Panel and related wall structure

Abstract

A unitary wall or ceiling panel comprising of a first solid layer solidified gypsum and a second layer of a solidified gypsum having a plurality cavities. The second layer is engaged with the first layer and disposed from one side thereof. The cavities each including anhydrate material of a kind having a water content dependent volumetric displacement. The cavities have been formed by the volumetric shrinking of the anhydrate material resultant from the dissipation of water from the unitary panel gypsum wet phase precursor during its curing to a solidified state.

1 . A unitary wall or ceiling panel comprising 
 a first layer predominantly of a solidified gypsum based material and of a non cavity defining structure, said first layer defining a first exterior major surface of the panel and    a second layer of a solidified gypsum based material having a plurality of preferably substantially homogenously provided cavities, said second layer engaged with the first layer and disposed from the side of said first layer opposite to said first exterior major surface,    said cavities each including anhydrate material of a kind having a water content dependent volumetric displacement, said cavities having been formed by the volumetric shrinking of said anhydrate material resultant from the dissipation of water from said unitary panel gypsum wet phase precursor during its curing to a solidified state.    
   
   
       2 . A unitary wall or ceiling panel as claimed in  claim 1  wherein said second layer is engaged directly to said first layer.  
   
   
       3 . A unitary wall or ceiling panel as claimed in  claim 1  wherein a third layer is provided as part of said panel capturing said second layer between said first and third layer, said third layer being of a solidified gypsum based material of a non cavity defining structure and defining a second exterior major surface of said panel.  
   
   
       4 . A unitary wall or ceiling panel as claimed in  claim 3  wherein said third layer is substantially similar to said first layer.  
   
   
       5 . A unitary wall or ceiling panel as claimed in  claim 3  wherein said first, second and third layers are coextensive.  
   
   
       6 . A unitary wall or ceiling panel as claimed in  claim 3  wherein at least one of said first and second major surface of said panel is provided with a patterned non planar surface.  
   
   
       7 . A unitary wall or ceiling panel as claimed in  claim 1  wherein at least one of said first and second major surface consists of a plurality of upstands.  
   
   
       8 . A unitary wall or ceiling panel as claimed in  claim 7  wherein each said upstand is prismatic in shape.  
   
   
       9 . A unitary wall or ceiling panel as claimed in  claim 1  wherein at least one of said first and second major surface of said panel is a cobbled surface.  
   
   
       10 . A unitary wall or ceiling panel as claimed in  claim 3  wherein said first and third layer is substantially of gypsum.  
   
   
       11 . A unitary wall or ceiling panel as claimed in  claim 9  wherein said third and first layers include EVA additive.  
   
   
       12 . A unitary wall or ceiling panel as claimed in  claim 9  wherein said first and third layers include a fibre re-enforcing material.  
   
   
       13 . A unitary wall or ceiling panel as claimed in  claim 1  wherein said anhydrate material is a polyacrylate.  
   
   
       14 . A unitary wall or ceiling panel as claimed in  claim 1  wherein said anhydrate material is a potassium polyacylate.  
   
   
       15 . A method of providing a unitary wall or ceiling panel which comprises the steps of 
 a) providing a layer of wet pre-solidified phase gypsum based material and anhydrate material homogenous mixture, onto a layer of wet pre-solidified phase gypsum based material without said anhydrate,    b) allowing curing to a solidified phase of said gypsum to occur.    
   
   
       16 . A method as claimed in  claim 15  where the method further includes the provision of a layer of wet pre-solidified phase gypsum based material onto to the exposed surface of the layer of pre-solidified phase based gypsum and anhydrate material homogenous mixture.  
   
   
       17 . A method as claimed in  claim 15  wherein the method further includes the provision of a layer of gypsum based material onto the exposed surface of wet pre-solidified phase gypsum and anhydrate material homogenous mixture by the dispersing of a gypsum based power form material onto the the exposed surface of wet pre-solidified phase gypsum and anhydrate material homogenous mixture.  
   
   
       18 . A method as claimed in  claim 15  wherein said third mentioned layer is absent of anhydrate material.  
   
   
       19 . A method as claimed in  claim 15  wherein said anhydrate is a polyacrylate.  
   
   
       20 . A method as claimed in  claim 19  wherein said polyacrylate is potassium acrylate.  
   
   
       21 . A method as claimed in  claim 16  wherein said third mentioned layer prior to it setting is screeded to provide a planar surface finish.  
   
   
       22 . A method as claimed in  claim 16  wherein a fibrous material is provided in at least one of the first and third mentioned layers.  
   
   
       23 . A method as claimed in  claim 22  wherein said fibrous material is fibreglass.  
   
   
       24 . A method as claimed in  claim 15  wherein said second mentioned layer is applied onto a horizontal moulding surface which during the curing of said layers provides upward support to said layers.  
   
   
       25 . A method as claimed in  claim 24  wherein said moulding surface has an patterned relief moulding surface to impart a non planar surface to said second mentioned layer.  
   
   
       26 . A wall structure of a building comprising 
 a vertically extending frame work spanning between a floor and ceiling of said building    a wall panel subassembly comprising a first panel and at least one other panel    said second panel engaged to said first panel in a substantially parallel manner and separated therefrom to define a space there between, said first and second panels engaged to each other in a separated manner by a compressible material spacer element,    wherein said subassembly is mounted from and affixed to said frame work by mechanical fastening means in a manner wherein said first panel is positioned facing said frame work and wherein a compressible material spacer element in provided intermediate of said first panel and said framework.    
   
   
       27 . A wall structure as claimed in  claim 26  wherein said first and second panels are coextensively engaged with each other.  
   
   
       28 . A wall structure as claimed in  claim 26  wherein said first panel comprises 
 a first layer predominantly of a solidified gypsum based material and being of a non cavity structure, said first layer defining a first exterior major surface of the panel and    a second layer of a solidified gypsum material having a plurality of substantially homogenously provided cavities, said second layer engaged with the first layer and disposed from the side of said first layer opposite to said first exterior major surface,    said cavities each including anhydrate material of a kind having a water content dependent volumetric displacement, said cavities having been formed by the volumetric shrinking of said anhydrate material resultant from the dissipation of water from said unitary panel gypsum wet phase precursor.    
   
   
       29 . A wall structure as claimed in  claim 28  wherein said second panel is of a homogenous gypsum based structure.  
   
   
       30 . A wall structure as claimed in  claim 27  wherein the surface of said first panel facing said frame structure side is non planar.  
   
   
       31 . A wall structure as claimed in  claim 30  wherein said surface of said first panel facing  30  said frame structure is of a cobbled or prismatic texture.  
   
   
       32 . A wall structure as claimed in  claim 26  wherein said compressible material spacer is a strip material and extends at least proximate to the perimeter of and between the first and second panels.  
   
   
       33 . A wall structure as claimed in  claim 26  wherein a second wall panel sub assembly is provided and disposed from the other side of said frame work, said second wall panel sub assembly comprising a first panel and at least one other panel 
 said second panel engaged to said first panel in a substantially parallel manner and separated therefrom to define a space there between, said first and second panels engaged to each other in a separated manner by a compressible material spacer element,    wherein said second subassembly is mounted from and affixed to said frame work by mechanical fastening means in a manner wherein said first panel is positioned facing said frame work and wherein a compressible material spacer element is provided intermediate of said first panel and said framework.    
   
   
       34 . A wall structure as claimed in  claim 33  wherein the distance between the first panel of said first wall panel subassembly and the first panel of the second wall panel sub assembly is approximately 170 mm.  
   
   
       35 . A wall structure as claimed in  claim 33  wherein said frame work comprises of vertically extending timber studs.  
   
   
       36 . A wall structure as claimed in  claim 33  wherein said frame work comprises two parallel and separated rows of studs a first row with which the first sub assembly is engaged and a second row with which said second sub assembly is engaged.  
   
   
       37 . A wall structure as claimed in  claim 33  wherein said first panel of said first sub assembly and said first panel of said second sub assembly each included a cobbled or prismatic surface detail.  
   
   
       38 . A wall or ceiling panel assembly comprising 
 a first planar panel of a rigid sheet material    a second planar panel of a rigid sheet material affixed to said first wall panel in a spaced apart disposition from said first wall panel, wherein the major surfaces of said first and second planar panels are parallel and in at least a significant overlapping relationship with each other    at least one resiliently flexible element disposed between the facing major surfaces the first and second panels and sealing engaged to the facing surfaces of each panel,    wherein at least one of said first and second panels (hereinafter the “cavity panel”) comprises    a first layer predominantly of a solidified gypsum based material and of a non cavity defining structure, said first layer defining a first exterior major surface of the panel and    a second layer of a solidified gypsum based material having a plurality of preferably substantially homogenously provided cavities, said second layer engaged with the first layer and disposed from the side of said first layer opposite to said first exterior major surface,    said cavities each including anhydrate material of a kind having a water content dependent volumetric displacement, said cavities having been formed by the volumetric shrinking of said anhydrate material resultant from the dissipation of water from said unitary panel gypsum wet phase precursor    a third layer predominantly of a solidified gypsum based material and of a non cavity defining structure, said third layer defining a second exterior major surface of the panel.    
   
   
       39 . A wall or ceiling panel assembly as claimed in  claim 38  wherein at least one of the first or second exterior major surfaces of said cavity panel(s) is of a non planar surface consisting of plurality closely or abuttingly spaced upstands.  
   
   
       40 . A wall or ceiling panel assembly as claimed in  claim 38  wherein one of the first or second exterior major surfaces of said cavity panel(s) is of a non planar surface consisting of plurality closely or abuttingly spaced upstands.  
   
   
       41 . A wall or ceiling panel assembly as claimed in  claim 38  wherein only one of said first and second panels is a cavity panel.  
   
   
       42 . A wall or ceiling panel assembly as claimed in  claim 38  wherein the exterior (to said assembly) facing major surface of said cavity panel is of a non planar surface consisting of plurality closely or abuttingly spaced upstands.  
   
   
       43 . A wall or ceiling panel assembly as claimed in  claim 38  wherein the major surface of said cavity panel facing the other of said first and second panels is of a non planar surface consisting of plurality closely or abuttingly spaced upstands.  
   
   
       44 . A wall or ceiling panel assembly as claimed in  claim 38  wherein said resiliently flexible element is a strip material and is provided between the first and second panels at or immediately inwardly of the overlying perimeter regions of said first and second panels.  
   
   
       45 . A wall or ceiling panel assembly as claimed in  claim 38  wherein said first and second panels are affixed to each other in a substantially coextensive relationship.