ACONNECTOR
This invention relates to a connector and particularly, but not exclusively, to a connector for connecting panels together to form a building or structure.
In developing or emerging countries such as South Africa and India, there is an urgent need for more housing. This is due to the existence of a large and often rapidly increasing population in such countries, which populations are generally often very poor. The existing accommodation is insufficient and inadequate often harbouring disease.
Under such conditions there is an urgent need for low cost housing which is simple and quick to erect.
In such countries there is often available only unskilled or semi-skilled labour. It is important therefore that any housing is capable of being erected by such a labour force.
It is also often necessary to build other structures such as warehouses quickly and economically.
It is known to build structures using concrete panels which are reinforced with steel and are held together by metal bolts.
It is further known to make concrete panels with a relatively thin outer face which face is formed with flanges around the edge of the face substantially perpendicular to the face.. A firεt concrete panel may then be connected to the second using bolts through holes formed in the flanges.
A disadvantage of this known system is that on tightening the bolts, a concentrated point load is applied to the flanges which leads to a tendency for the flanges to break.
A further disadvantage of such systems is that the steel reinforcement within the concrete panels is prone to rust which
weakens the structure and can sometimes cause structures made from such panels to collapse.
In addition, the panels must be preformed with apertures extending through the panels to receive the bolts. Such preforming of the panels is time consuming and expensive.
A further disadvantage is that the bolts are capable of being used in a range of engineering applications and therefore the bolts can have significant commercial value. Because of this it is often found that large quantities of bolts are stolen from building sites.
According to a first aspect of the present invention, there is provided: a connector for connecting a first panel to a second panel, the connector comprising; a first head retainable within a head receiving portion in the panel; a second head retainable within a head receiving portion in the panel; an elongate portion connecting the first and second heads, whereby each of the first and second heads may be positioned within a head receiving portion in the panel such that they are retained within the head receiving portion, and whereby the length of the elongate member corresponds with the depth of the head receiving portions formed in the panel such that when adjacent panels are connected to one another edges of the adjacent panels substantially abut.
By means of the present invention a structure may be erected using panels connected together by means of the connector according to the present invention. No bolts are necessary. The connectors may be snap fitted into the head receiving portions of the panels resulting in simple and quick erection of buildings.
In addition, the connectors are unlikely to be of use on the open market and therefore are unlikely to be stolen.
Preferably the panels are made from concrete reinforced with a rustless material.
The material may be in the form of an open mesh, a loose or fibrillated mat, or in the form of loose fibres, for example nylon, polypropylene or other plastics. Carbon fibre may also be used.
Advantageously the connectors are made of a non-rusting material such as a plastics material.
Conveniently, the elongate portion further comprises first barb means positioned along the length of the elongate portion.
The barb means ensures that the connector, once inserted, cannot pull out and this further contributes to the permanent stability of the structure.
In addition, each end of the connector is shaped so that the action of inserting the connector into respective head receiving portions draws together two adjacent panels. The ultimate relative position of adjacent panels, once a connector is securely in place is determined by the shape of the connector and the corresponding shape of the head receiving portion formed within each panel.
Preferably, the head receiving portion comprises second barb means which second barb means is shaped and positioned such that when a connector is positioned with each of the first and second head within a head receiving portion, the first barb means formed on the connector cooperates with the second barb means formed in each head receiving portion.
Advantageously, the connector further comprises one or more
batten receiving portions.
Battens formed from, for example, soft wood may be used to reinforce the structure of a building formed from the panel and connector according to the present invention. The battens also provide means for subsequent fixture of plaster board and other wall linings behind which insulation can be incorporated within the wall cavity and pipes and cables can be routed.
According to a second aspect of the present invention there is provided a panel formed with a plurality of first and/or second head receiving portions for receiving connectors according to the first aspect of the present invention.
Preferably, the panel comprises a front face and a flange forming an edge around the front face.
The flange may extend partially or completely around the front face.
The panel is preferably formed to have thickened portions surrounding the sockets.
By means of the present invention and particularly due to the thickened portion of the panels around the head receiving portions, the connector when inserted into the head receiving portion is embedded within the thickened region of the panel. This means that the tensions and stresses within the elongate portion are resisted by the head receiving portions and thus transferred to the thickened portion of the panel and ultimately distributed within the face or web of the panel. This reduces the amount of reinforcement necessary.
According to a third aspect of the present invention there is provided a building formed from a plurality of panels according to the second aspect of the invention which panels are connected together by means of the connector according to the
first aspect of the present invention.
Preferably, the connector is positioned within respective head receiving portions by means of hammering the connector into the head receiving portions.
According to a fourth aspect of the present invention there is provided a method of erecting a building comprising connecting together panels according to the second aspect of the invention using connectors according to the first aspect of the invention.
According to a fifth aspect of the invention there is provided a method of forming a panel according to a second aspect of the invention.
An embodiment of the invention will now be described by way of example only with reference to the accompanying drawings in which:
Figure 1 is a schematic representation of a connector according to the first aspect of the present invention;
Figures 2a, 2b and 2c are detailed representations of the connector of Figure 1;
Figure 3 is a schematic representation of a head receiving portion of a panel according to a second aspect of the invention;
Figures 4a, 4b and 4c are detailed representations of the head receiving portion of Figure 3;
Figures 5a, 5b and 5c are representations showing the connector of Figure 1 installed in two head receiving portions of Figure 3;
Figures 6a, 6b, 7a and 7b are schematic representations of a panel according to the third aspect of the present invention;
Figure 8 is a representation of the detail of the panels of Figures 6 and 7 ;
Figures 9a, 9b and 9c are schematic representations of the panels of Figures 6 and 7;
Figure 10 is a schematic representation of a panel, incorporating connectors and head receiving portions, and connected to an adjacent panels.
Figures Ila and lib are schematic representations of portions of a building according to a third aspect of the invention;
Figures 12a, 12b and 13 are schematic representations of buildings according to the third aspect of the present invention;
Figure 14 is a representation of a part of a building according to the third aspect of the invention showing the suspended floor/wall joint in a multi storey building;
Figure 15a and 15b are schematic representations showing the position of a ground floor of a building according to the third aspect of the present invention;
Figures 16a, 16b and 17 are representations of a part of a building according to a third aspect of the invention showing internal partition walls;
Figure 18 is a representation of a building according to a third aspect of the invention; and
Figure 19 is a schematic representation of a part of a building according to a third aspect of the invention showing typical
elevation of panels.
Referring to Figures 1 to 5 a connector according to a first aspect of the present invention is designated generally by the reference numeral 1. The connector comprises a first head 2 and a second head 3. The heads 2, 3 are connected to one another by means of an elongate portion 4. The connector 1 is formed from a plastics material. Each of the heads 2, 3 comprise head portions 5, 6. The elongate portion 4 is hollow and further comprises fixing points 7. In addition, the elongate portion 4 is formed with serrations 8 formed on each outer sides of the elongate portion 4.
The connector 1 is adapted to connect adjacent panels to one another of the type shown in Figures 6 to 10 and to be described hereinbelow. A panel 60 comprises a head receiving portion 30 into which a head 2 of the connector 1 may be fitted. The serrations 8 on the sides of the elongate portion 4 if the connector 1 co-operate with grooves 31 formed on the sides of the head receiving portion 30 and serve to hold the connector 1 within the head receiving portion 30. Portions 32 defining a neck 33 of the head receiving portion 30 co-operate with edge portions 9 of the head 2, 3 of the connector 1 to further secure the connector within the head receiving portion 30.
Referring to Figures 5a, 5b and 5c and 10, a connector 1 fitted within two head receiving portions 30 is shown. It can be seen that the length of elongate portion 4 compared with the dimensions of each head receiving portion 30 are such that when both heads 2, 3 of a connector are pushed into head receiving portions 30, the edges 51, 52 of the head receiving portions 30 which correspond to the edges 100, 110 of panels 60 abut with one another.
Referring to Figures 6a, 6b, 7a, 7b, 8, 9a, 9b and 9c, a mould 90 used to form a panel 60 is shown.
A panel 60 is formed by initially forming the mould 90 into a shape shown in the Figures. At points 70 defined by markers in the form of small accurately positioned raised portions (not shown) , head receiving portions 30 are placed. The mould 90 is shaped such that the thickness of the resulting panel will be greater around the points where the head receiving portions 30 are positioned. Thus in regions 91, the resulting panel will be thicker in order to distribute load.
The panel is formed by pouring the reinforced concrete mix into a flexible polyurethane mould liner which is supported in a stillage formed from steel, concrete or other rigid construction then preferably vibrating the mould to exclude air bubbles before compacting the concrete and allowing it to harden in the usual way before eventually removing the panel from the mould liner. The resultant panel will have the head receiving portions 30 embedded at appropriate points in the panel.
Figure 8 shows a detail of mould showing the thickened portions 91.
Referring to Figure 10, a schematic representation of a panel 60 formed from the mould 90 is shown. It can be seen that the panel 60 has a relatively thin face or web 115 with thicker flanges 120. The panel further comprises thickened portions 91 surrounding the head receiving portions 30 which have been positioned appropriately by positioning the head receiving portions in the mould before the concrete mixture is poured into the mould. Adjacent panels 60 are connected to one another by means of connector 1. In order to connect two panels together the two panels are placed side by side and a connector 1 is hammered into the aperture formed by two adjacent head receiving portions 30. When the elongate portion 4 of the connector is positioned within an elongate portion of each head receiving portion the serrations 8 on the elongate portion 4 cooperate with serrations 31 along an elongate
portion of each head receiving portion to provide a stable connection.
Figures 11 and lib show how a building may be erected by joining together panels 60.
Figures 12a, 12b and 13 show possible room layouts for a building 100 which may be formed from the panels 60 and connectors 1.
Referring to Figure 14, a vertical section through an intermediate floor joint of the building 100 is shown. Two panels 60 are connecting to either side of a pre-cast ring beam unit 140. The panels 60 are connected to the ring beam unit
140 by means of connectors 1 (not shown) . A timber floor joist
141 is notched into the rear of the ring beam unit 140 to form an intermediate floor joint between, for example, a ground floor and a first floor of a building. The joist may be reinforced by means of a restraining strap formed from perforated then galvanised steel 142.
A batten 143 fixed to connectors 1 (not shown) provides further strength to the building.
Plaster board 144 may then be positioned to form an internal wall surface and timber skirting 145 may also be added to form a skirting board.
Referring to Figures 15a and 15b, the relationship between panels 60 and an in situ concrete floor slab 150 is shown. A first layer of panels 60 is positioned directly onto the concrete slab 150. Due to the inclination of the flange 69 of the panel 60 a wedge 151 is positioned beneath the panel 60 forming the first layer to ensure that the panels and subsequent wall built from the panels are substantially upright. A floor screed 152 may be applied onto an upper surface of the concrete floor slab 150.
Figure 15b shows a detail of a top layer of panels 60. A wall plate 153 is bolted to a top flange 69 of panels 60. A ceiling board 154 is secured to the wall plate 153.
In both Figures 15a and 15b battens 143 of the type described with reference to Figure 14 are used to add further strength to the building.
Referring to Figures 16a and 16b horizontal cross sections of a building 100 are shown. A vertical member 160 may be screwed to connectors 1 in order to affix the vertical member 160 to the panel 60. One head of each of the connectors to which the vertical member 160 is screwed will previously have been fitted into a head receiving portion of a panel 60.
Figure 17 shows timber studding 170 formed from noggins 171 providing strength to an external wall of a building 100.
Referring to Figures 18a, 18b and 18c horizontal sections of a building 100 incorporating window and door reveals are shown. Figures 18a and 18b show how a window 180 may be affixed to a panel 60, whilst Figure 18c shows how a door frame 181 may be so affixed.
Referring to Figure 19 typical elevations of panels 60 forming a building 100 are shown.