Building panel assembly and method of manufacturing

Abstract

Building panel assemblies for use in the construction of new homes, commercial buildings and extensions having rectangular structural insulated panel (SIP) (10), comprises a pair of spaced-apart containment boards (12,12) an inner insulating core (13) and a low profile peripheral external rigid frame (14), preferably of metal, e.g. steel, extending around the entire periphery of the spaced-apart boards (12,12).

Claims

1. A building panel assembly comprising a pair of spaced-apart containment boards, separated by an inner insulating core, said inner insulating core comprising one or more preformed body around which a curable insulating foam is introduced; at least one peripherally disposed channel for receiving a rigid frame, said channel spaced apart from and disposed between the containment boards; wherein the rigid frame defining a pair of spaced-apart longitudinal channels extending around the periphery of the panel and into the space between the spaced-apart part of containment boards; at least one conduit disposed adjacent to and between at least one containment board and the inner insulating core; and wherein each preformed body comprised a plurality of alignment members disposed in order to maintain its position away from the at least one containment board.

2. A building panel assembly as claimed in claim 1 wherein the alignment members comprise one or more protrusions extending from the surface of the preformed body.

3. A building panel assembly as claimed in claim 1 having two conduits.

4. A building panel assembly as claimed in claim 1, in which the containment boards are selected from oriented strand board, cement particle board magnesium oxide wall board, plywood, pressure treated plywood, steel, aluminium, fibre reinforced plastics, or metal, or composite sheeting.

5. A building panel assembly as claimed in claim 1, in which the inner insulating core is comprised of expanded polystyrene foam, extruded polystyrene foam or polyurethane foam.

6. A building panel assembly as claimed in claim 1 wherein the one or more preformed body is solid.

7. A building panel assembly as claimed in claim 1 wherein the one or more preformed body accounts for 95% or less of an internal volume of the cavity between the containment boards.

8. A building panel assembly as claimed in claim 7 wherein the one or more preformed body accounts for 25-50% of the internal volume of the cavity between the containment boards.

9. A building panel assembly as claimed in claim 8 wherein the one or more preformed body accounts for 30% of the internal volume of the cavity between the containment boards.

10. A building panel assembly as claimed in claim 1 wherein the curable insulating foam accounts for h remaining volume of the inner insulating core.

11. A building panel assembly as claimed in claim 1 wherein the curable insulating foam is heat and/or UV cured.

Description

(1) The present invention will now be described, by way of example only, with reference to the accompanying drawings and examples, in which:

(2) FIGS. 1 to 5 shows the components and assembly of a panel frame according to the present invention;

(3) FIG. 6 shows a jig for use in the manufacture of a panel in accordance with the present invention;

(4) FIG. 7 shows the jig with panel and casket frames placed therein;

(5) FIG. 8 shows the jig and frames having preformed bodies;

(6) FIG. 9 shows an assembled panel contained within the jig for further processing.

(7) FIGS. 1 to 5 show the assembly of a steel frame for a panel 10 having two elongate side members 12, 12 and shorter elongate first 14 and second 14 end members.

(8) Each member comprises a planar base 20 from which two upstanding walls 22, 22 extend perpendicularly thereto and which extend along the entire length of the member.

(9) Each upstanding walls 22, 22 comprise two side walls 24, 24 which extend perpendicularly with respect to the plane of the base and an end wall 26 therebetween parallel to the plane of the base, forming a channel 28 running the length of the member.

(10) The longitudinal edge of the member has a flange 30 extending perpendicularly to the plane of the side wall and extending along the member's longitudinal length.

(11) The panel frame members sit over and are complementarily shaped to casket frame members 36, 36, 38, 38 which support the panel frame members during manufacture. The flange 40 of the casket steel extends beyond the flange 30 of the panel steel.

(12) The ends of each member are mitred to permit assembly of a rectangular frame having two perimetral channels extending around the outer surface of the frame and two walls extending into the interior of the frame around the inner surface of the frame.

(13) When all of the sections have been interlocked, the junction between casket and frame members is sealed with masking tape to prevent PU foam entering the joint during foaming thus minimising cleaning afterwards.

(14) FIG. 5 shows the use of right angled square member 50 that is received by the circumferential channels at their corners to provide structural integrity whilst a panel is being manufactured and to prevent the casket and panel steel from moving, locking the members together to facilitate easier handling.

(15) The assembly can then be inserted into a rectangular jig 60 for further processing.

(16) FIG. 6 shows the assembly of the jig 60 for receiving the assembled panel and casket frames. Similarly, it has two elongate side walls 62, 62 and two shorter end walls 64, 64 to form a rectangular jig complementarily shaped to receive the panel and casket assembly.

(17) The assembly is lowered into the jig 60 which has a centrally disposed aperture 66, 66 in the side walls through which a conduit may pass to deliver fluidised PU foam.

(18) FIG. 7 shows the jig of FIG. 6 with panel and casket frame members placed therein.

(19) FIG. 8 shows two lozenge-shaped preformed bodies 70, 70 placed within the interior of the jig 60. The bodies are arranged in series and fill a significant portion of the interior volume of the space between frame members.

(20) Each lozenge 70, 70 has a rectangular cross section, and has an upper 72 and lower 74 surface and a perimetral side wall 76. Extending over the upper and lower surface of the lozenge are spacer members consisting of spikes which space the lozenge away from the interior faces of the containment boards. This permits the foamed PU when injected to surround the lozenge and help adhere it to the integral structure of the containment boards and foamed PU. Without the spacer members, the upper or lower surface of the lozenge would rest on the interior surface of the containment board and would be unlikely to adhere thereto, compromising the structural integrity of the finalised panel.

(21) FIG. 9 shows the assembly of FIG. 8 having a second containment board 90 placed on top of the frame members and over the lozenges, sandwiching them between first and second containment boards. The assembly can then be further processed by introducing PU foam into the sandwich construction via aperture 66 and/or 66 and subsequently curing the foamed PU to form the panel.