[0001] This invention relates to a wall panel, hereinafter referred to as being of the kind
specified, in or for a building unit, hereinafter referred to as being of the kind
specified.
[0002] In this specification a wall panel of the kind specified comprises a structural sandwich
having inner and outer skins sandwiching therebetween and being bonded to an infilling.
Preferably the infilling is a rigid foam or expanded plastics material.
[0003] By a portable building unit of the kind specified we mean a portable building unit
which is factory assembled for delivery to a prepared site in an assembled condition
complete with at least a floor structure and a side wall comprising a wall panel.
The building unit may have four side walls, or where the unit is to be assembled with
other similar units it may have one or more side walls omitted. Where the unit is
for a single storey building or is for the top storey of a multi-storey building it
may have a roof structure.
[0004] The invention has been particularly devised in connection with a building unit of
the kind specified having a wall panel connected to a floor structure and to a leg
means whereby floor loads are transmitted through the wall panel to the leg means.
In addition, the wall panel may support a roof structure and so also transmit roof
loads to the leg means.
[0005] Hitherto a wall panel of the kind specified has comprised a timber peripheral frame,
a bottom member of which is fastened to the floor structure. However, in use of such
a wall panel in a building unit as described above, the connection of the wall panel
to the floor structure must transmit the above mentioned floor loads between the floor
structure and the wall panel. The presence of a timber bottom peripheral frame member
can lead to inadequacy in the connection, particularly because the timber is susceptible
to rot, especially as it is relatively close to the ground.
[0006] Accordingly, an object of the invention is to overcome or to reduce the above mentioned
disadvantages hitherto encountered with a wall panel of the kind specified.
[0007] According to a first aspect of the present invention we provide a wall panel of the
kind specified wherein the panel is provided with a frame member extending along or
adjacent one edge of the panel and the frame member comprising a frame element comprising
a channel shape formation comprising two spaced limbs defining an open mouth therebetween
at their one ends and interconnected by a transversely extending web and having a
plurality of bracing elements extending transversely between the limbs and disposed
between the one ends of the limbs and said web and arranged at spaced positions longitudinally
of the frame element.
[0008] Preferably the frame element is of channel shape and the web interconnects the limbs
at their other ends.
[0009] The provision of the bracing elements in combination with a frame element having
said channel form permits the use of a relatively thin wall member for the frame element
and made of suitable material such as steel or other metal or a plastics material
with or without suitable reinforcement, whilst providing adequate strength to resist
forces imposed during use of the structure as well as being rugged enough for transport
and manufacture of the panel.
[0010] A plurality of pairs of opposed apertures may be provided in the limbs to receive,
in the apertures of each pair, a fastener to connect the wall panel to a floor structure.
[0011] Preferably a recess is provided around an aperture of each pair in at least one limb
to receive a part of the fastener.
[0012] Preferably a recess is provided around each aperture of each pair.
[0013] The or each recess may be of generally frusto-conical configuration.
[0014] The or each recess may be provided by a deformed region of the limb in which the
apertures are provided.
[0015] Each bracing element may be retained between the limbs by engagement of an inwardly
deformed region of the limb with the bracing element.
[0016] Each bracing element may comprise a tube.
[0017] Each bracing element may comprise a generally cylindrical tube.
[0018] The inwardly deformed regions of the limbs may be engaged within the ends of the
tube to retain the tubular bracing element between the limbs.
[0019] The inwardly deformed region on the opposite side thereof to that which engages the
bracing element may provide a said recess.
[0020] The panel may have at least one other frame member extending along or adjacent at
least one other edge of the panel and preferably the panel has a peripheral frame
comprised of said frame element and other frame members.
[0021] The or each other frame member may be made of timber.
[0022] The frame members may be connected to each other.
[0023] The outer skin of the wall panel may comprise a plurality of sheets, the longer edges
of the sheets being disposed to extend vertically and having at their adjacent longer
edges inturned flanges which are secured together.
[0024] Openings may be provided in the channel shaped element to receive the flanges.
[0025] The frame element may be disposed with the one ends of the limbs facing outwardly
of the panel and the transversely extending web disposed transversely of the thickness
of the panel.
[0026] In this case the openings for the flanges may be provided in the transversely extending
part and in the limbs adjacent to the transversely extending part.
[0027] The limbs may be generally planar, as may be the transversely extending part which
may extend perpendicular to each limb.
[0028] Alternatively, the outer skin of the wall panel may comprise a plurality of sheets,
the longer edges of the sheets being disposed to extend horizontally and the shorter
edges of the sheets extending vertically and the sheets having at their adjacent longer
edges inturned flanges which are secured together.
[0029] In this case, since the flanges extend parallel to and spaced from the frame element
it need not be provided with openings.
[0030] In this case the frame element may have a rebate provided in the limb adjacent the
outer skin, the rebate providing a shoulder which faces towards the free end of the
associated limb and the outer skin may conform to the shape of the rebated limb.
[0031] In either case the frame element may be fastened to an element of the floor structure
by means of a threaded fastener comprising a shank and first and second abutments
provided on the shank, at least one of the abutments being threadedly engaged with
the shank for axial movement relative thereto, with one abutment in clamping relationship
with an outer limb of the channel section element and the other abutment in clamping
engagement with the element of the floor structure with the shank of the fastener
extending through a bracing element.
[0032] Preferably said one abutment is fixed to the shank and comprises, for example, a
head of a bolt and the other abutment comprises a nut threadedly engaged with the
shank.
[0033] The nut may be fixed relative to the frame element.
[0034] According to a second aspect of the present invention we provide a method of making
a wall panel of the kind specified comprising the step of taking a frame element comprising
a channel shape formation comprising two spaced limbs defining an open mouth therebetween
at their one ends and interconnected by a transversely extending part, positioning
a plurality of bracing elements to extend transversely between the limbs and disposed
between the one end of the limbs and said web at spaced positions longitudinally of
the frame element, and acting on the outwardly facing surface of at least one of the
limbs with a tool adjacent said bracing elements to provide an inwardly deformed formation
to engage a bracing element to retain it between the limbs.
[0035] Preferably the tool punches an aperture in the limb within the inwardly deformed
formation.
[0036] Preferably the method comprises acting on the outwardly facing surface of both limbs
with pairs of opposed tools adjacent said bracing elements to provide inwardly deformed
formations to engage opposite ends of the bracing elements to retain them between
the limbs.
[0037] Preferably said pairs of opposed tools punch apertures in the limbs within the respective
inwardly deformed formations.
[0038] The inwardly deformed formation may be of generally frusto-conical configuration
and may provide a recess in the outwardly facing surface of the limb.
[0039] The or each tool may comprise a leading, piercing, portion and a trailing, deforming,
portion of greater cross-sectional dimension than the piercing portion, the piercing
portion being adapted to pierce the aperture in a limb and the trailing portion being
adapted to bend or swage the material of the limb in co-operation with the bracing
element to form the inwardly deformed formation.
[0040] Preferably the bracing element is generally cylindrical, at least at the ends thereof,
and the deforming portion is frusto-conical having a larger diameter which is at least
equal to the internal diameter of the bracing element.
[0041] The piercing portion may be generally cylindrical and of a diameter corresponding
to the diameter of the smaller end of the deforming portion.
[0042] The or each tool may be caused to act on the channel shaped element by a fluid operated
piston and cylinder means.
[0043] Preferably an individual fluid operated piston cylinder means provided for each tool.
[0044] The method may comprise the step of disposing a plurality of bracing elements on
locating means at predetermined positions in a piercing and forming apparatus, the
locating means being disposed in a predetermined relationship with pairs of opposed
tools, disposing the channel section element with the one ends of the limbs facing
downwardly over the bracing elements and then carrying out said step of acting on
the outwardly facing surface of the limbs with the pairs of opposed tools.
[0045] According to a third aspect of the invention we provide a portable building unit
of the kind specified comprising a wall panel according to the first aspect of the
invention or a wall panel made by a method according to the second aspect of the invention.
[0046] Embodiments of the invention will now be described with reference to the accompanying
drawings, wherein:
FIGURE 1 is a transverse cross-section through a building unit embodying the invention;
FIGURE 2 is a longitudinal cross-section through the building unit of Figure 1;
FIGURE 3 is an enlarged fragmentary view showing the connection between a wall panel
and a floor structure of the building unit of Figure 1;
FIGURE 4 is a fragmentary perspective view showing the relationship between a frame
member of a wall panel of the building of Figure 1 and a seam between external skin
sheets;
FIGURE 5 is a fragmentary side elevation showing a connection between channel shaped
elements of a flat member or a wall panel of the building of Figure 1;
FIGURE 6 is a section on the line 6-6 of Figure 5;
FIGURE 7 is a fragmentary section showing the connection of a leg to the building
unit of Figure 1;
FIGURE 8 is a portion of Figure 7 drawn to an enlarged scale;
FIGURE 9 is an elevation of a wall panel for the building unit with an outer skin
omitted but with the position occupied by its periphery shown in dashed line;
FIGURE 10 is a section on the line 10-10 of Figure 9;
FIGURE 11 is a section on the line 11-11 of Figure 9;
FIGURE 12 is an elevation similar to that of Figure 9, but of an alternative wall
panel;
FIGURE 13 is a section on the line 13-13 of Figure 12;
FIGURE 14 is a side elevation of a channel shape element used in a wall panel of the
building of Figure 1;
FIGURE 15 is a view similar to that of Figure 1 but through an alternative embodiment
of the invention;
FIGURE 16 is a view similar to that of Figure 2 but through the embodiment of Figure
15;
FIGURE 17 is a fragmentary view of part of Figure 15 to an enlarged scale;
FIGURE 18 is a view similar to that of Figure 9 but in respect of a wall panel of
the embodiment of Figure 15;
FIGURE 19 is a side elevation, partly broken away, of a channel shape element for
use in the embodiment of Figure 15;
FIGURE 20 is a section to an enlarged scale on the line 20-20 of Figure 19;
FIGURE 21 is a plan view, with parts omitted, of part of a piercing and forming apparatus
for use in the manufacture of a bottom frame member for use in the wall panels of
the building unit of the preceding Figures;
FIGURE 22 is a side view of the part of the apparatus shown in Figure 21;
FIGURE 23 is a perspective view, with parts omitted, shown by an apparatus for making
wall panels embodying the invention;
FIGURE 24 is a fragmentary cross-section through part of the apparatus of Figure 23
showing the clipping of a channel shape element to a platen.
FIGURE 25 is a side elevation of an air release tube used in the apparatus of Figure
23;
FIGURE 26 is an end view of the air release tube of Figure 25, and
FIGURE 27 is an underneath plan view of the air release tube of Figure 25.
[0047] Referring now to the Figures, there is shown a portable building of generally right
parallelepiped configuration having two longer side walls 12 and two shorter end walls
13, a roof structure 14 and a floor structure 15. Door and window openings are provided
in the walls as shown at 16 and 17 respectively. Of course, if desired, the doors
and windows may be located at other positions than those shown.
[0048] The building unit is provided with four legs 18, two on each side of the building
arranged symmetrically. The floor structure 15 comprises two parallel longitudinally
extending floor side beams 19, 20 disposed to extend along the longitudinal sides
of the floor structure. The floor side beams 19, 20 are identical and are made as
rolled sections in steel and are of essentially channel configuration with the web
of the channel disposed vertically and the limbs extending inwardly of the floor structure.
[0049] Fastened by welding to the side beams 19, 20 are a plurality of cross-beams which
extend transversely of the floor structure and are located at spaced positions longitudinally
of the side beams. The outer cross-beams 23 are of channel configuration with the
web disposed horizontally and the limbs extending vertically downwardly and are provided
with out-turned lateral flanges. The intermediate cross-beams 23
a are of channel configuration but with the webs disposed vertically and the limbs
disposed so as to extend towards one side of the building unit and each upper limb
has a downwardly depending flange 23
b. The cross-beams are provided with cut-outs at each end to accommodate the limbs
of the side beams.
[0050] Supported on the cross-beams 23, 23
a and the upper limbs of the floor side beams 19, 20 is a floor deck 24 made of moisture
resistant structural board, such as wood particle board with a fully bonded veneer
covering. However, if desired, other material may be used.
[0051] The cross-beams 23, 23
a are connected to top hat section skids 27 made of galvanised rolled steel section
and provided to sit on a lorry bed during transportation.
[0052] Each wall of the building unit is formed as a panel having a stressed skin structural
sandwich of inner and outer skins 30, 31 which are sandwiched between and bonded together
by means of a polyurethane foam 32. In addition a peripheral frame 33 is provided
between the inner and outer skins. In the present example the outer skin 31 comprises
a coloured steel cladding, for example, galvanised steel sheet having a coloured PVC
coating on the external surface to give a long and maintenance free life. The outer
skin 31 is made up of a plurality of such galvanised steel sheets 37 which, as best
shown in Figures 4 and 10, are seamed vertically with one sheet being formed with
a wider flange 34 at one edge and a narrower flange 35 at the other edge. The joint
is formed by folding the free marginal portion 36 of the wider flange 34 around the
free edge of the narrower flange 35 to lie in face-to-face relation with the adjacent
portion of the latter on the side thereof remote from the remainder of the wider flange.
The folded over portion of the two flanges may then, if desired, be further folded
over as a whole through 180° to form a joint having five thicknesses of metal with
the marginal edged portion 36 of the wider flange sandwiched between portions of the
narrower flange and with such three layer portion itself sandwiched between portions
of the wider flange. Such a joint can be formed by rolling in two successive operations,
if desired. However, the panels 38 may be interconnected by other configurations of
interconnected flanges such as by clipping together equal length upstanding flanges
or otherwise securing flanges together, or indeed the sheets may be secured together
in any other desired convenient manner.
[0053] The internal skin 30 is made of galvanised steel sheet with a polyester powder coating,
or of gypsum wallboard, but may be made of any other desired material.
[0054] The polyurethane foam is 47mm thick which gives good thermal insulation and securely
bonds the sheets together.
[0055] As best shown in Figure 9, the peripheral frame 33 comprises an upper member 38 and
end vertical members 39. In addition, intermediate vertical members are provided as
shown at 40. As best shown in Figures 10 and 11, the intermediate members are provided
adjacent the seams between the sheets 37, the number and positioning of the intermediate
members 40 and the sizes of the sheets 37 being chosen in accordance with the overall
size of the particular panel desired and the available maximum width of the sheets
37. The inner skin 30 is also provided with inwardly directed flanges shown at 30
a in Figures 10 and 11 and these are received in a slot 30
b provided in the intermediate frame member 40 and also in a peripheral frame member
39. It will be seen that the sheets 37 of the inner and outer skins overlie the majority
of the extent of the peripheral frame member but leave a small portion 30
c, 31
a of the peripheral frame members exposed respectively.
[0056] Figures 12 and 13 show an example of an alternative configuration of panel and hence
the same reference numerals have been used to refer to corresponding parts.
[0057] The frame 33 also has a bottom member 41 which comprises a channel shaped element
made, in the present example, of galvanised cold rolled steel, as best shown in Figures
3 and 8, and comprises spaced generally parallel inner and outer limbs 42
a, 42
b which define an open mouth between their one ends 44 and which are interconnected
at their other ends by a transversely extending web 43. The channel is disposed so
that the web 43 is disposed inwardly of the panel whilst the one ends 44 of the limbs
are disposed facing downwardly. The panels 37 of the outer skin overlie an upper part
of the outer limb 42
b, to leave a lower part exposed, as shown at 31
a, whilst the panels of the inner skin overlie the inner limb 42
a to leave a lower part exposed, as shown at 30
a.
[0058] The inner and outer limbs 42
a, 42
b have an inwardly deformed formation 45 which is of frusto-conical configuration providing
an aperture 46 and a recess or countersink 47.
[0059] A countersink head 48 of a fastener 49 having a shank 49
a which extends through the apertures 46 and through an aperture 50 in the vertical
web of the floor side members 19, 20 or end transverse floor members 23 and is threadedly
engaged with a nut 51 which, in the present example, is a rivet nut captive with the
web of the floor frame member 20, 23. A cylindrical bracing element 53 is disposed
between the limbs 42
a, 42
b and, as hereinafter to be described, during assembly is retained theredisposed by
the formations 45.
[0060] At their upper ends the wall panels are connected to the roof structure 14 by means
of being screwed to the upper frame member 38 by wood screws 56.
[0061] Each leg 18 comprises an upper part 18
a of hollow rectangular tubular configuration to provide a socket which receives telescopically
a lower part 18
b with suitable means such as peg 18
c to permit the two parts of the leg to be interconnected at a desired extension.
[0062] The legs are attached to the building unit, as shown in Figure 1, by means of bolts
18
d, 18
e passing through brackets 18
f disposed on opposite sides of the legs 18 at the top and bottom of the unit respectively.
The bolts 18
d pass through the upper frame member 38 with their heads disposed inside a roof duct
and with a nut engaged with their threaded end adjacent the bracket 18
f. The bolts 18
e pass through the bottom member 41 with their heads disposed adjacent the brackets
18
f and are surrounded by a bracing element 53 and threadedly engaged with a rivet nut
captive with the web of the floor frame members 19, 20.
[0063] The unit described above has structural integrity which is afforded by the floor
side beams 19, 20 and cross-beams 23, 23
a, the stressed structural sandwich panels and in particular the channel shaped element
41 comprising the bottom frame member thereof in combination with the bracing elements
53 and the bolted connection to the side and cross-members 19, 20 and 23
a of the floor structure, together with the connection of the wall panels to the roof
structure 14 and the connection of the wall panels to the legs 18.
[0064] The manufacture of wall panels 12, 13 will now be described, referring first to Figures
21 and 22. These illustrate one station of an apparatus for acting on a channel section
steel element to form apertures and inwardly deformed formations in the limbs thereof
at predetermined positions along the length thereof to provide the channel shape element
41. At each station the apparatus comprises a V or U-section block 60 mounted in a
recess 61 of a support 62 in which opposed tools 63 are slidably mounted under the
control of hydraulic piston and cylinder unit 64. The support 62 is mounted on a base
65 for movement longitudinally of the apparatus and is guided by means of a co-operating
key and keyway assembly 66. A gauging arm 67 together with a locating screw 68 is
provided so that each mounting block 62 at each station can be positioned accurately
at a desired longitudinal relative position.
[0065] A cylindrical spacer element 53 is rested on each V-shaped block 60 and then a channel
shaped element 41 is disposed over the spacer elements 53 and moved downwardly until
it engages supports 69. The piston and cylinder units 64 are actuated to move the
tools 62 inwardly towards each other so that they act upon the limbs 42, 43 of the
channel shaped element 41 to pierce an aperture 46 therein and form the above described
frusto-conical inwardly deformed formation 45.
[0066] Each tool 63 has a leading portion 70 of cylindrical shape having a flat circular
end surface, and a trailing frusto-conical forming portion 71, the smaller diameter
end of which merges with the cylindrical portion 70 and the larger diameter end of
which has a diameter equal to the internal diameter of the spacer 53.
[0067] At its outer end the frusto-conical part 71 merges with a cylindrical part 72 of
the respective tool 63.
[0068] If desired, a recess may be provided in only one of the limbs where the element is
always to be used in a handed configuration. In such case the opposed punch would
be appropriately formed without a frusto-conical part so that only an aperture would
be provided.
[0069] Further, if desired, an aperture may be formed in one or both of the limbs by other
means than that described hereinbefore and the above described apparatus may be used
to provide a recess and aperture or only a recess in only one limb by providing a
single tool opposed to a fixed anvil arrangement.
[0070] In addition, at a suitable stage appropriate circular apertures are provided in the
web 42 to receive wood screws for connection to the vertical frame members 39, 40
whilst slots 75 are formed in the base 42 and limbs 43
a, 43
b at desired positions along the length of the element 41 to receive the flanged seams
34 - 36 between adjacent panels 37. Suitable sealing tape 76 is applied over such
slots which are to be used so as to provide a seal with the flanged formation (Fig.4)
and silicone sealant is also applied.
[0071] It should be appreciated that the formations 45 and slots 75 are provided symmetrically
in the elements so that they do not require to be handled during manufacture. If desired,
a symmetrical disposition could be provided since, for example, there is no requirement
to provide a recessed formation on the inner limb 43
a, nor is there need to provide slots 75 on this limb.
[0072] The thus apertured element 41 is then connected by wood screws to the other frame
members 38, 39 and 40 and the inner and outer skins 30, 31 are assembled on opposite
sides of the resultant frame and a plurality of such frames and sheets are assembled
in a stack, as illustrated in Figure 23. It will be seen from Figure 23 that the upper
and lower frame members 38, 41 are disposed alternately at opposite ends of the stack.
As best shown in Figure 24, each channel shape element 41 is clipped to a platen 77
by clips 78 which engage with slots 79 formed in the limbs 42
a, 42
b of the element 41 as well as in a groove 79
a of the platen 77 which contains a spring clip 79
b so that the element 41 is accurately positioned relative to the platen 77.
[0073] The upper frame members are provided with grooves 80 to permit egress of foam, as
hereinafter to be described, whilst the web part 42 of the channel section elements
41 is provided with feed openings 87 and with circular apertures 81 in which foam
ejection tubes 82 are mounted. As best shown in Figures 25-26, each foam ejection
tube is of frusto-conical internal and external shape and comprises a hollow tubular
spout part 83 having at one end a mounting part 83
a having a radially outwardly extending generally annular flange 84 and with a reduced
thickness weakened portion 85 between the mounting and spout parts. At its other end
the spout part 83 has a nozzle portion 86 which extends generally perpendicularly
to the spout part 83. The foam ejection tubes 82 are introduced into the apertures
81 from the interior of the frame prior to assembly with the skins 30, 31 until the
flange 84 abuts the surface of the web 42. The frusto-conical external configuration
of the mounting part 83
a ensures that the tube is a good sealing fit with the web 42.
[0074] In use, the above described assembly is introduced into a press, not shown, and pressure
is applied to the stack of components. Polyurethane foam material in fluid state is
then injected into the interior of each compartment 88 between frame members of each
panel by means of a lance 89 supplied with the foam material via a hose 90. As the
foam material is introduced air escapes through the grooves 80 and tubes 82 and excess
foam begins to escape through the grooves 80 and through the tubes 82. Because the
spout part 83 of the tubes is of sufficient length to ensure that the nozzle parts
86 project outwardly beyond the open mouth of the element 41 and hence of the edge
of the stack, any foam falling therefrom is guided away from the stack to avoid contamination
of the components and thus avoid build-up of foam which would prevent fitting of bottom
wall trims. In addition the tubes are dimensioned to limit the amount of foam which
is ejected. The dimensions, and in particular the tapered configuration, impedes the
flow of foam. Accordingly, whilst air is freely released as the space within the chambers
88 is filled with foam, the rate of foam movement along the tube 82 is restricted
because of the relative viscosity of the foam and dimensions of the tube so that a
relatively high pressure can be built up in the chambers 88, thereby enabling a high
density of foam to be achieved within the chambers 88 of the panel.
[0075] The length of the channel shaped element 41 is limited, in practice, by press brake
capacity and practical handling requirements. Where the wall of a building unit has
a length greater than such capacity more than one element is required. The elements
41 must be connected together to provide a rectilinear frame member and foam must
also be prevented from escaping at the joints. This connection is achieved by means
of a sleeved connection, as shown in Figures 5 and 6. The sleeve is indicated at 90
and comprises a channel shape section that is a mating fit into the channel shaped
element 41.
[0076] In order to maintain the accuracy of the spacing between the holes 46 in adjacent
elements, the elements and the sleeve have an accurately positioned tab and slot location
arrangement. Each element 41 has a vertical slot 91 in one flange 43. The slots are
accurately positioned from one end of the element within tight tolerances. The connection
sleeve 90 has two vertical tabs 92 which are partly punched through one flange, and
the centres of the tabs are also accurately positioned.
[0077] When the elements 41 are laid end to end, the sleeves are inserted into the channel
of the sleeves 41 and the elements are manipulated until the tabs 92 are located in
the slots 91 and the resultant assembly of elements 41 have a datum end to hole accuracy
of ± 1mm over an overall length of up to 18 metres. A desired number of thus assembled
elements is provided for a given desired wall length and are connected to the end
vertical frame members 39 adjacent their ends of the assembly and to appropriate intermediate
vertical frame members 40 at desired positions along the length thereof.
[0078] Referring now to Figures 15 - 20, there is shown an alternative embodiment of building
unit.
[0079] In this embodiment there is another form of portable building of right parallelepiped
configuration having two longer side walls 112, 113. In the embodiment illustrated
one of the side walls is omitted since the building unit is connected to an adjacent
side by side building unit which would be provided with an opposite side wall to side
wall 112 illustrated. The building has two shorter end walls 113, a roof structure
114 and a floor structure 115. Door and window openings are provided as desired.
[0080] The floor structure 115 comprises two parallel longitudinally extending floor side
beams 19, 20 disposed to extend along longitudinal sides of the floor structure. The
floor side beams 19, 20 are identical and are made as rolled sections in steel and
are essentially of channel configuration with the web of the channel disposed vertically
and the limbs extending inwardly of the floor structure. The limbs are provided with
inturned lips 19
a, 20
a.
[0081] Fastened by welding to the side beams 119, 120 are a plurality of cross-beams which
extend transversely of the floor structure and are located at spaced positions longitudinally
of the side beams. The cross-beams are of channel configuration with the web disposed
vertically and the limbs extending horizontally and the upper limb of each cross-beam
has a downturned lip 123
a whilst the edge cross-beams 123 have their lower lip provided with an upturned flange
123
b. Supported on the cross-beams and the upper limbs of the floor side beams is a floor
deck 24 made of moisture resistant structural board, such as wood particle board with
a fully bonded veneer covering.
[0082] The floor side beams 119, 120 comprise bottom members of two upstanding sub-frames
which lie in a vertical plane, each comprising respective horizontal roof beams 122
a, 122
b interconnected at their ends to the floor side beams by uprights 124
a 124
b. Each sub-frame affords a rectangular aperture defined by the beams and uprights
which may be closed by end and side wall panels 112, 113 as hereinafter to be described.
[0083] Each unit has a "roof' structure which extends between and is secured to the roof
beams 122
a, 122
b therebelow by attachment to the lower flanges thereof. The roof structure of each
unit intended to provide the top storey of a building has a roof panel 150. The roof
panel 150 comprises an inner skin 151 of plastic coated steel, an outer skin 152 also
of plastic coated steel, and a perimeter framework, part of which is shown at T with
the space between them being filled by an insulated infilling comprising a foam plastics
material 53 which, in the present example is polyurethane foam and which is bonded
to the inner and outer skins.
[0084] The roof panel 50 may be provided with reinforcing members made of steel or other
suitable material disposed between the inner and outer skins 151, 152.
[0085] The wall panels 112, 113 are of similar construction to the wall panels described
hereinbefore with the first embodiment except that the outer sheets are provided with
horizontally extending seams which are disposed adjacent transversely extending intermediate
members 140 of a framework. The framework, as with the first embodiment, comprises
a peripheral frame 133 having an upper frame member 138 and vertical frame members
139 all made of timber and a steel generally channel shape element 141 providing the
bottom frame member. The frame members are fastened together by suitable fastenings
as shown in Figure 18 with connecting blocks being provided which are screwed to the
channel shape element 141. As best shown in Figures 19 and 20 the element 141 has
inner and outer limbs 142
a, 142
b having an open mouth at their one ends 144 and interconnected at their other ends
by a transversely extending web 143. The outer limb 142
b is formed with a rebate 142
c which provides a downwardly facing shoulder 142
d. In all other respects the channel shape element 141 and the construction of the
wall panel is as described hereinbefore in connection with the first embodiment, except
that the inner skin is made of gypsum board. As best shown in Figure 17 the provision
of the rebate 142
c permits the outer skin 131 to be bent into the rebate and thus provide a styling
feature consistent with the horizontal seams described hereinbefore. Reference is
directed to EP-A-0546540 for a fuller description of the basic construction of the
building unit of this embodiment and the disclosure of that specification is incorporated
herein by reference.
[0086] Although in the hereinbefore described and illustrated examples of the invention
the peripheral frame elements have been disposed at an adjacent edge of a wall part
if desired one or more of the elements may extend along the edge by virtue of being
spaced from and adjacent to the associated edge.
[0087] The features disclosed in the foregoing description, or the following claims, or
the accompanying drawings, expressed in their specific forms or in terms of a means
for performing the disclosed function, or a method or process for attaining the disclosed
result, or a class or group of substances or compositions, as appropriate, may, separately
or in any combination of such features, be utilised for realising the invention in
diverse forms thereof.
1. A wall panel of the kind specified wherein the panel is provided with a frame member
extending along or adjacent one edge of the panel and the frame member comprising
a frame element comprising a channel shape formation comprising two spaced limbs defining
an open mouth therebetween at their one ends and interconnected by a transversely
extending web and having a plurality of bracing elements extending transversely between
the limbs and disposed between the one ends of the limbs and said web and arranged
at spaced positions longitudinally of the frame element.
2. A wall panel according to claim 1 wherein the frame element is of channel shape and
the web interconnects the limbs at their other ends.
3. A wall panel according to claim 1 or claim 2 wherein the frame element comprises a
cold rolled steel element.
4. A wall panel according to any one of the preceding claims wherein a plurality of pairs
of opposed apertures are provided in the limbs to receive, in the apertures of each
pair, a fastener to connect the wall panel to a floor structure.
5. A wall panel according to claim 4 wherein a recess is provided around an aperture
of each pair in at least one limb to receive a part of the fastener.
6. A wall panel according to claim 5 wherein a recess is provided around each aperture
of each pair.
7. A wall panel according to claim 5 or claim 6 wherein the or each recess is of generally
frusto-conical configuration.
8. A wall panel according to any one of claims 5 to 7 wherein the or each recess is provided
by a deformed region of the limb in which the apertures are provided.
9. A wall panel according to any one of the preceding claims wherein each bracing element
is retained between the limbs by engagement of an inwardly deformed region of the
limb with the bracing element.
10. A wall panel according to any one of the preceding claims wherein each bracing element
comprises a tube.
11. A wall panel according to claim 10 wherein each bracing element comprises a generally
cylindrical tube.
12. A wall panel according to claim 10 or claim 11 when dependent on claim 9 wherein the
inwardly deformed regions of the limbs are engaged within the ends of the tube to
retain the tubular bracing element between the limbs.
13. A wall panel according to claim 9 or any one of claims 10 to 12 when dependent on
claim 9 wherein the inwardly deformed region on the opposite side thereof to that
which engages the bracing element provides a said recess.
14. A wall panel according to any one of the preceding claims wherein the panel has at
least one other frame member extending along or adjacent at least one other edge of
the panel.
15. A wall panel according to claim 13 wherein the panel has a peripheral frame comprised
of said frame element and other frame members.
16. A wall panel according to claim 14 or claim 15 wherein the or each other frame member
is made of wood.
17. A wall panel according to any one of claims 14 to 16 wherein the frame members are
connected to each other.
18. A wall panel according to any one of the preceding claims wherein the outer skin of
the wall panel comprises a plurality of sheets, the longer edges of the sheets being
disposed to extend vertically and having at their adjacent longer edges inturned flanges
which are secured together.
19. A wall panel according to claim 18 wherein openings are provided in the channel shaped
element to receive the flanges.
20. A wall panel according to any one of the preceding claims wherein the frame element
is disposed with the one ends of the limbs facing outwardly of the panel and the transversely
extending web disposed transversely of the thickness of the panel.
21. A wall panel according to claim 20 when dependent on claim 19 wherein the openings
for the flanges are provided in the transversely extending part and in the limbs adjacent
to the transversely extending part.
22. A wall panel according to any one of the preceding claims wherein the limbs are generally
planar, as may be the transversely extending part which may extend perpendicular to
each limb.
23. A wall panel according to any one of claims 1 to 17 wherein the outer skin of the
wall panel comprises a plurality of sheets, the longer edges of the sheets being disposed
to extend horizontally and the shorter edges of the sheets extending vertically and
the sheets having at their adjacent longer edges inturned flanges which are secured
together.
24. A wall panel according to claim 23 wherein the frame element is not provided with
openings.
25. A wall panel according to claim 23 wherein the frame element has a rebate provided
in the limb adjacent the outer skin, the rebate providing a shoulder which faces towards
the free end of the associated limb and the outer skin may conform to the shape of
the rebated limb.
26. A wall panel according to any one of the preceding claims wherein the frame element
is fastened to an element of the floor structure by means of a threaded fastener comprising
a shank and first and second abutments provided on the shank, at least one of the
abutments being threadedly engaged with the shank for axial movement relative thereto,
with one abutment in clamping relationship with an outer limb of the channel section
element and the other abutment in clamping engagement with the element of the floor
structure with the shank of the fastener extending through a bracing element.
27. A wall panel according to claim 26 wherein said one abutment is fixed to the shank.
and the other abutment comprises a nut threadedly engaged with the shank.
28. A wall panel according to claim 27 wherein the nut is fixed relative to the frame
element.
29. A method of making a wall panel of the kind specified comprising the step of taking
a frame element comprising a channel shape formation comprising two spaced limbs defining
an open mouth therebetween at their one ends and interconnected by a transversely
extending part, positioning a plurality of bracing elements to extend transversely
between the limbs and disposed between the one end of the limbs and said web at spaced
positions longitudinally of the frame element, and acting on the outwardly facing
surface of at least one of the limbs with a tool adjacent said bracing elements to
provide an inwardly deformed formation to engage a bracing element to retain it between
the limbs.
30. A method according to claim 29 wherein the tool punches an aperture in the limb within
the inwardly deformed formation.
31. A method according to claim 30 wherein the method comprises acting on the outwardly
facing surface of both limbs with pairs of opposed tools adjacent said bracing elements
to provide inwardly deformed formations to engage opposite ends of the bracing elements
to retain them between the limbs.
32. A method according to claim 31 wherein said pairs of opposed tools punch apertures
in the limbs within the respective inwardly deformed formations.
33. A method according to any one of claims 29 to 32 wherein the or each inwardly deformed
formation is of generally frusto-conical configuration.
34. A method according to any one of claims 29 to 33 wherein the or each inwardly deformed
formation provides a recess in the outwardly facing surface of the limb.
35. A mthod according to any one of claims 29 to 34 wherein the or each tool comprises
a leading, piercing, portion and a trailing, deforming, portion of greater cross-sectional
dimension than the piercing portion, the piercing portion being adapted to pierce
the aperture in a limb and the trailing portion being adapted to bend or swage the
material of the limb in co-operation with the bracing element to form the inwardly
deformed formation.
36. A method according to claim 35 wherein the bracing element is generally cylindrical,
at least at the ends thereof, and the deforming portion is frusto-conical having a
larger diameter which is at least equal to the internal diameter of the bracing element.
37. A method according to claim 36 wherein the piercing portion is generally cylindrical
and of a diameter corresponding to the diameter of the smaller end of the deforming
portion.
38. A method according to any one of claims 29 to 37 wherein the or each tool is caused
to act on the channel shaped element by a fluid operated piston and cylinder means.
39. A method according to claim 38 wherein an individual fluid operated piston cylinder
means is provided for each tool.
40. A method according to any one of claims 29 to 39 wherein the method comprises the
step of disposing a plurality of bracing elements on locating means at predetermined
positions in a piercing and forming apparatus, the locating means being disposed in
a predetermined relationship with pairs of opposed tools, disposing the channel section
element with the one ends of the limbs facing downwardly over the bracing elements
and then carrying out said step of acting on the outwardly facing surface of the limbs
with the pairs of opposed tools.