U.S. patent application number 15/118114 was filed with the patent office on 2017-07-06 for a prefabricated panel building system.
This patent application is currently assigned to Arkistruct Ltd. The applicant listed for this patent is Arkistruct Ltd. Invention is credited to Walter Lee.
Application Number | 20170191260 15/118114 |
Document ID | / |
Family ID | 53799435 |
Filed Date | 2017-07-06 |
United States Patent
Application |
20170191260 |
Kind Code |
A1 |
Lee; Walter |
July 6, 2017 |
A PREFABRICATED PANEL BUILDING SYSTEM
Abstract
A prefabricated panel building system, including a plurality of
wall panels adapted to be joined together; a structural frame
defining the shape and configuration of a building; the frame
having horizontal tracks wherein the panels are adapted to be slid
against each other; each panel including specially adapted
interlocking edge members having complementary profiles configured
to interlock to form integrated stud or cross members, wherein the
arrangement confers substantial rigidity and integrity. A method of
building using the panels of the system.
Inventors: |
Lee; Walter; (Brisbane,
AU) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Arkistruct Ltd |
Brishbane, Queensland |
|
AU |
|
|
Assignee: |
Arkistruct Ltd
Brisbane, OLD
AU
|
Family ID: |
53799435 |
Appl. No.: |
15/118114 |
Filed: |
February 12, 2014 |
PCT Filed: |
February 12, 2014 |
PCT NO: |
PCT/AU2014/000111 |
371 Date: |
August 11, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 2001/3588 20130101;
E04C 2/296 20130101; E04C 2/384 20130101; E04B 1/6133 20130101;
E04B 2/56 20130101; E04B 1/14 20130101; E04B 1/34321 20130101; E04C
2002/004 20130101; E04B 2/88 20130101 |
International
Class: |
E04B 2/56 20060101
E04B002/56; E04C 2/296 20060101 E04C002/296 |
Claims
1. A prefabricated panel building system including: a plurality of
wall panels adapted to be joined together; a structural frame
defining the shape and configuration of a building; the frame
having horizontal tracks adapted to receive the panels; the panels
are slid along the tracks to abut against each other; each panel
including specially adapted interlocking edge members; the
interlocking edge members having complementary profiles wherein
opposite edge members of abutting panels are joined to form
integrated studs and/or cross members of the frame.
2. The system of claim 1 wherein 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.
3. The system of claim 1 wherein the top and bottom portions of the
panel or edge members include skids or buttons of an anti-friction
material whereby the panels are able to be slid in the tracks into
position against and on top of each other.
4. The system of claim 1 wherein there are edge members on all
sides of the panel.
5. The system of claim 1, wherein the panel is of a rectangular
configuration.
6. The system of claim 1, wherein one or more panels 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.
7. The system of claim 1, wherein the panel includes: an inner wall
decoration layer, a fiber calcium silicate board, a
thermal-protective layer and an external cladding, and wherein
there is a gap between the external cladding and the fiber calcium
silicate board.
8. The system of claim 1, wherein the panel has an external
cladding of prefinished metal coil skin.
9. The system of claim 1, wherein the panel has a cladding material
which includes magnesium oxide.
10. The system of claim 1, wherein the panels are fabricated or
manufactured on site in a moveable or relocatable factory or plant
from raw and component materials.
11. The system of claim 1, wherein the panels or edge members
include one or more slots into which a barbed bracket or mounting
is inserted to support accessories, including lights, ornaments,
removable cladding or decorative panels.
12. The system of claim 1, wherein there are passages along the
lengths of the edge members or which are created on interlocking
together edge members of adjacent panels wherein the passages are
adapted to accommodate the installation of supply services
including electric cables or water pipes.
13. The system of claim 1, wherein the panels have holes for any
article required to pass through the panels.
14. The system of claim 1, wherein the interlocked edge members are
permanently joined together by rivets or screws.
15. The system of claim 1, wherein the interlocked edge members are
permanently joined together by adhesive.
16. The system of claim 1, wherein decorative cover strips are used
to cover the interlocked edge members.
17. The system of claim 1, wherein 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.
18. The system of claim 1, wherein 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.
19. The system of claim 1, wherein the edge members are channels
provided with a connecting convex flange.
20. The system of claim 1, wherein the edge members are channels
provided with a connecting groove and a flange
21. The system of claim 1, wherein a thermal-protective layer is
provided with a hole.
22. The system of claim 1, wherein the external cladding comprises
a base plate and an external composite plate fixed to the base
plate.
23. The system of claim 1, 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.
24. The system of claim 1, used to construct a floor, ceiling or
roof by joining together edge members on all sides of the
panels.
25. The system of claim 1, wherein the panels include integrated
electrical conduit to accommodate electric cable or wires where
power outlets are required.
26. The system of claim 1, wherein the complementary profiles of
the edge members when interlocked together provide a water tight
seal.
27. The system of claim 1, wherein there is a thermal break fillet
strip which spans across the intersection of interlocking edge
members of abutting panels to confer requisite acoustic, thermal
and fire ratings.
28. A method of building using panels of the system according to
claim 1 including the steps of: (a) assembling the structural
frame; (b) sliding a first panel in a track to its predetermined
position; (c) sliding a next panel in the track to abut against the
first panel; (d) pushing the panels against each other to join
together their respective complementary edge members; (e) repeating
steps (b) and (c) and ( to join together further panels as
required.
Description
FIELD OF THE INVENTION
[0001] 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.
BACKGROUND OF THE INVENTION
[0002] 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.
[0003] 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.
[0004] 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.
SUMMARY OF THE INVENTION
[0005] In a preferred aspect, the invention resides in a
prefabricated panel building system including: [0006] a plurality
of wall panels adapted to be joined together; [0007] a structural
frame defining the shape and configuration of a building; [0008]
the frame having horizontal tracks adapted to receive the panels;
[0009] the panels are slid along the tracks to abut against each
other; [0010] each panel including specially adapted interlocking
edge members; [0011] the interlocking edge members having
complementary profiles wherein opposite edge members of abutting
panels are joined to form integrated studs and/or cross members of
the frame and wherein the arrangement confers substantial rigidity
and integrity to a building constructed using the system.
[0012] Preferably, the panels are of a rectangular configuration
and the edge members are on opposite longitudinal sides of each
panel.
[0013] Preferably, there are edge members on all sides of the
panel.
[0014] 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.
[0015] In the alternative to rollers, skids or buttons of an
anti-friction material such as Teflon may be used.
[0016] 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.
[0017] In a preferred example, the panel comprises: [0018] an inner
wall decoration layer, [0019] a fiber calcium silicate board,
[0020] a thermal protective layer and [0021] an external cladding,
[0022] and wherein there is an air gap between the external
cladding and the fiber calcium silicate board.
[0023] In a preferred example, the panel has an external cladding
of prefinished metal coil skin.
[0024] In another example, the panel has a cladding material which
includes magnesium oxide.
[0025] Preferably, the thermal-protective layer is provided with a
hole.
[0026] 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.
[0027] 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.
[0028] 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.
[0029] Suitably, the panels have holes for any article required to
pass through the panels.
[0030] Preferably, the interlocked edge members are permanently
joined together by rivets or screws.
[0031] In the alternative, the interlocked edge members can be
permanently joined together with adhesive.
[0032] Preferably, decorative cover strips are used to cover any
exposed interlocked edge members.
[0033] 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
[0034] 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.
[0035] In an alternative version, the edge members are channels
provided with a connecting convex flange.
[0036] In a further alternative version, the edge members are
channels provided with a connecting groove and a flange
[0037] The external cladding preferably comprises a base plate and
an external composite plate fixed to the base plate.
[0038] 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.
[0039] The system is used to construct a floor, ceiling or roof by
joining together edge members on all sides of the panels.
[0040] Preferably, the panels include integrated electrical conduit
to accommodate electric cable or wires where power outlets are
required.
[0041] Preferably, the complementary profiles of the edge members
when interlocked together provide a water tight seal.
[0042] 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.
[0043] 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: [0044] (a) assembling the
structural frame; [0045] (b) sliding a first panel in a track to
its predetermined position; [0046] (c) sliding a nest panel in the
track to abut against the first panel; [0047] (d) pushing the
panels against each other to join together their respective
complementary edge members; [0048] (e) repeating steps (b) and (c)
and (d) to join together further panels as required.
[0049] 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.
[0050] 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.
[0051] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] In order that the invention is better understood and able to
be put into practice, reference is made to the accompanying
drawings wherein:
[0053] FIG. 1 is a preferred prefabricated panel used in the
building system of the invention.
[0054] FIG. 2 shows detail of the top portions of adjacent panels
of FIG. 1.
[0055] FIG. 3 shows detail of a pair of complementary serrated
longitudinal edge members.
[0056] FIG. 4 shows a panel which includes a window frame and a
door frame as structural components of the panel.
[0057] FIG. 5 shows detail of a preferred thermal break fillet
strip according to the invention.
[0058] FIG. 6 shows detail of buttons of an anti-friction material
whereby the panels are able to be slid.
DETAILED DESCRIPTION OF EMBODIMENTS
[0059] 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 FIG. 1 includes
specially adapted interlocking edge members 12,14 having
complementary profiles configured to be interlocked with the edge
members of adjoining panels (not shown) to form integrated stud or
cross members. The resulting integrated arrangement conferring
substantial rigidity and integrity to the erected structure.
[0060] 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.
[0061] FIG. 2 shows partial detail of adjacent panels 16, 18 about
to be joined by clipping together their respective complementary
serrated longitudinal edge members 12, 14.
[0062] 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.
[0063] FIG. 3 shows detail of a pair of complementary serrated
longitudinal edge members 24, 26. The edge members which when
clipped together comprise an integrated stud are aluminum
extrusions incorporating a tongue profile 24a and a groove profile
26a wherein the grooves are serrated to lock the panels (not shown
in this view) when pushed together. There are also one or more
slots 28,30 adapted to receive a barbed bracket or mounting member
for the mounting of accessories, including lights, ornaments,
removable cladding and decorative panels. Other accessories can
also include a bookshelf, a desk, a wash stand and the like. When
in use, a barb is installed at the back of the article to be
mounted, and then the barb is located in the slot, thereby
providing a convenient and simple mounting system. In addition, the
slot system can be used with lights, PVC ornaments, trunkings or
other ornaments. Their use to attach removable wall cladding panels
also makes the panel system more versatile.
[0064] FIG. 4 shows panels 32, 34 which includes a window 36 and a
door 38 as structural components of panels 32, 34 which are
pre-fitted. As previously mentioned, the light construction of the
panels are such that they can be fabricated or manufactured on site
in a moveable or re-locatable factory or plant from raw and
component materials. Openings can therefore be cut into the panels
and prefabricated windows and doorways from suppliers installed on
site thereby eliminating the need for separate window frame and
door joinery.
[0065] FIG. 5 shows detail of preferred thermal break fillet strips
40, 42 which span across the intersection of interlocking edge
members 44, 46 of abutting panels 48, 50 to confer requisite
acoustic, thermal and fire ratings. The fillet strips are
preferably of a magnesium oxide and fiber glass construction which
is affixed by mastic based adhesive over the intersecting edge
members.
[0066] FIG. 6 shows detail of buttons 62, 64 of an anti-friction,
material such as Teflon whereby panel 60 is able to be slid in the
tracks (not shown) into position against and on top of other
panels.
[0067] 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.
* * * * *