This application claims the benefit of priority to application Ser. No. 102022000025908, filed Dec. 19, 2022 in Italy, and which application is incorporated herein by reference. To the extend appropriate, a claim of priority is made to the above-disclosed application.
The present invention relates to the standardization of a construction system mainly based on a “prefabricated structural panel” for building which can be used as a wall and as a slab when assembled with a series a different materials, thus performing seismic, thermal, hygrometric, and acoustic functions.
In particular, the invention relates to a prefabricated structural frame to be used in civilian, commercial or industrial buildings, which forms outer and inner walls and slabs when assembled with an accurate manufacturing method in the fashion of an assembly line.
Specifically, the present invention relates to a completely industrialized construction system which can be used to build any housing type and/or building project without limitations or restrictions when preassembled in a factory or on site.
Multilayer wall panels are known, for example, from CH699149B1, EP0921243A2, EP1273729A2, U.S. Pat. No. 6,625,948 B2, EP1892350A2 and WO2020079479A1 to the same inventor.
It is the object of the present invention to provide a standard structural system comprising a single prefabricated panel made either of concrete or steel or wood which can generate different types of panels, walls or slabs according to the position it takes in the project and according to the application of layers of different materials such as to meet the following assumptions:
These and other objects are achieved by the standard prefabricated structural panel with its layers and assembly methods.
In order to better understand the invention and appreciate the advantages thereof, some non-limiting exemplary embodiments thereof will be described below with reference to the accompanying drawings, in which:
With reference to the drawings, a prefabricated panel is generally indicated by reference numeral 1 and can be made of concrete, steel, or wood.
The prefabricated panel 1 is adapted to make a structural construction system 2, in particular a building.
The prefabricated panel 1 defines a vertical or horizontal panel plane 3 with a peripheral edge 4.
The prefabricated panel 1 comprises a load-bearing frame 5 defining at least one through opening 6 extending through the load-bearing frame 5 in a direction transverse to the panel plane 3.
Moreover, the prefabricated panel 1 comprises at least one filling layer 7 housed in the load-bearing frame 5 so as to close at least one through opening 6.
The prefabricated panel 1 comprises a covering layer 9 positioned opposite to the filling layer 7.
The filling layer 7 and the covering layer 9 are spaced apart from each other in a direction transverse to the panel plane 3 so as to mutually define a gap 10 which is substantially parallel to the panel plane 3.
The prefabricated panel 1 comprises a plurality of metal profiles 8 positioned in gap 10 and interposed between the filling layer 7 and the covering layer 9.
Advantageously, gap 10 allows a circulation of air over the whole prefabricated panel 1 and over the whole structural system 2 formed by prefabricated panels 1. Such an air circulation is particularly advantageous for eliminating moisture, impure air and gas, e.g., radon, which are among the main causes of the lack of living comfort and deterioration of the structures.
Further advantageously, the thus-configured prefabricated panel 1 is usable both as a vertical wall of a structural system 2 and as a slab of a structural system 2.
Further advantageously, the thus-configured prefabricated panel 1 is easily standardizable and industrializable for the production of structures 2 in series and allows reducing the construction times and costs, as well as increasing the thermal-hygrometric protection performance of the panel and the structural system, and increasing the versatility of construction of structural systems, in particular housings, with reference to the dimensions, number of floors, and distribution of the indoor spaces. Indeed, the standardization of the components of the prefabricated panel 1 and the structural system 2 allows forming a warehouse stock to be used at any time and thus reducing the purchase costs of the materials.
Further advantageously, the prefabricated panel 1 allows, in the filling element 7, the passage of ducts and electric cables to form the housing system network without driving holes or making channels in the coverings and/or structural frames.
Preferably, the through opening 6 is rectangular in shape.
According to an embodiment of the walls, the metal profiles 8 are preferably Omega-shaped and are positioned parallel and spaced apart from one another (
According to an embodiment of the possible false ceilings of the slabs, the metal profiles 8 are positioned according to a grid configuration comprising metal profiles 8 intersected with one another (
According to an embodiment, the metal profiles 8 are profiles made of perforated sheet having a thickness of 1.5 mm.
According to an embodiment, the filling layer 7 is formed by at least three filling sheets 11 stacked in a direction transverse to the panel plane 3, including at least one inner filling sheet 11 and two opposite outer sheets 11.
Moreover, at least two of the three filling sheets 11 are formed by panels made of high strength compacted phenolic or marine wood.
According to an embodiment, the filling layer 7 formed by/on the three layers 11 has a thickness between 80 mm and 120 mm.
According to an embodiment, the filling layer 7 is fixed to the load-bearing frame 5 by means of threaded connections by means of screws, bolts or dowels, for example, or by gluing, for example by bicomponent glues, or by means of a combination thereof.
Advantageously, the thus-configured filling layer 7 increases the solidity and stability of the load-bearing frame 5 to which it is connected, and therefore of the whole prefabricated panel 1, especially when used as a slab.
Further advantageously, the filling layer 7 is the element on which to make the systems for the sanitary apparatuses such as sinks, toilets, bidets, showers, sink drains, and/or electrical panels or furnishing components such as wardrobes, bookcases.
According to an embodiment, the load-bearing frame 5 preferably has two through openings 6 extending through the load-bearing frame 5 in a direction transverse to the panel plane 3.
The two through openings 6 are separate from each other.
Moreover, the prefabricated panel 1, used as a wall, with the two openings 6 thereof, can comprise a blind filling layer 7 and a glass filling element 12, or two blind filling layers 7, housed in the load-bearing frame 5 so that the blind 7 and glass 12 filling layers, or the two blind ones, close the two through openings 6.
Alternatively, the prefabricated panel 1, used as a slab, comprises two blind filling layers 7 housed in the load-bearing frame 5 so that each filling layer 7 closes a respective through opening 6.
According to an embodiment, the covering layer 9 comprises at least two covering sheets 15 fixed to each other in a direction transverse to the panel plane 3.
According to an embodiment of the walls, the two covering sheets 15 are formed from two different materials, respectively, preferably fiber cement panels and plasterboard sheets.
According to an embodiment, the plasterboard covering sheet 15 optionally forms the false ceiling of a prefabricated panel 1 used as a slab.
According to an embodiment, the visible surface of the covering layer 9 opposite to the load-bearing frame 5 is trimmed and painted, or can be covered as desired with wallpaper or decorative wood panels, for example.
According to an embodiment, the load-bearing frame 5 is formed from concrete (
According to an embodiment, the load-bearing frame 5 is made as a one-piece body.
Advantageously, the load-bearing frame 5 performs the load-bearing, support, and stability function of the prefabricated panel 1.
According to an embodiment, the prefabricated panel 1 comprises one or more layers 13 of isolating material.
The isolating layers 13 are connected to the load-bearing frame 5, opposite to the covering layer 9.
The isolating layers 13 are configured to provide the thermal and acoustic insulation of the prefabricated panel 1.
Therefore, the layers 13 act as a thermal cladding for the structural system 2 comprising the prefabricated panel 1.
According to an embodiment, the isolating layers 13 are formed from self-extinguishing expanded polystyrene (“EPS”) or rock wool or wood fiber or cork or polystyrene, for example, or a combination thereof.
According to an embodiment, the isolating layer 13 has a thickness between 100 mm and 200 mm.
According to an embodiment, the isolating layer 13 is reinforced with a plasticized mesh, trimmed and painted with quartz paint.
According to an embodiment, the isolating layer 13 can be reinforced or supported with marine wood panels or plumbed wood panels 14.
According to an embodiment, the isolating layer support 14 has a thickness between 16 mm and 20 mm; a commercially-made vapor barrier sheet optionally can be applied to support 14.
According to an embodiment, the isolating layer support 14 is fixed to the load-bearing frame 5 by means of a threaded connection by means of screws, bolts or dowels, for example, or by gluing, for example by bicomponent glues, or by means of a combination thereof.
According to an embodiment, when used as a slab, a waterproofing cladding sheet preferably made of polymeric material is applied to the prefabricated panel 1.
Advantageously, the waterproofing cladding sheet is configured to prevent the passage of any water from an upper floor to a lower floor.
According to an embodiment, when used as a slab, the prefabricated panel 1 comprises a raised technical floor or a floating parquet. According to a further embodiment, the prefabricated panel 1 comprises a layer of screed or mortar suitable for gluing tiles.
According to a further aspect of the invention, a structural system 2 comprises at least two prefabricated panels 1 connected to each other by means of a connection system 16.
According to an embodiment, the connection system 16 is positioned interposed between two prefabricated panels 1.
According to an embodiment, the connection system 16 comprises a first connection element 17 and a second connection element 18.
The first connection element 17 is connected to one of the two prefabricated panels 1, while the second connection element 18 is connected to the other one of the two prefabricated panels 1.
The first connection element 17 and the second connection element 18 are connected to each other by means of geometric coupling.
According to an embodiment, the first connection element 17 is preferably T-shaped, varying in thickness, size, and length.
The second connection element 18 is preferably Omega-shaped with recess 20 varying in thickness, size, and length to promote interlocking 21.
The housing cavity 21 is open towards the insertion portion 19 of the connection element 17.
In connected configuration, the insertion portion 19 is inserted into the housing cavity 21.
According to an embodiment, the first connection element 17 and the second connection element 18 have a height substantially equal to the height of the load-bearing frame 5.
According to an embodiment, the peripheral edge 4 of each prefabricated panel 1 of the structural system 2 comprises at least one edge side 24 facing another prefabricated panel 1.
According to an embodiment, the first connection element 17 and the second connection element 18 are positioned at the respective edge sides 24 of two respective connected prefabricated panels 1.
According to an embodiment, the longitudinal groove 23 extends along the entire length of the edge side 24.
Preferably, the second connection element 18 is fixed in the longitudinal groove 23 by embedding when the prefabricated panel 1 is made of concrete, welded when made of steel and screwed when made of wood.
Specifically, the two guide walls 22 are inserted into the longitudinal groove 23.
According to an embodiment, the insertion portion 19 and the housing portion 20 both define at least one fixing through hole 26.
Specifically, the insertion portion 19 and the housing portion 20 are configured so that when the insertion portion 19 is completely inserted into the housing portion 20, the fixing hole 26 of the insertion portion 19 is aligned with the housing holes 20.
According to this embodiment, the connection system 16 comprises a fixing member 27.
The fixing member 27 is configured to be inserted into the fixing holes 26 of the insertion portion 19 and the housing portion 20 so as to fix the first connection element 17 to the second connection element 18.
According to an embodiment, the first connection element 17, the second connection element 18 and the load-bearing frame 5 define a plurality of fixing holes 26 and through holes 28 at the side edge 24 of the load-bearing frame 5.
Advantageously, the thus-configured connection system 16 allows connecting at least two prefabricated panels 1 with a straight angle or in parallel so that the two prefabricated panels 1 extend substantially along a same panel plane 3 (
According to an embodiment, the connection system 16 comprises a spacer element 29 configured to be interposed between two prefabricated panels 1 connected to each other along the same panel plane 3 so as to define a seat for the housing of the third prefabricated panel 1.
According to this embodiment, the structural system 2 comprises at least three prefabricated panels 1, two prefabricated panels 1 of which connected to each other along a same panel plane 3 and a third prefabricated panel 1 interlocked between the two prefabricated panels 1, thus forming a three-dimensional node substantially representing a lower wall, a floor slab and an upper wall (
According to an embodiment, the spacer element 29 is a section bar preferably having a rectangular or square section.
According to an embodiment, the third prefabricated panel 1 is positioned to abut against the spacer element 29.
According to an embodiment, the spacer element 29 is fixed to the third prefabricated panel 1 by means of a threaded connection.
Specifically, the spacer element 29 is positioned to abut against the base walls 25 of the two connection elements 17, opposite to the two second connection elements 18.
According to an embodiment, the spacer element 29 is connected to the two first connection elements 17 by means of a threaded connection.
According to an embodiment, the structural system 2 is formed by at least six prefabricated panels 1 connected to one another, four prefabricated panels 1 of which connected to one another at an angle and forming the vertical walls of the structural system 2, and two further prefabricated panels 1 connected to each other in parallel and forming the treading slab of the structural system 2 (
According to an embodiment, the structural system 2 has at least one structural compensating element placed in the center of the two prefabricated panels 1, which acts as a bracing and structural reinforcement for higher structural stability needs than standard ones (
According to an embodiment, the structural system 2 comprises a plurality of prefabricated panels 1 so as to form housing units or accommodations starting from two rooms (
According to a further aspect of the invention, a method of manufacturing a prefabricated panel 1 provides for a warehouse stock of all the components of the system, in particular:
According to an embodiment, the method includes positioning each load-bearing frame 5 in vertical position on a movable device equipped with wheels.
The movable device equipped with wheels is configured to move, preferably translate, each load-bearing frame 5 through different working stations so as to apply the various layers or components to the load-bearing frame 5, thus starting the assembly steps, in particular:
Number | Date | Country | Kind |
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102022000025908 | Dec 2022 | IT | national |