BACKGROUND There are various types of building systems. In general, the most common building systems cannot satisfy the demands of industrialization and the need of intelligent and smart construction.
One possible solution to the overall complexity and resource inefficiency issues of traditional construction is the use of prefabricated construction technologies. Generally, a prefabricated system includes a primary framing structure and a secondary closure of panels, assembled on-site. Although there have been certain improvements in prefabrication building construction systems, including panels, walls, buildings, methods of making building panels, methods of constructing walls, wall systems and buildings systems, there are still unmet needs and a wide field of developments of more efficient and ambitious systems. Prefabricated construction systems are increasingly common in single-family homebuilding, but are virtually absent at a serious scale in multifamily developments. This is primarily due to the cost of investing in building facilities, the risk of trying a new construction method, and the startup cost of research and development.
There is a need in the construction industry for additional improvements in lightweight building panels and construction systems to reach a mid-rise building with a clear and simple system that attends the different needs of this typology. The present disclosure provides the art with a construction system that overcomes all the disadvantages of the previous systems and can fulfil the requirement of mid-rise building.
SUMMARY Some embodiments include a single, self-supporting and formwork panel, which behaves like temporal structure. The said formwork is to be concreted on site and division of space at the same time. Thus, a standard building system contains various construction elements assembled on-site. Aspects of the disclosed subject matter include wall panels, slab panels and window frames, that integrate all constructive elements needed: structural capacity (once the steel-frame formwork are poured with concrete), thermal and acoustic insulation, impermeability, and pre-installations in a very efficient and flexible manner.
Some embodiments include a system having modular panels for simplifying the constructions of buildings and/or interior spaces, as well as methods for using those panels to construct those buildings and/or interior spaces. In some embodiments, the panels include a number of functional layers to endow the panels with desired properties. In some embodiments, the panels provide for buildings and interior spaces with walls, floors, and ceilings. In some embodiments, the composition of wall panels differ from the composition of floor and/or ceiling panels. In some embodiments, the panels are configured to be lightweight for easier construction, assembly and concreting.
In some embodiments, the panels have an internal structure. In some embodiments, the panels are self-supporting during construction works. In some embodiments, the internal structure includes both horizontal and vertical components. In some embodiments, the internal structure profiles constitute the formwork for the concrete. In some embodiments, panels include the structural corrugated steel bars attached to the formwork. In some embodiments, panels are connectable to adjacent panels via the internal structure. In some embodiments, the internal structure includes extension areas configured to interface with adjacent panels. In some embodiments, panels include recessed areas for accepting the extensions of adjacent panels. In some embodiments, the internal structure includes longitudinal components. In some embodiments, the internal structure is comprised of C and U shaped profiles as temporal beams and joists. In some embodiments, internal structure components are combined with fasteners such as screws. In some embodiments, adjacent panels are combined with such fasteners.
In some embodiments, the components of the internal structure define interior space within each panel. In some embodiments, the functional layers are provided in the interior space. In some embodiments, the functional layers are a modular block sized to fit the interior spaces defined by the modular internal structure and an outer layer. In some embodiments, opposing profiles flanking functional layers are a modular block.
In some embodiments, wall panels have the internal structure which is comprised of C and U shaped profiles. In some embodiments, the internal structure includes a principal frame which serves as the structure of the system and a secondary frame which serves as the structure of functional layers and complementary to the principal structure. In some embodiments, the vertical profiles in the internal structure also serve as the formwork for the concrete columns. In some embodiments, wall panels include the structural corrugated steel bars attached to the formwork. In some embodiments, wall panels include at least one outer layer forming a side of the panel. In some embodiments, wall panels include at least one acoustic insulation layer. In some embodiments, wall panels include at least one filler layer. In some embodiments, the filler layer is a thermal insulating layer. In some embodiments, the filler layer comprises expanded polystyrene (EPS). The thickness of the wall panels are of any desired size, and configured to connect to adjacent panels on at least one of a horizontal axis and a vertical axis. In some embodiments, the outer layer is connected directly to the internal structure. In some embodiments, an additional outer layer is provided on the side opposite the first outer layer of the wall panel. In some embodiments, wall panel includes baseboard in the bottom and lightning channel in the top. In some embodiments, the baseboard and lighting channel in the wall panel are made of U shaped profiles. In some embodiments, wall panel includes vertical channel made of L shaped profiles in the exterior façade.
In some embodiments, floor and/or ceiling panels, referred to herein as “slab” panels, also include at least one outer layer, forming the side of the slab panel. In some embodiments, the internal structure, comprised of C and U shaped profiles form the formwork for the concrete beams and joists. In some embodiments, slab panels include at least one metal layer. In some embodiments, the metal layer is a corrugated metal sheet. In some embodiments, wall panels include the structural corrugated steel bars attached to the formwork. In some embodiments, slab panels include at least one filler layer. In some embodiments, the filler layer is a thermal insulating layer. In some embodiments, slab panels include at least one acoustic insulation layer. In some embodiments, an additional outer layer is provided on the side opposite the first outer layer of the slab panel.
In some embodiments, window frame panel includes at least one functional layer. In some embodiments, the functional layer in the aforementioned window frame is a sliding window, but in some situation, the functional layer is a fixed window. In some embodiments, the functional layer is a combination of sliding and fixed windows. In some embodiments, the sliding/fixed window has the function as acoustic and thermal insulation. In some embodiments, the internal structure of the aforementioned window frame is comprised of C and U shaped profiles filled with thermal and acoustic insulation. In some embodiments, the window frame is the enclosure element which satisfies the demand of natural illumination and ventilation. In some embodiments, the window frame are connected with adjacent wall panel, slab panel and truss panel. In some embodiment, the window frame is prefabricated with installation equipment and fixture.
The disclosure includes the method and the process of construction system. The panels of the present disclosure can be manufactured on an assembly line and easily transported. The modular nature of the panels also enables advantageous quality control, cost reduction, waste reduction, improvement of working conditions for workers, use of specialized equipment, and reduction of construction times, complexity, and injury risk. Further, the panels provide for advantageous ductility and tolerances. The panels are assembled and concreted in phases. The assembling phases correspond to the logic of construction, being assembled by element and level.
The disclosure includes a plurality of elements which is capable to be prefabricated and hoisted on-site. The elements in current disclosure include but is not limited to the cabinet element, the stair element, the kitchen element, the bathroom element, the shaft closet element and the interior facade element. All the elements in the disclosure have internal structure and are self-supporting. In some embodiment, the element is prefabricated with plumbing, electrical, mechanical fixture and furniture kit. In some embodiment, the installation fixture and furniture kit are fabricated in a modular manner.
In some embodiments, elements include different types of internal functional features of the building. In some embodiments, elements can be combined and arranged to generate different interior spaces. In some embodiments, elements are prefabricated with the necessary features to be connected between each other. In some embodiments, elements are prefabricated with the necessary features to be connected with the main building mechanical, piping and electrical features. In some embodiments, elements satisfy the comfort, ventilation and usability needs of the building.
The elements of the present disclosure can be manufactured on an assembly line and easily transported. The modular nature of the panels also enables advantageous quality control, cost reduction, waste reduction, improvement of working conditions for workers, use of specialized equipment, and reduction of construction times, complexity, and injury risk. Further, the panels provide for advantageous ductility and tolerances. The elements are assembled in phases. The assembling phases correspond to the logic of construction, being assembled by level and element.
The disclosure includes a plurality of assembly modules which are combination of different construction panels and prefabricated elements. The feasible combination based on the disclosure is not limited with the assembly module. At least the factors such as building code, space quality and the diversity of user's demand are considered in the assembly modules.
BRIEF DESCRIPTION OF THE DRAWINGS The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
FIG. 1 is a front elevation of the wall panel “32F”, showing the internal lightweight truss structure formed by cold-formed steel profiles, consistent with some embodiments of the present disclosure;
FIG. 2 is a front elevation of the wall panel “32F”, showing the internal substructure, consistent with some embodiments of the present disclosure;
FIG. 3 is a front elevation of the wall panel “32F”, showing the finish panels, consistent with some embodiments of the present disclosure;
FIG. 4 is a transversal section of the wall panel “32F”, consistent with some embodiments of the present disclosure;
FIG. 5 is a plan-view cross-section of the wall panel “32F”, showing the internal lightweight truss structure and substructure formed by cold-formed steel profiles, consistent with some embodiments of the present;
FIG. 6 is a is a plan-view cross-section of the wall panel “32F”, showing the completed panel, consistent with some embodiments of the present disclosure;
FIG. 7 illustrates an axonometric view of the wall panel “32F”, showing the total volume of the panel, consistent with some embodiments of the present disclosure;
FIG. 8 illustrates an axonometric view of the wall panel “32F”, showing the different exploded layers of the panels; consistent with some embodiments of the present disclosure;
FIG. 9 is a front elevation of the wall panel “30F”, showing the internal lightweight truss structure formed by cold-formed steel profiles, consistent with some embodiments of the present disclosure;
FIG. 10 is a front elevation of the wall panel “30F”, showing the internal substructure, consistent with some embodiments of the present disclosure;
FIG. 11 is a front elevation of the wall panel “30F”, showing the finish panels, consistent with some embodiments of the present disclosure;
FIG. 12 is a transversal section of the wall panel “30F”, consistent with some embodiments of the present disclosure;
FIG. 13 is a plan-view cross-section of the wall panel “30F”, showing the internal lightweight truss structure and substructure formed by cold-formed steel profiles, consistent with some embodiments of the present;
FIG. 14 is a is a plan-view cross-section of the wall panel “30F”, showing the completed pane, consistent with some embodiments of the present disclosure;
FIG. 15 illustrates an axonometric view of the wall panel “30F”, showing the total volume of the panel, consistent with some embodiments of the present disclosure;
FIG. 16 illustrates an axonometric view of the wall panel “30F”, showing the different exploded layers of the panels; consistent with some embodiments of the present disclosure;
FIG. 17 is a front elevation of the wall panel “26F”, showing the internal lightweight truss structure constituted by cold-formed steel profiles, consistent with some embodiments of the present disclosure;
FIG. 18 is a front elevation of the wall panel “26F”, showing the internal substructure, consistent with some embodiments of the present disclosure;
FIG. 19 is a front elevation of the wall panel “26F”, showing the finish panels, consistent with some embodiments of the present disclosure;
FIG. 20 is a transversal section of the wall panel “26F”, consistent with some embodiments of the present disclosure;
FIG. 21 is a plan-view cross-section of the wall panel “26F”, showing the internal lightweight truss structure and substructure formed by cold-formed steel profiles, consistent with some embodiments of the present;
FIG. 22 is a is a plan-view cross-section of the wall panel “26F”, showing the completed pane, consistent with some embodiments of the present disclosure;
FIG. 23 illustrates an axonometric view of the wall panel “26F”, showing the total volume of the panel, consistent with some embodiments of the present disclosure;
FIG. 24 illustrates an axonometric view of the wall panel “26F”, showing the exploded different layers of the panels; consistent with some embodiments of the present disclosure;
FIG. 25 is a top view of the slab panel “A”, showing the internal lightweight structure and formwork constituted by cold-formed steel profiles, consistent with some embodiments of the present disclosure;
FIG. 26 is a top view of the slab panel “A”, showing the completed slab including a corrugated steel sheet and the structural rebars, consistent with some embodiments of the present disclosure;
FIG. 27 is an elevation-view longitudinal-section of the slab panel “A”, showing the material layers and the internal structure, consistent with some embodiments of the present disclosure;
FIG. 28 is an elevation view cross-section of the slab panel “A”, showing the completed panel with the different layers, consistent with some embodiments of the present disclosure;
FIG. 29 illustrates an axonometric view of the slab panel “A”, showing the material layers and the internal structure, consistent with some embodiments of the present disclosure;
FIG. 30 illustrates an axonometric view of the slab panel “A”, showing the total volume of the panel, consistent with some embodiments of the present disclosure;
FIG. 31 illustrates an axonometric view of the slab panel “A”, showing the exploded different layers of the panels; consistent with some embodiments of the present disclosure;
FIG. 32 is a top view of the slab panel “B”, showing the internal lightweight structure and formwork constituted by cold-formed steel profiles, consistent with some embodiments of the present disclosure;
FIG. 33 is a top view of the slab panel “B”, showing the completed slab including a corrugated steel sheet and the structural rebars, consistent with some embodiments of the present disclosure;
FIG. 34 is an elevation-view longitudinal-section of the slab panel “B”, showing the material layers and the internal structure, consistent with some embodiments of the present disclosure;
FIG. 35 is an elevation view cross-section of the slab panel “B”, showing the completed panel with the different layers, consistent with some embodiments of the present disclosure;
FIG. 36 illustrates an axonometric view of the slab panel “B”, showing the material layers and the internal structure, consistent with some embodiments of the present disclosure;
FIG. 37 illustrates an axonometric view of the slab panel “B”, showing the total volume of the panel, consistent with some embodiments of the present disclosure;
FIG. 38 illustrates an axonometric view of the slab panel “B”, showing the exploded different layers of the panels; consistent with some embodiments of the present disclosure;
FIG. 39 is a top view of the slab panel “C.1”, showing the internal lightweight structure and formwork constituted by cold-formed steel profiles, consistent with some embodiments of the present disclosure;
FIG. 40 is a top view of the slab panel “C.1”, showing the completed slab including a corrugated steel sheet and the structural rebars, consistent with some embodiments of the present disclosure;
FIG. 41 is an elevation-view longitudinal-section of the slab panel “C.1”, showing the material layers and the internal structure, consistent with some embodiments of the present disclosure;
FIG. 42 is an elevation view cross-section of the slab panel “C.1”, showing the completed panel with the different layers, consistent with some embodiments of the present disclosure;
FIG. 43 illustrates an axonometric view of the slab panel “C.1”, showing the material layers and the internal structure, consistent with some embodiments of the present disclosure;
FIG. 44 illustrates an axonometric view of the slab panel “C.1”, showing the total volume of the panel, consistent with some embodiments of the present disclosure;
FIG. 45 illustrates an axonometric view of the slab panel “C.1”, showing the exploded different layers of the panels; consistent with some embodiments of the present disclosure;
FIG. 46 is a top view of the slab panel “C.2”, showing the internal lightweight structure and formwork constituted by cold-formed steel profiles, consistent with some embodiments of the present disclosure;
FIG. 47 is a top view of the slab panel “C.2”, showing the completed slab including a corrugated steel sheet and the structural rebars, consistent with some embodiments of the present disclosure;
FIG. 48 is an elevation-view longitudinal-section of the slab panel “C.2”, showing the material layers and the internal structure, consistent with some embodiments of the present disclosure;
FIG. 49 is an elevation view cross-section of the slab panel “C.2”, showing the completed panel with the different layers, consistent with some embodiments of the present disclosure;
FIG. 50 illustrates an axonometric view of the slab panel “C.2”, showing the material layers and the internal structure, consistent with some embodiments of the present disclosure;
FIG. 51 illustrates an axonometric view of the slab panel “C.2”, showing the total volume of the panel, consistent with some embodiments of the present disclosure;
FIG. 52 illustrates an axonometric view of the slab panel “C.2”, showing the exploded different layers of the panels; consistent with some embodiments of the present disclosure;
FIG. 53 is a top view of the slab panel “D”, showing the internal lightweight structure and formwork constituted by cold-formed steel profiles, consistent with some embodiments of the present disclosure;
FIG. 54 is a top view of the slab panel “D”, showing the completed slab including a corrugated steel sheet and the structural rebars, consistent with some embodiments of the present disclosure;
FIG. 55 is an elevation-view longitudinal-section of the slab panel “D”, showing the material layers and the internal structure, consistent with some embodiments of the present disclosure;
FIG. 56 is an elevation view cross-section of the slab panel “D”, showing the completed panel with the different layers, consistent with some embodiments of the present disclosure;
FIG. 57 illustrates an axonometric view of the slab panel “D”, showing the material layers and the internal structure, consistent with some embodiments of the present disclosure;
FIG. 58 illustrates an axonometric view of the slab panel “D”, showing the total volume of the panel, consistent with some embodiments of the present disclosure;
FIG. 59 illustrates an axonometric view of the slab panel “D”, showing the exploded different layers of the panels; consistent with some embodiments of the present disclosure;
FIG. 60 is a elevation-view of the facade panel Type 1, showing prefabricated frame for exterior facade constituted by cold-formed steel profiles, consistent with some embodiments of the present disclosure;
FIG. 61 is a top view of the facade panel Type 1, showing the connection with wall panel, consistent with some embodiments of the present disclosure;
FIG. 62 is an elevation view cross-section of the facade panel Type 1, showing the frame with the fan-coil box, consistent with some embodiments of the present disclosure;
FIG. 63 illustrates an axonometric view of the facade panel Type 1, showing the material layers and the internal structure, consistent with some embodiments of the present disclosure;
FIG. 64 illustrates an axonometric view of the facade panel Type 1, showing the exploded different layers of the panel, consistent with some embodiments of the present disclosure;
FIG. 65 is a elevation-view of the facade panel Type 2, showing prefabricated frame for exterior facade constituted by cold-formed steel profiles, consistent with some embodiments of the present disclosure;
FIG. 66 is a top view of the facade panel Type 2, showing the connection with wall panel, consistent with some embodiments of the present disclosure;
FIG. 67 is an elevation view cross-section of the facade panel Type 2, showing the frame with the fan-coil box, consistent with some embodiments of the present disclosure;
FIG. 68 illustrates an axonometric view of the facade panel Type 2, showing the material layers and the internal structure, consistent with some embodiments of the present disclosure;
FIG. 69 illustrates an axonometric view of the facade panel Type 2, showing the exploded different layers of the panel, consistent with some embodiments of the present disclosure;
FIG. 70 illustrates an axonometric view, of the construction process of Construction Module Type 1, of the wall panel in the first floor, presenting the assembled panels erected on the base as the first step of construction process, showing the rebars extending from the wall panel as disponible connections; consistent with some embodiments of the present disclosure;
FIG. 71 illustrates an axonometric view, of the construction process of the Construction Module Type 1, of the slab panels of the first floor, being settled on the top of the wall panels, with whose overlap rebars being fixed with the wall panel as the second step of construction process; consistent with some embodiments of the present disclosure;
FIG. 72 illustrates an axonometric view, of the construction process of the Construction Module Type 1, of the first floor, showing state after the placement of concrete, as the third step of construction process; consistent with some embodiments of the present disclosure;
FIG. 73 illustrates an axonometric view, of the construction process of the Construction Module Type 1, of the first floor and the second floor, showing repetitive constructing operation as indicated in the last three steps; consistent with some embodiments of the present disclosure;
FIG. 74 illustrates an axonometric view, of the Construction Module Type 1, of the whole six-floor module, showing the optimal application of the building system; consistent with some embodiments of the present disclosure;
FIG. 75 illustrates an axonometric view, of the Construction Module Type 1, of six-floor module, showing whole structure consisting different panels with preformed opening, preserving space for the stairs or plumbing; consistent with some embodiments of the present disclosure;
FIG. 76 illustrates an axonometric view, of the construction process of the Construction Module Type 2, of the wall panel in the first floor, presenting the assembled panels erected on the base as the first step of construction process, showing the rebars extending from the wall panel as disponible connections; consistent with some embodiments of the present disclosure;
FIG. 77 illustrates an axonometric view, of the construction process of the Construction Module Type 2, of the slab panels of the first floor, being settled on the top of the wall panels, with whose overlap rebars being fixed with the wall panel as the second step of construction process; consistent with some embodiments of the present disclosure;
FIG. 78 illustrates an axonometric view, of the construction process of the Construction Module Type 2, of the first floor, showing state after the placement of concrete, as the third step of construction process; consistent with some embodiments of the present disclosure;
FIG. 79 illustrates an axonometric view, of the construction process of the Construction Module Type 2, of the first floor and the second floor, showing repetitive constructing operation as indicated in the last three steps;
FIG. 80 illustrates an axonometric view, of the Construction Module Type 2, of the whole six-floor module, showing the optimal application of the building system; consistent with some embodiments of the present disclosure;
FIG. 81 illustrates an axonometric view, of the Construction Module Type 2, of six-floor module, showing whole structure consisting different panels with preformed opening, preserving space for the stairs or plumbing; consistent with some embodiments of the present disclosure;
FIG. 82 is a elevation-view of the integrated cabinet element, showing prefabricated module for interior space, constituted by a principal wall with different furnitures and systems, closed by sliding doors consistent with some embodiments of the present disclosure;
FIG. 83 is an elevation view cross-section of the integrated cabinet element, showing the wall and the different integrated systems, consistent with some embodiments of the present disclosure;
FIG. 84 is an elevation view cross-section of the integrated cabinet element, showing the wall and the different integrated systems, consistent with some embodiments of the present disclosure;
FIG. 85 is a plan-view cross-section of the integrated cabinet element, showing the wall and the different integrated systems, consistent with some embodiments of the present disclosure;
FIG. 86 illustrates an axonometric view of the integrated cabinet element, showing the total volume of the cabinet element, consistent with some embodiments of the present disclosure;
FIG. 87 is a plan-view cross-section of the stair element, showing the structure of the stair, the walls and the different integrated systems, consistent with some embodiments of the present disclosure;
FIG. 88 is a top view of the stair element, showing the stair, consistent with some embodiments of the present disclosure;
FIG. 89 is an elevation view cross-section of the stair element, showing the walls, the floor, the stair and the different integrated systems, consistent with some embodiments of the present disclosure;
FIG. 90 is an elevation view cross-section of the stair element, showing the wall, the floor and the different integrated systems, consistent with some embodiments of the present disclosure;
FIG. 91 illustrates an axonometric view of the stair element, showing the total volume of the stair element, consistent with some embodiments of the present disclosure;
FIG. 92 is a plan-view cross-section of the kitchen element, showing the structural wall and the furniture kit with the integrated systems, consistent with some embodiments of the present disclosure;
FIG. 93 is an elevation view cross-section of the kitchen element, showing the structural wall and the furniture kit with the integrated systems, consistent with some embodiments of the present disclosure;
FIG. 94 is an elevation view cross-section of the kitchen element, showing the furniture kit with the integrated systems, consistent with some embodiments of the present disclosure;
FIG. 95 illustrates an axonometric view of the kitchen element, showing the total volume of the kitchen element, consistent with some embodiments of the present disclosure;
FIG. 96 is a plan-view cross-section of the bath element, showing the functional layer wall, the plumbing fixtures and the integrated systems, consistent with some embodiments of the present disclosure;
FIG. 97 is an elevation view cross-section of the bath element, showing the functional layer wall, the plumbing fixtures and the integrated systems, consistent with some embodiments of the present disclosure;
FIG. 98 is an elevation view cross-section of the bath element, showing the functional layer wall, the plumbing fixtures and the integrated systems, consistent with some embodiments of the present disclosure;
FIG. 99 illustrates an axonometric view of the bath element, showing the total volume of the bath element, with the integrated systems, consistent with some embodiments of the present disclosure;
FIG. 100 is a plan-view cross-section of the shaft closet element, showing the plumbing, the ducts and the integrated systems in the closet, consistent with some embodiments of the present disclosure;
FIG. 101 is an elevation view cross-section of the shaft closet element, showing the plumbing, the ducts and the integrated systems in the closet, consistent with some embodiments of the present disclosure;
FIG. 102 illustrates an axonometric view of the shaft closet element, showing the total volume of the shaft element, consistent with some embodiments of the present disclosure;
FIG. 103 is a front elevation of the interior facade element, showing the walls and doors of the corridor, consistent with some embodiments of the present disclosure;
FIG. 104 is a plan-view cross-section of the interior facade element, showing the walls and doors of the corridor, consistent with some embodiments of the present disclosure;
FIG. 105 is an elevation view cross-section of the interior facade element, showing the wall of the corridor, consistent with some embodiments of the present disclosure;
FIG. 106 illustrates an axonometric view of the interior facade, showing the total volume of the interior facade, consistent with some embodiments of the present disclosure;
FIG. 107 illustrates an axonometric view of the space proposal 1, showing the total volume of the structure module Type 1, consistent with some embodiments of the present disclosure;
FIG. 108 illustrates an axonometric view of the space proposal 1, showing the total volume of the structure module Type 1, with the optional elements, consistent with some embodiments of the present disclosure;
FIG. 109 illustrates an axonometric view of the space proposal 2, showing the total volume of the structure module Type 2, consistent with some embodiments of the present disclosure;
FIG. 110 illustrates an axonometric view of the space proposal 2, showing the total volume of the structure module Type 2, with the optional elements, consistent with some embodiments of the present disclosure;
FIG. 111 illustrates an axonometric view of the space proposal 3, showing the total volume of the structure module Type 3, consistent with some embodiments of the present disclosure;
FIG. 112 illustrates an axonometric view of the space proposal 3, showing the total volume of the structure module Type 3, with the optional elements, consistent with some embodiments of the present disclosure;
FIG. 113 illustrates an axonometric view of the space proposal 4, showing the total volume of the structure module Type 4, consistent with some embodiments of the present disclosure;
FIG. 114 illustrates an axonometric view of the space proposal 4, showing the total volume of the structure module Type 4, with the optional elements, consistent with some embodiments of the present disclosure;
DESCRIPTION The standard building system of the present disclosure contains various construction elements assembled on-site, aspects of the disclosed subject matter include three categories of panels: wall panel, slab panel and facade panel.
The standard building system of the present disclosure contains various construction module. The construction module refers to the combination of construction element and the construction process.
The standard building system of the present disclosure contains various elements assembled on-site, aspects of the disclosed subject matter include different categories of elements: one category of cabinet element,one category of stair element, one category of kitchen element, one category of bathroom element, one category of shaft closet and one category of interior facade.
In some embodiments, a plurality of wall panels are provided as a kit wherein the plurality of wall panels are approximately the same size. In some embodiments, a plurality of wall panels are provided as a kit, whereas modularity is used in the design. The module of wall panel is ultimately the decision of the user and depends upon the following non-limiting list of factors: human-scale, space quality, industrial sizes, and transportation margins. In some embodiments, these different sizes are complementary in denomination, i.e., the wall panels come in at least three sizes in this disclosure, with a 32′, a 30′and a 26′ size. In some embodiments, 32′ wall panels 65 are approximately 32 feet in width and approximately 8 feet in height. In some embodiments, 30′ wall panels 66 are approximately 30 feet in width and approximately 8.5 feet in height. In some embodiments, 26′ wall panels 67 are approximately 26 feet in width and approximately 8.5 feet in height.
Referring to FIGS. 1 and 2, in some embodiments, the 32′ wall panels for use with the system of the present disclosure have internal structure configured to operate as a support skeleton. Referring to FIG. 1, in some embodiments, the main internal structure is comprised of truss 1 and column 16. In some embodiments, the panels are self-supporting during construction work. In some embodiments, the panels have a vertical crush resistance of at least 2000 pounds per linear foot; length of said wall panel when tested according to ASTM E72, and using a safety factor of 3. In some embodiments, the panels have a bending resistance when subjected to uniform loading in accord with ASTM E72 of up to 2000 pounds per square foot surface area.
As shown in FIGS. 4, 5, and 6, the internal structures component of the panels provide ample interior space between these components for the application of functional layers 7 to endow each panel with not only structural stability, but desired properties derived from the composition of materials filling that space. In some embodiments, the panels can have different interior spaces based on the purpose of the panel (wall versus slab and the like) and the needs of the system user. Some embodiments of interior spaces and compounding functional layers 7 are discussed below in FIG. 7 and 8.
In some embodiments, the wall panels have internal structure. In some embodiments, the internal structure includes a principal structure and a substructure 15. In some embodiments, the principal structure comprises columns 16 and trusses 1. I in some embodiments, profiles 6 constitute the column which act as the formwork 16 for on-site concrete 14. In some embodiments, a plurality of prefabricated rebars 8 is contained in the column for the possible connection to the upper panels. In some embodiments, a plurality of C-profile 4 and U-profiles 5 constitute the truss 1. In some embodiments, the distance between two columns is 8 feet. In some embodiments, the 32′ wall panels have three columns and four trusses. In some embodiments, two trusses of 8 feet are held among three columns and a trusses of 8 feet is attached on each end of panel.
In some embodiments, the truss is held between two columns and is fastened by two substructure 15 on both side. In some embodiments, the substructure is constituted by U-profiles 3 and C profile 2 from FIG. 5. In some embodiments, these profiles support and encase compounding functional layers 7. In some embodiments, the horizontal distance between two profiles in the substructure is 2′. In some embodiments, the profiles in substructure along with the functional layers held therebetween define a functional layer block that can be stacked with other functional layer blocks to fill the interior space of a panel.
In some embodiments, panels are configured to be connected to other panels and/or a building foundation. In some embodiments, the connections are made via the internal structures of adjacent panels and via rebbars. In some embodiments, the connection between the various panels and/or the connection between the panels and the foundation is reversible. In some embodiments, panels are connected directly to a foundation using any suitable means. In some embodiments, an interface is provided to stabilize the connection between a panel and the foundation. Referring to FIGS. 5 and 6,In some embodiments the column comprises rebars that allow for connection with panels installed above them, as will be discussed in the construction process below. In some embodiments panels are connected with possible facade element using L-shaped profile 9, which is fastened to the U profile on the edge of panel. In some embodiments, at least one water-proof sealing gasket 13 is put between the L-shape profile and the structure as protection of wall panel.
Referring again to FIG. 5-7, the 32′ wall panel includes at least two side boards 10. In some embodiments, side boards are disposed on opposing sides of the interior space of wall panel. In some embodiments, side boards are comprised of at least one of wood, cement, fiber cement, drywall, suitable metal sheets, and the like. In some embodiments, the thickness of side boards is approximately 0.5-1 inches.
In some embodiments, wall panels includes fireproof board 12. In some embodiments, the thickness of fireproof board 12 is designed to comply with the relevant fire codes applicable to the building. Increasing the thickness of fireproof board can increase the fire resistance of the layer. By way of example, a 30 mm fireproof board 12 may be fire resistant for about 90 minutes, while a 40 mm fireproof board 20 may be fire resistant for about 120 minutes. In some embodiments, fireproof board 12 is comprised of any suitable fireproof or fire resistant material. In some embodiments, fireproof board 12 is comprised of calcium silicate. In some embodiments, opposing fireproof boards 12 enclose the main structural truss 1 of the panel. In some embodiments, the internal structure is connected to the fireproof board 12.
In some embodiments, wall panel further includes at least one acoustic insulation layer (such as rockwool 11). In some embodiments, the thickness and composition of rockwool 11 are configured to provide the desired level of sound insulation to wall panel. In some embodiments, the thickness of rockwool is approximately 45-50 mm (2 inch) in each side. In some embodiments, the rockwool is filled in the inner space of substructure. In some embodiments, the substructure 15, the rockwool 11, the cement board 10 and fireproof board 12 form a compound wall attaching on both side of principal structure.
In some embodiments, wall panel further includes EPS layer 11. In some embodiments, the thickness of EPS is approximately 180 mm (7 inch). In some embodiments, the density of EPS layer 11 is approximately 25-35 kg/m3. In some embodiments, the EPS layer is filled in the inner space of the truss 1.
The overall thickness of wall panel is the summation of at least the layers described in the above paragraphs. In some embodiments, the overall thickness of wall panel is adapted according to local needs, such as climate conditions, building codes, constructions budget, and the like. In some embodiments, the total thickness of wall panel is approximately 12¾ inches. In some embodiments, this thickness includes the internal principal structure and the substructure. In some embodiments, the main internal structure is disposed between fireproof dry panels 12 and the substructure is disposed between fireproof dry panel and the cement board 10.
Referring to FIG. 9-16, the 30′ wall panels have similarities in internal structure, layers and difference in the length. In some embodiments, 30′ wall panels have a 2 feet module less than the 32′ wall panel. In some embodiments, the 30′ wall panels have three columns and four trusses. In some embodiments, two trusses of 8 feet are held among three columns and a trusses of 8 feet is attached on one end of panel and a truss of 4 feet in other end. In some embodiments the 30′ wall panel can be used in the construction module type 1 as seen in FIG. 70-FIG. 76. In some embodiments, the internal structure of wall comprises columns and profile which forms the main frame. In some embodiments, some trusses are held between two columns and some are fastened on one side of the column. In some embodiments, substructures 15 with functional layers 7 are installed on both side of truss like the 32′ wall panel. In some embodiments, the components and order of functional layers in the 30′ wall panels are the same as those in 32′ wall panels.
Referring to FIG. 17-24, the 26′ wall panels have similarities in internal structure, layers and difference in the length. In some embodiments, 26′ wall panels have a 4 feet module less than the 30′ wall panel, where the lack of length leaves space for a corridor as seen FIG. 73. In some embodiments, the internal structure of wall comprises columns and profile which forms the main frame. In some embodiments, some trusses are held between two columns and some are fastened on one side of the column. In some embodiments, substructures with functional layers are installed on both side of truss like the 30′ wall panel. In some embodiments, the components and order of functional layers in the 26′ wall panels are the same as those in 30′ wall panels.
In some embodiments, a plurality of slab panels are provided as a kit, wherein slab panels come in a number of different sizes. In some embodiments, these different shapes are complementary in denomination, i.e., the slab panels could have openings for installation tubes, piping or an opening for stairs. In some embodiments, slab panels are approximately 6-8 feet in width and approximately 16-18 feet in length. The size of slab panel is ultimately the decision of the user and depends upon the following non-limiting list of factors: human-scale, space quality, industrial sizes, and transportation margins. In some embodiments, the slab panel used in the building system in the disclose consisted 5 types: A, B, C.1,C.2 D.
In some embodiments, slab panel A 60 includes at least one side board and two 6 mm cement boards. In some embodiments, the slab panels have steel frame 27 as seen in FIG. 25. In some embodiments, the steel frame includes two group 20 on each sides. In some embodiments, a number transversal C-profile 21 connect two group 20 between them. In some embodiments, two U profile 19 fixed on the outer side of 20, forming the bottom for fromwork of on-site concrete 26. Referring to FIG. 26-28, in some embodiments, interior space of slab panel includes at least one of rockwool layer 22, metal corrugated sheet 23. In some embodiments, acoustical panel layer 22 has a thickness of approximately 1 inch. In some embodiments, metal corrugated sheet 23 has a thickness of approximately 2-3 inches (54 mm). Further embodiments of the functional layers of slab panel 39 are portrayed in FIG. 29-31. In some embodiments, the slab panel have two group of rebars 18 on both side, attached on top the profile 19. In some embodiments the rebars 18 in the slab panel could fasten with the rebars on wall panel. In some embodiments, the rebars could be concreted on either side. In some embodiments, concrete could cover the metal corrugated sheet 23, the side rebars of slab panel and the top rebars of wall panel as a whole.
Referring to FIG. 32-38, in some embodiments, slab panel B has a similar steel frame and functional layers as type A. In some embodiments, the U-shaped profile 25 is installed in the center of the frame as the formwork of on-site concrete beam. In some embodiments, the distance the central beam to nearest edge of panel is 3′-5′. In some embodiments, two groups 20 are installed on both side of profile 25 and forming the internal frame with the transversal profile 21 in-between. In some embodiments, the rebars 18 is fixed on the profile 25 and concreted together with other rebars on site. In some embodiments, the U-profiles is installed with the transversal profile 21 and forming the structure of opening shaft for installation 31.
Referring to FIG. 39-45, in some embodiments, slab panel C.1 has the similar steel frame and functional layers as type B. In some embodiments, the slab C.1 has some transversal profiles 21 fastened with U-profiles 28 which serve as formwork of on-site concrete beam. In some embodiments, the concrete beam upon U-profile 28 in the edge of floor form an opening for stairs 32. In some embodiments, the width of the the opening is 3′-5′ and the length is 3′-5′.
Referring to FIG. 46-52, in some embodiments, slab panels C.2 have similar steel frame and functional layers to C.1. In some embodiments, the slab panels C.2 only have an opening for stairs, which is complementary for the opening of stairs in C.1. In some embodiments, the width of the the opening is 3′-5′ and the length is 8′.
Referring to FIG. 53-59, in some embodiments, slab panels D don't have functional layers. In some embodiments, the slab panels D have a group profiles 20 fastened with U-profile 19 which work as the formwork of on-site concrete beam. In some embodiments, the concrete beam can be connected with the adjacent panels. In some embodiments, the slab panels D has the facade element 29 and 33 which is capable of fixing mechanical equipment and pipes. The slab panel D has the void for double height space.
In some embodiments, a plurality of window frame elements referred to facade panels are provided as a kit, wherein facade panels come in a number of different sizes. In some embodiment the facade panel includes at least one sliding window and a structural frame. In some embodiments, the difference in frame are complementary in denomination. Referring to FIGS. 60-64, facade panel Type 1 include an attached frame as structure which comprises U-profiles and C-profiles. In some embodiments, the facade panel Type 1 include a box 37 on one side which is part of the structural frame and is prefabricated with all the needed mechanical fixtures 36 and connections. In some embodiments, modulated grilled panels 38 are fixing in the outer side of facade panel Type 1. In some embodiments, glass or methacrylic railing 39 are fastened in the inner side of window frame as protection. In some embodiment the facade panel includes a temporal substructure which comprises C-profiles and U-profiles. The temporal substructure can be easily dismounted after the hoisting and assembling on-site.
Referring to FIG. 65-69, facade panels Type 2 has the similar structural frame. In some embodiments, the window frame type 2 include a sliding window 34. The window frame type 2 don't have component for mechanical equipment.
In the current disclosure a plurality of construction module are provided. Referring now to FIG. 70-75, wall panel 30′, 26′ and slab panel A, B, C.1, C.2, D and facade panel type 1 can be applied into the construction module type 1. Slab panels and wall panels are connected via rebars and other connections. In some embodiments, vertical rebars 56 in the prefabricated column of wall panel are connected to horizontal rebars 57 of the slab panel. In some embodiments, on-site concrete unifies the rebars on different panels to the entirety. In some embodiments, on-site concrete acts as the finishing layer of the floor.
In some embodiments, the present disclosure is directed to a method of assembling modular panels to produce a building or interior space. In some embodiments, the modular panels are self-supporting, so individual panels can be installed one at a time and remain in place while adjacent panels are installed until a desired size and shape of the building or interior space is completed. FIG. 70-75 portray exemplary processes for connecting panels consistent with some embodiments of the present disclosure and as discussed above.
Once the panels arrive at a building site, wall panels are first installed on a foundation. In some embodiments, the first wall panel installation occurs through an interface between a U-profile and an embedding plate. Slab panels for the first floor would then be installed at the bottom of the installed wall panels. Facade panel would be installed after the ground floor being concreted. Slab panels for the second floor would then be installed at the top of the installed wall panels. In some embodiments, prefabricated groups of rebars 58 are put on the top of wall panel and connected with the rebars of the slab panel. In some embodiments, concrete on site connects the panels on the first floor into a whole. In some embodiments, some extension of rebars are left outside of the concrete for the upper floor. In some embodiments, any gaps at the joints between wall and slab panels are filled with polyurethane foam spray, which is fast-solidifying and has thermal insulation properties. In some embodiments, gaps between adjoining panels are stuck with adhesive. The facade panel would be hosted into its place and fixed with the existed concreted panel. In some embodiments, construction of subsequent floors of a building begins after the underlying floor has settled. In some embodiments, the second floor is formed by installing wall panels on the internal structures of the foundation, with slab panels defining the ceiling of the lower floor subsequently installed on the wall panels of the second floor, with the facade panel defining the enclosure. Upper floors are subsequently constructed in a similar manner.
Referring to FIG. 76-81, the wall panel 32F, the slab panel A, B and the facade panel Type 2 can be applied in the construction module type 2. In some embodiments, the construction module Type 2 uses different panel type but is similar as the Type 1. FIGS. 90-91 portray exemplary processes for connecting panels in the construction module “Type 2” consistent with some embodiments of the present disclosure and as discussed above.
In some embodiments, a plurality of prefabricated elements are provided as a kit wherein the plurality of the elements are of the same type. In some embodiments, a plurality of elements are provided as a kit, wherein wall panels come in a plurality of different types. In some embodiments, these different types are complementary in denomination, i.e., the elements could come in six types: integrated cabinet element, stair element, kitchen element, bathroom element, shaft closet element and interior facade element. The size of each type of the elements is ultimately the decision of the user and depends upon the following non-limiting list of factors: human-scale, space quality, industrial sizes, and transportation margins.
Referring to FIG. 82-86, the cabinet element is integrated with a plurality of functions such as bathroom and kitchen. In some embodiments, the cabinet element is integrated with a plurality of fixture such as electrical fixture 49, mechanical equipment 50, plumbing fixture 48 and the correspondent ducts 47 or piping 46. In some embodiments, a grilled panel is fixed on the top of the cabinet element for ventilation. In some embodiments, a plurality of modulated furniture kit is integrated in the cabinet element. The integrated cabinet element can be applicated in construction module type 2 as seen in FIG. 113-114 to provide a linear space.
Referring to FIGS. 87-91, stair elements includes an internal structure. In some embodiments, the internal structure of stair element comprises U-profiles 42, 43 and C-profiles 40, 41. In some embodiments, functional layer 44 are embedded in the internal structure. In some embodiments, to the structure is attached cement board 45 as finishing layer. In some embodiments, the structure with the functional layer and finishing layer form the structural wall of the element. In some embodiments, the structural wall support the tread and riser of stair and permit hoisting method of entire element. In some embodiments, the structural wall provides opening for piping. In some embodiments, the structure the structural wall includes a door 52. In some embodiments, the stair element could be installed with slab panel C.1 and C.2. In some embodiments, the space below the stair element contain a bathroom. In some embodiments, the stair element is fabricated with metal corrugated sheet and concrete floor 54 on the top of bath room. In some embodiments, stair elements are prefabricated with all the needed plumbing fixtures and pipes. In some embodiments, stair elements are prefabricated with all the needed electrical fixtures and connection. In some embodiments, stair elements are prefabricated with all the needed mechanical fixtures and connections.
Referring to FIGS. 92-95, kitchen elements should be installed next to the walls panels 66,67. In some embodiments, kitchen elements are prefabricated with modulated furniture kit 51.In some embodiments, the kitchen element include a structural wall with the similar internal structure as the stair element. In some embodiments, kitchen elements are prefabricated with all the needed piping fixtures 46 and connections. In some embodiments, kitchen elements are prefabricated with all the needed electrical fixtures 49 and connection. In some embodiments, kitchen elements are prefabricated with all the needed mechanical fixtures 50 and connections.The modulated furniture kit and the installation equipment can be prefabricated and hoisted as a entirety on-site.
Referring to FIGS. 96-99, bathroom elements includes the similar structure as kitchen element. The bathroom element could be installed next to the walls panels 66,67. In some embodiments, bathroom elements are prefabricated with all the various furniture elements. In some embodiments, bathroom elements are prefabricated with all the needed piping fixtures 46 and connections. In some embodiments, bathroom elements are prefabricated with all the needed electrical fixtures and connection. In some embodiments, bathroom elements are prefabricated with all the needed mechanical fixtures and connections.
Referring to FIGS. 100-102, shaft closet elements should be installed with the opening shaft 31 on slab panel 61. In some embodiments, the shaft closet element includes an internal structure. In some embodiments, shaft closet elements are prefabricated with all the needed piping fixtures and connections 46. In some embodiments, shaft closet elements are prefabricated with all the needed electrical fixtures 49 and connection. The piping fixture and electrical element can be separated by functional layer 44 and cement board 45 attached in the structure frame. In some embodiments, the shaft closet element is accessible from corridor.
Referring to FIGS. 103-106, interior facade should be installed between wall panels 26F 67, along the corridors, next to the wall openings 59. In some embodiments, interior facade elements are prefabricated with all the apartment's doors 52. In some embodiments, interior facades are prefabricated with all the needed shaft closet openings. In some embodiments, interior facades elements are prefabricated with all the needed electrical fixtures and connection.
In some embodiments, internal elements are prefabricated to be connected with each other. In some embodiments, elements are prefabricated to be connected with the building vertical piping 46.
Referring to FIG. 107-108, the construction wall panel 67 and slab panel 60, 61 are applicated into the assembly module type 1. The assembly module type 1 is one storey-height space. In some embodiments, the kitchen element, the bathroom element, the shaft closet element can be placed in the space. The size of the element can be varied with the different demands.
Referring to FIG. 109-110, the construction wall panels 66,67 and slab panels 60,61,62,64 are applicated into the assembly module type 2. The assembly module type 2 is a double-height space. In some embodiments, the kitchen element, the bathroom element, the stair element, the shaft closet element can be placed in the space. The size of the element can be varied according to the different demands.
Referring to FIG. 111-112, the construction wall panels 66,67 and slab panels 60,61,62,63,64 are applicated into the assembly module type 3. The assembly module type 3 is a double height space. In some embodiments, the kitchen element, the bathroom element, the stair element, the shaft closet element can be placed in the space. The size of the element can be varied according to the different demands.
Referring to FIG. 113-114, the construction wall panel 65 and slab panel 60, 61 can be applicated into the assembly module type 4. The assembly module type 4 have the similar construction process and assembly process as other type. The integrated cabinet element can be applicated into the assembly module type 4.
