AU2009201753A1 - Assembly Method and Connecting System for Panel Designed Structures - Google Patents

Description

(Cover Page) AUSTRALIA Patents Act 1990 Complete Specifications Assembly Method And Connecting System For Panel Designed Structures The invention is described in the following statement.

-2 Assembly Method And Connecting System For Panel Designed Structures This invention relates to improvements in connecting components and assembling methods for 5 dwellings and other structures, including industrial and commercial buildings designed using panel type construction, including mono skin or laminated panels. For many people the problems associated with building a panel designed structure have been overwhelming. The end result was either too expensive, too complicated or looked too much like a 10 caravan or cool room. For example a finished structure is very easy to identify by its appearance, having distinct joins or evenly spaced cover strips or other unattractive characteristics that detract from its appearance when compared to a conventionally built structure. This invention has designed a novel method to overcome the problems evident in existing systems, by providing a simplified system, and assembly process, that achieves a finished result that looks the same as a conventual built 15 structure. Another difficult problem to overcome for other people was the complicated and vast number of different components requiring assemble on site, usually resulting in increased man hours and hidden cost. This invention has designed methods to overcome these problems evident in existing systems, by 20 eliminating the need for so many and varied complicated components. In the past people with limited technical skills found the process of assembling an existing panel designed structure too complicated, and far more difficult to finish than their expectations perceived in the beginning. Most tradesmen prefer not to build panel designed structures for the same reasons. For 25 example if a floor or platform that the system will be set on is slightly out of level but within the Australian building standards, the problem this creates usually transfers around the system, slowing and complicating construction, and the problem usually becomes visually evident in the finished work as a detraction from the final appearance. Additionally if during the construction process a tradesman found valid reason to modify or correct the panel to fit, or rectify a dimension error, or similar event, it 30 usually meant having to change more detail than was possible on site, and usually results in returning panels or components back to the manufacturer for modifications, unnecessarily adding to time delays and cost. This invention has designed novel methods to overcome these problems that are evident in existing systems. By providing a bottom plate with the means for adjustment to compensate for dimensional, uneven or out of level problems, and by providing a design for panel connectors that 35 allow for easy panel modifications using conventional tools and methods familiar to most tradesman or experienced handymen. A problem with existing panel systems, is they are so limited by the design of their connecting components to allow wide variations of design or shape of a structure, and therefore fail to lend 40 themselves to architectural variances desired by some end users. For example the typical top plate of existing systems matched to their hold down system and joined to their engineered panel usually form a total engineered entity and this eliminates for example the application of combining, flat roofs with raked roofs, or trussed roof systems. The invention can be liberally used to create building designs at the discretion of an architect. This invention has designed a novel method to overcome this problems 45 evident in existing systems by providing a simplified two piece top plate system, connectors and assembly process that achieves almost unlimited design freedoms including multi story abilities and an almost unlimited choice of roof types and shapes even multiple roof types on the same building and a combination of wall types including raked and or flat top plates. 50 Existing panel structures make difficult the installation and scheduling for the service trades to install their wires or pipes. During the construction process when using existing panel structures, any -3 accessible service cavity is quickly closed off, as the next component is put in place, frustrating the placement of electrical wires, phone cables, audio wires and pipes etc. For example the electrician has great difficulty compared with conventionally built structures in installing the electrical cables once the panel structure is erected. The reason for this is that existing panel structures have components that 5 closes off access spaces as each panel is joined to the newly installed component. This invention has designed a novel method to overcome this problem, by allowing structural integrity to be achieved while leaving access open to service trades during construction. This is achieved by creating an integrated continuous service void in one section of the new two part top plate system, and a second service cavity in the bottom plate which is easily accessible after the panels have been erected and 10 joined. This is done by way of a novel design in the top plate connectors and assembly. These cavities create direct access to each panel for easy placement of services down or up an individual panel, and are now made available to the service trades at precisely the same time as conventional building schedules. 15 A major problem with using existing panel designed systems for structural buildings is the difficulty on site during construction of holding the top of the panels securely in place while the next few panels are placed in position. This is especially a problem on windy days or multistorey construction sites when OH&S issues become a serious concern. This invention has designed a novel method to overcome this problem to the point where one person can potentially erect the system. The invention 20 creates a method for temporally securing the top of the panels during erection with flexibility of handling and structural integrity and the same component now in position, becomes an integral section of a clip together two part top plate, having design features that allow for variations of roof pitch and or terrain category classification fixings. 25 A problem in existing panel designed structures is what to do with the triangle piece above the normal height of a standard panel to fit a sloping roof or ceiling line. Existing methods is to either make a longer panel and cut it on the same angle as the slop. This creates waste material and adds to the cost of the structure or increases the engineering requirements of the panel to accommodate for the additional height. Or stack the panels on top of each other showing an unsightly horizontal join. The 30 invention creates a method in the new top plate section having provision for a glazing channel incorporated directly in the closure of the top plate to receive glazed infill or other solid single skin materials to close in the triangle sections. In another form of this invention a novel way has been made for creating a structural member with a 35 moisture and termite barrier to secure and protect internal partitions and joinery using fewer components than in other systems available. This invention has designed a novel method to achieve this using a structural bottom plate designed with a series of longitudinal internal cavities with longitudinal risers to secure the panels in an elevated position and create a void between the base of the panels and the bottom plate having an impervious base to effectively create a moisture barrier and 40 an effective internal barrier against the infestation of termites . In another form of this invention a novel way has been made for creating a perimeter structural member with a moisture and termite barrier using fewer components than in other systems available. This invention has designed a novel method to achieve this using a structural bottom plate designed 45 with a longitudinal protruding external angular fin along the full length of one side and an internal cavity with longitudinal risers to secure the panels in an elevated position to create a void between the base of the panels and the bottom plate having weepholes adjacent to and above the fin to release any entrapped moisture and create an impervious base to effectively create a moisture barrier and an effective external perimeter barrier against the infestation of termites in one unit. 50 To assist in understanding this invention reference will now be made to the accompanying drawings which show one example of this invention.

-4 In the drawings: Fig. 1 shows one example of the top plate structural base member 1 of the two piece top plate having a full length service void in the top division 2 of the two parallel channels separated by a 5 planner section 3 creating a longitudinal captive lower section 4 and a longitudinal void top section 2 with integrated longitudinal captive snap elements 5 to receive a longitudinal structural top plate closer section figure 2. item 6 that completes a structural top plate according to this invention. Fig. 2 shows one example of the longitudinal structural top plate closer member 6 of the two 10 piece top plate invention having two lower parallel longitudinal channels 7 & 8 separated by a structural perpendicular fin 9 and one planner top section with a single upper recessed longitudinal channel 10 to receive fasteners and an extended longitudinal fin 12 to accommodate for additional or alternative ceiling or roof fasteners. The lower portion creating a longitudinal captive section with integrated longitudinal captive snap elements 11 to receive the top plate structural base member 15 section that completes a structural top plate according to this invention. Fig. 3 shows one example of the longitudinal structural top plate closer member of the two piece top plate invention having two lower parallel longitudinal channels separated by a structural perpendicular fin and one angled planner top section 13 and a second vertical leg 9A with a single 20 upper recessed longitudinal channel to receive fasteners and an extended longitudinal fin to accommodate for additional or alternative ceiling or roof fasteners. The lower portion creating a longitudinal captive section with integrated longitudinal captive snap elements 11 to receive the top plate structural base member section that completes a structural top plate according to this invention. 25 Fig. 4 shows one example of an intersecting structural bracing wall connector system having one light weight vertical longitudinal channel 14 and one planner connector plate 15 according to this invention. Fig. 5 shows one example of a panel to panel connector system having two light weight vertical 30 concealed longitudinal inserts 16 according to this invention. Fig. 6 shows one example of a structural bottom plate having a service void space 19 and designed having two open 17 and 18 parallel channels and a planner base 20 to create an impervious base to effectively create a moisture barrier and supporting three planner longitudinal shelves 21 35 creating a longitudinal captive member having two longitudinal risers 22 to support and secure the panels in an elevated position to create a void between the base of the panels and having a longitudinal protruding external angular fin 23 along the full length of one side to create an effective external perimeter barrier against the infestation of termites and the bottom plate having holes 24 adjacent to and above the external angular fin to position fastners into the panel according to this invention. 40 Fig. 7 shows one example of a structural bottom plate 25 having service void spaces within and having provision for captive fastners 24. Fig. 8 shows one example of a panel 26 having service void spaces 29 within the panel the 45 panel been in position in another example of a bottom plate 27 having a void space below the panel 17, 18 and 19 and the panel been captive within the bottom plate according to this invention. Fig. 9 shows one example of a top plate with a glazing channel 28 and the position of fastners 24 that secure the panel to the top plate according to this invention . 50

Claims (5)

1. Snap together two piece top plate

2. A top plate with a protruding fin for underside fixing

3. A concealed method of connecting panels to form a dwelling or structure

4. One piece Bottom plate having continuous longitudinal Moisture and Ant barrier.

5. Method of assembling an extended or sloped wall using a top plate with a glazing channel.