufacturing systems are applicable, and may include, for example, a computer processing apparatus. In one embodiment, the desired parameters for panels to be produced by the system are input to a computer processing apparatus. The computer processing apparatus calculates parameters for operation of the system, including for example a feed rate for one or more casing materials, a rise time required for a liquid bulk material precursor, a curing time for a bulk material, an adhesion time for securing a solid bulk material to a casing James & Wells ref: 306040/108 material, the positioning of a frame member on a casing material or within a bulk material or precursor thereof, the separation for top and bottom casing material, and the like.

The term “feed rate” as used herein should be understood as referring to the rate (typically meters per minute) of casing material through the system (that is, the rate of movement of the casing material along its direction of travel through the system).

Building systems comprising a plurality of building panels described herein, and methods for using building panels and building systems as described herein in the construction of a building structure are also contemplated.

Generally, a method of constructing a building using the panels and systems described herein comprises arranging a first plurality of the panels to construct walls to form a course of panels or a story of a building, optionally constructing formwork engaged with or adjacent to an uppermost surface of the lower story or course of building panels and extending at least partially across the panels of the lower story or course of panels; optionally pouring concrete onto the formwork to form upon setting, a suspended slab wherein a peripheral edge of the slab is supported on the first panels or adjacently to the first panels; and, coupling a second plurality of further panels to the uppermost surface of the first plurality of panels to construct a second course of panels or a wall of a second story, optionally via engagement of one or more locking elements placed at the periphery of one or more of the building panels, and/or optionally via one or more framing members configured to engage with one or more framing studs of a panel present in the first plurality of building panels with a framing stud of a vertically adjacent building panel, such as a building panel in the second plurality of panels.

In one embodiment, a method of constructing a building includes providing two or more building panels as described herein, wherein one or more of the frame members, such as one or more of the framing studs, are aligned with and optionally engage with a frame member of an adjacently positioned building panel, and wherein the one or more locking elements disposed at or toward the periphery of the building panel is engaged with at least one locking element of the adjacently positioned building panel.

The panels described herein allow the construction of walls and buildings which require a minimum of additional structural elements – tie rods and the like – to be employed yet still deliver a building having the desired performance characteristics, whether they be wind loading, static load bearing, earthquake rating, or thermal and acoustic performance. For example, in certain embodiments where walls of a building comprise multiple adjacently-positioned panels as herein described each James & Wells ref: 306040/108 locked one to the other, the locking inter-engagement creates a single load bearing structure, which will typically require far fewer tie-rods or other structural elements to meet building requirements as not every individual panel need be tied down.

In various embodiments, one or more of the building panels comprises a void in the space defined by the first casing material, the second casing material, and the frame, for example the at least two load bearing framing studs, into which is introduced a load bearing material after the panel is arranged. For example, a load bearing bulk material such as concrete is poured into the void once one or more of the first plurality of building panels is positioned. In certain examples where concrete is used, the concrete is allowed to at least partially harden or cure before a further course of panels are placed. However, through appropriate selection of components of the building panels described herein and parameters of production, in certain embodiments the structural robustness of the building panels described herein is such that there is no need to allow full or in some cases even partial hardening or curing of the concrete, and the positioning of further panels and further courses of panels can continue.

In one example, two or more vertically adjacent building panels each comprise, prior to arrangement, a void in the space defined by the first casing material, the second casing material, and the at least two load bearing framing studs, wherein on arrangement a contiguous void is formed into which the load bearing material is introduced. For example, a load bearing bulk material such as concrete is introduced into the void when two or more vertically adjacent panels are positioned.

In certain embodiments, a bulk material such as concrete is installed on site, for example when one or more building panels is positioned in situ, in a manner to ensure the loading pressure on the outer skins is applied evenly over the entire panel. Those skilled in the art are able, with the aid of this disclosure, to select concrete and other bulk infill material with suitable compressive strength ratings (MPa) and curing rates for such in situ application.

In certain embodiments, particularly those in which a bulk material is to be introduced into one or more building panel on site, one or more frame members in addition to the load bearing framing studs are present within the space defined by the casing materials. For example, one or more horizontal rails are present extending between the load bearing framing studs, optionally together with one or more additional reinforcing members, to accommodate the stress imparted on the one or more building panels due to the characteristics of the bulk material introduced on site, such as the tension and modulus of elasticity of a concrete bulk material.

James & Wells ref: 306040/108 In certain embodiments one or more top plates 140 may be positioned on one or more courses of panels. When required, a roofing substructure 150, for example comprising a roof truss or roof frame, is positioned, for example by coupling to the top plate 140 to further the construction of the building.

It will be appreciated that the building system enables panels of desired thickness, including relatively thick building panels, to be used without compromising strength or aesthetics, and in particular to provide building walls which have a thickness generally corresponding to the thickness of walls of conventional buildings. In some embodiments, thick panels will be desirable, comparable to walls typically implemented in double brick wall type buildings. In other embodiments, thinner panels are employed to provide walls comparable to those of curtain concrete walled buildings, without compromising strength.

It will be understood that since walls of a desired thickness and having particular characteristics are possible without compromising strength and/or load bearing properties, buildings with desired, and in some embodiments exceptional, thermal performance, acoustic performance, and energy ratings can be constructed rapidly and simply. Furthermore, appropriate selection of building panel parameters allows the use of other conventional building components, such as conventional windows, doors, vents, and the like, without compromising aesthetic appearance or performance.

The invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, in any or all combinations of two or more of said parts, elements or features.

Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof as defined in the appended claims.

James & Wells ref: 306040/108

Claims (8)

WHAT WE CLAIM IS:

1. A building panel, comprising: a first casing material, a second casing material, one or more bulk materials disposed between the first and second casing materials, a frame disposed substantially within the first and second casing materials, and optionally one or more locking elements, wherein the one or more locking elements is disposed at or towards the periphery of the building panel to allow engagement with a locking element of an adjacently positioned building panel.

2. The building panel of claim 1 wherein the frame is substantially embedded in and/or coupled to the one or more bulk materials.

3. The building panel of claim 1 wherein at least a part of the frame is coupled to one or more of the casing materials.

4. The building panel of any one of claims 1 to 3 wherein the frame comprises two or more frame members.

5. The building panel of claim 4 wherein the two or more frame members are two or more load bearing framing studs; and optionally one or more rails extending between and coupled to the at least two load bearing framing studs.

6. The building panel of any one of the preceding claims wherein the first casing material, the second casing material, or both the first and the second casing materials are secured to one or more of the frame members.

7. The building panel of any one of the preceding claims wherein the first casing material, the second casing material, or both the first and the second casing materials are secured to the bulk material.

8. The building panel of any one of claims 5 to 7 wherein the coupling of one or more of the rails to one or more of the framing studs is by a coupling portion of the rail, the coupling portion shaped to engage with the cross-sectional profile of the framing stud to which it is coupled. James & Wells ref: