GB2502658A - Building panel with spaced frames - Google Patents

Abstract

A building panel is shown having a first planar sub-assembly 501 and a second planar sub-assembly 601. Connecting members (701, 702) connect the first planar sub-assembly to the second planar sub-assembly to define a box assembly, with said connecting members at a plurality of locations within said box. A first planar material is attached to a first large outer surface of the box assembly and a second planar material is attached to the second large outer surface of the box assembly to produce a closed box assembly. Solidifying foam material is injected into the box assembly. The panels can be assembled to form a plurality of building sections at a factory, which sections are connected on a building site by an elongate connector received in channels of the sections.

Description

A Building Component and a Method of Construction The present invention relates to a method of constructing a building component and a building component.

Structural insulated panels are known that consist of an insulating layer of rigid polymer foam sandwiched between two layers of structural board. It is known for them to be used for many different applications, such as exterior walls, roofs, floors and foundation systems.

It is known that a well built house using structural insulated panels has a tighter building envelope compared to a conventionally built house and the walls will have higher insulating properties, leading to fewer drafts and a decrease in operational costs. However, in existing systems, the panels are brought to site and construction generally takes place on site in order to complete the structure.

To provide structural integrity, it is necessary to include a framework structure which will result in areas that provide thermal conduction from one side of the panel to the other side of the panel. Conduction pathways of this type are generally referred to as cold bridges and, in order to improve the heat retention properties of the building, it is preferable to reduce the cross-sectional area of these cold bridges. However, in known systems, there is a limit to which this can be achieved while retaining structural integrity.

A further problem with known structural insulated panels is that, when used in significant number, the overall structural integrity may be compromised due to racking properties. Thus, although known panels have good integrity with respect to individual loading, problems may occur when torsional loads are applied creating a twisting effect which exhibits itself as racking. Thus, again, further structural measures may be required in order to prevent racking which again undermines thermal integrity.

According to an aspect of the present invention, there is provided a method of constructing a building component as set out in claim 1.

According to a second aspect of the second invention, there is provided a building component as set out in claim 9.

The invention will now be described by way of example only with reference to the accompanying drawings, of which: Figure 1 shows a jig for constructing a building panel; Figure 2 shows the insertion of a first elongate element within the jig of Figure 1: Figure 3 shows the addition of transverse elements;

Figure 4 shows the introduction into a press;

Figure 5 shows the removal of a sub-assembly from the jig; Figure 6 illustrates the positioning of a second sub-assembly; Figure 7 shows the construction of a box assembly; Figure 8 shows the attachment of the box assembly to a first board; Figure 9 shows the attachment of a second board; Figure 10 shows the application of shuttering elements Figure 11 shows the shuttering elements in position; Figure 12 shows the completed boarding component; Figure 13 shows the construction of a wall; Figure 14 shows a construction of a floor; Figure 15 shows further construction; Figure 16 shows the construction of a complete transportable section; Figure 17 shows examples of transportable sections used to construct a building; Figure 18 shows a building cOnstructed from the sections identified in Figure 17; Figure 19 details the combining devices; Figure 20 shows a cross-section of the combining devices identified in Figure 19, Figure 21 shows an apparatus for receiving water from a building structure; Figure 22 shows a cross sectional view of the apparatus previously shown in Figure 21; s Figure 23 shows an alternative view of the apparatus previously described; Figure 24 shows an alternative apparatus for receiving water from a building structure so as to direct water to a discharge pipe; Figure 25 shows a further apparatus comprising a channel; Figure 26 shows an apparatus for receiving water from a building structure comprising the apparatus of Figure 24 and the apparatus of Figure in combination; Figure 27 shows a further embodiment for receiving water from a building structure so as to direct water to a discharge pipe; and is Figure 28 shows an apparatus for receiving water from a building strUcture so as todirect water from a discharge pipe in accordance with any of the previous embodiments described.

Figure 1 In this example, a building component is described in the form of a composite panel, typically having outer surfaces of 4 metre by 1.2 metre and a depth of 15 centimetre. A further embodiment of the composite panel has outer surfaces of 2.5 metre by 1.2 metre with a depth of 15 centimetre.

However, it should be appreciated that any size of panel may be produced, possibly being substantially larger or substantially smaller.

* 25 In this example, the building component is initially constructed within a jig 101 supported on table 102. The jig 101 defines an outer frame 103, a first channel 104, a second channel 105 and a third channel 106.

* Figure 2 * * To initiate the construction, a first elongate element 201 is inserted within the first channel 104, a second longitudinal element202 is inserted within the second channel 105 and a third longitudinal element 203 is inserted within the third channel 106.

A first transverse element 204 is introduced to abut against the three elongate elements (201 to 203). In addition, a second transverse element 205 is introduced at the opposite end, again abutting against the three longitudinal elements.

Figure 3 The addition of the transverse elements 204 and 205 result in the combination of elements abutting at six places. At each of these abutment locations, a nail plate is introduced such that six nail plates are introduced in the embodiment, shown at 301, 302, 303, 304, 305 and 306.

Figure 4 In order to apply even forces to the nail plates 301 to 306, the jig 101 is introduced to a press 401. Thus, in the example shown in Figure 4, nail plates 301, 302 and 304 are introduced into the press 401. Pressure is applied thereby forcing the nail plates 301 to 303 to enter the abutting elements and thereby secure these elements. The jig 301 is then rotated to facilitate the engagement of nail plates 304, 305 and 306.

Figure 5 After removal from the press 401, a planar sub-assembly 501 is removed from the jig 101 and rotated 180 degrees about longitudinal axis 502.

The planar sub-assembly is then re-introduced into the jig to allow a further six nail plates to be engaged at the abutting locations. The completed first planar sub-assembly is then removed from the jig 101 and a similar second planar sub-assembly is constructed in accordance with the procedures described with respect to Figures ito 5.

Figure 6 The first planar sub-assembly 501 is held in a second jig (not shown) and a second planar sub-assembly 601 is supported above the first planar sub-assembly 501, displaced vertically therefrom.

Figure 7 The first planar sub-assembly 501 is connected to the second planar sub-assembly 601 at a plurality of locations, so as to displace the plane of the second sub-assembly substantially above the plane of the first sub-assembly, thereby defining a box assembly; with many of the plurality of locations being within this box assembly. In this embodiment, further nail plates are deployed, identified as nail plates 701 to 709. In an embodiment, a further nine nail plates may be added at respective locations opposing each nail plate location 701 to 709.

Figure 8 Opposing nail plates, such as nail plates 801, 802 and 803 are shown in Figure 8. Thus, in this example, there are now a total of 18 crQss-planar nail plates. However, it should be appreciated that different configurations of nail plate may be used and alternative devices may be used for connecting individual planar sub-assemblies and for providing the cross-planar connections.

In an embodiment, the application of the cross planar additional nail plates, or similar connecting devices, minimises the cross-sectional area of cold bridges between the planar sub-assemblies while at the same time increasing racking integrity between these sub-assemblies.

The box assembly is attached to a first planar material 804, such as a sheet of oriented strand board (OSB). In alternative embodiments, other materials may be used, such as metal, plywood or composite board materials etc. Figure 9 A second planar material 901 is attached to the second large outer surface of the box assembly to produce a closed box assembly, as illustrated in Figure 9.

In an embodiment, the longitudinal elements 201 to 203 and the transverse elements 204, 205 are formed from standard G16 timbers, substantially similar to those used in traditional timber frame buildings.

Thus, in an embodiment, OSB boards 804 and 901 may be attached to the elements using conventional nails or screws, as indicated at 902.

Each of the transverse elements, such as element 205, includes a channel 903 cut therein such that a groove is defined by the channel 903 and the application of its respective planar material, such as planar material 804.

These grooves are to facilitate interconnection.

Figure 10 To complete the construction of the building component, solidifying foam material is injected into the closed box assembly. A first shuffering element 1001 is introduced to the component which in turn cooperates with a second shuttering element 1002. This fully encloses the box assembly, so that the solidifying foam may be introduced. In an embodiment, timber shuttering may be deployed to seal the ends while the panels are filled with foam, thereby preventing the foam from escaping. Inserts 1003 1004 and 1005 define rebates, again facilitating the interconnection of panels.

To provide a better weather type join, aluminium shuttering is deployed to provide a more precise profile for the rebates. Furthermore, the aluminium shuttering may be coated with a silicone based release agent, so as to ensure that the solidified foam is released easily from the shuttering when the shuttering is removed thereby presenting a clean surface. In this way, clean surfaces meet together and a better seal results.

* The provision of a solid aluminium shuttering system also allows the foam to be introduced at a greater level of pressure without yielding to this pressure. It allows the shuttering to be strapped in place without requiring additional securing devices.

Figure 11 With the shuttering secure, the solidifying foam material is injected. In an embodiment, closed cell high density polyurethane foam is deployed, although in alternative embodiments, other available foams may have advantages for specific applications. In the current preferred embodiment, the building component is configured such that it may be used for flooring, wailing and roofing while providing high levels of thermal insulation, acoustic damping and structural integrity. in terms of thestructural integrity, the construction must be capable of withstanding wind loads from outside, along with the application of point loads and dispersed loads on the inside.

The use of polyurethane foam also provides additional benefits in terms of structural strength. By injecting the foam into the closed box assembly, the is internal frame becomes encapsulated and foam is forced to enter into every available void and to come into contact with every available surface, thereby further enhancing the overall strength characteristics. Due to the adhesive characteristics of the polyurethane foam, the foam also acts as an adhesive and sticks and binds the surfaces together as it fills the voids.

Figure 12 After the foam has curS the shuttering 1002, 1003 is removed in order to present the building component. Thus, as described, the building component has a first planar sub-assembly and a second planar sub-assembly. Connácting members connect the first planar sub-assembly to the second planar sub-assembly defining a box assembly with connecting members at a plurality of locations within the box. A first planar material 804 is attached to a first large outer surface of the box assembly and a second planar material 904 is attached to a second large outer surface of the box assembly to produce the closed box assembly. Solid foam material is located within the closed box assembly.

In the embodiment described, the first planar sub-assembly comprises abutting elements and these abutting elements may be timber elements secured by nail plates. In the embodiment, the building element includes plates connecting the first sub-assembly to the second sub-assembly, thereby providing racking integrity while minimising the cross-sectional area of cold bridges.

Figure 13 In an embodiment, when used to construct walls, floors or roofs, the building components are secured in a vertical configuration, as shown in Figure 13. A first component 1301 is shown in alignment with a second component 1302. As the components (1301, 1302) are brought together, a first tongue 1303 is held within a first rebate and a second tongue 1304 is held within a second rebate. The tongues are not brought into contact with each other and therefore do not provide a cold bridge. To assist with the connection of component 1301 and component 1302, the tongues are sprayed with polyurethane foam prior to securing the components together. This introduces an adhesive property as the foam expands to provide an adhesive connection between the tongues and rebates in the components. Components 1301 and 1302 are secured to the tongues by means of screws, in an embodiment.

Thus, as shown in Figure 13, after being secured, the two components provide a first section of a wall assembly 1305.

Figure 14 *The construction of a floor assembly is shown in Figure 14; the construction process is substantially similar to the construction of the wall assembly 1305. To complete the floor, the building components are surrounded by lengths of extruded aluminium. The extruded aluminium provides integrity to the individual sections, accommodates the provision f communication channels and ducting channels, and also facilitates the combining of sections transported to site.

In the example of Figure 14, a longitudinal section 1401 cooperates with a first transverse section 1402 and a second transverse section 1403. After building components, such as component 1404 and component 1405 have been located within the space defined by extrusions 1401, 1402 and 1403, the floor section is completed by the application of a second longitudinal extrusion 1406.

Figure 15 A transverse wall section 1501 is built upon lower transverse extrusion 1403. In this example, transverse wall section 1501 includes a plurality of components (such as those shown in previous Figures and, in particular, as connected in Figure 13) and a door 1502. The door becomes part of a habitable space, which in turn becomes part of the overall building when fully assembled on-site. Door 1502 may be positioned as shown in Figure 15 such that it is fitted into a single one of the components which make up transverse wall section 1501. Alternatively, in another embodiment, door 1502 is positioned across two components without compromising structural integrity.

Figure 16 A further vertical extrusion 1601 is added to wall 1501, along with a first transverse upper extrusion 1602. A longitudinal wall 1603 is constructed which, in this example, consists of eight vertical panels. An opposite wall 1604 is added and the main structure is completed by an inclusion of a first longitudinal upper extrusion 1605, a second upper longitudinal extrusion 1606 and a second transverse upper extrusion 1607.

In this example, there is an buter longitudinal wall 1603 but the opposite side remains open. As shown, there is a floor but no ceiling. This represents an example of a factory constructed section which will be attached to cooperating sections, as shown in Figures 17 and 18, in order to create a building having an internal living space and an external appearance of a nature that is not immediately apparent as being constructed from transportable sections; such as the types shown in Figure 16. The section of Figure 16 presents a habitable space in that internal fixtures are included such that, when attached to other sections as described below, the space can be used and additional construction work on-site is minimal.

In practice, a ceiling is added to the section as shown before the section is transported as a whole and connected to other habitable sections. The ceiling provides protection for the internal living space and any fixtures and furnishing therein when thefactory constructed sections are in tranit. Thus, the overall approach of the embodiment provides a construction technique that goes well beyond conventional prefabrication, in that the sections delivered to site are considered habitable in themselves, when appropriately enclosed by the addition of other sections. Thus, the overall habitable section may be identified as 1608, In an embodiment, the habitable section will include fittings and components for the provision of utility services, such as incoming water, electricity, gas and waste removal. Cooperating sections are designed such that theycan be quickly combined together with appropriate connections being made for the utility elements. In this way, the amount of skill and labour required on-site is significantly reduced.

In a further embodiment, habitable section 1608 includes an additional wall section that separates the habitable section into separate rooms. Any number of such wall sections may be present depending on the requirements for the whole building.

Figure 17 The habitable section 1608 is shown in Figure 17 and may be considered as a first habitable section. In this embodiment, to complete the building, in the factory, a second habitable section 1701 is fabricated, along with a third habitable section 1702 and a fourth habitable section 1703. Each of these sections is transported independently to site for assembly on-site.

In an embodiment, for transportation purposes, the width of each section should not be greater than 4 metre. In an embodiment, a standard height of a building of 2.5 metre has been adopted and a typical length is up to 12 metre. For a section with a pitched roof, the height of the section may be up to 4.5 metre. In this example, section 1702 is provided with a pitched roof at an angle of twenty two degrees. In this example; a double pitch is deployed, but the pitch is off centre, providing a system referred to as north lighting to enhance the cooling properties of the building. The join also provides a strong ridged beam.

The sections are delivered to site and combined in a fashion that is substantially similar to zipping" the boxes together. One section is the master for connected services, such as water and electricity and. the other sections have consumer panels that connect to the master panel.

One of the sections may provide a bathroom and the water connections may be crimped together, such that the plumbing has effectively been done..

All of the finished walls and floors, in an embodiment, are dompleted before the section leaves the factory. The habitable sections therefore provide substantially more than what has been provided in previous systems known as "prefabricated" or "modular". The habitable sections may also include further wall sections to create a plurality of rooms in addition to those shown.

Each section includes a floor and a ceiling such that the habitable sections are contained when being transported. Thus, the habitable sections and interior furnishings can be protected from external factors such as poor weather when in transit on a vehicle. It is appreciated that each of the habitable sections may differ from those shown. For example, in an embodiment, the window sections shown on habitable sections 1701 and 1703 may be positioned at any point on the wall components, and may cross the joins between components.

Systems are known in which a frame is built on-site and the panels are then delivered. The basic structure goes up quickly but traditional work is then required in order to complete the building. With the embodiment described herein, substantially all of the work is done in the factory in a quality controlled environment. It is then only necessary to lock the sections together after the sections have been delivered to site.

Figure 18 The building configuration achieved on-site is illustrated in Figure 18.

On-site, services are established and the sections are then delivered. It is envisaged that a whole housing estate could be completed in a matter of days.

Channels are formed in abutting edges and elongate members effectively zip the sections together. This creates air tightness, weather tightness and adds significantly to the structural integrity. The resulting box structure provides a building, as shown in Figure 18, which is stronger than the individual sections illustrated in Figure 17.

The thermal properties of the components used to produce the sections in combination with the air tightness of the sections individually and in combination results in a substantial energy saving. It is calculated that, by the addition of solar panels, it should be possible to satisfy the energy requirements of the building such that there is no net inflow of energy.

Each section has a floor and a ceiling. Thus, when upper sections 1702, 1703 are added, each floor sits on top of a respective ceiling with an air gap between the two. This configuration is different from traditional building approaches, in which a big box would be divided into a number of floors. The sound insulation between floors in therefore significantly enhanced.

Figure 19 A central combining portion of the four sections identified in Figure 18, is detailed in Figure 19. Region 1901 represents the central location where everything is brought togther. The two ground floors are brought together and locked. The upper units are then positioned and locked so that all four are * bound together along their complete length, creating what may be referred.to * asaspinebeam. * * In an embodiment connecting portions run the full (12 metre) length.

Alternatively, the length could be made up *of several shorter sections of 1 metre of less.

The sections are secured together by a plurality of channel keys, such as key 1902 having a substantially H-shaped cross-section in this embodiment. In an embodiment, a channel key may have dimensions of between 6 millimetre and 8 millimetre at its central portion and may define a square of 20 millimetres, although preferred dimensions may vary, determined by its application and available materials.

The key 1902 is secured within channels to define a key-way, such as channel 1903 which, in an embodiment, is constructed from heat treated aluminium 696. Again, in an embodiment, the thickness of the aluminium may be between 4 millimetre and 5 millimetre. In a further embodiment, the thickness is up to 8 millimetre. The key 1902 could be fabricated from nylon or another polymer or alternatively a metal or metallic material such as aluminium. It is also appreciated that after the building has been put together, it is not going to be taken apart again. An embodiment relates to a permanent structure not a temporary structure. It is therefore possible that the key 1902 could be fabricated from aluminium such that oxidation of the aluminium could assist in terms of bonding the components. Thus, adopting this approach, the materials would effectively become bonded together after approximately three months.

In an embodiment, a guide is provided by a polymer which is then replaced by aluminium.

The function of the channels, defining a key-way, in combination with the key effectively converts I-sections into a box and it is recognised that this provides a significantly stronger assembly; stronger than the two individual I-sections. In an embodiment, four independent beams have become one significant beam, capable of supporting a substantial load.

Figure 20 A cross-section of the central-combining region is shown in Figure 20.

The building structure comprises a first factory constructed section 1608 defining a habitable space and having a first edge 2001 with a first channel 2002 therein. A second factory constructed section 1701 defines a second habitable space and has a second edge 2003 with a second channel 2004 therein. An elongate member (see Figure 19) is configured to locate in both said first channel 2002 and said second channel 2004-so as to force said first / edge 2001 into contact with said second edge 2003.

In an embodiment, the elongate member is configured to run the entire length of one of the factory constructed sections. However, in an alternative embodiment, the elongate member may be constructed from a plurality of shorter members. -In an embodiment, the elongate member is substantially H-shaped although it should be appreciated that alternative configurations could be ad?pted while obtaining substantially similar levels of functionality.

The elongate member may be fabricated from a plastics material, such as nylon.

The first edge 2001 and the second edge 2003 may be fabricated from a metal and said metal may be aluminium. In an alternative embodiment, the elongate member is also fabricated from aluminiuni.

As illustrated in the example, the first factory constructed section 1608 and the second factory constructed section 1701 are positioned at ground level: In this embodiment, the first edge 2001 and the second edge 2003 are substantially vertical but it should be appreciated that other configurations may be adopted. - In this example, a third factory constructed section 1702 is located - above the first factory constructed section 1608, defining a third substantially -vertical edge with a third channel 2006 therein. The third factory constructed section also defines a fourth substantially vertical edge with a fourth channel 2008 therein.

In an embodiment, a fourth factory constructed section 1703 is located above the second factory constructed section, defining a fifth substantially vertical edge with a fifth channel 2010 therein. In addition, there is provided a sixth substantially vertical ede with a sixth channel 2012 therein.

In an embodiment the first factory constructed section has a seventh substantially vertical edge with a seventh channel 2013 therein. The second factory constructed section as an eighth substantially vertical edge with an eighth channel 2014 therein. Further sets of elongate members are configured to locate in both said fQurth channel 2006 and said seventh channel 2013.

Additional sets of elongate members are configured to locate in both said sixth channel 2012 and said eighth channel 2014.

Figure 21 Apparatus for receiving water from a building structure so as to direct water to a discharge pipe is shown in Figure 21. Apparatus 2101 comprises a channel 2102 having an inner surface 2103 and an outer surface 2104 so as to define a gutter 2105. The apparatus 2101 further includes a hole 2106 which extends through channel 2102 to provide an outlet from gutter 2105 to a discharge pipe.

In this illustrated embodiment, channel 2102 also comprises a second hole 2107 which provides a further out!et from gutter 2105 to a discharge pipe.

In the embodiment shown, the outlet of second hole 2107 may be provided to an additional discharge pipe to that which the outlet of hole 2106 is connected or a single discharge pipe for feeding water from both hole 2106 and hole 2107.

Channel 2102 includes a plurality of rib-like structures 2108 which extend from inner surface 2103 of channel 2102 over hole 2106 and in this case hole 2107, thereby restricting the access of solid matérial, through each of the holes (2106, 2107) and into the discharge pipe. . In the illustrated embodiment of Figure 21, the plurality of rib-like structures 2108 extend along the entire length of the gutter. Thus, the plurality of rib-like structures 2108 assist in increasing the flexural strength of channel 2102. It is appreciated, however, that the rib-like structures 2108 also increases the flexural strength and rigidity of the gutter even if they do not extend along the entire length of the gutter.

In the embodiment shown in Figure 21 it can be seen that channel 2102 also includes a side wall 2109 which can be used to attach the apparatus 2101 to a complementary surface of a building structure, such as the building structure shown in Figures 16 and 17. Alternatively, side wall 2109 can be used to attach the apparatus 2101 to another apparatus for receiving water from a building structure so as to direct water to a discharge pipe in the manner shown in Figures 26 or 27.

Figure 22 Figure 22 shows a cross sectional view of apparatus 2101 previously shown in Figure 21. Apparatus 2101 is configured to receive water from a buildin structure, so as to direct water to a discharge pipe 2201. Apparatus 2101 comprises a channel 2102 having an inner surface 2103 and an outer surface 2104. Inner surface 2103 and outer surface 2104 define a gutter 2105 such that water is able to flow from gutter 2105 to discharge pipe 2201.

Apparatus 2101 further comprises a plurality of rib-like structures 2108, each of which extends from inner surface 2103 of channel 2102 and restricts the access of solid material, such as leaves, detritus or other debris, into discharge pipe 2201.

As shown in Figure 22, channel 2102 is defined with a U-shaped cross sectional profile, and, in this illustrated embodiment the U-shaped profile includes substantially squared corners. In an alternative embodiment, the U-shaped cross section of the channel includes rounded corners depending on the requirements of *the building structure in question. In a particular embodiment, the channel is formed as an aluminium extrusion and, in a further embodiment, the rib-like structures 2108 are formed as an integral part of the channel 2102. Thus, in manufacture, it is appreciated that the rib-like structures may be formed from a continuous sheet of extruded aluminium with the channel. In an alternative embodiment, the rib-like structures may be separate parts added to the channel after the channel itself has been formed.

The plurality of rib-like structures 2108 are, as previously discussed, configured to increase the flexural and bending strength of channel 2102 and extend from inner surface 2103 of channel 2102. In this illustrated embodiment, it can be seen that the plurality of rib-like structures 2108 are positioned on a horizontal section 2202 of the inner surface 2103 of channel 2102. The rib-like structures 2108 therefore provide guidance for water to flow through the channel and into discharge pipe 2201. Each of the plurality of rib-like structure 2108 comprises an upper exposed edge 2203 which is configured to support any solid material which enters channel 2102.

It is appreciated that any number of rib-like structures may be present in channel 2102 and this is not limited to the six shown in Figures 21 to 23. It is therefore appreciated that if a larger gutter is required, for example, a larger number of rib-like structures may be required to allow a satisfactory flow of water through channel 2102. Similarly, a smaller number of rib-like structures may be required for smaller gutters. Alternatively, larger gutters may include less rib-like structures if this is required in the application.

Figure 23 An alternative view of apparatus 2101 is shown in Figure 23. As with the illustrated examples shown in Figures 21 and 22 previously, apparatus 2101 comprises a channel 2102 having an inner surface 2103 and an outer surface 2104, which define a gutter 2105. Channel 2102 further comprises a hole 2106 extending through channel 2102 to provide an outlet from gutter 2105 to a discharge pipe. The discharge pipe is configured to be aligned with hole 2106 to allow the release of water from channel 2102. Apparatus 2101 further indudes a plurality of rib-like structures 2108 which extend from inner surface 2103 of channel 2102 and extend over hole 2106, thereby restricting the access of any solid material through hole 2106 and into the discharge pipe.

The plurality of rib-like structures 2108 are configured to increase the flexural strength of the channel 2102 in addition to preventing any solid material from passing through hole 2106. Thus, the upper exposed edges 2203 of each rib-like structure 2108 (such as upper exposed edge 2203B of rib-like structure 2108B) support the solid material and prevent access to the discharge pipe. Thus, the problem of blockages occurring in discharge pipes due to the entry of detritus and debris is addressed by means of the rib-like structures and the exposed edges.

In an embodiment the apparatus 2101 is manufactured by means of an aluminium extrusion, whereby the rib-like structures are formed as an integral part of the channel. Once the extrusion has been completed, the apparatus can be machined appropriately and, in particular, hole 2106 is drilled from the outer surface 2104 to the edge of inner surface 2103, such that the hole does not cut into the rib-like structures 2108. This creates a grill-type effect from the rib-like structures 2108 as they extend over the hole 2106 enabling the restriction. of solid, material through. the hole.21Q6 and thus, maintaining such solid material away from the discharge pipe.

Figure 24 An alternative apparatus for receiving water from a building structure so as to direct water to a discharge pipe is shown in Figure 24. Apparatus 2401 comprises a first channel 2402 having an inner surface 2403 and an outer surface 2404 so as to define a gutter 2405. Apparatus 2401 further includes a hole 2406 which extends through first channel 2402 and between the inner surface 2403 and outer surface 2404 to provide an outlet from gutter 2405 to a discharge pipe. A plurality of rib-like structures 2407 extend from inner surface 2403 of channel 2402 and extend over hole 2406, thereby restricting the access of solid material through hole 2406 and into a discharge pipe.

The structure of apparatus 2401 is substantially similar to that of apparatus 2101, previously described in Figures 21 to 23. However1 in this illustrated embodiment, the channel includes a single hole extending through the channel to provide the outlet to the discharge pipe.

Figure 25 Figure 25 shows a further apparatus 2501 comprising a channel 2502 which is substantially similar in structure to channel 2402. Channel 2502 has an inner surface 2503 and an outer surface 2504 which define a gutter 2505.

Apparatus 2501 further comprises a plurality of rib-like structures 2506 which extend from the inner surface 2503 of the channel 2502.

It is noted that, in this particular embodiment, channel 602 does not include a hole providing an outlet to a discharge pipe. However, apparatus 2501 includes a side waIl 2507 for connection to a building structure such as a house or a further apparatus comprising a channel, such as that shown in Figure 24.

Figure 26 Figure 26 shows an apparatus 2601 for receiving water from a building structure so as to direct water to a discharge pipe comprising the apparatus 2401 of Figure 24 and the apparatus 2501 of Figure 25 in combination.

Thus, in this illustrated embodiment, first channel 2402 is connectable to second channel 2502 by a suitable connection means. This may be in the form of any suitable fastening to provide a seal at join 2602 such that water does not escape through the bottom of channel 2402 or 2502. In this illustrated embodiment, first channel 2402 and second channel 2502 are connected * * along the width of each channel as shown, with a bond being formed between side wall 2408 and side wall 2507. The connection means may beany suitable fastening, adhesive or joint which holds the two channels together.

Thus, when fitted to a building structure, water and solid material can enter either channel 2402 or channel 2502 and flow along both channels towards hole 2406 which provides an outlet to a discharge pipe. In an alternative embodiment to that shown, a further hole for providing an outlet to a discharge pipe is provided, either in the first channel or the second channel.

Any combination of channels can be connected in this manner, such that the required number of holes are present in the channels as a whole.

Figure 27 A further embodiment of apparatus for receiving water from a building structure so as to direct water to a discharge pipe is shown in Figure 27.

Apparatus 2701 includes a first channel 2702 and a second channel 2703.

Each channel, 2702 and 2703, has an inner surface, 2704 and 2705 respectively and an outer surface 2706 and 2707 respectively which define a gutter. Each channel 2702 and 2703 provide outlets from the gutter to discharge pipes, such as discharge pipe 2708 and discharge pipe 2709. A plurality of rib-like structures 2710 extend from inner surface 2704 of channel 2702 and, similarly, a plurality of rib-like structures 2711 extend from inner surface 2705 of channel 2703. The rib-like structures 2710 and 2711 restrict the access of solid material into the discharge pipe.

It is appreciated that channels 2702 and 2703 may take the form of any of the previous embodiments described herein, as required by the particular application and building structure to which the gutter system is connected.

In this illustrated embodiment, first channel 2702 and second channel 2703 are connected along the length of each channel by means of side wall 2712 and side wail 2713. Side walls 2712 and 2713 may be connected together by any suitable connection means such as fastenings, screws or adhesives.

Figure 28 Figure 28 shows an apparatus for receiving water from a building structure so as to direct water from a discharge pipe in accordance with any of the previous embodiments described.

Apparatus 2801 comprises a channel 2802, which, as previously described, has an inner surface and an outer surface so as to define a gutter and a first hole and a second hole, each of which extends through the channel to provide an outlet from the gutter to a discharge pipe. While the channel in Figure 28 shows two separate holes for releasing water to a discharge pipe, it is appreciated that a single or more than twoholes may be present in the channel, as illustrated in previous embodiments.

Apparatus 2801 further comprises sealing plates 2803 and 2804 positioned at opposite ends of channel 2802. As shown in the Figure, first sealing plate 2803 is positioned at a first end 2805 of channel 2802 and sealing plate 2803 comprises an aperture 2806. In this particular embodiment, sealing plate 2803 further comprises a second aperture 2807. In an alternative embodiment, however a single aperture only is present in sealing plate 2803.

Similarly, apparatus 2801 comprises a second sealing plate 2804 which is positioned at a second end 2808 of channel 2802. Sealing plate 2804 also comprises a first aperture 2809 and a second aperture 2810. Again, it is appreciated that, in other embodiments, the number of apertures present in the sealing plate may be a single aperture or, alternatively, each sealing plate may have more than two apertures as required.

The sealing plates are positioned such as to prevent water or solid material from exiting the channel from either end, such that water is directed towards the holes which extend through the bottom surface of the channel.

However, a build up of solid material in the channel may reduce the amount of water which can flow through the holes. Thus, the apertures in the sealing plates allow for any excess water to escape if necessary.

In use, a channel as descrthed herein is installed to the building having an inner surface and an outer surface so as to define a gutter. The channel is substantially similar to any of the embodiments as previously described herein.

An putlet is provided from the gutter to the discharge pipe by means of a hole extending through the channel. Rain water and debris then enters the channel which diverts water from the building structure.

Once water has entered the channel, the water flows between rib-like structures present in the channel and though the hole towards the discharge pipe. However, the solid material such as debris, leaves or detritus is supported by the upper exposed edge of the rib-like structures such that they do not fall into the discharge pipe. The solid material is continually supported by the rib-likestructures as they enter the, channel.

In the event that a large amount of solid material is present within the channel, the channel can be cleaned and such solid material can be removed from the channel under normal maintenance procedures. However, if this maintenance procedure is not carried out, excess water is permitted to fill up is within the channel, and escape through overflow apertures on the sealing plates as described in Figure 28. Thus, in the event that excessive water cannot escape through the holes in the channel, water is still permitted to flow away from the building structure via the overflow apertures present in the sealing plate seen in Figure 28. 20]

Claims (22)

1. Claims 1.. A method of constructing a building component, comprising the steps of: constructing a first planar sub-assembly and a secohd planar sub-assembly; donnecting said first planar sub-assembly to said second planar sub-assembly at a plurality of locations so as to displace the plane of said second sub-assembly substantially above the plane of said first sub-assembly to define a box-assembly, with many of said plurality of connecting locations being within said box-assembly; attaching a first planar material to a first large outer surface of said box-assembly and attaching a second planar material to the second large outer surface of said box-assembly to produce a closed-box-assembly; and injecting a solidifying foam material into said closed-box-assembly.
2. 2.. The method of claim 1, wherein said first planar sub-assembly is constructed from abutting elements.
3. 3. The method of claim 2, wherein said abutting elements are timber elements secured by nail-plates.
4. 4. The method of claim 1 wherein said step of connecting the first planar sub-assembly to the second planar sub-assembly includes the application of additional nail plates, thereby minimizing the cross-sectional area of cold bridges between the planes while increasing racking integrity between said planes. . .
5. 5. The method of claim 1, wherein a plurality of building components are assembled for constructing a building comprising the steps of: fabricating a first section in a factory that defines a habitual space, including a first edge with a first channel therein: fabricating a second section in a factory that defines a habitual space, including a second edge with a second channel therein; transporting said first section and said second section from respective factories of fabrication to a construction site; and at said construction site, placing said first section and said second section on locations such that said first edge is substantially in contact with said second edge: and locating at least one elongate member in both said first channel and said second channel so as to force first edge into structural contact with said second edge.
6. 6. The method of claim 5, further comprising the steps of; fabricating a third section in a factory that defines a habitual space and a third substantially vertical edge with a third channel therein and a fourth substantially vertical edge with a fourth channel therein; and locating said third section above said first section.
7. 7. The method of claim 6, further comprising the steps of; fabricating a fourth section in a factory defining a fifth substantially vertical edge with a fifth channel therein and a sixth substantially vertical edge with a sixth channel therein; and locating said fourth section above said second section.
8. 8. The method of claim 7, wherein said first section has a seventh substantially vertical edge with a seventh channel therein and said second section as an eighth substantially vertical edge with an eighth channel therein, further comprising the steps of: s locating a second set of elongate members in both said fourth channel and said seventh channel; locating a third set of elongate members in both said sixth channel and said eighth channel.
9. 9. A building component, comprising:.a first planar sub-assembly and a second planar sub-assembly; connecting members connecting said fist planar sub-assembly to said second planar sub assembly defining a box-assembly, with said connecting members at a plurality of connecting locations within said box assembly; a first planar material attached to a first large outer surface of said box assembly and a second planar material attached to the second large outer surface of said box assembly to produce a closed-box-assembly; and solid foam material located within said closed-box-assembly.
10. 10. The building component of claim 9, wherein said first planar sub-assembly comprises abutting elements.
11. 11. The building component of claim 9, wherein said abutting elements are timber elements secured by nail plates
12. 12. The building component of claim 9, including plates connecting the first sub assembly to the second sub-assembly to provide racking integrity while minimising the cross-sectional area of cold bridges.
13. 13. A building structure fabricated from building components according to any of claims 9 to 12, wherein: a first factory-constructed section defines a habitable space having a first edge with a first channel therein: a second factory-constructed section defines a second habitable space having a second edge with a second channel therein: and a first elongate member is configured to locate in both said first channel and said second channel so as to first said edge into contact with said second edge.
14. 14. The building structure of claim 13, wherein each said elongate member is configured to run the entire length of one of said factory- 16 constructed sectiona
15. 15. The building structure of claim 13 or claim 14,. wherein said elongate member is substantially H-shaped
16. 16. The building structure of any of claims 13 to 15, wherein said elongate member is fabricated from a plastics materiaL
17. 17. The building structure of any of claims 13 to 16, having an apparatus for receiving water and directing the water to a discharge pipe, wherein said apparatus comprises: a channel having an inner surface and an outer surface so as to define a gutter; . a hole extending through said channel to provide an outlet from said gutter to said discharge pipe; and a plurality of rib-like structures extending from said inner surface to said channel and extending over said hole, thereby restricting the access of solid material through said hole and into the discharge pipe.
18. 18. Apparatus according to claim 17, wherein each said plurality of rib-like structures is formed as an integral part of said channeL
19. 19. Apparatus according to claim 17 or claim 18, wherein each df said plurality of rib-like structures comprises an upper exposed edge which supports said solid material.
20. 20. The building structure of any of claims 17 to 19, wherein said apparatus further comprises a sealing plate positioned at a first end of said 15. channel, said sealing plate comprising an aperture.
21. 21. A method of constructing a building component substantially as herein described with reference to the accompanying drawings.
22. 22. A building component substantially as herein described with reference to the accompanying drawings.