PREFABRICATED WALL PANELS AND A METHOD FOR MANUFACTURING THE SAME
A multi-layer prefabricated wall panel for modular building and a method for manufacturing the same. The panel comprises a load-bearing and vapor barrier core layer; an interior insulating and utility installation layer bonded to the inner face of the core layer; an exterior sheet of a first rigid building material bonded to the interior insulating layer; and an interior sheet of a second building material bonded to the outer face of said core layer. The method for manufacturing the wall panel comprises the steps of forming a stack of the panel layers with adhesive coating between successive layers and bonding the layers to each other by uniform compressing forces.
1. Field of the Invention
The present invention generally relates to modular construction and more specifically to prefabricated wall panels for use in modular buildings, to a method for fabricating the panels and to building components including the same.
2. Discussion of the Related Art
Industrialized building methods are becoming more popular over the last decades in the construction industry for both domestic and public buildings, Also referred to as large-panel construction, such methods utilize high degree of factory prefabrication in order to reduce site work and improve the quality and speed of construction. The large prefabricated panels are transported from the factory to the construction site where they are assembled in a modular manner to form walls, ceiling and/or floors. Optionally, the panels may be assembled, at least partially, at the factory site to form larger building components, where limitation to the size of pre-assembled components is mainly due to transportation possibilities. In either case, work and debris at the construction site is reduced significantly as compared with traditional and/or conventional construction methods.
Various prefabricated large panels for modular building are known in the art, including multi-layer sandwich panels. However, available building panels and the manufacturing methods for fabricating such panels still suffer from a number of drawbacks. In particular, fabrication of known large building panels involves mechanical fastening for joining the different components and/or layers of the panel to each other. Thus, not only the assembling of the panels to form larger building components walls requires manual work, but in many cases the fabrication of the panel themselves require manual work which slows down the manufacturing and increase costs. Furthermore, the panels so produced may suffer from uneven fastening and consequently from insufficient flatness and from weak points or seaming lines susceptible to instabilities. Moreover, many times known prefabricated panels do no provide all the properties required from building components in terms of stability, insulation, easiness of utility installation, etc.
Therefore there still exists a need for improved prefabricated building panels and for an improved process for manufacturing the same.
Accordingly, it is the object of the present invention to provide a building panel which is fabricated as one solid integral piece, which is structurally strong and dimensionally stable, which provides high level of thermal and acoustic insulation and is moisture and vapor resistant as well as fire resistant.
A further object of the invention is to provide a building panel having the above features which allows for easy installation of utility lines such as electricity wiring and plumbing and which provides flexibility at the planning and manufacturing stage so that it can be easily tailored to specific needs and allows for future changes.
An additional object of the invention is to provide prefabricated panels having the above features, which allow for joining individual panels to each other as well as to floor and ceiling by welding rather than by mechanical fasteners.
Yet, a further object of the invention is to provide a method for fabricating large-size and extra-large-size panels having the above features, which minimizes manual work at the fabrication site as well as reduces assembling and finishing work at the construction site.
Other advantages of the invention will be apparent from the following description.
SUMMARY OF THE PRESENT INVENTIONThe present invention provides improved prefabricated wall panels for modular building and an improved method for fabricating the same.
One aspect of the present invention is a multi-layer prefabricated wall panel having an interior planar surface and an exterior planar surface. The panel comprises: a load-bearing and vapor barrier core layer having an inner face and an opposite outer face; an interior insulating and utility installation layer bonded to the inner face of the core layer; an exterior sheet of a first rigid building material bonded to the interior insulating layer; and an interior sheet of a second building material bonded to the outer face of the core layer.
The core layer preferably comprises at least two tubular metal members and one or more interior sandwich panels extending between the at least two metal members, wherein the one or more sandwich panels preferably comprise thermal insulating material, selected from the group consisting of mineral wool, polymer foam and timber, sandwiched between two flat metal skins. The wall panel further comprises a top frame member and a bottom frame member welded to the least two metal tubular member for forming a frame around the panel.
The interior insulating and utility installation layer comprises a plurality of channels extending from top to bottom thereof for accommodating utility lines. In accordance with one embodiment of the invention the interior insulating and utility installation layer comprises a plurality of spaced apart elongated blocks of insulating material. In accordance with another embodiment, the insulating and utility installation layer comprises a mattress-like body made of insulating material provided with a plurality of channels extending the entire length of the mattress-like body and having openings at the top and bottom edges of the body. The one or more sandwich panels and the metal members are having substantially the same length and thickness so as to form in combination a solid layer with two opposite flat faces. Preferably, the exterior sheet is selected from the group consisting of a cement board, a timber board, a metal sheet and a reinforced plastic sheet and the interior sheet is selected from the group consisting of a gypsum board, a cement board and a timber board. The thickness of the wall panel, defined as the distance between interior and exterior planar surfaces of the wall panels is preferably in the range of 140 to 260 mm.
A second aspect of the invention is a method for fabricating a building panel, the method comprising the steps of: forming a stack of horizontally placed building layers in a successive manner; coating the upper surface of each layer with an adhesive before the next layer is placed thereon; and subjecting said stack to uniform compression forces. The method may further comprise the step of incorporating a frame metal into said stack of building layers. The step of subjecting the stack to uniform compression forces may be performed by means of a vacuum manifold or alternatively by means of a compression plate. The stack preferably comprises a first sheet of a building material, a core layer, an insulating and utility installation layer and a second sheet of building material.
The present invention will be understood and appreciated more fully from the following detailed description taken in conjunction with the drawings in which:
It will be realized that the drawings are not drawn to scale and that the aspect ratio of the elements illustrated, as well as the dimensional ratios between different elements, are distorted in order to better demonstrate various features of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTThe present invention provides improved wall panels and improved methods for manufacturing the same. The panels of the invention comprise multiple layers, each designed to impart the panel a particular functionality and/or benefit, while the method of the invention for fabricating the multi-layer panel as one integral unit with no mechanical fasteners between elements, further imparts the panel structural stability and enhanced flatness and smoothness. In accordance with the novel method of the invention, the different layers of the panel are bonded to each other under pressure by one compression step rather than being fastened to each other by mechanical fasteners such as screws and bolts. Besides enhancing stability and appearance, this allows for manufacturing extra large panels which significantly reduces the number of joints and consequently reduces site work and cost as well as the amount of defects that might be introduced during joints assembling.
Referring to the
Core layer 20 comprises at least two rectangular, preferably square, tubular metal members 25 extending about the full length L of panel 10 and one or more interior sandwich panels 22 extending between members 25 and in contact therewith to fill the space therebetween. Members 25 and panels 22 are of the same length and thickness so as to form a mattress-like layer having two opposite flat faces, a flat top edge and a flat bottom edge. The outward sides 26 of members 25 define the side edges of layer 20. Members 25 constitute the main load-bearing construction elements of panel 10 and therefore should be distributed at appropriate intervals. Thus, depending on the size of panel 10 and on the total construction requirements, one or more additional members 25 may be incorporated into layer 20 between panels 22. In practice, frame members 62 and 64 are welded to members 25 to form structural metal frame 60, which is incorporated into panel 10 at the manufacturing process as explained below.
Interior panels 22 are sandwich panels comprising an insulating core material 24 sandwiched between opposite skins 26 and 28. Preferably, skins 26 and 28 are metal sheets, preferably 0.2-0.8 mm thick steel sheets. Skins 26 and 28 serve as vapor barrier between the interior and exterior of panel 10. Insulating material 24 may be any insulating material and may be in the form of prefabricated blocks or as a bulk material. Possible materials for insulator 24 include mineral wool, expanded or extruded polymer foam or polymer fibers, timber blocks or wood fibers and the like. Preferably, insulator 24 is mineral wool of 100-140 kg/m3 density. However, insulator 24 may be selected in accordance to the thermal and acoustic insulation requirements at the particular location where the building is to be built. Thus, for rough weather conditions where thermal insulation is crucial, insulator 24 is preferably polyurethane or polystyrene foam while under milder weather conditions insulator 24 is preferably mineral wool, being a better acoustic insulator. Sandwich panels 22 may be prefabricated off-the-shelf panels or may be especially fabricated to suit particular insulation and dimensional requirements. Alternatively, when insulating material 24 is in the form of blocks, panels 22 may be formed during the manufacturing process of panel 10. The width (horizontal dimension) of panels 22 can vary and is mainly determined by the width of available metal sheets. When layer 20 comprises more than one panel 22, panels 22 are abutted against each other to form continuous insulating layer between the two metal skins.
Next to core layer 20 toward the interior face of panel 10, is insulating and utility installation layer 30. In accordance with the embodiment illustrated in
The interior faces of blocks 32, opposite the faces in contact with panels 22, are covered by interior sheet 50 of length Li. Interior sheet 50 may be of any building material suitable as interior wall including a gypsum board, a cement board, a timber board and the like. Preferably sheet 50 is an off-the-shelf gypsum board of 9 to 32 mm thickness. It will be appreciated that panel 10 requires no further finishing on the interior side of the building as it is well known in the art to cover inner surfaces with gypsum boards. Exterior sheet 40, of length L, bonded on the outward surface of core layer 20 may be of any durable building material suitable for withstanding the climate conditions where the building is to be located, including cement, timber, metal, reinforces polymer sheets and the like. Preferably, sheet 40 is a cement board of 7.5 to 20 mm thick. It will be appreciated that although not necessary, any type of cladding (i.e. siding, stucco, EIFS, brick, stone) may be applied to the interior and/or exterior faces of the panel similar to traditional construction methods. The cladding may be applied at the manufacturing site or may be applied later at the construction site after the building is erected. It will be appreciated that the structure of wall 10 is designed such that there is minimum continuous metal thermal conductive path from one face of the wall to opposite face. It will be further appreciated that the interior sandwich panel of the core layer serve as vapor barrier between inside and outside.
Referring to
The overall combined thickness T of panel 10 is preferably in the range of 120 to 300 mm, where the core layer 20 is about 80-140 mm thick, the interior insulating layer 30 is about 40-100 mm thick, the interior sheet 50 is about 9-32 mm thick and the exterior sheet is about 7.5 to 20 mm thick. The vertical dimensions of panel 10, L and Li, correspond to the exterior and interior heights of the building, respectively, and are determined according to construction plan. Preferably, L is in the range of 3 to 4 m, while Li is 20 to 60 cm shorter. The horizontal dimension of panel 10 can be of up to 15 m, meaning that for some buildings, depending on the building size, a complete wall can be prefabricated as one integral piece having continuous smooth flat surfaces. It will be appreciated that the possibility to provide an extra-large multi-layer wall panel significantly reduces assembling work and cost. It will be also appreciated that as no mechanical fasteners are required for joining the multiple layers to each other or for joining adjacent portions of the same layer in order to form a larger component, the structural integrity and stability of the panel as well as surface flatness and smoothness, are significantly enhanced compared with prior art panels. Furthermore, the unique multi-later structure of panel 10 provides high level of thermal and acoustic insulation, vapor barrier properties, easiness of installation of utility lines and enhanced flexibility in tailoring the wall panels to fit specific construction requirements.
Referring to
An alternative embodiment of panel 10, generally designated 110, is illustrated in
Turning now to
As mentioned above, pressure P may be applied by a compression plate 125 pressed from above, as illustrated in
It will be appreciated that the method of the invention allows for enhanced flexibility in designing a wall panel in terms of the panel dimensions and the panel specific structure, to be tailored to specific requirements depending on location of the building and the location of the specific panel in relation to the building. It will be further realized that the fact that during assembling, the layers of the panel are horizontally displayed one following the other, enhances the easiness by which different materials may be selected for specific zones within the same panel in order to optimize the panel functionality. For example, when knowing in advance where cupboards are to be installed, the insulator material of interior insulating layer 30 (or 130) at the known locations may be specifically selected as wood blocks, instead of the polystyrene foam, for enhancing connection strength between cupboard and wall. Further, threading of utility lines may be performed while the panel is still in horizontal position or even before completion of the assembling process.
It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the present invention is defined only by the claims which follow.
Claims
1. A multi-layer prefabricated wall panel, the panel having an interior and exterior planar surfaces and a thickness defined therebetween, the panel comprising:
- a load-bearing and vapor barrier core layer having an inner face and an opposite outer face;
- an interior insulating and utility installation layer bonded to the inner face of said core layer, the interior insulating and utility installation layer comprising a plurality of channels extending from top to bottom thereof for accommodating utility lines;
- an exterior sheet of a first rigid building material bonded to said interior insulating layer; and
- an interior sheet of a second building material bonded to the outer face of said core layer.
2. The wall panel of claim 1 wherein the core layer comprises at least two tubular metal members and one or more interior sandwich panels extending between said two metal members, the one or more sandwich panels and the metal members having substantially the same length and thickness so as to form in combination a solid layer with two opposite flat faces.
3. The wall panel of claim 2 wherein said one or more sandwich panels comprise thermal insulating material sandwiched between two flat metal skins.
4. The wall panel of claims 3 wherein said thermal insulating material is selected from the group consisting of mineral wool, polymer foam and timber.
5. The wall panel of claim 1 wherein said insulating and utility installation layer comprises a plurality of spaced apart elongated blocks of insulating material.
6. The wall panel of claim 1 wherein said insulating and utility installation layer comprises a mattress-like body made of insulating material provided with a plurality of channels extending the entire length of said mattress-like body having openings at top and bottom edges of the body.
7. The wall panel of claim 1 wherein said exterior sheet is selected from the group consisting of a cement board, a timber board, a metal sheet and a reinforced plastic sheet.
8. The wall panel of claim 1 wherein said interior sheet is selected from the group consisting of a gypsum board, a cement board and a timber board.
9. The wall panel of claim 1 wherein said thickness is in the range of 140 to 260 mm.
10. The wall panel of claim 2 further comprising a top frame member and a bottom frame member welded to said at least two metal tubular members for forming a frame around the panel.
11. A method for fabricating a building panel, the method comprising the steps of:
- forming a stack of horizontally placed building layers in a successive manner;
- coating the upper surface of each layer with an adhesive before the next layer is placed thereon; and
- subjecting said stack to uniform compression forces.
12. The method of claim 11 wherein said stack comprises a first sheet of a building material, a core layer, an insulating and utility installation layer and a second sheet of building material.
13. The method of claim 11 further comprising the step of incorporating a frame metal into said stack of building layers.
14. The method of claim 11 wherein said subjecting step is performed by means of a vacuum manifold.
15. The method of claim 11 wherein said subjecting step is performed by means of a compression plate.
16. The method of claim 11 wherein said compression forces are in the range of 0.2 to 0.6 Kg/cm2.
17. A building component comprising at least one prefabricated wall panel as defined in claim 1.
Type: Application
Filed: May 29, 2007
Publication Date: Dec 4, 2008
Inventor: Yitzhak Yogev (Qiryat Tivon)
Application Number: 11/754,406
International Classification: E04C 2/36 (20060101);