An improved wall

Abstract

A wall component or panel for a building comprises a core sheet 8, an internal sheet 4 and an external sheet 6. The internal and external sheets 4,6 are spaced from opposing sides of the core sheet 8

Description

Field of the Invention The present invention relates a wall, a structure incorporating the wall, as well as methods of forming and decommissioning said wall. More particularly, the invention relates to a cavity wall with offset stud members. Background of the Invention This section is intended to introduce various aspects of the art, which may be associated with exemplary embodiments of the present invention. This discussion is believed to assist in providing a framework to facilitate a better understanding of particular aspects of the present invention. Accordingly, it should be understood that this section should be read in this light, and not necessarily as admissions of prior art. The importance of energy conservation and sustainability in the construction industry has led to increased attention towards improving the thermal properties of buildings. Adequate insulation is vital in minimizing heat transfer between interior and exterior structures, thereby reducing heating and cooling costs in addition to lowering greenhouse gas emissions associated with energy consumption. Wall insulation, in particular, plays a crucial role in achieving these goals as walls are often a significant source of heat loss or gain in buildings. A particularly common wall insulation method is cavity wall insulation where an empty cavity between the inner and outer sheets of a wall is filled with an insulating material, such as polystyrene, or foam board. However, such methods are associated with certain limitations and challenges. For example, the conventional manufacture of cavity walls results in thermal bridging across the framing members or other structural components within the walls, reducing overall effectiveness. Moreover, while the preferred insulating materials are associated with a relatively low U value (also known as thermal transmittance or thermal conductance), they are not easily recyclable, meaning their usage very often results in a significant increase to the lifetime carbon footprint of insulated walls. Furthermore, the materials are regularly deposited in landfill at the end of the wall’s service life. It is evident that there is a need for a sustainable wall insulation system that provides a sufficient U value and mitigates thermal bridging, while being more environmentally friendly than existing systems. It is therefore an objective of the present invention to obviate or mitigate the aforementioned disadvantages with existing cavity wall arrangements. Summary It is an objective of the present invention to provide an improved wall and a structure incorporating the improved wall. This objective can be achieved by the features as defined by the independent claims. Further enhancements are characterized by the dependent claims. The invention is defined by the claims. According to a first aspect of the present invention, there is provided a wall component for a building, the wall component comprising: a core sheet; and an internal sheet and an external sheet spaced from opposing sides of the core sheet so as to define internal and external cavities; a first plurality of upright stud members extending transversely across the internal cavity; and a second plurality of upright stud members extending transversely across the external cavity; wherein the stud members in the internal cavity are longitudinally offset from the stud members in the external cavity; and wherein at least one of the cavities is at least partially filled with a first insulating material. Preferably, the first insulating material comprises a flowable solid material. Alternatively, the first insulating material comprises textile fragments. In a further alternative the first insulating material may comprise textile fragments and a flowable solid material. Preferably, the flowable solid material comprises pieces of one or more plastics materials. On a preferred embodiment the first insulating material comprises textile fragments and pieces of one or more plastics materials formed into one or more insulating panels. At least one of the one or more plastics materials may be a recycled plastics material. Preferably, at least one of the cavities is at least partially filled with a second insulating material. The second insulating material may be selected from a group comprising: Polyethylene Terephthalate, High-Density Polyethylene, Expanded polystyrene (EPS), Extruded polystyrene (XPS), Polyurethane foam, Polyisocyanurate (PIR) boards and Mineral wool. Preferably, the internal cavity is at least partially filled with the second insulating material, and the external cavity is at least partially filed with the first insulating material. Preferably, the plurality of stud members in each cavity are equidistantly spaced from one another in the longitudinal direction. Preferably, the internal sheet and external sheet are of different heights. Preferably, the internal sheet comprises a lower internal sheet portion and an upper internal sheet portion which are vertically spaced from one another such that an inner recess is defined in an inner surface of the wall component. According to a second aspect of the present invention there is provided a building having at least one wall component according to the first aspect. According to a third aspect of the present invention there is provided a method of forming a wall component, the method comprising: providing a wall component according to the first aspect, where the first insulating material comprises a flowable solid material; and pumping the flowable solid material into the at least one cavity. According to a fourth aspect of the present invention there is provided a method of forming a wall component, the method comprising: providing a wall component according to the first aspect, where the first insulating material comprises textile fragments; and blowing the first insulating material into the at least one cavity. According to a fifth aspect of the present invention there is provided a method of decommissioning a wall component according to the first aspect, wherein the first insulating material comprises a flowable solid material, the method comprising suctioning the first insulation material from the at least one cavity. Brief Description of the Drawings The accompanying drawings illustrate presently exemplary embodiments of the disclosure and serve to explain, by way of example, the principles of the disclosure. FIG. 1 is a view of a horizontal section through a wall; FIG. 2 is a view of a vertical section through a wall and other components of a building structure; and FIG. 3 is the horizontal section view of Figure 1, detailing a method of forming and / or decommissioning the wall. Detailed Description The technical solution of the present invention will be clearly and completely described below, in conjunction with the drawings listed above. FIG. 1 illustrates a wall component 2 (herein referred to as the ‘wall’). Figure 1 is a horizontal section view of the wall. In other words, Figure 1 is a plan or top view of the wall when it has been cut through horizontally. The wall 2 has a generally upright structure and may serve various purposes, such as defining boundaries between parts of a building, offering protection or support, and offering heat insulation. In a most basic configuration, the wall 2 comprises an internal sheet 4, an external sheet 6, and a core sheet 8 sandwiched between the internal and external sheets 4, 6. The internal sheet 4 and external sheet 6 are spaced on opposing sides of the core sheet 8 to define an internal cavity 10 and an external cavity 12 respectively. The sheets are arranged such that they are orientated substantially parallel to each other and extend vertically from a bottom edge end of the wall 2 to a top edge. The core sheet is preferably formed from a fireproof material. The internal and / or external sheet(s) may also be formed from a fireproof material, which may be the same material as used for the core sheet, or it may be a different form of material to that of the core sheet. Each of the internal and external cavities 10, 12, is at least partially filled an insulating material. “Insulating materials” shall be defined as materials with an insulating effect, meaning they have a thermal conductivity functional to restrict the transfer of heat across the wall 2. In other words, the insulating materials are functional to provide a reduced air circulation and heat transfer across the cavity relative to that of a reference wall having non-insulating materials. Preferably, the insulating materials are recyclable, which may be defined as a substance of low thermal conductivity that can be efficiently recovered or diverted from the non-hazardous solid waste stream for the purpose of recycling, and a substantial portion of which is consistently used in the manufacture of products, which may otherwise be produced using raw or virgin materials. The insulating material within the wall 2 may comprise a first insulating material 14 and a second insulating material 16. The first insulating material 14 may be formed as a flowable solid material, which is a solid which has been fragmented into chunks, flakes, pellets or the like such that it flows and may be handled in a similar manner to a liquid. For example, the flowable solid can be pumped into or out of each panel cavity. A flowable solid is different from a material which is initially in liquid form but which then hardens into a single, solid mass, such as cavity foam insulation. A flowable solid does not form into a single solid mass but instead remains in the fragmented form of its many constituent elements. The flowable solid material may comprise a mixture of plastics, one or more of which may be a recycled plastics material. The plastics may be sourced from non-insulating materials. Alternatively the first insulating material may comprise fragments of textiles, most preferably recycled textiles. In a further alternative the first insulating material may comprise textile fragments and a flowable solid material, which may be formed into panels prior to insertion into a respective cavity. Where the first insulating material comprises textile fragments, whether alone or in combination with the flowable solid material, the first insulating material may be blown into the respective cavity using a blower. The second insulating material may be produced by conventional means, and may be selected from a group comprising: Polyethylene Terephthalate, High-Density Polyethylene, Expanded polystyrene (EPS), Extruded polystyrene (XPS), Polyurethane foam, Polyisocyanurate (PIR) boards and Mineral wool. The insulating material of one of the cavities may comprise the first insulating material 14, while the insulating material of the other cavity comprises the second insulating material 16. In examples such as FIG. 1, the internal cavity 10 comprises the second insulating material 16, and the external cavity 12 comprises the first insulating material 14. This arrangement can beneficially provide a Toom facing’ side of the wall 2 with fire-resistant materials such as those belonging to the group of second insulating materials 16. Since second insulating materials 16 of the type described previously described are specifically designed for the purpose of use in insulating systems, they have lower U values in comparison to the first insulating materials 14. However, the utilization of the first insulating materials 14 in the present invention is particularly advantageous. Since the first insulating materials 14 may be formed from a combination of textile(s) and / or plastics materials, they do not require a separation process for re-use. By contrast, the second insulating materials would require transport to a processing facility after decommissioning to separate the materials from impurities in the wall 2. As a result, the utilization of first insulating materials 14 provides the wall 2 with a lower lifetime carbon footprint than conventional cavity wall systems. The distance from the internal sheet 6 to the external sheet 8 of the wall 2 in addition to the composition of the first insulation materials 14 may be selected to provide a U value between 0.1 - 0.4 W / m2K. across the wall 2. The wall 2 thickness may be larger than conventional cavity wall systems beneficially allowing increased space within the walls for the routing of service cables to provide power, data, or other services to different parts of a building. A bottom edge of the wall 2 may be attached to a suitable supporting structure, such as a foundation or lower ground level. Each of the core, internal and external sheets 8, 4, 6 may be formed from wood-based sheeting. Alternatively, the core sheet 8 and external sheet 6 may be formed from wood-based sheeting and the internal sheet is formed from plasterboard 6. The wood-based sheeting may be selected from a group comprising: chipboard, plywood and oriented strand board. The wood-based sheeting may be provided with a breathable membrane on at least one surface thereof. As stated above at least the core sheet, and preferably the internal and / or external sheet(s) too, is / are formed from a fireproof material, or may have a fireproof coating. An external wall cladding 18 may be provided adjacent to the external sheet 6. The external wall cladding 18 may have properties to further enhance the thermal performance of the wall 2, and further functions as a protective barrier against elements including rain, snow, wind, and harsh sunlight. The external wall cladding 18 may be selected from a group comprising: brick, stone, wood, metal, vinyl, fiber cement, composite materials, or any combination thereof. The wall 2 comprises a first plurality of stud members 11 extending transversely across the internal cavity 10, and a second plurality of stud members 13 extending transversely across the external cavity 12. In other words, the stud members are as thick as the cavity is wide. The stud members of each cavity may be equidistantly spaced from one another in a longitudinal direction. Preferably, the first plurality of stud members 11 are longitudinally offset from the second plurality of stud members 13, thereby preventing the formation of a thermal bridge which extends across the wall between exterior and interior. In other words, the stud members of each cavity may be arranged such that there is no localized region having two proximate studs to define a pathway of significant heat transfer extending across both cavities in the wall. FIG. 2 illustrates a structural system 1 incorporating a wall 2 having similar features to that of FIG. 1. Figure 2 is a vertical section view, where the wall and other adjacent components of a building structure have been cut through vertically. In this example, a recess 20 is formed in the wall 2 between two adjacent stud members in one of the cavities. The recess is structured to receive the first end of a joist, such that a bottom side of the joist 20 rests upon a stud member in the internal cavity 10, yet the joist 20 does not protrude into the external cavity 12. The internal sheet 4 may have a first height which is shorter than a second height of the core sheet 8 and the external sheet 6. Optionally, the wall 2 may comprise a rainwater collection system to capture rainwater entering the wall 2 for re-use in building sanitation systems. As shown in FIG 3, there may be provided a pumping apparatus 22 to facilitate a method of forming or decommissioning of the wall 2. The pumping apparatus 22 comprises suction and / or pumping arrangement; a transfer vessel 24 housing a storage space for the insulating materials, and tubing 26, the tubing 26 having a first end connected to the transfer vessel 24 and a second end to be inserted into an aperture in the wall 2. Accordingly, the method of forming the wall comprises the following steps. First, the core sheet 8 is provided and stud members are formed on either side of the core sheet, with an internal set of stud members on an internal side of the core sheet being longitudinally offset or staggered from an external set of stud members on an external side of the core sheet. The internal and external sheets 4, 6 are then attached to the internal and external sets of stud members respectively, such that the core sheet 8 is sandwiched between the internal and external sheets 4, 6. This results in an internal cavity 10 between the internal sheet 4 and core sheet 8, and an external cavity 12 between the external sheet 6 and core sheet 8. Next, one of the cavities is at least partially filled with insulating materials. Preferably, the cavity is at least partially filled by pumping or blowing the insulating materials from the transfer vessel 24 into the wall 2 via the tubing 26 disposed in the wall aperture. Alternatively, if pre-formed panels of insulation are being used these can be placed in the cavities by hand, either before or after the internal and external sheets have been attached to the stud members and core sheet to form the cavities. Conversely, the method of decommissioning the wall 2 comprises the following steps. First, an aperture is formed in the internal or external sheet 4, 6. Next, the insulating materials are removed from the internal or external cavities 10, 12. Preferably, the insulating materials are removed from the cavity by sucking the insulating materials into the transfer vessel 24 via the tubing 26 disposed in the wall aperture. Again, if pre-formed panels have been used then the panels can simply be removed and recycled along with the remaining components of the wall system. The wall, system, and methods of the present invention address various shortcomings in the prior art. Offsetting the sets of studs in each cavity, having sheets of different heights, and / or providing joists that only extend into one cavity of the two cavities limits the formation of thermal bridges across the first and second cavities 10, 12, thereby improving the wall's overall thermal performance. In the manufacture of cavity walls, it is conventional to fill cavities with a selection of insulation materials that are difficult to recycle. In accordance with the present invention, one can use existing recycled plastics from non-insulation sources in flowable form as a ready source of insulation. The material can be removed and re-used at the end of the wall’s lifecycle, thereby providing a lower lifetime carbon footprint associated with the cavity walls. Furthermore, using a flowable solid material and / or fragmented textiles for the insulating material allows the materials to be pumped or blown into the wall and then suctioned out when the wall is to be taken down, thereby providing a more efficient manufacturing / decommissioning process. Components ancillary to walls such as, but not limited to service cables, interior / exterior finishes, doors, windows, and sheathing have not been depicted for clarity purposes, though the inclusion and use of such equipment in the current disclosure would be known and appreciated by those skilled in the art. The scope of the disclosure is not intended to be limited to the precise details of the embodiment or exact adherence with all method steps. Variations will be apparent to a skilled person and are deemed also to be covered by the description. Descriptive terms should also be given the broadest possible interpretation; e.g. the term "comprising" as used in this specification means "consisting at least in part of" such that interpreting each statement in this specification that includes the term "comprising", features other than that or those prefaced by the term may also be present. Related terms such as "comprise" and "comprises" are to be interpreted in the same manner. Directional terms such as “vertical”, “horizontal”, “up”, “down”, “top”, “bottom" “upper” and “lower” are relative terms that may be used for convenience of explanation usually with reference to the illustrations and are not intended to be ultimately limiting if an equivalent function can be achieved with an alternative dimension and / or direction.

Claims

1. A wall component for a building, the wall component comprising:a core sheet; andan internal sheet and an external sheet spaced from opposing sides of the core sheet so as to define internal and external cavities;a first plurality of upright stud members extending transversely across the internal cavity; anda second plurality of upright stud members extending transversely across the external cavity;wherein the stud members in the internal cavity are longitudinally offset from the stud members in the external cavity; andwherein at least one of the cavities is at least partially filled with a first insulating material.

2. The wall component of claim 1, wherein the first insulating material comprises a flowable solid material.

3. The wall component of claim 1, wherein the first insulating material comprises textile fragments.

4. The wall component of claim 1, wherein the first insulating material comprises textile fragments and a flowable solid material.

5. The wall component of claim 2 or claim 4, wherein the flowable solid material comprises pieces of one or more plastics materials.

6. The wall component of claim 1, wherein the first insulating material comprises textile fragments and pieces of one or more plastics materials formed into one or more insulating panels.

7. The wall component of claim 5 or claim 6, wherein at least one of the one or more plastics materials is a recycled plastics material.

8. The wall component of any preceding claim, wherein at least one of the cavities is at least partially filled with a second insulating material.

9. The wall component of claim 8, wherein the second insulating material is selected from a group comprising: Polyethylene Terephthalate, High-Density Polyethylene, Expanded polystyrene (EPS), Extruded polystyrene (XPS), Polyurethane foam, Polyisocyanurate (PIR) boards and Mineral wool.

10. The wall component of claim 8 or claim 9, wherein the internal cavity is at least partially filled with the second insulating material, and the external cavity is at least partially filed with the first insulating material.

11. The wall component of any preceding claim, wherein the plurality of stud members in each cavity are equidistantly spaced from one another in the longitudinal direction.

12. The wall component of any preceding claim, wherein the internal sheet and external sheet are of different heights.

13. The wall component of any preceding claim, wherein the internal sheet comprises a lower internal sheet portion and an upper internal sheet portion which are vertically spaced from one another such that an inner recess is defined in an inner surface of the wall component.

14. A building having at least one wall component according to any preceding claim.

15. A method of forming a wall component, the method comprising: providing a wall component according to claim 2 or claim 4; and pumping the flowable solid material into the at least one cavity.

16. A method of forming a wall component, the method comprising: providing a wall component according to claim 3 or claim 4; and blowing the first insulating material into the at least one cavity.

17. A method of decommissioning a wall component, comprising:providing the wall component according to any of claims 2;to 4 and suctioning the first insulation material from the at least one cavity.

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