PANEL

Abstract: A modular heat insulating panel (12, 14) includes a plurality of slabs (13, 15) of a composition including a lightweight heat insulating aggregate and a cementitious component. Means (16, 17, 18, 20, 24, 26) keys the slabs (13, 15) in an array in which the slabs together define a broadly planar front face (12a, 14a) and a broadly planar back face (12b, 14b) and in which the or each edge face (21, 23) of a slab which faces an adjacent slab includes a bend preventing a direct heat conductive path between said front and back faces over at least the major part of the respective edge face. Also disclosed is a generally planar structural element (13, 15) of cementitious material having keying means (16, 17, 18, 20, 24, 26, 50, 52) along a plurality of its edges for engaging a complementary panel in a tongue-and-groove configuration.

Description: "PANEL" Technical Field This invention relates generally to a structual element adaptable as a component of a modular panel, and in a particular aspect to a modular heat insulating panel suitable as a hearth or protective wall for a heater or stove within a room. Background Art Slow combustion stoves and heaters, which include so-called "pot belly" heaters, are typically installed within an existing room and as such require a suitable heat insulating hearth and often one or more protective partitions where they are mounted close to a wall. The hearth and partition typically comprise brickwork on a purpose designed cement sheet, requiring the services of a bricklayer and entailing a not insignificant cost. Any hearth or partition must usually meet requirements of the local building code which generally stipulates a maximum allowable temperature for the underlying floor or wall. Disclosure of the Invention It is an object of the invention to reduce the cost of providing an adequate hearth and partition in accordance with building code requirements, in particular by reducing installation time. It is a more general object of the invention to provide a structural element adaptable as a component of a modular panel useful for facing or lining existing walls. The invention accordingly provides, in one aspect, a modular heat insulating panel comprising: a plurality of slabs of a composition including ~ a lightweight heat insulating aggregate and a cementitious component; and means keying the slabs in an array in which the slabs together define a broadly planar front face and a broadly planar back face and in which the or each edge face of a slab which faces an adjacent slab includes a bend preventing a direct heat conductive path between said front and back faces over at least the major part of the respective edge face. The panel advantageously further.includes means on each slab defining a ventilation cavity in said back face of the partition, and means communicating the or each ventilation cavity with the exterior of the partition. The keying means preferably comprises a tongue-and-groove configuration, which may be defined, for example by complementary grooves respectively in the front and back edges of adjacent slabs or by a rib in a face of one slab and a complementary groove in an opposing face of an adjacent slab. The lightweight heat insulating aggregate is conveniently vermiculite and the cementitious component may be portland cement. Said slab composition may further include sand, and water proofing, fire proofing and colouring agents. Each said ventilation cavity preferably comprises a shallow recess in most of the back face of the respective slab. Said means communicating the cavity to the exterior may comprise a direct opening of the cavity through a side face of the slab, or may alternatively include multiple slots in the back face of the slab. The shallow recesses of the slabs may form a continuous channel in the back face of the partitions. The slabs are preferably formed in a mould whereby said front face has the appearance of brickwork, stonework, marble or a ceramic. A suitable mould for this purpose, and a moulding technique, are described in Australian Patent Application 39946/78. The invention also affords a compartment including a floor and an upright partition each comprising a modified heat insulating panel as aforesaid. Preferably, said floor comprises at least four of said slabs arranged in at least two rows, and said upright partition comprises a plurality of said slabs in a single or double vertical stack. In another aspect, the invention comprises a generally planar structural element of cementitous material having keying means along a plurality of its edges for engaging a complementary panel in a tongue-and-groove configuration. The structural element is advantageously moulded in said cementitous material, preferably whereby a major face of the element has the appearance of brickwork or stonework. The tongue-and-groove configuration may be a rib in one or more edge faces of the element. In one embodiment, the tongue-and-groove configuration at said one or a further edge of the element includes projecting lands and recesses arranged alternately along the edge. The invention still further provides a modular panel comprising a plurality of the aforesaid structural elements. Brief Description of the Drawings The invention will be further described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of a compartment for a slow combustion heater, comprising a hearth and rear upright partition each formed in accordance with the invention; Figures 2, 3 and 4 are respectively side elevational, front elevational and plan views of the compartment illustrated in Figure 1, with the detail of the brickwork face omitted for clarity; Figures 5 and 6 are cross sections on the lines 5-5 and 6-6 in Figures 3 and 4; Figures 7 and 8 respectively show various detail views of the front right and front left slabs of the hearth, in each case a plan view and an underneath view respectively above and below front and side elevations; Figure 9 shows front and end elevation, a plan view and an underneath view of a slab of the upright partition; Figure 10 is an underneath view of an intermediate front slab for a wider hearth; and Figures 11A and 11B depict two laterally interlocking slabs for use in a wider upright partition. Modes for Carrying out the Invention The illustrated compartment 10 comprises a floor or hearth 12 and an upright partition 14. Hearth 12 is formed from four structural elements in the form of slabs 13a-13d, as shown, arranged in two rows, two at the front and two at the rear. Partition 14 in contrast is formed of four somewhat elongated structural elements comprising slabs 15a-15d butted edge-to-edge in a single vertical stack. The rear slabs 13c, 13d of the hearth butt against the bottom slab 15a of the upright partition. Partition 14 will normally be fastened to the wall by nails or other suitable fasteners through the top slab 15d, whereas the hearth 12 will usually rely for its stability on the weight of the slow " combustion heater: this weighty object will normally rest with one leg on each of the slabs of the hearth. If desired, however, the hearth may be fastened to the floor and the partition may include further fastenings to the wall. Each slab is cast in a rubber mould, with the detailed construction to be explained, in a lightweight cementitious composition which includes a lightweight heat insulating aggregate and a cementitious component. A suitable composition for the purpose comprises vermiculite, sand and cement, with water proofing, fire proofing and colouring agents. It is desirable to maximise the vermiculite relative to the sand and cement so as to correspondingly minimise the thermal conductivity of the slab without degrading its strength or appearance. A suitable composition is found to comprise: 5 parts by volume of vermiculite for 3 parts each by volume of sand and portland cement. The water proofing agent is then typically about 5% by volume and the fire proofing agent about 1.6%. A suitable mould and moulding technique is described in Australian Patent Application 39946/78. By virtue of the composition of the slabs, hearth 12 and upright partition each form a modular heat insulating panel of four like slabs. In the illustrated case, the moulds are designed so that the slabs are finished to provide a brick-like appearance with a rough texture simulating the surface of bricks and multiple grooves 11 simulating the mortar spaces between bricks. Each slab 5a-15d exhibits four courses of bricks. The mortar grooves 11 are located so that the slab interfaces lie within grooves (Figures 5 and 6) and are thereby not readily visible to the passing observer - a feature well demonstrated by Figure 1. The various slabs are provided with means for keying them together in the illustrated arrays so that the slabs together define broadly planar front and back surfaces, 12a, 12b and 14a, 14b respectively. As illustrated, the keying means comprises butt joins of a tongue-and-groove configuration. For example, with particular reference to Figures 5, 7 and 8, the front right slab 13a of hearth 12 has respective grooves 16, 17 in its back face along its rear and left edges (as viewed from above) . These grooves match with corresponding tongues or lips 18, 20 formed by correspondingly grooving the opposed edges of the upper faces of the right rear and left front slabs. By forming substantially rectilinear grooves, each of the various edge faces 21, 23 of the slabs which face an adjacent slab includes a pair of sharp bends arranged to prevent a direct heat conductive path between the front face 12a and the back face 12b of the hearth over at least the major part of the edge face. A space 22 may be left in part of this interface, as best seen in Figure 5 and filled with an elastomer or other suitable bonding or heat insulating composition. In the case of the upright partition, a direct heat conductive path is prevented by an upstanding rounded section tongue or rib 24 (Figure 6) formed in the upper edge of all except the top slab, which tongue mates with a corresponding groove 26 in the lower edge of the overlying slab. This arrangement also prevents back and forward movement of slabs 15 on each other. If desired, a similar secondary tongue-and-groove may be formed in the horizontal portions 19 (Figure 5) of the interfaces between the slabs 13 of the hearth, to prevent separation of the slabs by sliding along the floor. All of the slabs are further provided with a ventilation cavity in their back face and the arrangement of the slabs is such as to provide means communicating these cavities with the exterior of the partition. In the case of the hearth slabs 13, this cavity is a shallow rectangular recess 28 in the back face of the slab and the communication means is formed y respective grooves 11a of the aforesaid brickwork pattern, extended if necessary into each cavity. In the case of the upright partition 14, the cavities are broad, shallow channels 30 in the back faces of the slabs 31. The channels register and thereby define a continuous vertical airway in the back of partition 14. The communication means comprises the opening 31 of the channel in the top edge of the top slab 15d and two registering pairs of rebates 32, 33 in the front face of bottom partition slab 15a and in the adjacent edges of hearth slabs 13c, 13d. Rebates 32, 33 connect channel cavities 30 to two of the cavities 28 and thence through grooves 11a to the side exterior of the hearth. With broader stoves or heaters, it may be necessary to provide a wider hearth and partition than that illustrated in Figures 1 and 9. To this end, there may be provided intermediate slabs for the hearth which might be placed respectively between slabs 13a and 13b and between slabs 13c and 13d. A representative such slab 13', suitable for the front is shown by way of an underneath view in Figure 10. In the case of the partition, a preferred approach is to divide each slab into a pair of complementary structural elements or half slabs 40, 42 shown in Figures 11A and 11B. These maintain the principal features of slabs 15a-15d, including ribs 24' and channel ' 30', and interlock together at the centre, in this case in a manner complementary to the brick appearance. Specifically, it will be noted that the interface between half slabs 40, 42 includes a tongue-and-groove formation which on one hand includes a rib 24' ' and longitudinal groove 26' ' as elsewhere, in order to prevent a direct heat conductive path between the slab faces, and on the other hand defines complementary rectilinear projecting lands 50a, 50b and recesses 52a, 52b. Lands 50 and recesses 52 are arranged alternately along opposed vertical edges of the half slabs and are of a width substantially equal to a course of the apparent or simulated brickwork on the face of the half slabs. In an alternative embodiment, partition 14 may be formed from an array of substantially square slabs such as slabs 13 of hearth 12.

Claims: Λ O CLAIMS : 1. A modular heat insulating panel comprising: a plurality of slabs of a composition including a lightweight heat insulating aggregate and a cementitious component; and means keying the slabs in an array in which the slabs together define a broadly planar front face and a broadly planar back face and in which the or each edge face of a slab which faces an adjacent slab includes a bend preventing a direct heat conductive path between said front and back faces over at least the major part of the respective edge face. 2. A modular heat insulating panel according to claim 1 wherein said keying means comprises a tongue-and-groove configuration. 3. A modular heat insulating panel according to claim 2 wherein said tongue-and-groove configuration is defined by complementary grooves respectively in front and back edges of- adjacent slabs. 4. A modular heat insulating panel according to claim 2 wherein said tongue-and-groove configuration is defined by a rib in a face of one slab and a complementary groove in an opposing face of an adjacent slab. 41 5. . A modular heat insulating panel according to any preceding claim further comprising: means on each slab defining a ventilation cavity in said back face of the partition; and means communicating the or each ventilation cavity with the exterior of the partition. 6. A modular heat insulating panel according to claim 5 wherein each said ventilation cavity comprises a shallow recess in most of the back face of the respective slab. 7. A modular heat insulating panel according to claim 6 wherein said shallow recesses of the slabs form a continuous channel in the back face of the partition. 8. A modular heat insulating panel according to any one of claims 5 to 7 wherein said means communicating the cavity to the exterior comprises a direct opening of the cavity through a side face of the slab. 9. A modular heat insulating panel according to any one of claims 5 to 7 wherein said means communicating the cavity to the exterior comprises multiple slots in said back face of the slab. 10. A modular heat insulating panel according to any preceding claim wherein said lightweight heat insulating aggregate is vermiculite. 11. A modular heat insulating panel according to any preceding claim wherein each slab is formed in a mould whereby said front face has the appearance of brickwork, stonework, marble or a ceramic. 12. A compartment including a floor and an upright partition each comprising a modular heat insulating panel according to any preceding claim. 13. A compartment according to claim 12 wherein said floor comprises at least four of said slabs arranged in at least two rows, and said upright partition comprises a plurality of said slabs in a single or double vertical stack. 14. A generally planar structural element of cementitous material having keying means along a plurality of its edges for engaging a complementary panel in a tongue-and-groove configuration. 15. A structural element according to claim 14, moulded in said cementitous material. 16. A structural element according to claim 15, moulded whereby a major face of the element has the appearance of brickwork or stonework. 17. A structural element according to claim 14, 15 or 16 wherein said tongue-and-groove configuration includes a rib in one or more edge faces of the element. 18. A structural element according to claim 17 wherein the tongue-and-groove configuration at said one or a further edge of the element includes projecting lands and recesses arranged alternately along the edge. 19. A structural element according to claim 18 wherein a major face of the element has the appearance of brickwork and said projecting lands and recesses are of a width substantially equal to a course of the apparent brickwork. 20. A structural element according to any one of claims 14 to 19 wherein said cementitous material includes a lightweight aggregate such as vermiculite. 21. A modular panel comprising a plurality of structural elements according to any one of claims 14 to 20.

Inventors: FAMULARI SALVATORE, FAMULARI, SALVATORE
Applicants: TRIANGLE BUILDING PRODUCTS, TRIANGLE BUILDING PRODUCTS PTY. LTD.
Application year: 1986
Main classification: E04B1
IPC codes: E04B1