WO2005078204A1

WO2005078204A1 - Panel jointing system

Info

Publication number: WO2005078204A1
Application number: PCT/NZ2005/000012
Authority: WO
Inventors: Christopher James Hodgkinson
Original assignee: Christopher James Hodgkinson
Priority date: 2004-02-13
Filing date: 2005-02-07
Publication date: 2005-08-25
Also published as: NZ531144A; AU2005213578A1

Abstract

The invention comprises a panel joining system comprising a panel (1) having in use a top edge, a bottom edge and side edges, at least one of the edges being a joining edge and a connector member (6). A groove member (13) and tongue member (21, 22) are provided one of which is formed or provided on the joining edge and the other of which is formed or provided on the connector member (6). The groove member (13) removeably inter fits with the tongue member (21, 22) to form the joining system. The invention also comprises a method of erecting such panels.

Description

PANEL JOINTING SYSTEM

This invention relates to a panel jointing system. The invention is directed particularly, but not solely, toward modular wall panels for house construction.

BACKGROUND OF THE INVENTION Modular panels are generally used in interior construction for example office partitions. These partitions are removable and modular and making them relatively easy to assemble and reassemble as required.

These modular systems are not designed for exterior use. Also building construction is performed on site with walls and ceilings made up of timber framing and cladding. These systems can use preformed trusses. Some concrete precasting is also done whereby concrete panels are used, but there is little use and acceptance of premade modular building panel systems in buildings.

However one example in use is the tri-board construction system. This system comprises a three layered panel joined to other panels by simple abutment, stepped joints, or grooved panel edges with hardboard biscuits coupled with batten joint covers.

It is the object of the present invention to provide an improved panel jointing system which will obviate or minimize the aforementioned problems in a simple yet effective manner or which will at least provide the public with a useful choice.

STATEMENT OF INVENTION Accordingly in a first aspect the invention consists in a panel jointing system comprising a panel having in use a top edge, a bottom edge and side edges, at least one of the edges being a joining edge and a connector member, a groove member and tongue member one of which is formed or provided on the joining edge and the other of which is formed or provided on the connector member, such that the groove member removeably inter fits with the tongue member to form the jointing system.

Preferably the grooved portion is formed by an elongate member.

Preferably the elongated member is an extruded member.

Preferably the joining edge or edges is or are located at least on a side edge or side edges.

Preferably the grooved member includes a central channel portion having two spaced tabs forming a second channel portion therewithin the central channel wherein the second channel is made up of two spaced apart channels.

Preferably the tongue member includes a member having a body portion with two fin members that are adapted to be a frictional fit into the spaced apart channels.

Preferably the body portion is a box section adapted to allow panels to be joined at an angle to each other.

Alternatively the body portion is a planar member such that the tongue member being a channel member or H-shaped allows inline joining of at least two panels.

Preferably the panel is a sandwich construction including a core member and outer planar member(s).

Preferably the core is fabricated from polystyrene (EPS).

Preferably the planar member(s) includes a two layered assembly including an inner layer of ply and an outer layer of plaster-board.

Alternatively the planar member(s) includes a two layered assembly including at least one layer of ply.

Preferably fastening means fasten the grooved portion to the tongue member.

Alternatively the grooved portion is provided by a recess formed by having the core member recessed below the outer planar members.

Preferably in use, the panel is a wall panel or roof panel or floor panel. Preferably further fastening means fasten each panel to the core.

Preferably the panel has the recess at the top edge and the recess at the bottom edge being adapted to capture a top and bottom fixing member respectively.

Accordingly in a second aspect the invention consists a method of erecting a panel, each panel having at least one joining edge portion and there being at least one connecting member such that the panel can be joined to the connecting member, the joining edge and connecting member each forming or providing one of a groove member and a tongue member, wherein the following steps are carried out: locating the panel in an upright position; - engaging the panel and connecting member so that the tongue member engages the groove member; engaging another panel on the connector member; affixing fastening means to tongue member and panel; affixing the base of the panel to substrate.

Preferably the elongate is an extruded member.

Preferably the joining edge is located at least on the side edges.

Preferably the tongue member includes a member having a body portion with two fin members that are adapted to frictional fit into the spaced apart channels.

Alternatively the body portion is a planar member such that the tongue member being a channel member or H-shaped allows inline joining of at least two panels. Preferably the panel is a sandwich construction including a core member and outer planar member(s).

Preferably the planar member (s) includes a two layered assembly including an inner layer of ply and an outer layer of plasterboard.

Alternatively the planar member (s) includes a two layered assembly including at least two layers of ply.

Preferably fastening means are provided which fasten the groove member on to the tongue member.

Alternatively the groove portion is provided by a recess formed by having the core member recessed below the outer planar members.

Preferably in use, the panel is a wall panel or roof panel or floor panel.

Preferably further fastening means fasten each panel to the substrate.

Preferably the panel has a recess on the top edge and a recess on the bottom edge being adapted to capture a top and bottom fixing member respectively.

DRAWING DESCRIPTION

Preferred forms of the invention will now be described with reference to the accompanying drawings.

Figure 1 shows a plan view of the panel jointing system of the invention showing various jointing examples.

Figure 2 is a perspective view of a system similar to the system shown in figure 1

Figure 3 is a cross sectional view of a first female jointing member.

Figure 4 is a cross sectional view of a second female jointing member.

Figure 5 is a cross sectional view of a third female jointing member.

Figure 6 is a cross sectional view of a fourth female jointing member. Figure 7 is a cross sectional view of a sixth female jointing member.

Figure 8 is an end cross sectional view of a panel having a top cap member.

Figure 9 is a top plan view of a panel having j oining means.

Figure 10 is a top perspective view of one panel having the joining means.

Figure 11 is a top plan view of several panels j oined together.

Figure 12 is a perspective view of another panel type.

Figure 13 is a perspective view of a typical panel.

Figure 14 is a cross section of roof to roof and roof to wall panel connections.

Figure 15 is a cross section of another roof to wall type connection.

Figure 16 is a close up cross sectional view of a wall to foundation connection

Figure 17 is another cross section close up view of a wall to foundation connection.

Figure 18 is yet another cross section close up view of a wall to foundation connection.

Figure 19 is a view in Figure 1 of an alternative joint construction according to the invention,

Figure 20-23 show plan views of the various joints of Figure 19 on an enlarged scale,

Figure 24 shows a member which forms a groove for use in the jointing system of the invention, and,

Figure 25-28 shows various members which form tongues for use in a jointing system according to the invention.

To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the description herein are purely illustrative and are not intended to be in any sense limiting.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the preferred form of the invention panels are provided which in use have top, bottom and side edges. At least one edge provides a joining edge. A connector is also provided and the joining edge and connector each provide one of a groove and tongue member. The groove or tongue member are inter engageable.

Referring now to specific constructions the invention is provided as follows.

Figures 1 and 2 show various forms of the jointing system for panels. For example there are the corner joint, the inline joint, the angled joint and the abutting angled joint. As shown there are panels 1, 2, 3, 4 and 5 which use these various jointing types. The first type is the corner joint type 6 which is normally used as the starting point for building construction. Obviously this would depend on the order of panels delivered to the site. This order can be changed depending on which order of wall construction is required. The inline jointing system 7 is shown as well as the end wall abutting angle system 8 which is followed by the angled joint system 9.

As shown in figures 1, 2 & 13 the panel 1 to 5 has a cored portion 10 and an outer portion 11. The cored portion can be any material that is both light, has insulation qualities and is easily adapted to different situations in that it can be moulded or shaped on site or before to allow construction in different situations as the need arises. Preferably the core is fabricated from polystyrene (EPS) which may be in the form of strips or in one piece. The outer material in this case can be at least one layer of material having different properties depending on the in use conditions. For example the outer material can be plywood for external or corrosive or harsh situations - i.e. outside. In internal situations the layer can include plaster-board. Plywood also provide excellent strength and fixing characteristics. Any variation on these layers is envisaged such that there could be two layers of ply or two layers of plasterboard where required. These layers can be laminated and or glued or fastened in place. Each panel 1 to 5 has at least one female jointing member which provides at least a first channel 13. The female member can be termed a groove member and is shown in detail in figure 3. The female member 12 has a first channel 13 formed by a base 17 and upstanding walls portions 18 and 19. In this example walls 18 and 19 can be formed by hollow boxed sections. At least two tab members 14 and 15 protrude from base 17 and are substantially parallel to the wall members 18 and 19, to thereby form second channels 15 and 16. These second channels 15 and 16 are shaped and sized to allow the removable insertion of a male member as per the various jointing types 6, 7, 8 and 9. The male member can be a tongue member.

The first jointing system as shown in figure 1, is the comer jointing system. The comer jointing system like the other jointing systems cover different male members for different panel orientations. Preferably the female member 12 as shown in figure 3, is the same for all the panels. All the panels have female members 12 when in use, on each end or vertical of panels 1 to 5. Each side of the channel 13 may have a rebate 13a at the entrance thereto.

As shown in figure 4 male member 20 is made up of a base 20 having protruding members 21 and 22. The protruding members in this example can comprise prongs 23, 24, 26 and 28 which respectively form channels 25 and 27 respectively. In this example the base can be a boxed section to save on material and if desired, provide a conduit for the reception of services if required. Male member 20 is adapted for use in corner sections of a building wall construction whereby the panels have to be substantially 90° with respect to each other. The corner jointing area can be the starting point for the wall construction. A thickened position 29 may be provided at the base of prong 23 to 28 on the mutually outsides of the prongs.

Figure 5 shows a male member 30 having a substantially H-shaped section. The H-shaped section is made up of a central web member 30a with flange members 31, 32, 33 and 34. Again the thickened positions 29 may be provided.

The male member 30 as shown in figure 5 is used for in-line panel jointing whereby the panels can be put on either side of the web member 30a to allow a straight line of walls to be erected.

During construction the thickened parts 29 engage into the rebates 13a to assist stability of the joint. As shown in figure 6 there is a U-shaped member or male member 35 which is made up of a base 35a and protruding members 36 and 37 which again form a channel shaped section. This member is used in the situation where the end of one wall meets another wall at 90°. This wall joint is not a comer situation but it is used where, for instance, you have a straight wall in which another wall must meet this wall at 90°. In this situation the male member 35 as shown in figure 2 is attached to the outside face of one panel 4. Panel 4 has a series or one piece or a block e.g. a fixing member 42 within the core portion- see figure 2. This member can be a timber block member.

As shown in figure 7 there is a male jointing member 40. Member 40 is similar in construction to the comer member 20 used in the comer jointing system 6. The member 40 comprises a central base section 40a that can hollow to allow for the routing of services, save weight and cost and make transportation easier. This member like the comer member has protruding members 43, 44, 45 and 46 which form channel portions to allow for the attachment of the female members 12 of adjoining panels.

Figures 8, 9, 10 and 11 show another form of the panels 1 to 4 schematically whereby as shown in the plan view of figure 11 each panel has a female jointing member on one edge and a male jointing member on the other. The panels of Figures 1 to 7 have female joining members 12 on both end edges, however in the case of Figures 8 tO 11 a male member is provided on the panel.

Figure 12 shows another panel type which includes a core portion made up of at least two portions. The core is recessed in use at the top and bottom portion to allow for a timber portion. The sides of the core and timber portions are covered by planar member such as plywood or plasterboard.

There is also a grooved portion in the bottom of the panel. This allows the panel to be joined to the top plate and the bottom plate during the construction process.

Each panel 1-5 as previously discussed has a top, a base and end edges. The panels generally being of a height 2.4 metres which will match the normal stud height and the width can be 3.6 metres. These dimensions may vary depending on circumstances. The top and base portions of the panel will be slotted or recessed or grooved. This slot will be dimensioned to allow for the insertion of a top plate and bottom plate respectively. The slot can be formed by either removing polystyrene or forming it of smaller dimensions than the outer layers. This slot can be dimensioned to suit other fixing on the floor and ceiling. The end edges of the panel have female members 12 on both edges which allow for the mating with the male jointing member depending on which jointing type is being used.

The panel jointing system can be achieved by carrying out some of the following steps:

Step 1 - Normally the installation procedure is started at a comer as this is the most stable end to begin with. Though other starting points are also envisaged.

Step 2 - Normally there will be a foundation in place. The foundation can be concrete or timber.

Step 3 - There is normally a bottom plate near the edge of the foundation. The bottom plate may be fixed in the normal manner to the foundation. This can be screwing, fixing, glue or bolting.

Step 4 - Stand up a first panel over the bottom plate. The panel bottom recess fits over the bottom plate. The bottom of the panel is then fixed to the bottom plate by glue and or screws or any fixing means that enables this to be done.

Step 5 - A male member is then slid into the female member.

Step 6 - Another panel is then turned upright onto the same bottom plate and is slide into and against the male member.

Step 7 Fixing means fastenings are used to fix the male member to the female member as shown in the figures screws are shown.

Step 8 - The same process just mentioned is repeated until all the walls are put in place.

Step 9 - Once all the wall members are in place then a continuous top plate member is put into the top of each panel. The top of each panel having a recess to allow the positive fixing of the top plate. Step 10 - Various roofing members such as rafters and the normal roof process is carried on after that.

The order of these steps need not be strictly adhered to. For example fixing of the panel to the base and or the male member can be rescheduled accordingly. This method has been developed to allow sliding into place of the components with out the need for lifting and precise measurements. Other sequence of steps can also be followed.

As shown in figure 13 there is a typical panel 100 which is adapted for use in all parts of buildings. The buildings can be both residential and industrial.

Minimally panel 100 can have a grooved or female edge section on any or all edges 101, 102, 103 and 104. The choice of edges to have the connections will depend on the use that the panel(s) been used in and the orientation that the panel must be put in with respect to other panels which are being joined thereto.

The male joining member in all these connection cases for the standard panel is preferably a separate elongate member which has dimensions that depend on both the interfit with the female panel and its orientation. Each panel will have a core portion and an outer portion. As previously described the core portion can be any material that enables the panel to fulfil its function and be useful as a wall or ceiling panel. Therefore the core can be formed by a polystyrene material to assist in the insulative and structural integrity of the panel. Each panel in use for example can have vertical and horizontal edges having female jointing edges. The female edge can be formed integrally with the panel or the internal core can be a recessed to form a groove or it can be formed from a separate member in combination or with a recess.

In figure 14 there is shown the panel 100 in a wall to roof jointing situation and a roof to roof panel situation. The only difference here is that the male members 112, 113 and 114 have a cross section dimensioned and shaped to enable the wall panels to be joined to the ceiling panels or to roof panels and the appropriate configuration as per the building design.

Figure 15 shows another variation on the ceiling to wall connection whereby we have a typical rafter to wall connection. In this case panel 120, which is formed by core 121 and an outer planar member 122, has been formed with a recess. The core 121 has been recessed below the planar member 122. This recess allows a top plate member 123 to be fixed inside the recess and joined by appropriate fastening means 124 which go through the planar member 122 and through to the top plate member 123. The rafters 125 are typically joined to the top plate member 123 by fastening means 126.

Figures 16, 17 and 18 show various forms of the wall to foundation connection. This connection will depend to some extent, on what layers are required on the outer weathering face of the wall or roof panel of the building with respect to the concrete foundation. Figure 16 shows in one form, the lower edge of the wall member 127 being recessed as in figure 15, to allow the bottom plate member 128 to be covered by the recess of the panel. Again fixing means 129 are used to attach the planar member 130 through to the bottom plate member 128. The bottom plate member 128 as typically the case is fixed in the normal way to the concrete foundation by further fixing means such as dynabolts. Other methods of fixing the top plate and bottom plate to respective supporting members are also equally possible.

Figure 17 shows a similar detail to figure 16 except for the fact that the outer cladding is now weatherboards over timber battens.

Figure 18 shows another form of the wall to foundation detail whereby the outer layer is now a masonry veneer. In both of these variations of a wall to foundation detail, the wall member has been recessed to allow for the bottom plate to be fitted therein. Equally in combination with or in place of the recess, the male member as shown in figures 4 - 7 and 1 and 14 can also be used therewith. The panel can be equally formed as a wall panel, roof panel or floor panel. Floor panels will need a stronger core - e.g. polypropylene with a honeycomb structure.

The panels can be any shape depending on the orientation of the panels and the design required e.g. rectangular, square, polygonal etc e.g. gable ends or sloping roofs, or curved roofs. The panels can be curved or angular or flat.

Referring now to Figures 19 to 28 an alternative groove and tongue arrangement is shown. This arrangement is particularly suitable for narrowed wall sections, having say a core thickness of 38mm, whilst the construction of Figures 1 tO 7 may be preferred for panels having a larger core thickness. The core portions 10 and outer portions 11 are provided as before. Again various connections may be made such as an angled comer 9, an inline connection 7, a wall abutting connection 8 and a comer 6.

Figures 20, 24 and 25 show an angled comer.

A female connector 150 having a groove 151 is positioned in the joining, edge of a pair of panels 10 to be joined at an angle as shown at 9. The groove 151 is preferably flanked by a pair of grooves 152 which serve a similar purpose to rebates 13a. The connector 153 has a prong 154 for each female connector 150 and a pair of ribs or prongs 155 to engage the grooves 152 in use.

Figure 26 shows an in-line connector having two prongs 160 and a pair of ribs 161 for each female connector 150. The rib 161 together with a supporting web 162 form a rib which is substantially "T" shaped in cross section.

Figure 27 shows a wall abutting connector 170 with prong 171 and side ribs 172 supported on webs 173.

Figure 28 shows connector 180 carrying prongs 181 and side ribs 182 to form a right angled comer.

The use of the construction of Figures 19 to 28 is substantially as for the constructions of Figures 1 to 7.

Referring again to Figures 1 and 2 conducts 130 may be provided through the panel to run service wires or pipes. A cut out 131 can be provided to mount a switch box or other device on the panel.

Throughout the description and claims of this specification the word "comprise" and variations of that word, such as "comprises" and "comprising", are not intended to exclude other additives, components, integers or steps.

The panel jointing system has the following advantages:

1. Simple and quick installation. 2. Modest production/manufacturing costs.

3. Structural and non-structural uses.

4. Easy to manufacture.

5. Lightweight making easy transport and installation.

6. Easy sliding installation.

Claims

WHAT WE CLAIM IS:

1. A panel joining system comprising a panel having in use a top edge, a bottom edge and side edges, at least one of the edges being a joining edge and a connector member, a groove member and tongue member one of which is formed or provided on the joining edge and the other of which is formed or provided on the connector member, such that the groove member removeably inter fits with the tongue member to form the joining system.

2. A panel system as claimed in claim 1 wherein the groove is provided on the join edge and the connector marker provides or carries the tongue member.

3. A panel jointing system as claimed in either one of the claims 1 or 2 wherein the grooved portion is formed by an elongate member wherein the member.

4. A panel jointing system as claimed in claim 3 wherein the elongate member is an extruded member.

5. A panel joining system as claimed in any one of the preceeding claims wherein the joining edge or edges is or are located at least on a side edge or side edges.

6. A panel jointing system as claimed in anyone of the preceeding claims wherein the grooved member includes a central channel portion having two spaced tabs forming a second channel portion there within the central channel wherein the second channel is made up of two spaced apart channels.

7. A panel jointing system as claimed in any one of the preceeding claims wherein the tongue member includes a member having a body portion with two fin members that are adapted to be a frictional fit into the spaced apart channels.

8. A panel jointing system as claimed in claim 7 wherein the body portion is a box section adapted to allow panels to be joined at an angle to each other.

9. A panel system as claimed in claim 7 wherein the body portion is a planar member such that the tongue member being a channel member or H-shaped allows inline joining of at least two panels.

10. A panel system as claimed in anyone of the preceeding claim wherein the panel is a sandwich construction including a core member and outer planar member(s).

11. A panel system as claimed in claim 10 where in the core is fabricated from polystyrene (EPS).

12. A panel system as claimed in either one of claims 10 and 11 wherein the planar member(s) includes a two layered assembly including an inner layer of ply and an outer layer of plaster-board.

13. A panel system as claimed in either one of claims 10 and 11 wherein the planar member(s) includes a two layered assembly including at least one layer of ply.

14. A panel system as claimed in any one of the preceeding claims further including fastening means to fasten the grooved portion to the tongue member.

15. A panel system as claimed in any one of the claims 10 to 13 wherein the grooved portion is provided by a recess formed by having the core member recessed below the outer planar members.

16. A panel system as claimed in any one of the preceeding claims where the panel is a wall panel or roof panel or floor panel.

17. A panel system in claim 13 wherein further fastening means fasten each panel to the core.

18. A panel system as claimed in any one of the preceding claims wherein the panel has the recess at the top edge and the recess at the bottom edge being adapted in use to capture a top and bottom fixing member respectively.

19. A method of erecting a panel, each panel having at least one joining edge portion and there being at least one connecting member such that the panel can be joined to the connecting member, the joining edge and connecting member each forming or providing one of a groove member and a tongue member wherein the following steps are carried out: locating the panel in an upright position; - Engaging the panel and connecting member so that the tongue member engages the groove member; engaging another panel on the connector member; affixing fastening means to tongue member and groove edge; - affixing the base of the panel to a substrate.

20. A method as claimed in claim 19 wherein the elongate is an extruded member.

21. A method as claimed in either one of claims 19 and 20 wherein the joining edge is located at least on the side edges.

22. A method as claimed in any one of the claims 19 to 21 wherein the grooved member includes a central channel portion having two spaced tabs forming a second channel portion therewithin the central channel wherein the second channel is made up of two spaced apart channels. '

23. A method as claimed in any one of claims 19 to 22 wherein the tongue member includes a member having a body portion with two fin members that are adapted to frictional fit into the spaced apart channels.

24. A method as claimed in claim in 23 wherein the body portion is a box section adapted to allow panels to be joined at an angle to each other.

25. A method as claimed in claim 23 wherein the body portion is a planar member such that the tongue member being a channel member or H-shaped allows inline joining of at least two panels.

26. A method as claimed in any one of claim 19 to 25 wherein the panel is a sandwich construction including a core member and outer planar member(s).

27. A method as claimed in claim 26 wherein the planar member (s) includes a two layered assembly including an inner layer of ply and an outer layer of plasterboard.

28. A method as claimed in claim 26 wherein the planar member (s) includes a two layered assembly including at least two layers of ply.

29. A method as claimed in any one of the claims 19 to 28 wherein fastening means are provided which fasten the groove member to the tongue member.

30. A method as claimed in any one of claims 26 to 28 wherein the groove portion is provided by a recess formed by having the core member recessed below the outer planar members.

31. A method as claimed in any one of claim 19 to 30 wherein the panel is a wall panel or roof panel or floor panel.

32. A method as claims in claimed further fastening means fasten each panel to the substrate.

33. A method as claimed in any one of claims 19 to 32 wherein the panel has a recess on the top edge and a recess on the bottom edge being adapted to capture a top and bottom fixing member respectively.