Building panel assembly and method of manufacturing

Abstract

The invention comprises building panel assemblies for use in the construction of new homes, commercial buildings and extensions of one or more storeys. There is provided a rectangular structural insulated panel (SIP) (10), which comprises a pair of spaced-apart containment boards (12′, 12″) an inner insulating core (13) and a low profile peripheral external rigid frame (14), preferably of metal, e.g. steel, extending around the entire periphery of the spaced-apart boards (12′, 12″), the insulating core (13) having spaced-apart slots (16), which also extend around the entire periphery of the panel.

The invention claimed is: 
     
       1. A building panel assembly comprising:
 a pair of spaced-apart containment boards, separated by an inner insulating core, said inner insulating core having at least one peripherally disposed channel for receiving a rigid frame, 
 wherein the rigid frame defines a pair of spaced-apart longitudinal channels, with both of said spaced-apart channels extending around the entirety of the periphery of the panel, said channels spaced apart from and disposed between the containment boards and extending into a space between the spaced-apart pair of containment boards. 
 
     
     
       2. An assembly as claimed in  claim 1  wherein the rigid frame is integrally formed with the insulating core such that the insulating core extends over the rigid frame. 
     
     
       3. An assembly as claimed in  claim 1  wherein two or more panels can be connected by means of a mating member. 
     
     
       4. An assembly as claimed in  claim 3  wherein the mating member has ‘I’ or ‘H’ cross section and is received by the one or more channels in the insulating core or rigid frame. 
     
     
       5. An assembly as claimed in  claim 3  wherein, the mating members are universal columns. 
     
     
       6. An assembly as claimed in  claim 5 , further comprising additional support wherein the additional support comprises I-section and/or H-section supports. 
     
     
       7. An assembly as claimed in  claim 1  comprising at least one conduit disposed adjacent to and between the containment board and the inner insulating core. 
     
     
       8. An assembly as claimed in  claim 7  having two conduits. 
     
     
       9. An assembly as claimed in  claim 8  wherein each conduit is spaced apart from one another and disposed opposite one another and adjacent to its respective containment board. 
     
     
       10. An assembly as claimed in  claim 1  further comprising an alignment track upon which individual ones of the panels may be disposed. 
     
     
       11. An assembly as claimed in  claim 1 , in which the containment boards are selected from oriented strand board, cement particle board magnesium oxide wall board, plywood, pressure treated plywood, steel, aluminium, fibre reinforced plastics, or metal, or composite sheeting. 
     
     
       12. An assembly as claimed in  claim 1 , in which the inner insulating core is comprised of expanded polystyrene foam, extruded polystyrene foam or polyurethane foam. 
     
     
       13. An assembly as claimed in  claim 1 , further including a sole plate, which is securable to a foundation or floor, and having upstanding alignment rails correspondingly spaced for insertion into the spaced-apart longitudinal channels on a bottom edge of the building panel assembly, in use. 
     
     
       14. An assembly as claimed in  claim 1 , in which a second panel of the building panel assembly is connectable to, and alignable with, a first panel of the building panel assembly, by means of a pair of alignment tracks, which engage in the respective spaced-apart longitudinal channels of the respective adjacent panels. 
     
     
       15. An assembly as claimed in  claim 1 , in which a vertical rigid frame member is provided having correspondingly spaced alignment tracks for engagement in respective spaced-apart longitudinal channels on the edge of an adjacent panel. 
     
     
       16. A method of manufacturing a building panel assembly as claimed in  claim 1  comprising the use of a jig having the frame comprising a plurality of frame members, having at least one ridge extending substantially around the inner surface of the frame and means for releasably securing the frame members together to form the frame, such that once a panel has been formed, the frame members can be released and the panel removed from the jig. 
     
     
       17. A method as claimed in  claim 16  wherein the frame has two ridges extending substantially around the inner surface of the frame. 
     
     
       18. A method as claimed in  claim 16 , further comprising providing the frame with an inlet to allow the passage of inner insulating core material therethrough.