AU2011201755B1

AU2011201755B1 - Panel Support Member

Info

Publication number: AU2011201755B1
Application number: AU2011201755A
Authority: AU
Inventors: Mark Winfield
Original assignee: Pearls Miihome IP Pty Ltd
Current assignee: Miihome International Ip Pte Ltd
Priority date: 2011-04-19
Filing date: 2011-04-19
Publication date: 2012-05-17
Anticipated expiration: 2031-04-19
Also published as: WO2012142660A1

Abstract

A member (10) for supporting a panel (30) in a generally upright position comprises a first wall (12) extending in a generally upright orientation, a second wall (14) spaced 5 from the first wall(12), the second wall (14) extending in a generally upright orientation, and an intermediate portion (16) extending between the first wall (12) and the second wall (14), the intermediate portion (16) comprising a floor portion (18) and a gutter portion (20) positioned between the first wall (12) and the floor portion (18). The gutter portion (20) extends below the floor portion to form a drip edge. The gutter portion 10 provides a volume for collecting water that runs down the outside of the wall panel (30). Drain holes (28) are provided in the gutter portion (20) to enable water to drain therefrom.

Description

AUSTRALIA Patents Act 1990 COMPLETE PATENT SPECIFICATION Name of Applicant: Pearls MiiHome IP Pty Ltd Actual Inventor: Mark Winfield Address for Service: Cullens Patent & Trade Mark Attorneys Level 32, 239 George Street Brisbane QLD 4000 Australia Invention Title: Panel Support Member The following statement is a full description of this invention, including the best method of performing it, known to the applicant: PANEL SUPPORT MEMBER FIELD OF THE INVENTION 5 The present invention relates to a member for supporting a panel. In particular, the present invention relates to a member for supporting a panel in a generally upright position. BACKGROUND TO THE INVENTION 10 Composite panels are starting to become used in the construction of buildings. Composite panels typically include a core material that is laminated on either side by a sheet material. The core material may, for example, comprise expanded polystyrene and the sheet material that is laminated on either side of the polystyrene core may comprise steel 15 sheet. Other panel constructions are also known. When constructing buildings using composite panels, or other panels, for external walls, there is a requirement to provide a member to support the walls and secure the walls to the floor. Such members that are commonly used are often described as base channel 20 sections. These member provides a rigid fixing between the floor and the walls. Such members typically comprise a U-channel having opposed and spaced upright walls interconnected by a generally horizontal floor. In use, fasteners (such as bolts or other known fasteners) fix the floor of the U-channel to a slab, foundations or floor structure of the building. This holds the U-channel in place relative to the slab, foundation or floor 25 structure of the buildings. The panels are then inserted into the U-channel. The U-channel has a width that is just slightly larger than the width of the panel. In this manner, the panel snugly fits between the opposed and spaced upright walls of the U-channel. Appropriate fasteners are then used to secure the panel to the U-channel. Typically, bolts or screws (such as Tek screws) are used to secure the panel to the upright walls of the U 30 channel. The bolts or screws will normally pass through the upright walls of the U- 2 channel and into the panel. In some instances, adhesives may be used to secure the panel to the U-channel. The members that are used to support the walls and secure the walls to the floor structure 5 of the building are frequently laid down along the entire perimeter of the building, although it may also be possible that the members may only extend along part of the perimeter of the building. Although known base channel sections are very effective in securing the wall panels in 10 position, potential problems arise where the base channel sections are used to support external walls of the building. One of these problems involves the possibility of having water move into the building by way of the water passing through the space between the underneath surface of the floor of the base channel section and the slab, foundation or floor structure. 15 A further issue of concern arises from water running down the external face of a wall panel that is mounted in the base channel section and collecting in the base channel section. Once the water is inside the base channel section, it is possible that the water can migrate along the floor of the base channel section and into the building. 20 Throughout this specification, the term "comprising" should be taken to have an inclusive meaning unless the context of use indicate otherwise. The present applicant does not concede that the prior art discussed in this specification 25 forms part of the common general knowledge in Australia or elsewhere. BRIEF DESCRIPTION OF THE INVENTION It is an object of the present invention to provide a member for supporting a panel that 30 overcomes or at least ameliorates one or more of the above-mentioned disadvantages, or that provides a commercial alternative.

3 In a first aspect, the present invention provides a member for supporting a panel in a generally upright position, the member comprising: - a first wall extending in a generally upright orientation; - a second wall spaced from the first wall, the second wall extending in a generally upright orientation; and - an intermediate portion extending between the first wall and the second wall, the intermediate portion comprising a floor portion and a gutter portion positioned between the first wall and the floor portion, the gutter portion extending below the floor portion. A wall structure for a building, the wall structure comprising a panel supported in a generally upright position by a member, the member comprising a first wall extending in a generally upright orientation, the panel being fastened to the first wall of the member by one or more fasteners extending through the first wall and into the panel, the member further comprising a second wall spaced from the first wall, the second wall extending in a generally upright orientation, the panel being fastened to the second wall of the member by one or more fasteners extending through the second wall and into the panel, the member further comprising an intermediate portion extending between the first wall and the second wall, the intermediate portion comprising a floor portion and a gutter portion positioned between the first wall and the floor portion, the gutter portion extending below the floor portion, wherein the member is mounted to a slab, a foundation or a floor structure of the building by one or more fasteners extending though the floor portion such that the floor portion of the member is positioned on the slab, foundation or floor structure, the first wall of the support member is positioned externally to the building and the gutter portion extends below a region between the floor portion of the member and the slab, foundation or floor structure. In one embodiment of the present invention, a lower part of the first wall and the gutter portion define a part of the member that extends below the floor portion of the member. In this manner, the first wall and the gutter portion can act as an effective drip edge. It will be understood that, in a wall structure that incorporates the member of the present invention, the floor portion of the member will positioned on and above an outer peripheral part of the slab, foundation or floor structure of the building and appropriate 4 fasteners (typically bolts) will be used to securely fix the member to the slab, foundation or floor structure. The gutter portion will extend below the floor portion such that any water that runs down the exterior of the first wall of the member will drip off the lower edge or surface of the gutter portion. In this manner, the likelihood of water entering the 5 building along any gap that exists between the floor portion of the member and the slab, foundation or floor structure is greatly reduced. Effectively, the gutter portion forms a drip edge. In a wall structure that incorporates a member in accordance with the present invention, 10 in some embodiments the member is mounted or fixed to the slab, foundation or floor structure of the building such that an inner periphery of the gutter portion is spaced from the slab, foundation or floor structure. Suitably, the gutter portion is spaced from the slab, foundation or floor structure by a distance that is sufficient to prevent any capillary action drawing water between the inner periphery of the gutter portion and the slab, foundation 15 or floor structure. This can be easily achieved by mounting the member to the slab, foundation or floor structure such that the gutter portion is set out from the edge of the slab, foundation or floor structure. In some embodiments, the gutter portion can be set out far enough to allow other building materials and external finishes, such as under skirting claddings, to be concealed behind the gutter portion. This provides a neat finish for such 20 external finishes and claddings whilst still preserving the benefits of the gutter portion in the member. The gutter portion also serves to collect any water that may run down the external wall of the panel and through any space between the panel and the first wall of the member. In 25 some embodiments, the gutter portion is arranged such that any water that collects in the gutter portion drains from the gutter portion. For example, the gutter portion may be provided with one or more drain holes located along a bottom of the gutter portion. The drain holes allow any water that collects in the gutter to drain out of the gutter portion without ever penetrating into the building. In another embodiment, the gutter portion may 30 be inclined along the length of the member such that water runs downwardly along the inclined gutter and out through an opening or a drain hole.

5 In some embodiments, the gutter portion provides a gap or an air pocket between the lower part of the gutter portion and a lower surface of the panel mounted in the member. It will be understood that a panel that is mounted in the member will have its lower 5 surface effectively resting on the floor portion of the member. The gutter portion will therefore extend below the lower surface of the panel. Any water that collects in the gutter portion will be spaced from the lower surface of the panel by the air pocket. This reduces or eliminates the chance for penetration of water into the building by way of any capillary action between the member and the wall panel. to The member in accordance with the present invention may be made from steel or other metal or metal alloy. The member may be formed by stamping or extrusion. The member may be an elongate member. The elongate member may have a generally constant cross section along the length of the member. 15 The member in accordance with the present invention can be used to effectively prevent water penetration into a building for a variety of construction types where wall panels or similar need to be fixed to floors, slabs or foundations. 20 In other aspects of the present invention, it may be possible to omit the second upright wall in the member. Accordingly, in a third aspect, the present invention provides a member for supporting a panel in a generally upright position, the member comprising: - a first wall extending in a generally upright orientation; - a floor portion and a gutter portion positioned between the first wall and the floor 25 portion, the gutter portion extending below the floor portion. In a fourth aspect, the present invention provides a wall structure for a building, the wall structure comprising a panel supported in a generally upright position by a member, the member comprising: 30 - a first wall extending in a generally upright orientation; 6 - a floor portion and a gutter portion positioned between the first wall and the floor portion, the gutter portion extending below the floor portion; wherein the member is mounted to a slab, a foundation or a floor structure of the building such that the floor portion of the member is positioned on the slab, foundation or floor 5 structure, the first wall of the support member is positioned externally to the building and the gutter portion extends below a region between the floor portion of the member and the slab, foundation or floor structure. 10 BRIEF DESCRIPTION OF THE DRAWINGS Figure I shows a perspective view of a member in accordance with one embodiment of the present invention; 15 Figure 2 shows a cross sectional view of the member having a wall panel mounted to it; Figure 3 shows a cross sectional view of a member in accordance with an embodiment of the present invention mounted to a traditional slab; 20 Figure 4 shows a cross sectional view of a member in accordance with an embodiment of the present invention mounted to a suspended floor system; Figure 5 shows a cross sectional view of a member in accordance with an embodiment of the present invention mounted to a hinged floor system; 25 Figure 6 shows a perspective view, partly in cross section, of a member in accordance with an embodiment of the present invention mounted to a floor structure; and Figure 7 shows a perspective view, in cross-section, of a hinged wall panel mounted to a 30 floor using a member in accordance with an embodiment of the present invention.

7 DETAILED DESCRIPTION OF THE DRAWINGS It will be understood that the drawings have been provided for the purposes of illustrating preferred embodiments of the present invention. Therefore, the present invention should 5 not be considered to be limited solely to the features as shown in the drawings. Figure I shows a perspective view of a member in accordance with one embodiment of the present invention. The member 10 shown in figure 1 is in the form of an elongate member having an essentially constant cross section along its length. The member 10 is 10 suitably made from steel and it may be made by stamping or folding a strip or sheet of steel into the desired shape. The member 10 shown in figure 1 has a first wall 12 and a second wall 14. First wall 12 extends in a generally upright orientation (throughout this specification, terms such as 15 "upright", horizontal"," vertical" and other terms denoting orientation are provided to describe the orientation adopted during normal use of the member). Similarly, second wall 14 also extends in a generally upright orientation. The first wall 12 and the second wall 14 form opposed walls that are spaced from each other. 20 The member 10 also includes an intermediate portion 16 located between the first wall 12 and the second wall 14. The intermediate portion includes a floor portion 18 and a gutter portion 20 that is positioned between the first wall 12 and the floor portion 18. As can be seen from figure 1, the floor portion 18 extends in a generally horizontal orientation. The floor portion 18 forms a significant part of the width of the intermediate portion 16, with 25 the total portion 20 forming the remainder of the intermediate portion 16. The gutter portion 20 includes an inner wall 22 that extends in a downwards direction from the floor portion 18 and a gutter base 24. 30 The first wall 12 includes a plurality of holes or openings 25 formed therein. Similarly, second wall 14 includes a plurality of holes or openings 26 formed therein. The gutter 8 portion 20 includes a plurality of drain holes 28 that enable any water that collects in the gutter portion 20 to drain out of the gutter portion 20. Figure 2 shows a wall panel 30 mounted to the member 10. The wall panel 30 may 5 comprise a composite panel having external sheets of metal laminated to a core of expanded polystyrene. Other panel structures may also be used. Other wall structures may be used. As can be seen from figure 2, the first wall 12 and the second wall 14 of the member 10 10 are spaced from each other by a distance that is slightly larger than the width of the panel 30. In this manner, the panel 30 can be easily located between the first wall 12 and the second wall 14. When the wall panel 30 is positioned in the member 10, the lower edge of wall panel 32 comes into contact with the floor portion 18 of the member 10. Appropriate fasteners, such as screws 34, 36 pass through the respective openings 26, 25 15 in the respective second wall 14 and first wall 12 and into the panel 30 in order to securely mount the wall panel 30 to the member 10. As can be seen from figure 2, the base 24 of the gutter portion 20 is spaced below the floor portion 18 of the member 10 and, as a result, the base 24 of the gutter portion 20 is 20 also spaced below the lower edge 32 of the panel 30. Thus, the gutter portion 20 provides a volume in which any water that runs down the external wall 38 of the wall panel 30 and subsequently passes through any gap or space between the first wall 12 and the external wall 38 can collect. Any water that does collect in gutter portion 20 can drain therefrom through drain holes 28. It will also be noted that an air gap is formed between the base 24 25 of the gutter portion 20 and the lower edge 32 of the wall panel 30. The presence of this air gap reduces or eliminates the likelihood of any water that may collect in the gutter portion 20 being drawn into the panel and into the building by capillary action. Figure 3 shows a member in accordance with the present invention being used to mount a 30 wall panel to a traditional concrete slab. The features shown in figure 3 that are common 9 with the features shown in figure 2 are denoted by the same reference numerals as used in figure 2. For brevity of description, these features need not be described further. In figure 3, the member 10 is positioned along the outer periphery of a concrete slab 50. 5 The concrete slab 50 is provided with a rebate 52 around its periphery. However, it will also be understood that the member 10 may be positioned on a concrete slab that does not have such a rebate. The member 10 is securely mounted to the concrete slab 50 by way of bolts 54. The person skilled in the art will appreciate that a number of alternative bolts or alternative fasteners may be used to secure the member 10 to the concrete slab 50. 10 It will be readily understood that the member 10 is positioned on the concrete slab 50. Although the member 10 is in contact with the upper surface of the concrete slab 50, a space or gap 56 will exist that may allow water to migrate between the lower surface of the floor portion 18 of the member 10 and the upper surface of the concrete slab 50. 15 However, the lower part of first wall 12 and the gutter portion 20 extend below that space 56 (by virtue of the gutter portion 20 extending below the floor portion 18 of the member 10). Therefore, any water that comes into contact with the first wall 12 of the member 10 (which constitutes the external wall of the member) will run down the first wall until it reaches lower edge 29. Lower edge 29 represents the junction between the first wall 12 20 and the base 24 of the gutter portion 20. Any water running down the first wall 12 will tend to drip off the first wall 12 at the lower edge 29. As the lower edge 29 is also below the space 56, the likelihood of water being able to migrate through the space 56 between the member 10 and the concrete slab 50 and into the building is minimised or eliminated. 25 Furthermore, as mentioned with reference to figure 2, any water that collects in the gutter portion 20 of the member 10 can easily drain out of the gutter portion 20 through the drain holes 28. An air gap is also formed between any water that may collect in the base 24 of the gutter portion 20 and the lower edge 32 of the wall panel 30. 30 As can also be seen from figure 3, the inner wall 22 of the gutter portion 20 is spaced outwardly from a side wall 58 of the concrete slab 50. Suitably, the space between the 10 inner wall 22 and the side wall 58 of the concrete slab is sufficiently large such that water is unlikely to be drawn up into that space by virtue of capillary action. Figure 4 shows a member 10 being mounted to a suspended floor system. The suspended 5 floor system includes a bearer section 60. Bearer section 60 may be mounted on a screw pier (not shown) or any other suitable foundation system. The bearer section 60 supports a panel floor system 62 or, indeed, any other floor system. The member 10 is positioned on the panel floor system 62 such that the inner wall 22 of gutter portion 20 is spaced outwardly from an outer section 64 of panel floor system 62. The panel floor system 62 is 10 connected to the bearer section 60 and also to the member 10 by use of cyclone bolts 66. Other fasteners, such as screws 68 may also be used to further fix the member 10 to the panel floor system 62. Similarly, other fasteners, such as screws 70 may be used to further fix the panel floor system 62 to the bearer section 60. 15 In the embodiment shown in figure 4, the outer section 64 of the panel floor system 62 is formed by a C-section made from steel. The cyclone bolts 66 also affix the C-section to the bearer section 60, the floor panel system 62 and the member 10. Following mounting of the member 10 to the floor structure as shown in figure 4, the wall 20 panel 30 may be mounted to the member 10 in a manner similar to that shown in figure 2. Figure 5 shows a member 10 in accordance with the present invention mounted to a hinged floor system. Such hinged floor systems may be used, for example, in remote area housing that may be formed as a fold-out house in a container. In the embodiment shown 25 in figure 5, a panel floor 80 (or other floor system) has a metal C-section 82 mounted to its outer face by use of screws 84 or other fasteners. A heavy duty hinge 86 is mounted to C-section 84 and panel floor 80. The hinge 86 forms part of the floor structure of the building. The member 10 is mounted to the heavy duty hinge 86 by use of screws or bolts (or other fasteners) 88. A wall panel can then be mounted to the member 10 in a manner 30 similar to that shown in figure 2.

I1 Figure 6 shows a perspective view of a construction similar to that shown in figure 4 but with further details shown. Where the features shown in figure 6 are in common with the features shown in figure 4, similar reference numerals to those used in figure 4 will be used to denote those features in figure 6. For brevity of description, these features will not 5 be described further. In figure 6, an adjustable screw pier head 90 carrying a height adjustable bracket 92 is used to carry the bearer section 60. Additional cyclone bolts 94 are used to tie the bearer section 60 to the height adjustable bracket 92. 10 In order to provide a neat finish or a more aesthetically pleasing finish to the building, external cover boards 96 are mounted via screws 98 to C-section 64. As can be seen from figure 6, the upper end of the external cover boards 96 are positioned in the gap between the inner wall 22 of the gutter portion 20 of member 10 and the outer wall of C-section 15 64. It will be appreciated that other cladding panels could also be used to cover the underfloor section of the building. Figures 7 shows a perspective view of a construction similar to that shown in figure 5, but with further details shown. For brevity of description, the features of figures 7 that are 20 common to earlier figures will be denoted by like reference numerals. These features need not be described further. In figure 7, a height adjustable bracket 92 that is part of an adjustable screw pier head (not shown) has a bearer section 100 mounted to it by cyclone bolts 102. The bearer section 100 carries the floor panel 80. An external metal C-section 104 is connected to the floor panel 80 and the bearer section 100 by cyclone bolts 106. 25 The remainder of the construction shown in figure 7 is largely the same as that shown in figure 5. The member in accordance with at least preferred embodiments of the present invention serves to: 30 - improve water penetration resistance of a building; 12 -maintain an effective and robust connection between the floor and the panel walls; - accommodate and dispose of any water that passes between the wall panel and the first wall of the member and into the member; - provide a better visual finish when fixing under-skirting type claddings; and 5 - further strengthen the structure of the member by adding two additional folds and another vertical section to the member (when compared to a conventional U-channel member). In some embodiments, the gutter portion of the member may extend up to 50 mm below 10 the floor portion of the member, for example, from 5 to 50 mm below the floor portion, or from 10 to 40 mm below the floor portion, or from 10 to 30 mm below the floor portion, or from 15 to 25 mm below the floor portion. It will be understood that these dimensions should not be considered to be limiting. 15 In some embodiments, the inner wall of the gutter portion may be spaced at least 1 mm from the exterior side face of the slab, foundation or floor structure, for example 2 to 50 mm, or from 2 to 40 mm, or from 5 to 25 mm, or from 10 to 20 mm, from the exterior face of the slab, foundation or floor structure. These distances are considered to be sufficiently large to ensure that capillary action is unlikely to draw water into the space. It 20 will be understood that these distances should not be considered to be limiting. Those skilled in the art will understand that the present invention may be susceptible to variations and modifications other than those specifically described. It will be understood that the present invention encompasses all such variations and modifications that fall 25 within its spirit and scope.

Claims

1. A wall structure for a building, the wall structure comprising a panel supported in a generally upright position by a member, the member comprising a first wall extending 5 in a generally upright orientation, the panel being fastened to the first wall of the member by one or more fasteners extending through the first wall and into the panel, the member further comprising a second wall spaced from the first wall, the second wall extending in a generally upright orientation, the panel being fastened to the second wall of the member by one or more fasteners extending through the second 10 wall and into the panel, the member further comprising an intermediate portion extending between the first wall and the second wall, the intermediate portion comprising a floor portion and a gutter portion positioned between the first wall and the floor portion, the gutter portion extending below the floor portion, wherein the member is mounted to a slab, a foundation or a floor structure of the building by one 15 or more fasteners extending though the floor portion such that the floor portion of the member is positioned on the slab, foundation or floor structure, the first wall of the support member is positioned externally to the building and the gutter portion extends below a region between the floor portion of the member and the slab, foundation or floor structure. 20

2. A wall structure as claimed in claim I wherein the first wall and the gutter portion act as an effective drip edge.

3. A wall structure as claimed in claim 2 wherein the floor portion of the member is 25 positioned on and above an outer peripheral part of the slab, foundation or floor structure of the building and fasteners are used to securely fix the member to the slab, foundation or floor structure, and the gutter portion extends below the floor portion such that any water that runs down an exterior of the first wall of the member will drip off the lower edge or surface of the gutter portion 30 14

4. A wall structure as claimed in any one of claims 1 to 3 wherein the member is mounted or fixed to the slab, foundation or floor structure of the building such that an inner periphery of the gutter portion is spaced from the slab, foundation or floor structure. 5

5. A wall structure as claimed in claim 4 wherein the gutter portion is spaced from the slab, foundation or floor structure by a distance that is sufficient to prevent any capillary action drawing water between the inner periphery of the gutter portion and the slab, foundation or floor structure. 10

6. A wall structure as claimed in claim 4 or claim 5 wherein the gutter portion is spaced from the slab, foundation or floor structure by a distance that is far enough to allow other building materials and/or external finishes to be concealed behind the gutter portion. 15

7. A wall structure as claimed in any one of claims I to 6 wherein the gutter portion also serves to collect any water that runs down the external wall of the panel and through any space between the panel and the first wall of the member. 20

8. A wall structure as claimed in any one of claims I to 7 wherein the gutter portion is arranged such that any water that collects in the gutter portion drains from the gutter portion.

9. A wall structure as claimed in claim 8 wherein the gutter portion is provided with one 25 or more drain holes located along a bottom of the gutter portion.

10. A wall structure as claimed in any one of claims I to 9 wherein the gutter portion provides a gap or an air pocket between the lower part of the gutter portion and a lower surface of the panel mounted in the member. 30 15

11. A wall structure as claimed in any one of claims I to 10 wherein the member is an elongate member having a generally constant cross section along the length of the member. 5

12. A wall structure as claimed in any one of the preceding claims wherein the one or more fasteners comprise screws or bolts.

13. A wall structure as claimed in any one of the preceding claims wherein the slab, the foundation or the floor structure of the building comprises a floor structure that 10 includes a hinge, the member being mounted to the hinge by one or more fasteners that pass through the floor portion and through an arm of the hinge.

14. A wall structure substantially as hereinbefore described with reference to the accompanying drawings. 15