Patent Application
20170191260
The present invention relates in particular but not exclusively to a versatile prefabricated panel building system incorporating wall panels having a roller track sliding means and an integrated stud assembly which confers substantial rigidity and integrity and which significantly reduces construction time by dispensing with traditional and prior art stud framing. The lightweight construction of the panels are such that they can also be prefabricated or manufactured on site in a portable or re-locatable factory or plant from raw and component materials thereby further reducing or eliminating time and transport costs.
The main disadvantage of prior art prefabricated wall building systems is that they require labor and time in which to erect traditional stud framing, to affix wall cladding panels, insert insulation material and then render, sand and paint the finished product. Furthermore, prior art composition boardroom wallboard panels are not designed for convenient water and electricity installation. Water pipes and electric cables are usually installed on the outside surface of prior art panels. While it is possible to install water pipes and electric conduits under the panel surface, this requires cutting into the surface and then having to restore and redecorate the panel post installation. If this is not skillfully undertaken, the repair work will not only be unsightly, but may result in permanent damage to the structural integrity of the panel thereby degrading overall performance. Most prior art wallboard panels have poor weight bearing capacity. Upright walls constructed from these panels inevitably have poor wind shear load resistance.
Existing composition panels must also be able to withstand diagonal torsion or twisting forces according to various relevant municipal building regulations and requirements. This results in prior art wallboard panels having to be of a substantial construction which are not conducive to being prefabricated on site which is not only costly but is often also aesthetically less pleasing in appearance.
In view of the above-mentioned limitations, it is an object of the present invention to overcome the disadvantages of the prior art by providing & novel prefabricated wall panel building system which confers substantial rigidity and integrity and which is also characterized by relatively speedy installation and construction, high fire resistance, high weight bearing capacity, good sound, insulation and most importantly, is cost effective relative to performance when compared to existing and traditional building systems.
In a preferred aspect, the invention resides in a prefabricated panel building system including:
Preferably, the panels are of a rectangular configuration and the edge members are on opposite longitudinal sides of each panel.
Preferably, there are edge members on all sides of the panel.
In a more preferred example, the top and bottom portions of the panel or edge members include integrated rollers whereby the panels are able to be slid in the tracks into position against and on top of each other.
In the alternative to rollers, skids or buttons of an anti-friction material such as Teflon may be used.
Preferably there are panels which include window frames or door frames as in built structural components of the panels or wherein windows and doors are pre-fitted in the panels.
In a preferred example, the panel comprises:
In a preferred example, the panel has an external cladding of prefinished metal coil skin.
In another example, the panel has a cladding material which includes magnesium oxide.
Preferably, the thermal-protective layer is provided with a hole.
Preferably, the light construction of the panels are such that they can be fabricated or manufactured on site in a moveable or relocatable factory or plant from raw and component materials.
Preferably, the panels or edge members include one or more slots into which a barbed bracket or mount is inserted to support accessories, including lights, ornaments, removable cladding or decorative panels.
Preferably, there are passages along the lengths of the edge members or which are created on interlocking together edge members of adjacent panels, and wherein the passages are adapted to accommodate the installation of supply services including electric cables or water pipes.
Suitably, the panels have holes for any article required to pass through the panels.
Preferably, the interlocked edge members are permanently joined together by rivets or screws.
In the alternative, the interlocked edge members can be permanently joined together with adhesive.
Preferably, decorative cover strips are used to cover any exposed interlocked edge members.
In a preferred version, the edge members are channels with a recessed connecting groove wherein panels are joined by a connecting piece inserted into the space created by the opposite grooves
More preferably, the edge members comprising an integrated stud are aluminum extrusions incorporating a tongue profile and a groove profile wherein the tongues and grooves are serrated to lock the panels when pushed and clipped together.
In an alternative version, the edge members are channels provided with a connecting convex flange.
In a further alternative version, the edge members are channels provided with a connecting groove and a flange
The external cladding preferably comprises a base plate and an external composite plate fixed to the base plate.
The system is used to construct a wall of a room or building by interlocking the top and bottom edge members of panels stacked on top of each other.
The system is used to construct a floor, ceiling or roof by joining together edge members on all sides of the panels.
Preferably, the panels include integrated electrical conduit to accommodate electric cable or wires where power outlets are required.
Preferably, the complementary profiles of the edge members when interlocked together provide a water tight seal.
In another preferred example, there are thermal break fillet strips which span across the intersections of interlocking edge members of abutting panels to confer requisite acoustic, thermal and fire ratings.
In another aspect, the invention resides in a method of building using panels of the system according to any one of the above claims including the steps of:
It is submitted that the invention has the following beneficial effects. Both right and left sides of upright panels are provided with recessed channels that are interlocked with the channel of an adjacent panel to create the integrated stud thereby eliminating the need for traditional stud framing. Similarly, reinforced edge members are installed at the top and bottom of the panel wherein a weight bearing joint is affected between one panel and another panel stacked on top of it. To substantially reduce onsite assembly time, the top and bottom edge members can include integrated roller track means whereby adjacent panels are able to be slid into position against and on top of each other. Furthermore, passages of edge members in alignment facilitate convenient and rapid installation of both water pipes and electric conduits in both horizontal and vertical directions. For this and other reasons, the edge members are also preferably in the order of being one to two times stronger than the edges of ordinary laminated board in terms of vertical load bearing, and horizontal wind shear resistance. It is submitted that a building of the subject system gives nothing away to a permanently and traditionally built house.
The present system and method solves shortcomings of constructing prior art composition board rooms and container houses by providing a novel and inventive method of splicing together panels. It provides a prefabricated structure having good thermal insulation properties with characteristics of fast installation and greatly improved architectural aesthetic appearance.
It is submitted that compared with existing stud separated wall systems, the invention is significantly advanced in its provision of rapidly and conveniently constructed buildings of equivalent structural integrity and most importantly, a low cost to performance advantage.
In order that the invention is better understood and able to be put into practice, reference is made to the accompanying drawings wherein:
As shown in the following drawings, the invention aims to provide a novel and versatile prefabricated panel building system characterized by fast installation, rapid construction, high fire resistance, high weight capacity, high cost performance and good sound insulation when compared to the prior art. The present invention comprises a plurality of wallboard panels joined together. Each panel 10 as typically shown in
The preferred panel includes an inner waif decoration layer, a fiber calcium silicate board, a thermal-protective layer and an external wallboard cladding, which are preferably arranged in this sequence. A gap is preferably provided between the external wallboard cladding and the thermal-protective layer. In a preferred example, the thermal-protective layer is made up of PU or EPS foaming as a thermal insulation layer. The fiber calcium silicate hoard which is in contact with the thermal-protective layer is located between the thermal-protective layer and the external wallboard cladding. The external wallboard cladding is comprised of a base plate of fiber calcium silicate board and an external aluminum composite plate glued to the base plate. The edge members can have passages (not shown) extending their length wherein water and electric pipe and lines can be installed. Both top and bottom ends of the panels are provided with integrated rollers 20,21 and 23, 25 which engage tracks of the building's frame (not shown) whereby adjacent panels are able to be slid into position against each other.
Both top and bottom (not shown) ends of the panels are provided with integrated rollers 20,22 which engage tracks of the building's frame (not shown) whereby adjacent panels are able to be slid into position against and on top of each other thereby substantially reducing onsite assembly time. In the alternative to rollers, skids or buttons of an anti-friction material such as Teflon may be used.
It will be apparent to the skilled addressee that, in addition to the embodiments mentioned above, other equivalent technical solutions are also within the scope of the invention.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/AU2014/000111 | 2/12/2014 | WO | 00 |
