Building Panels - Systems Components & Methods

Abstract

A modular building panel ( 10 ) for use in forming walls. The panel comprises: an inner foam core ( 36 ) and a frame ( 12 ) surrounding the inner foam ( 5 ) core ( 36 ). The frame ( 112 ) is provided for standing upright to provide two primary faces ( 18 ) joined by a number of side portions ( 20 ). The side portions ( 20 ) of the frame ( 12 ) are provided by structural channel members ( 42 ). The structural channel members ( 42 ) provide a perimeter around the foam core ( 36 ). The structural channel members ( 42 ) providing flange portions ( 96 ) to allow rigid connection of the panel ( 10 ) using fasteners extending through the primary faces ( 18 ) into the flange portions ( 98 ) to provide the panel with a desirable cyclone rating.

1 - 48 . (canceled) 
     
     
         49 . A modular building panel for use in forming walls, the panel comprising:
 an inner foam core and a frame surrounding the inner foam core;   the frame for standing upright to provide two primary faces joined by a number of side portions;   the side portions of the frame being provided by structural channel members;   the structural channel members providing a perimeter around the foam core;   the structural channel members providing flange portions to allow rigid connection of the panel using fasteners that extend through the primary faces into the flange portions.   
     
     
         50 . A modular building panel as claimed in  claim 49  wherein the structural channel members provide the flange portions to allow rigid connection of the panel using fasteners that extend through the primary faces into the flange portions to provide the panel with a desirable cyclone rating, the desirable cyclone rating corresponding with an external pressure loading of greater than 6 kPa. 
     
     
         51 . A modular building panel as claimed in  claim 49  wherein the flange portions extend substantially around the full periphery of each primary face of the frame; and each structural channel member comprises a u-shaped channel member; with the structural members being welded together in the frame; 
     
     
         52 . A modular building panel as claimed in  claim 49  wherein each structural channel member comprises an extending channel portion provided by two flanges and a base portion; the base portion connecting the two flanges to form the channel; the base portion extending between the primary faces of the frame; the channel being generally perpendicular to the to the surface normal of the primary faces. 
     
     
         53 . A modular building panel as claimed in  claim 49  wherein the frame includes at least one internal structural member provided as a vertical strut extending vertically when then frame is standing upright. 
     
     
         54 . A modular building panel as claimed in  claim 49  wherein the panel includes a series of spaced apart internal structural members; each provided as a vertical strut extending vertically when then frame is standing upright; and the or each internal structural member comprises a structural channel member. 
     
     
         55 . A modular building panel as claimed in  claim 49  wherein the structural channel members are formed from steel between 1 to 1.5 mm thick where the thickness is a base metal thickness. 
     
     
         56 . A modular building panel as claimed in  claim 49  wherein the structural channel members providing the perimeter have at least one of the structural channel members facing outwardly to provide a channel for receiving a corresponding panel and allowing fastening of the panels through the flange of the channel into an adjoining flange of the corresponding panel; and the structural channel members providing the perimeter have at least one of the structural channel members facing inwardly to provide a projection for receiving an corresponding panel and allowing fastening of the panels through the flange of the channel of the corresponding panel into a corresponding flange of the projection. 
     
     
         57 . A modular building panel as claimed in  claim 49  wherein the frame is rectangular; and the side portions of the frame comprise an upper side portion, a lower side portion and two lateral side portions when the frame is standing upright; and the panel is able to support a load on its primary face greater than 4 ton with a four point bend test. 
     
     
         58 . A modular building panel as claimed in  claim 49  wherein the panel, when upright, is able to support a vertical load greater than 20 ton. 
     
     
         59 . A modular building panel as claimed in  claim 49  where the panel weighs at least 70 kg; the primary faces of the panel each provide a surface area between 2.5 and 3.5 m 2 ; and the panel is between 70 mm and 90 mm thick. 
     
     
         60 . A modular building panel as claimed in  claim 49  including air-cell material in addition to the foam core; and the air cell material comprises sheet material that is laid between the structural channel members of the panel; and the sheet material overlaps the structural channel members to substantially provide a relatively continuous layer of air-cell material behind at least one primary face of the panel, separated by the structural members. 
     
     
         61 . A corner piece of a modular building system comprising an elongate body providing a female channel and a male projection; the female channel and male projection extending along a substantial portion of the length of the elongate body. 
     
     
         62 . A corner piece as claimed in  claim 61  wherein the female channel and male projection define an L shaped cross-section in the corner piece. 
     
     
         63 . A corner piece as claimed in  claim 61  including a u-shaped structural channel member, the opening of the u-shaped channel facing the female channel of the corner piece, the base of the u-shaped channel positioned adjacent a first wall face of the corner piece and one of the arms of the u-shaped channel positioned adjacent a second wall face of the corner piece, the second wall face being substantially at right angles to the first wall face to provide an outwardly facing corner. 
     
     
         64 . A corner piece as claimed in  claim 61  wherein the corner piece includes a hole for receiving a foundation securing rod. 
     
     
         65 . A corner piece as claimed  claim 61  including a v-shaped portion providing two wall faces; and the female channel and the male projection are formed in a unitary piece of rigid foam material; and the body of rigid foam material is provided as an L-shaped extrusion. 
     
     
         66 . A modular building system comprising a first joiner having flange portions and a second joiner having flange portions wherein the first joiner is adapted to receive flange portions of a number of upper side portions of a number of modular panels and the second joiner is adapted to receive flange portions of a number of lower side portions of the modular panels. 
     
     
         67 . A modular building system as claimed in  claim 66  wherein each modular panel comprises: an inner foam core and a frame surrounding the inner foam core; the frame for standing upright to provide two primary faces joined by a number of side portions; the side portions of the frame being provided by structural channel members; the structural channel members providing a perimeter around the foam core; the structural channel members providing flange portions to allow rigid connection of the panel using fasteners extending through the primary faces into the flange portions to provide the panel with a desirable cyclone rating. 
     
     
         68 . A modular building system as claimed in  claim 67  wherein the joiners comprise u-shaped channel members; and the joiners are used to fix upper sides and lower sides of the modular panels. 
     
     
         69 . A modular building panel for use in providing a recess for a window, the panel comprising:
 a frame for standing upright to provide two primary faces joined by a number of side portions;   the side portions of the frame being provided by structural channel members;   the panel having vertical side that provides a stepped configuration where a portion of the side mates with another panel to provide a recess the recess extending between the two panels, the recess able to accommodate a window.   
     
     
         70 . A modular building panel as claimed in  claim 69  wherein the recess is able to accommodate a window and a further panel than spans the two panels above the window. 
     
     
         71 . A modular building panel as claimed in  claim 70  wherein the stepped configuration comprise a first step into the panel to accommodate and support the window and then a second further step into the panel to increase the depth of the recess to accommodate and support the further panel. 
     
     
         72 . A method of providing a modular building panel comprising:
 providing a wall facing;   providing a frame having the structural channel members providing a perimeter for receiving a foam core; and   applying a further wall to provide a mould for the foam core; and   filling the mould to provide the foam core;   wherein the structural channel members provide flange portions that lie against each wall facing;   the flange portions allowing rigid connection of the panel to another panel or structural element using fasteners extending through the wall facings into the flange portions in the vicinity of the perimeter of the panel to provide the panel with a desirable cyclone rating.