WO2015120502A1

WO2015120502A1 - A prefabricated panel building system

Info

Publication number: WO2015120502A1
Application number: PCT/AU2014/000111
Authority: WO
Inventors: Walter Lee
Original assignee: ARKISTRUCT Ltd
Current assignee: ARKISTRUCT Ltd
Priority date: 2014-02-12
Filing date: 2014-02-12
Publication date: 2015-08-20
Anticipated expiration: 2016-08-12
Also published as: AU2014383001A2; CN106103859A; EP3105388A1; AU2014383001A1; EP3105388A4; US20170191260A1

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.

Description

PCT SPECIFICATION

A PREFABRICATED PANEL BUILDING SYSTEM

FIELD OF TH E INVEN ION

The present invention relates in particular but not exclusively to a versatile prefabricated panel bui lding system incorporating wall panels hav ing a rol ler track sliding means and an integrated stud assembly which confers substantial rigidity- arid 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 elim inating time and transport costs.

BACKGROU D OF TH E INVENTION

The main disadvantage o f prior art prefabricated wall building sy stems is that they require labor and tim e in which to erect traditional stud fram ing, to affix wall claddi ng pane ls, insert insulation material and then render, sand and paint the finished product. Furthermore, prior art composition boardroom wallboard panels are not designed for convenient wafer and electricity installation. Water pipes and electric cables are us ual ly installed On the outside surface of prior art panels. Wh ile it is possible lo 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 instal lation. If this is not skilfu lly undertaken, the repair work wi ll not only be unsightly, but may result in permanent damage to the structu ral integrity of the panel thereby degrading overall performance. Most prior art wallboard panels have poor weight bearing capac ity. Upright wa l ls constructed from these panels inevitably have poor w ind shear load resistance.

Ex ist ing composition panels m ust also be able to w ithstand diagona l torsion or twisting forces according to various relevant municipal building regulations and requirements. This results in prior art allboard panels having to be of a substantial construction which are not conducive to being prefabricated on site which is not only costly but is often also aesthetically less pleasing in appearance.

In view of the above-mentioned limitations, it is an object of the present invenli n to overcome the disadvantages of the prior art by providing a novel prefabricated wai l panel building system which confers substantial rigidity and integrity and which is also characterized b 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 bui lding systems.

SUMMARY OF THE INVENTION

In a preferred aspect, the invention resides in a prefabricated panel building system including:

a pluralit 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 inc luding specially adapted interlocking edge members;

the interlocking edge members havin 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 substantia) rigidity and integrity to a building constructed using the system.

Preferably, the panels are of a rectangular configuration and the edge members are on opposite longitudinal sides of each panel.

Preferably, there are edge members on all sides of the panel. in a more preferred example, the top and bottom portions of the pane! or edge members include integrated rollers whereby llie panels are able to be slid in the tracks into position against and on lo of each other.

In the alternative to rollers, skids or buttons of an anti-friction material such as Teflon may be used.

Preferably there are panels which include window frames or door frames as in built structural components of the panels or wherein windows and doors are pre-fitted in the panels.

In a preferred example, the panel comprises:

an inner wall decoration layer,

a fiber calcium silicate board,

a ihermal-proteetive layer and

an external cladd ing,

and wherein there is an air gap between the external cladding and the fiber C3te ium silicate board.

In a preferred example, the panel has an external cladding of prefinlshed metal c il skin.

In another example, the panel has a cladd ing material which includes magnesium o ide.

Preferably, the thermal-protective layer is provided with a hole.

Preferably, the light construction of the panels are such that they can be fabricated or manufactured on site in a moveable or re-locatable factory Of plant from raw and component materials. Preferably, the panels or edge members include one or more slots into which a barbed bracket or mount is inserted lo support accessories, inc luding lights, ornaments, removable cladding or decorative pane ls. Preferabl , there are passages along the lengths of the edge mem bers or which arc created on interlocking together edge members of adjacent panels, and wherein the passages are adapted to accommodate the installation of supply serv ices includi g elec tric cables or water pipes. Suitably, the panels have holes for any article required to pass through the panels.

Preferably, the interlocked edge members are permanently joined together by rivets or screws. In the alternative, the interlocked edge members can be permanently joined together with adhesive .

Preferably, decorative cover strips are used to cover any exposed interlocked edge members.

(it a preferred version, the edge members are channels with a recessed connecting groove wherein panels are joined by a connecting piece inserted into the space created by the opposite grooves More preferably, the edge members comprising an integrated stud are aluminum extrusions inc orporating a tongue profile and a groove profile wherein the tongues and grooves are serrated to lock the panels when pushed and clipped together.

In an alternative version, the edge members are channels provided with a connecting convex flange.

In a further alternative version, the edge members are channels prov ided with a connecting groove and a flange

The external cladding preferably comprises a base plate and an external composite plate fixed to the base plate.

The system is used to construct a. wall of a room or building by interlocking (he top and bottom edge members of panels stacked on top of each other.

The system is used to construct a floor, ceiling or roof by jo ining together edge members on all sides of the panels,

Preferably, the panels include integrated electrical conduit to accommodate electric cable or wires where power Outlets are required.

Preferably, the complementary profiles of the edge members when interlocked together provide a water tight seal.

In another preferred example, there are thermal break fillet strips which span across the intersections of interlocking edge members of abutting panels to confer requisite acoustic, thermal and fire ratings.

In another aspect, the invention resides in a method of building using panels of the system according to any one of the above claims including the steps of.

(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 (d) to join together further panels as required.

I t is submitted that the in vention has the following beneficial e ffects : Both ri ght and le ft sides of upright panels are provided with recessed channe ls that are interlocked with the channel of an adjacent panel to create the integrated stud thereby elim inating the need for traditional stud framing. S imilarly, reinforced edge members are installed at the top and bottom of the pane! wherein a weight bearing joint is a ffected between one pane l 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 adj acent panels a e able to be sl id 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 bu ilding of the subject system gives noth ing away to a permanently and traditionally bui it house.

The present system and method solves shortcomings of constructing prior art com pos ition board rooms and container houses by providing a novel and inventive method of spl icing together panels. It provides a prefabricated structure having good thermal insulation properties with characteristics of fast installation and greatly improved architectural aesthetic appearance.

It is submitted that compared w ith ex isting stud separated wall systems, the S invention is significantly advanced in its provision of rapidly and conveniently constructed buildings of equivalent structural integrity and most importantly, a low cos! to performance advantage. 0 BRIEF DESCRI PTION OF T I I I ! DRAWINGS in order that the invention is better understood and able to be put in to practice, re ference is made to the accompany ing drawings wherein: 5 FIG. I is a pre ferred prefabricated panel used in the building system of the invention.

FIG. 2 shows detail of the top portions of adjacent panels of FIG. I .

F !G. 3 shows detail of a pair of complementary serrated longitudinal edge mem bers.

0 FIG. 4 shows a panel which inc ludes a window frame and a door frame as structural components of the panel.

FIG, 5 shows detail of a preferred thermal break fillet strip according to the invention.

FIG. 6 shows detai l of buttons of an anti-friction material whereby the panels are5 able to be sl id.

DETAILED DESCRIPTION OF EMBODI MEN TS

As shown in the following drawings, the invention aims to provide a novel and versatile pre fabricated panel buildi ng system characterized by fast installation,0 rapid con truction, high fire resistance, high weight capacity, h igh cost performance and good sound insulation when compared to the prior art. The present invention comprises a piurai ity of wallboard panels joined together. Each panel 1 0 as typically shown in Figure I inc ludes spec ial ly adapted interlockin edge members 1 2, 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 subsla.nl.ial rigidity and integrity to the erected structure.

The preferred panel includes an inner wall decoration layer, a fiber calcium silicate board, a. thermal-protective layer and an external wal lboard 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 board 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 (net shown) whereby adjacent panels are able to be slid into position against each other.

Figure 2 shows partial detail of adjacent panels 16, 1 8 about to be joined by clipping together their respective complementary serrated longitudinal edge members 12, 14.

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 OT buttons of an anti-friction material such as Teflon may be used.

Figure 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 profi le 26a wherein the grooves are serrated to lock the panels (no) 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 l or 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, (rankings or other ornaments. Their use to attach removable wall cladding panels also makes the panel system more versatile.

Figure 4 shows panels 32, 34 which includes a window 36 and a door 38 as structural components of panels 32, 34which 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 movea ble or re-ioeatahie factory or plant: from raw and component materials. Openings can therefore be tut into the panels and prefabricated windows and doorways from suppliers installed on site thereby eliminating the need for separate window frame and door joinery.

Figure S 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 preferabl of a magnesium oxide and fiber glass construction which is affixed by mastic based adhesive over the intersecting edge members.

Figure. 6 show s 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 show n) into position against and on top of other panels. j

It will be apparent to the skilled addressee that, in additioh to the embodiments mentioned above, other equivalent technical solutions are also within the scope of i 0 the invention.

Claims

CLA!MS

I . A prefabricated panel building system including:

a plural ity of wall panels adapted to be joined together;

a structural frame defining the shape and configuration of

a bui ldin g;

the frame having horizontal tracks adapted to rece ive 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 hav ing compleme ntary profiles wherein opposite edge me mbers of abutiing panels are joined to form integrated studs and/or cross mem bers of the frame .

2. The system of claim 1 w herei n the top and bottom portions of the panel or edge members include integrated rollers whereby the panels are able to be sl id in the tracks into position against and on top of each other.

3. The system of c laim 1 wherein the top and bottom portions of the pane l 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 agai nst and on top of each other.

4. The system of c laim 1 where in there are edge members on all sides o the panel.

5. The system of c laim 1 , wherein the panel is of a rectangular configuration.

6. The system of cla im 1 , wherein one or more panels inc lude window frames or door frames as in built structural components of the panels or wherein w indo ws and doors are pre-fitted in the panels.

7. The system of claim 1 , wherein the panel includes:

an inner wail 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 externa! cladding of prefinishcd metal coil skin.

9. The sy stem of claim .1 , wherein the panel has a cladding material which includes magnesium oxide.

1 0. The system of claim I, wherein the panels are fabricated or manufactured on site in a moveable or re-locatable factory or plan! from raw and component materials.

1 1. The system of claim I , 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 I , wherein there are passages a long 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 of water pipes.

1 3. The system of claim ! , wherein the panels have holes for any article required to pass through the panels.

)2 ) 4. The system of claim 1 , wherei n the interlock ed edge members are permanently joined together by rivets or screws.

1 5 The system of claim 1 , wherein the interlocked edge members are permanently joined together by adhesive.

10

1 6. The system of claim 1 , wherein decorative cover strips are used to cover the interlocked edge members.

1 7. The system of claim 1 , wherein the edge members are channels with a recessed 15 connecting groove wherein panels are joined by a connecting piece inserted into the space created by the opposite grooves.

1 8. The system of claim 1 , wherein the edge members comprising an integrated stud are aluminum extrusions incorporating a tongue profi le and a groove profile

20 wherein the tongues and grooves are serrated to lock the pane ls when pushed and clipped together.

19. The system of claim 1 , wherein the edge members are channels provided with a connecting conv ex flange.

25

20. The system of claim 1 , where in the edge members are channels provided with a connect ing groove and a flange

21. ^'fhe system of claim 1 , where in a thermal-protective layer is provided wi th a ^0 hole .

22. The system of cla im 1 , wherein the external cladding comprises a base plate and an external composite plate fixed to the base plate.

5 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 1 0 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 requ ired.

15 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

20 requisite acoustic, thermal and fire ratings.

28. A method of building using panels of the system according to any one of the above claims including the steps of:

( a) assembling the structural frame;

25 (b) sliding a first panel in a track to its predetermined position;

(c) slidin a next panel in the track to abut against the first panel;

(e) repeating steps (b) and (c) and ( to join together further pane ls as required.

30