AU2016101403A4 - Wall panel assembly - Google Patents

Abstract

H:\stp\Interwoven\NRPortbl\DCC\STP\10627560_ 1.docx-24/10/2011 -22 A wall panel assembly for use in constructing a wall, the apparatus including a pair of opposing wall panels, a number of stud pairs, each stud pair including opposing studs extending in first direction along opposing surfaces of the wall panels, with the number of stud pairs being spaced along the panels in a second direction and a number of spacers interconnecting the studs in each stud pair, each spacer being pivotally mounted to each stud to allow the wall panels to be moved between collapsed and operative positions, wherein in the operative position a spacing between the opposing walls panels is greater than in the collapsed position. Fig. 1A 12> \- Y 121x V~ ~ Fg 1 A MN >zr

Description

WALL ΡΑΝΕΙ, ASSEMBLY

Background of the Invention [0001] The present invention relates to a wall panel assembly and method of construction thereof, as well as to a stud assembly for use in a wall panel assembly.

Description of the Prior Art [0002] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that the prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

[0003] A wide range of wall structures and methods for constructing both dry walls and concrete filled walls are known.

[0004] W02009/070830 describes a method of constructing a wall, the method including providing first and second spaced apart wall portions for receiving a filling material. Each wall portion includes at least one track on a support, at least two support members, each support member being aligned with the track and extending from the support, a wall panel supported by the at least one track and the at least two support members and at least one joining member coupled to the wall panel and the support members. Spacers are also coupled to and extend between the wall portions.

[0005] W02005/019552 describes a building system in which paired studs attach to inside surfaces of facing sheets to provide panel formwork for concrete walls. The studs comprise a head and outwardly extending spaced flanges with inwardly directed teeth and lips. Spacer elements are engaged with the recess between the flanges and may be formed from off-cuts of sheet material or as specifically formed elements. The latter are formed from hard plastic and in a preferred embodiment are formed as a rectangular box which can be orientated in alternate directions. The system may include end elements, internal top and bottom plates, internal comers, external comers and a shadow line junction between panels.

[0006] AU2011100636 describes apparatus for use in constructing a wall, the apparatus including a wall panel having first and second wall sheets, a number of elongate spacer members for supporting the wall sheets in a spaced apart arrangement to allow a filling material to be provided therebetween and at least one end spacer member positioned substantially at an end of the first and second wall sheets, the end spacer member including at least one connector for allowing the wall panel to be connected to other parts of a wall.

[0007] US-7,082,732 describes a bridging web for linking a first and second wall panel, the first and second wall panels extending parallel to one another. The bridging web has a first and second end member, each of which extend between a first edge mountable within the wall panels and a second edge. The second edge has a first hinge element. The first end member is mountable within the first wall panel and the second end member is mountable within the second wall panel. A central section extends between a pair of second hinge elements and is mountable between the first hinge element of the first end member and the first hinge element of the second end member. One of the first and second hinge elements is a pin and the other of the first and second hinge elements includes at least one first knuckle and at least one second knuckle. The pin defines a vertical hinge axis. The first knuckle is vertically displaced from the second knuckle, and the first and second knuckles are adapted to bear on opposing surfaces of the pin.

Summary of the Present Invention [0008] In one broad form the present invention seeks to provide a wall panel assembly for use in constructing a wall, the apparatus including: a) a pair of opposing wall panels; b) a number of stud pairs, each stud pair including opposing studs extending in first direction along opposing surfaces of the wall panels, with the number of stud pairs being spaced along the panels in a second direction; and, c) a number of spacers interconnecting the studs in each stud pair, each spacer being pivotally mounted to each stud to allow the wall panels to be moved between collapsed and operative positions, wherein in the operative position a spacing between the opposing walls panels is greater than in the collapsed position.

[0009] Typically each stud includes: a) a head coupled to a surface of the wall panel in use; and, b) a channel extending away from the head, the spacer being coupled to the channel in use.

[0010] Typically each stud includes a pair of substantially parallel spaced apart channel side walls extending outwardly from the stud to define the channel, and wherein the spacer is pivotally mounted to the side walls.

[0011] Typically a lip extends from each channel side wall, the lip being substantially parallel to the head.

[0012] Typically, in the collapsed position the lips of opposing studs abut against each other so that the channel side walls support the panels in the collapsed configuration.

[0013] Typically the lips at least one of: a) extend inwardly to thereby partially enclose the channel; and, b) extend outwardly to thereby define an external recess.

[0014] Typically each spacer is pivotally mounted to the side walls using a fastener.

[0015] Typically in the collapsed position at least part of each spacer is received within the channel.

[0016] Typically the studs are made of an extrusion.

[0017] Typically the studs are bonded to the wall panels using an adhesive.

[0018] Typically each spacer is adapted to hinge substantially mid-way along the length of the spacer thereby allowing the spacer to move between folded and extended positions when the wall panels are moved between collapsed and operative positions.

[0019] Typically each spacer includes first and second pivotally connected spacer portions.

[0020] Typically the wall panel assembly includes a locking mechanism for locking at least some of the spacers in position when the wall panels are in the operative position.

[0021] Typically the locking mechanism locks at least some of the spacers to the studs.

[0022] Typically the locking mechanism locks a hinge provided substantially mid-way along the length of the spacer.

[0023] Typically the spacers include: a) an elongate body; b) at least one end projecting laterally from the body; and, c) at least one rounded corner to allow pivotal movement of the spacer.

[0024] Typically the spacers have at least one of: a) a "Z" shape; b) a "C" shape; and, c) a dual "L" shape.

[0025] Typically the wall panel assembly includes: a) a number of stud assemblies, each stud assembly including: i) a respective stud pair including the opposing studs; and, ii) the spacers interconnecting the studs in each stud pair, each spacer being pivotally mounted to each stud to thereby allow the studs to be moved between collapsed and operative positions, wherein in the operative position a spacing between the studs is greater than in the collapsed position; and, b) the opposing wall panels.

[0026] Typically each spacer pivots along a respective axis that is perpendicular to the first direction and parallel to the second direction.

[0027] In another broad form the present invention seeks to provide a stud assembly for use in constructing a wall panel assembly, the stud assembly including: a) a stud pair including opposing studs; and, b) spacers interconnecting the studs in each stud pair, each spacer being pivotally mounted to each stud to thereby allow the studs to be moved between collapsed and operative positions, wherein in the operative position a spacing between the studs is greater than in the collapsed position.

[0028] In another broad form the present invention seeks to provide a method of a constructing wall panel assembly for use in constructing a wall, the method including: a) providing a number of stud assemblies including: i) a stud pair including opposing studs; and, ii) spacers interconnecting the studs in each stud pair, each spacer being pivotally mounted to each stud; and, b) bonding the stud assemblies to opposing walls panel so that the studs in each stud pair extend in first direction along opposing surfaces of the wall panels, with the stud assemblies being spaced along the panels in a second direction to thereby allow the wall panels to be moved between collapsed and operative positions, wherein in the operative position a spacing between the wall panels is greater than in the collapsed position.

[0029] Typically the method includes: a) constructing a number of wall panel assemblies; and, b) stacking a number of wall panel assemblies in the collapsed configuration to allow a bonding adhesive to cure.

Brief Description of the Drawings [0030] An example of the present invention will now be described with reference to the accompanying drawings, in which: - [0031] Figure 1A is a schematic isometric view of an example of a wall panel assembly in an operative position; [0032] Figure IB is a schematic end view of the wall panel assembly of Figure 1A in the operative position; [0033] Figure 1C is a schematic side view of the wall panel assembly of Figure 1A in the operative position; [0034] Figure ID is a schematic plan view of the wall panel assembly of Figure 1A in the operative position; [0035] Figure IE is a schematic plan view of the wall panel assembly of Figure 1A in a partially collapsed position; [0036] Figure IF is a schematic end view of the wall panel assembly of Figure 1A in a partially collapsed position; [0037] Figure 1G is a schematic plan view of the wall panel assembly of Figure 1A in a fully collapsed position; [0038] Figure 1H is a schematic end view of the wall panel assembly of Figure 1A in a fully collapsed position; [0039] Figure 2A is a schematic end view of an example of a stud; [0040] Figure 2B is a schematic end view of the stud of Figure 2A coupled to a spacer and wall panel; [0041] Figure 2C is a schematic end view of an alternative example of a stud; [0042] Figure 2D is a schematic end view of the stud of Figure 2C abutting against another stud; [0043] Figure 2E is a schematic end view of an alternative example of a stud; [0044] Figure 2F is a schematic end view of the stud of Figure 2E abutting against another stud; [0045] Figure 2G is a schematic end view of an alternative example of a stud coupled to a spacer; [0046] Figure 3 A is a schematic cross sectional view along the line A-A' of Figure 2B with an example spacer; [0047] Figure 3B is a schematic cross sectional view along the line A-A of Figure 2B with a an alternative example spacer; [0048] Figure 3C is a schematic cross sectional view along the line A-A' of Figure 2B with a an alternative example spacer; [0049] Figure 3D is a schematic cross sectional view along the line A-A' of Figure 2B with a an alternative example spacer; [0050] Figure 4A is a schematic end view of an example of a wall panel assembly in an operative position; [0051] Figure 4B is a schematic plan view of the wall panel assembly of Figure 4A in the operative position; [0052] Figure 4C is a schematic end view of the wall panel assembly of Figure 4A in a partially collapsed position; [0053] Figure 4D is a schematic end view of the wall panel assembly of Figure 4A in a fully collapsed position; [0054] Figure 5A is a schematic cross sectional view along the line B-B' of Figure 4A; [0055] Figure 5B is a schematic cross sectional view along the line C-C' of Figure 5 A; [0056] Figure 6A is a schematic end view of the stud of Figure 2C coupled to panels; [0057] Figure 6B is a schematic end view of the stud of Figure 2E coupled to panels; [0058] Figure 6C is a schematic end view of an alternative example of a stud coupled to panels; [0059] Figure 7A is a schematic front side view of an example of a spacer; [0060] Figure 7B is a schematic front side view of a second example of a spacer; [0061] Figure 7C is a schematic front side view of a third example of a spacer; [0062] Figure 8A is a schematic front side view of a further example of a spacer in a wall panel assembly in an operative position; [0063] Figure 8B is a schematic front side view of the spacer of Figure 8A with the wall panel assembly of in a partially collapsed position; [0064] Figure 8C is a schematic front side view of the spacer of Figure 8A with the wall panel assembly of in a fully collapsed position; [0065] Figure 9A is a schematic front side view of a further example of a spacer in a wall panel assembly in an operative position; [0066] Figure 9B is a schematic front side view of the spacer of Figure 9A with the wall panel assembly of in a partially collapsed position; [0067] Figure 9C is a schematic front side view of the spacer of Figure 9A with the wall panel assembly of in a fully collapsed position; [0068] Figure 10A is a schematic front side view of a further example of a spacer in a wall panel assembly in an operative position; [0069] Figure 10B is a schematic front side view of the spacer of Figure 10A with the wall panel assembly of in a partially collapsed position; and, [0070] Figure 10C is a schematic front side view of the spacer of Figure 10A with the wall panel assembly of in a fully collapsed position.

Detailed Description of the Preferred Embodiments [0071] An example of a wall panel assembly for use in constructing a wall will now be described with reference to Figures 1A to 1H.

[0072] In this example, the wall panel assembly 100, includes a pair of opposing wall panels 111, 112. The wall panels can be made of any suitable material, but are typically fibre cement sheets, or the like.

[0073] A number of stud pairs are provided between the wall panels 111,112. Each stud pair including opposing studs 121, 122 extending in first direction along opposing surfaces of the wall panels 111,112, with the number of stud pairs being spaced along the panels in a second direction typically perpendicular to the first direction. In this example, the studs extend substantially vertically and are spaced in a horizontal direction along a length of the wall panels 111,112, but it will be appreciated that other arrangements could be used. The studs can be of any appropriate form, but are typically extruded aluminium or the like, and are bonded to the wall panels 111, 112 using an adhesive or the like.

[0074] A number of spacers 131 interconnect the studs 121, 122 in each stud pair, each spacer being pivotally mounted to each stud 121, 122. This arrangement allows the spacers to pivot relative to the studs, so that the wall panels 111, 112 and hence the wall panel assembly 100 can be moved between collapsed and operative positions. In the operative position shown in Figures 1A to ID the spacers 131 extend substantially perpendicularly between the studs 121, 122 so that a spacing between the opposing wall panels 111, 112 is greater than in the fully or partially collapsed positions shown in Figures IE and IF and 1G and 1H, when the spacers are angled relative to the studs 121, 122.

[0075] In use, the wall panel assembly 100 is provided in the operative position when constructing a wall, in particular to maximise the internal volume, allowing this to be filled with concrete. In contrast, in the collapsed position, spacing between the wall panels is minimised, which is useful for transport and storage.

[0076] Thus, the ability of the wall panel assembly to move between the collapsed and operative configurations provides a number of advantages compared to traditional arrangements. In this regard, traditional wall panel assembly arrangements are either preconstructed with laterally extending spacers fitted and fixed in place during manufacture to save on onsite construction requirements, or are assembled onsite from component parts, which minimises volume during transport, but increases onsite labour requirements.

[0077] In contrast to this, the above described arrangement allows the wall panel assemblies to be collapsed for storage and transport, minimising the volume taken up by the panel assemblies, whilst allowing the wall panel assemblies to be simply expanded by pivoting of the spacers relative to the studs, minimising the time and effort required to use the wall panel assemblies. Thus, this saves the need for labour to construct the panel assembly onsite from component parts, whilst also allowing the volume of the wall panel assemblies to be minimised during storage and transport, thereby significantly reducing labour and/or storage and transport costs compared to traditional arrangements.

[0078] A number of further features will now be described with reference to Figures 2A to 2G, which show example stud arrangements in more detail.

[0079] In the example of Figures 2A and 2B, each stud includes 121, 122 includes a head 221 that is coupled to a surface of the wall panel 111 in use and a channel 224 extending away from the head 221, with the spacer 131 being coupled to the channel in use.

[0080] The head 221 is typically in the form of an elongate substantially planar body that extends away from either side of a base of the channel 224 to thereby provide a surface for bonding to the wall panel 111, 112 using an adhesive, or the like. Additionally, by virtue of this arrangement, the head 221 can extend over a significant proportion of the surface area of the wall panel 111, 112, allowing this to provide structural support for the wall panel 111, 112.

[0081] In one particular example, the head 221 extends substantially vertically along the entire height of the wall panel 111, 112 (when the wall panel is arranged in situ) and extends horizontally along a length of the wall panel by an amount required to provide adequate structural support to the wall panel 111, 112, which will depend on a range of factors, such as the strength and thickness of the wall panel material, the strength and thickness of the head material and the spacing of the studs. In one example, for every 200mm of wall panel, at least one stud is provided having a head width W of approximately 40-80mm and more preferably 75mm. Thus, in general, studs have a head width W of 40-80mm and are spaced apart by 150-200mm, although it will be appreciated that other configurations could be used. In any event, this allows the wall panels to be formed in lengths that are multiples of 200mm, which are standard lengths used in the building industry, for example, for spacing of reinforcement bars or the like. This allows different wall panel lengths to be easily incorporated into different lengths of wall, allowing the panel assembly to be used in a wide range of circumstances.

[0082] It will also be appreciated however that other arrangements could be used, such as to produce a head that extends to the width of the channel, and/or which is attached to the wall panel using other techniques, such as fasteners, or the like.

[0083] The channel 224 is typically defined by a pair of substantially parallel spaced apart channel side walls 222, 223 extending outwardly from the head 221, and in particular substantially perpendicular to the head 221, along the length of the stud. It will be appreciated from this that the stud typically has a constant cross sectional shape along the stud length, allowing the stud to be made of an extrusion, such as an aluminium, plastic or composite extrusion. The side walls can also be shaped, for example to include a flared profile, so that the channel widens at least towards an open end of the channel, to thereby assist with insertion of the spacer 131 into the channel 224.

[0084] In this example, the spacer 131 is pivotally mounted to the side walls 222, 223, for example using a fastener 225, such as a bolt, screw, rivet, or the like, extending through the side walls 222, 223 and the spacer 131, so that the spacer pivots about an axis perpendicular to the first direction and parallel to the second direction. It will be appreciated that the use of a fastener is one example arrangement, but that other suitable pivoting arrangements could be used. The fastener can be positioned offset from a centre of the spacer as will be described in more detail below.

[0085] In the example of Figures 2C to 2F, the stud 121, 122 further includes a lip 226, 227 extending from each channel side wall 222, 223, the lip being substantially parallel to the head 221. In this arrangement, when the wall panel assembly 100 is in the collapsed position, the lips 226, 227 of opposing studs 121, 122 abut against each other so that the channel side walls 222, 223 support the studs 121, 122 and the wall panels 111, 112 in the collapsed configuration. This is advantageous as it allows the studs 121, 122 to accommodate any pressure on the wall panels 121, 122, for example in the event that a number of wall panels are stacked on top of each other during transport or storage, as well as during compression for curing of the adhesive used to bond the head 221 to the wall panels. This also helps accommodate lateral loading of the wall panels 111, 112 that may occur during transport, preventing stressing, fracturing or other failure of the spacers 131 and/or studs 121, 122.

[0086] In the example of Figure 2C and 2D, the lip extends outwardly to thereby define an external recess between the lips 226, 227 and the head 221. As shown in Figure 6A, this can assist in accommodating insulation panels. In contrast in the arrangement of Figures 2E and 2F, the lips 226, 227 extend inwardly to thereby partially enclose the channel 224. This latter arrangement allows a joining member, such as a rectangular cross section peg, to be inserted into the ends of two segments of stud, allowing lengths of stud members to be joined in an end-to-end arrangement. This can allow off-cuts of stud length of be coupled together to form a required stud length, thereby significantly reducing the amount of wastage during manufacture, which in turn helps minimise manufacturing costs.

[0087] As shown in Figures IE and 1G, at least part of each spacer 131 is received within the channel 224. Accordingly, at least part of the spacer 131 has a width that allows this to be accommodated within the channel 224, thereby allowing for the lips 226, 227 of opposing studs 121, 122 to contact each other. However, it will be appreciated that this is not essential, and instead only partial collapsing of the wall panel assembly may be performed, as shown for example, in Figure IE.

[0088] In a further variation shown in Figure 2G, the studs 121, 122 can be modified to avoid the need for a channel through the use of a single side wall 222, with the spacer 131 being pivotally mounted thereto using a fastener 225, such as a rivet or the like. It will be appreciated that this arrangement reduces the volume of material required to form the stud 121, 122, whilst also allowing for greater variation in the shape of the spacer 131. However, in general this arrangement provides less structural strength and therefore is not generally preferred.

[0089] A number of examples of spacer arrangements will now be described in more detail with reference to Figures 3A to 3C.

[0090] In the example of Figure 3A, the spacer 131 includes a rounded end 331, allowing for free rotation of the spacer 131 within the channel 224. However, it may be desirable to provide some form of locking mechanism to prevent pivotal movement of at least some of the spacers 131, for example to lock the wall panel assembly in the operative position. The locking mechanism can assist in providing structural rigidity, as well as making handling of the wall panel assembly during construction and filling with material easier. The locking mechanism could be of any appropriate form and could include frictional, interference or clip mechanisms, for example formed by suitable configuration of the stud 121, 122 and/or spacers 131, or use the separate locking members. A number of examples will now be described.

[0091] In the example of Figure 3B, the spacer includes a flattened end portion 332, with curved corners. In use the curved comers allow the spacer to be pivoted from the collapsed to operative positions. Once in the operative position, the flattened portion 332 abuts against the head 221, thereby preferentially locking the spacer 131 in the position shown in Figure 3B using an interference mechanism. It will be appreciated that whilst the locking force provided in this situation may be limited, it will nevertheless be significant if each of the spacers is configured in this manner.

[0092] As a further alternative, as shown in Figure 3C, the spacer can include a squared comer 333 provided on one comer of the spacer, which abuts against the head 221 of the stud 121, 122 when the spacer 131 is in the operative position. In this instance, the other corner is curved, allowing the spacer to be moved from the collapsed to operative positions. Thus, it will be appreciated that this allows the spacer to be pivoted in only a single direction, helping provide some restriction as compared to free rotation.

[0093] In the example of Figure 3D this is further exaggerated, with the fastener 225 extending through one corner of the spacer, offset from a centre line of the spacer, so that the comer 333 provides greater locking functionality.

[0094] A further locking mechanism is also shown in Figure 3C. In this example, a locking pin 334 is provided extending through the spacer 131 and at least one of the channel side walls 222, 223. The locking pin 334 is offset from the pivot, thereby locking the spacer in position. It will be appreciated that the locking pin arrangement could also be used with the spacer arrangements of Figures 3 A and 3B.

[0095] In an event, whilst the locking pin 334 can provide absolute locking of the spacer 131 relative to the stud 121, 122, it requires the use of an additional component in the form of the locking pin 334, which in turn requires additional labour during construction and additional costs during manufacture. Accordingly, locking is typically achieved using a combination of locking mechanisms, with interference, clip or frictional locking being performed for most spacers and the use of locking pins being performed for a limited number of spacer, such as two or three spacers on each wall panel assembly. This minimises requirements for additional labour and parts, whilst ensuring sufficient locking is achieved.

[0096] In the current examples, the spacer 131 includes generally straight edges to define planar upper and lower surfaces. However, this is not essential and alternatively, the edges and/or surfaces could be profiled, for example to assist with positioning of reinforcing bars on upper surfaces of the spacer in use.

[0097] In the example of the panel assembly shown in Figures 1A to 1H, the wall panels 111, 112 are offset when the panel assembly is in a collapsed configuration. It will be appreciated that this is not essential however and an alternative arrangement is shown in Figures 4A to 4D.

[0098] In this example, the wall panel assembly 400 includes similar components to those shown in Figures 1A to 1H, with reference numerals increased by three hundred and these will not therefore be described in any detail.

[0099] In this example, each spacer 431 is adapted to hinge substantially mid-way along the length of the spacer 431, thereby allowing the spacer 431 to move between folded and extended positions when the wall panels are moved between collapsed and operative positions, as shown in Figures 4D and 4A respectively. In this example, the wall panels 411, 412 remain aligned when in the collapsed configuration, which it will be appreciated can assist in storage and transport of the wall panel assemblies. Additionally, this ensures that the opposing studs 421, 422 are aligned along their entire length when in the collapsed position. This can ensure even distribution of loading and hence pressure along the length of the studs 421, 422, which can reduce the likelihood of failures and assist in ensuring even bonding of the adhesive between the stud and the wall panels during manufacture.

[0100] It will be further noted that in the example of Figure 4D, whilst spacers are shown as projecting from between the wall panels 411, 412 in the collapsed configuration, this is not essential and suitable selection of the pivot points, pivot direction and/or spacer length, could ensure the spacers 431 are entirely contained within the perimeter of the wall panels 411, 412.

[0101] An example of the spacer and stud configurations are shown in more detail in Figures 5A and 5B. In this example, the studs 421, 422 again include a head 521 and channel side walls 522, 523. Lips (not shown) could also be provided, so that the studs could be the same as the studs of any one of Figures 2A to 2G.

[0102] The spacer 431 includes first and second spacer portions 531, 532, interconnected by a pivot pin 533 to thereby form a hinge 530 mid-way along the length of the spacer 431. In this example, the spacer portions 531, 532 are rebated and overlapped, with the pivot pin 534 extending through the rebated portions. This arrangement allows the spacer portions to be identical, thereby reducing manufacturing costs. However, this is not essential and any suitable arrangement could be used.

[0103] Additionally, the hinge 530 can incorporate a locking mechanism, thereby allowing the spacer to be locked into the extended position. The locking mechanism can be of any suitable form and could include for example an interference coupling between the two spacer portions 531, 532, a shaped pivot pin 533, a pivot pin that could be tightened to provide frictional engagement, or the like. A separate locking pin (not shown) could also be used, as well as squared comers 534, in a manner similar to that used to lock the spacers relative to the studs, as described above. Again in this example, the fastener 525 extends through upper comers of the spacer, so that lower comers abut against the head 521, thereby assisting in locking the spacer in the extended position.

[0104] Accordingly, it will be appreciated that the example of Figures 4 and 5 is otherwise substantially similar to the examples of Figures 1 to 3 and will not therefore be described in any further detail.

[0105] The wall panel assembly can also incorporate additional components and an example of this will now be described with reference to Figures 6A to 6C. In this example, similar reference numerals are used to denote similar features and these will not therefore be described in detail.

[0106] In this example, the wall panel assembly further includes insulation panels 613, 614, extending along an inner surface of one of the wall panels 611, 612. The insulation panels can be adapted to provide different insulating properties depending on the materials used. Thus, materials such as EPS (expanded polystyrene), XPS (extruded polystyrene), PUR (Rigid polyurethane) or PIR (polyisocyanurate) sheets can be used to provide thermal or acoustic insulation, whilst application of a suitable coating can be further used to provide fire insulation.

[0107] In the example of Figure 6A, the stud of Figure 2C is used, with the external channel between the lips 626, 627 and the head 621 being used to receiving the insulation panels 613, 614. In the example of Figure 6B, the stud of Figure 2E is used, with the insulating panels 613, 614 abutting against the channel side walls 622, 623. In contrast, in the example of Figure 6C a modified version of the stud of Figure 2E is provided with a stem 629 being used to position the channel 624 away from the head, allowing the insulation panels 613, 614 to be received between the head 621 and a channel base 628.

[0108] As shown in Figures 7A to 7C, a variety of profiles can be used for upper and/or upper and lower surfaces of the spacers. In the example of Figure 7 A the spacer 731 includes a concave profile 732, allowing reinforcing bars to be easily centred thereon. A similar arrangement can be used with a spacer including two hinged spacer portions 731.1, 731.2, whilst in a further example, multiple convex portions are spaced along the surface of the spacer 731, allowing multiple reinforcing bars to be spaced thereon.

[0109] Further example spacers will now be described with reference to Figures 8A to 8C, 9A to 9C and 10A to 10C.

[0110] In the example of Figures 8A to 8C, the spacer includes an elongate body 831 having laterally extending ends 832 so that the spacer has a "Z" shape. Comers of the spacer are rounded 833, allowing for rotation of the spacer. In this example, the ends 832 abut against the studs 121, 122 to prevent further rotation of the spacer once the wall panel assembly is in the operative position.

[0111] In the example of Figures 9A to 9C, the spacer includes an elongate body 931 having laterally extending ends 932 so that the spacer has a "C" shape. Comers of the spacer are rounded 933, allowing for rotation of the spacer. In this example, the ends 932 abut against the studs 121, 122 to prevent further rotation of the spacer once the wall panel assembly is in the operative position.

[0112] In the example of Figures 10A to 10C, each spacer includes a pair of spacers having respective elongate bodies 1031.1, 1031.2 each having a laterally extending end 1032 so that each spacer has an "L" shape, arranged in opposition to provide a dual "L" shape configuration. Comers of the spacer are rounded 1033, allowing for rotation of the spacer. In this example, the ends 1032 abut against the studs 121, 122 to prevent further rotation of the spacer once the wall panel assembly is in the operative position.

[0113] In use, the above described wall panel assemblies can be constructed by attaching studs 121, 122 to the wall panels 111, 112 using a suitable adhesive, and then providing spacers 131 therebetween. However, in practice such an approach is difficult, as it can be problematic to position and attach spacers in the middle of the wall panel assembly.

[0114] Accordingly, more typically, the studs 121, 122 and spacers 131 are connected to each other to form individual stud assemblies, with each stud assembly including a respective stud pair including the opposing studs and the spacers interconnecting the studs in each stud pair. In this example, the studs 121, 122 with the spacers 131 in situ can simply be coupled to the wall panels 111,112, allowing the wall panels to be formed.

[0115] In particular, typically a first wall panel 111 is provided, so that multiple stud assemblies can be positioned spaced apart along the length of first wall panel 111. Adhesive is applied to the first studs 121 of each stud assembly and/or the first wall panel 111, allowing the stud assemblies to be attached to the first wall panel 111. Following this, adhesive is applied to the second studs 122 of each stud assembly and/or the second wall panel 112, allowing the second wall panel 112 to be coupled to the stud assemblies already mounted to the first wall panel 111.

[0116] Pressure is then applied to the wall panel assembly 100, whilst in the collapsed configuration, so that the adhesive cures, thereby bonding the stud assemblies to the wall panels. It will be appreciated that during this process, the wall panel assembly is typically in the collapsed configuration so that the studs 121, 122 abut against each other, to thereby reduce loads on the spacers 131 and ensure even pressure along the length of the studs 121, 122. This process can be performed in a press, but can also in part be performed by stacking multiple wall panel assemblies 100 on top of one another. Thus the adhesive can be partially cured in a press, with curing being finished as the wall panel assemblies are stack for storage and transport.

[0117] The completed wall panel assemblies can then be transported to site, and moved into the operative position. At this point, locking may be performed if required, before the panel assembly is positioned and filled with concrete or other filling material as required.

[0118] Accordingly, the above described panel arrangement provides a pivoting configuration, allowing panel assemblies to be pre-formed and transported or stored in a collapsed configuration. Once on site, the panel assembly can be easily expanded and used with minimal labour requirements, thereby maximising transport and construction efficiency.

[0119] Throughout this specification and claims which follow, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated integer or group of integers or steps but not the exclusion of any other integer or group of integers.

[0120] Persons skilled in the art will appreciate that numerous variations and modifications will become apparent. All such variations and modifications which become apparent to persons skilled in the art, should be considered to fall within the spirit and scope that the invention broadly appearing before described.

Claims (22)

1. THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS: 1) A wall panel assembly for use in constructing a wall, the apparatus including: a) a pair of opposing wall panels; b) a number of stud pairs, each stud pair including opposing studs extending in first direction along opposing surfaces of the wall panels, with the number of stud pairs being spaced along the panels in a second direction; and, c) a number of spacers interconnecting the studs in each stud pair, each spacer being pivotally mounted to each stud to allow the wall panels to be moved between collapsed and operative positions, wherein in the operative position a spacing between the opposing walls panels is greater than in the collapsed position.
2. 2) A wall panel assembly according to claim 1, wherein each stud includes: a) a head coupled to a surface of the wall panel in use; and, b) a channel extending away from the head, the spacer being coupled to the channel in use.
3. 3) A wall panel assembly according to claim 2, wherein each stud includes a pair of substantially parallel spaced apart channel side walls extending outwardly from the stud to define the channel, and wherein the spacer is pivotally mounted to the side walls.
4. 4) A wall panel assembly according to claim 3, wherein a lip extends from each channel side wall, the lip being substantially parallel to the head.
5. 5) A wall panel assembly according to claim 4, wherein, in the collapsed position the lips of opposing studs abut against each other so that the channel side walls support the panels in the collapsed configuration.
6. 6) A wall panel assembly according to claim 4 or claim 5, wherein the lips at least one of: a) extend inwardly to thereby partially enclose the channel; and, b) extend outwardly to thereby define an external recess.
7. 7) A wall panel assembly according to any one of the claims 3 to 6, wherein each spacer is pivotally mounted to the side walls using a fastener.
8. 8) A wall panel assembly according to any one of the claims 2 to 7, wherein in the collapsed position at least part of each spacer is received within the channel.
9. 9) A wall panel assembly according to any one of the claims 1 to 8, wherein the studs are made of an extrusion.
10. 10) A wall panel assembly according to any one of the claims 1 to 9, wherein the studs are bonded to the wall panels using an adhesive.
11. 11) A wall panel assembly according to any one of the claims 1 to 10, wherein each spacer is adapted to hinge substantially mid-way along the length of the spacer thereby allowing the spacer to move between folded and extended positions when the wall panels are moved between collapsed and operative positions.
12. 12) A wall panel assembly according to claim 11, wherein each spacer includes first and second pivotally connected spacer portions.
13. 13) A wall panel assembly according to any one of the claims 1 to 12, wherein the wall panel assembly includes a locking mechanism for locking at least some of the spacers in position when the wall panels are in the operative position.
14. 14) A wall panel assembly according to claim 13, wherein the locking mechanism locks at least some of the spacers to the studs.
15. 15) A wall panel assembly according to claim 13, wherein the locking mechanism locks a hinge provided substantially mid-way along the length of the spacer.
16. 16) A wall panel assembly according to any one of the claims 1 to 15, wherein the spacers include: a) an elongate body; b) at least one end projecting laterally from the body; and, c) at least one rounded comer to allow pivotal movement of the spacer.
17. 17) A wall panel assembly according to claim 16, wherein the spacers have at least one of: a) a "Z" shape; b) a "C" shape; and, c) a dual "L" shape.
18. 18) A wall panel assembly according to any one of the claims 1 to 17, wherein the wall panel assembly includes: a) a number of stud assemblies, each stud assembly including: i) a respective stud pair including the opposing studs; and, ii) the spacers interconnecting the studs in each stud pair, each spacer being pivotally mounted to each stud to thereby allow the studs to be moved between collapsed and operative positions, wherein in the operative position a spacing between the studs is greater than in the collapsed position; and, b) the opposing wall panels.
19. 19) A wall panel assembly according to any one of the claims 1 to 18, wherein each spacer pivots along a respective axis that is perpendicular to the first direction and parallel to the second direction.
20. 20) A stud assembly for use in constructing a wall panel assembly, the stud assembly including: a) a stud pair including opposing studs; and, b) spacers interconnecting the studs in each stud pair, each spacer being pivotally mounted to each stud to thereby allow the studs to be moved between collapsed and operative positions, wherein in the operative position a spacing between the studs is greater than in the collapsed position.
21. 21) A method of a constructing wall panel assembly for use in constructing a wall, the method including: a) providing a number of stud assemblies including: i) a stud pair including opposing studs; and, ii) spacers interconnecting the studs in each stud pair, each spacer being pivotally mounted to each stud; and, b) bonding the stud assemblies to opposing walls panel so that the studs in each stud pair extend in first direction along opposing surfaces of the wall panels, with the stud assemblies being spaced along the panels in a second direction to thereby allow the wall panels to be moved between collapsed and operative positions, wherein in the operative position a spacing between the wall panels is greater than in the collapsed position.
22. 22) A method according to claim 21, wherein the method includes: a) constructing a number of wall panel assemblies; and, b) stacking a number of wall panel assemblies in the collapsed configuration to allow a bonding adhesive to cure.