MULTIFUNCTIONAL CONSTRUCTION PANEL

Abstract

The disclosure is directed to integrated, multifunctional load bearing or non-load-bearing construction panels. More particularly, the disclosure is directed to thermally, acoustically and moisture insulated construction panels, which additionally are compliant with fire resistance codes without forming cold bridging using selectably configured staggered studs' array with selectably variable gap between the arrays and the slabs forming the panel walls.

Claims

1. An integrated construction panel comprising: a. an internal wall section; b. an internal studs' array operably coupled to the internal wall section, extending externally; c. a moisture control layer coupled to the internal wall section; d. an internal thermal insulation layer, e. an external thermal insulation layer; f. an external wall section; and g. an external studs' array operably coupled to the external wall section, extending internally, wherein, the internal studs' array is staggered with respect to the external studs' array

2. The panel of claim 1, wherein each of the internal wall section and the external wall section consists of a slab having front side and a back side.

3. The panel of claim 2, wherein each stud in the internal studs' array has a proximal end coupled to the front side of the internal wall section and a distal end opposite the proximal end; and wherein each stud in the external studs' array has a proximal end coupled to the back side of the external wall section and a distal end opposite the proximal end.

4. The panel of claim 3, wherein the distal end of each of the studs in the internal studs' array defines a gap between the distal end and the back side of the external wall section.

5. The panel of claim 3, wherein the distal end of each of the studs in the external studs' array defines a gap between the distal end and the front side of the internal wall section.

6. The panel of claim 4, wherein the gap between the distal end of each of the studs in the internal stud's array and the back side of the external wall is no less than about 10 mm.

7. The panel of claim 5, wherein the gap between the distal end of each of the studs in the external stud's array and the front side of the internal wall is no less than about 10 mm.

8. The panel of claim 1, wherein the internal and/or external studs' arrays have variable periodicity.

9. The panel of claim 1, wherein the internal stud's array is out of phase with the external stud's array by a variable distance.

10. The panel of claim 4, wherein the integrated construction panel defines a quadrilateral prism having a basal facet, an apical facet, a pair of side walls disposed on opposing sides of the basal and apical facets forming a frame and coupled to the front side internal wall section and the back side of the external wall section.

11. The panel of claim 10, wherein each of the studs in the internal and/or external studs' array is a beam defining a longitudinal axis with a rectangular cross-section transverse to the longitudinal axis.

12. The panel of claim 11, wherein the cross section is no less than 10 mm by 63 mm.

13. The panel of claim 12, wherein the beam spans the length of the panel between basal and the apical facets.

14. The panel of claim 1, wherein the internal and/or external insulation layer comprises multiple or single layers.

15. The panel of claim 14, wherein the insulation is mineral wool fibers, rock wool fibers, slag wool fibers, glass wool fibers, polymer based insulation or a composition comprising one or more of the foregoing.

16. The panel of claim 1, wherein the internal wall section is particle wood, cement particle, magnesium oxide, calcium silicate, gypsum based board or a composition comprising one or more of the foregoing.

17. The panel of claim 16, wherein the distance between the front end of the external wall section and the back end of the internal wall section is between about 89 mm and about 450 mm.

18. The panel of claim 5, wherein the integrated construction panel defines a quadrilateral prism having a basal facet, an apical facet, a pair of side walls disposed on opposing sides of the basal and apical facets forming a frame and coupled to the front side internal wall section and the back side of the external wall section.

19. The panel of claim 18, wherein each of the studs in the internal and/or external studs' array is a beam defining a longitudinal axis with a rectangular cross-section transverse to the longitudinal axis.

20. The panel of claim 19, wherein the cross section is no less than 10 mm by 63 mm.

21. The panel of claim 20, wherein the beam spans the length of the panel between basal and the apical facets.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0012] For a better understanding of the thermally, acoustically and moisture insulated construction panels, that additionally are compliant with fire resistance codes without forming cold bridges, reference is made to the accompanying drawings, in which like numerals designate corresponding elements or sections throughout and in which:

[0013] FIG. 1, is a schematic of a X-Y cross section of an embodiment of the construction panel;

[0014] FIG. 2 is a schematic isometric cutaway view of an embodiment of the construction panel; and

[0015] FIG. 3A, illustrates a X-Y Cross section plan view of an embodiment of the construction panel, while FIG. 3B illustrating a modification to increase structural performance of the embodiment illustrated in FIG. 3A, while FIG. 3C illustrating a modification adapted to allow for increased thermal (and acoustic) performance and FIG. 3D, illustrating an even greater thermal (and acoustic) performance.

DESCRIPTION

[0016] Provided herein are embodiments of thermally, acoustically and moisture insulated construction panels, that additionally are compliant with fire resistance codes without forming cold bridges and methods for their use.

[0017] A more complete understanding of the components, methods, and devices disclosed herein can be obtained by reference to the accompanying drawings. These figures (also referred to herein as FIG.) are merely schematic representations based on convenience and the ease of demonstrating the present disclosure, and are, therefore, not intended to indicate relative size and dimensions of the devices or components thereof, their relative size relationship and/or to define or limit the scope of the exemplary embodiments. Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings, and are not intended to define or limit the scope of the disclosure. In the drawings and the following description below, it is to be understood that like numeric designations refer to components of like function.

[0018] Likewise, cross sections are referred to on normal orthogonal coordinate apparatus having XYZ axis, such that Y axis refers to front-to-back, X axis refers to side-to-side, and Z axis refers to up-and-down.

[0019] Turning now to FIGS. 1-3B, illustrating in FIG. 1, a schematic of a X-Y cross section of an embodiment of the construction panel whereby integrated, multifunctional construction panel 10 can comprise: internal wall section 100; internal studs' array 104.sub.i operably coupled to internal wall section 100, extending externally (in other words, away from internal wall 100. Also shown is moisture (or vapour) control layer 102 coupled to the internal wall section, with internal thermal insulation layer 103, and external thermal insulation layer 107. Under certain circumstances, internal and external thermal insulation layers (103, 107 respectively) can be combined to a single insulation layer, where gap G.sub.1=0. Also shown is external wall section 108 and external studs' array 105.sub.j operably coupled to external wall section 108, extending internally (in other words, away from external wall section 108, towards internal wall section 100), wherein, internal studs' array 104.sub.i can be staggered with respect to the external studs' array 105.sub.j.

[0020] Moisture control layer 102, or moisture barrier layer, can be comprised, for example, of a resin saturated overlay in a laminate that provides resistance to the passage of air and airborne water vapour. The moisture control layer can be completely or selectively water vapour impermeable and substantially liquid water impermeable, and be comprised of composite sheet material and include an outer non-woven fiber layer, a semi-permeable film, and a reinforcing layer. Other examples of the moisture control layer can be lightweight, non-wet laid polyester nonwoven, a polymer-coated, high tenacity polyester mesh, and a lightweight, non-wet laid, polyester nonwoven material. The moisture control layer 102 can also be abrasion, tear, mildew and fire resistant, thus assisting in the fire retardation capabilities of the construction. The term control layer as used herein in connection with moisture, refers to the selective nature of the moisture barrier in being water vapor and liquid water impermeable. Being water vapor impermeable refers to the moisture control layer having according to BS EN 12524 a water vapour diffusion-equivalent air layer thickness S.sub.d>50 m, while having bulk water holdout with hydrostatic head of between about 160 cm and about 200 cm.

[0021] Breathable waterproof layer 106, or breather membrane, can be comprised, for example, of a non-woven polypropylene fabric that provides resistance to the passage of liquid water. The breathable layer can have a fixed or variable water vapour permeability, be substantially liquid water impermeable, and be comprised of composite sheet material and include an outer non-woven fiber layer, a semi-permeable film, and a reinforcing layer. Other examples of the breathable layer can be resistant to ultraviolet light, have fire retardant additives, be fire resistant glass fibre, metal foil laminated bubble film, paper. The breathable layer 108 can also be abrasion, tear, mildew, ultaviolet and fire resistant, thus assisting in the fire retardation capabilities of the construction. The term breathable as used herein in connection with moisture, refers to the selective nature of the moisture barrier in being water vapor permeable while simultaneously being substantially liquid water impermeable. Being water vapor impermeable refers to the moisture control layer having according to BS EN 12524 a water vapour diffusion-equivalent air layer thickness S.sub.d<0.50 m. while having bulk water holdout with hydrostatic head of between about 160 cm and about 200 cm.

[0022] The term staggered studs refers in an embodiment to metal studs or studs of other materials, being arranged with the elements (in other words, the studs) in the at least one row, optionally being offset relative to one another in an X and or Y dimension. The offset of the studs can be fixed or variable in each of the X or Y direction.

[0023] Each of internal wall section 100 and external wall section 108 comprised in the construction panels described herein can consist of a slab having front side and a back side. Turning now to FIGS. 3A-3B, showing back side 161 of internal wall section 100 in FIG. 3A, with front side 162 of internal wall section 100 in FIG. 3B, which also shows the back side 181 and front side 182 of external wall section 108. The term slab is intended to be interpreted broadly. Apart from its usual meaning, referring to a flat layer of construction material laid or cast in situ with or without reinforcement, the term also includes reference to a layer of wall panels or roof panels covered with a concrete or plaster topping.

[0024] Also illustrated in FIG. 1, is first closing rail 101 (second closing rail 110 is shown in FIG. 2 e.g.), as well as panel thickness metric W3, measuring from front side 182 of external wall 108, to back side 161 of internal wall 100. D.sub.1 illustrates the gap formed between internal studs' array 104.sub.i, and back side 181 of external wall section 108, while D.sub.2 illustrates the gap formed between external studs' array 105.sub.j, and front side 162 of internal wall section 100. Waterproof breathable membrane 106 can also be added where application requires. Fixing means 115.sub.p, for example self-drilling cement board screw can be used in an embodiment to couple internal and/or external studs' arrays (104.sub.i, 105.sub.j respectively) to internal and/or external wall sections (100, 108 respectively).

[0025] Likewise, (see e.g., FIG. 3A) each i.sup.th stud in internal studs' array 104.sub.i, has proximal end 141 coupled to front side 162 (see e.g., FIG. 3B) of internal wall section 100 and distal end 142 opposite proximal end 141; and wherein each j.sup.th stud in external studs' array 105.sub.j has proximal end 151 coupled to back side 181of external wall section 108 and distal end 152 (see e.g., FIG. 3C) opposite proximal end 151 of each j.sup.th stud in external studs' array 105.sub.j.

[0026] As indicated hereinabove, distal end 142 of each i.sup.th stud in internal studs' array 104.sub.i, can be configured to define gap D.sub.1 between distal end 142 and back side 181 of external wall section 108, while distal end 152 of each j.sup.th stud in external studs' array 105.sub.j defines gap D.sub.2 between distal end 152 and the front side 162 of internal wall section 100. Moreover, D.sub.1 between distal end 142 and back side 181 of external wall section 108, is no less than about 10 mm, while gap D.sub.2 between distal end 152 and the front side 162 of internal wall section 100, is likewise no less than about 10 mm.

[0027] In an embodiment, the internal and/or external studs' arrays (104.sub.i, 105.sub.j respectively) can be further configured to have variable periodicity (referring to any periodic characteristic of the studs elements). Furthermore, the term fixed periodicity and/or variable periodicity is intended to refer to the degree center-to-center spacing by which each of an array of interspersed stud is separated. In an embodiment, periodicity can increase in those sections where structural load is increased, for example next to floor boards, above windows etc. In the event a specific numerical value for a periodicity of distribution is provided herein, a margin of error of 20 percent may be assumed.

[0028] In addition, internal stud's array 104.sub.i, used in the multifunctional construction panels provided herein, can be out of phase (in other words, staggered) with external stud's array 105.sub.j by a variable distance. In other words, the periodicity of internal stud's array 104.sub.i, can vary identically or variable with respect to external stud's array 105.sub.j. Again, the variability and the degree of staggering between the studs is a function, in an embodiment, of the functions sought to be imparted on multifunctional construction panel (MCP) 10. For example, the staggering of the internal stud's array 104.sub.i, in relation to external stud's array 105.sub.j means that the insulation 103, 107 protects internal stud's array 104.sub.i, once the fire-side board (in other words, the wall exposed to the fire) has degraded following exposure to fire. In an embodiment protection resulting from internal stud's array 104.sub.i, being out of phase, or staggered in relation to external stud's array 105.sub.j prolongs the integrity of MCP 10 significantly during fire test and 90 minutes structure and integrity performance and 60 mins insulation performance were achieved, which is not typical for a system comprising only a single board of fire protection.

[0029] In an embodiment, by using staggered studs' arrays (104.sub.i, 105.sub.j respectively), defining gaps D.sub.1, D.sub.2 insulation 103, 107 (see e.g., FIG. 1) can be dispersed continuously throughout the panel interior defined between front side 162 or internal wall section 100, and back side 181 of external wall section 108, thus preventing the formation of cold bridges between external wall section 108 and internal wall section 100, without compromising on structural integrity of MCP 10.

[0030] As illustrated in FIG. 2, integrated, multifunctional construction panel 10 can be configured to define a quadrilateral prism having basal facet 111, apical facet (102, not shown), a pair of side walls (e.g., first closing rail 101 and second closing rail 110, see e.g., FIGS. 1 and 2 respectively) disposed on opposing sides of basal 111 and apical 112 facets forming a frame and operably coupled to front side 162 of internal wall section 100 and back side 181 of external wall section 108 (see e.g., FIGS. 3A-3B). As illustrated in FIG. 2, each i.sup.th and/or j.sup.th studs in internal and/or external studs' arrays (104.sub.i, 105.sub.j respectively) can be a beam defining longitudinal axis XL, with a rectangular X-Y cross-section, transverse to longitudinal axis XL, defined by the beam. In an embodiment, and to maintain minimal allowable structural integrity, the K-Y cross section is no less than 38 mm (W, see e.g., FIG. 2) by 63 mm (L, see e.g., FIG. 2), wherein beam forming each i.sup.th and/or j.sup.th studs in internal and/or external studs' arrays (104.sub.i, 105.sub.j respectively) can be configured to span the length of the MCP 10 between basal 111 and apical 112 facets, or alternatively, between the pair of side walls (e.g., first closing rail 101 and second closing rail 110, see e.g., FIGS. 1 and 2 respectively). It stands to reason, that the minimum and maximum cross section dimensions (e.g., 38 mm (W, see e.g., FIG. 2) by 63 mm (L, see e.g., FIG. 2)), as well as the shape of the cross section are material-specific and here refer to structural timber. Using different materials for forming the stud panel, for example, using metal, composite or polymer studs will allow forming narrower cross section, for example between about 10 mm, to about 63 mm. Likewise, the cross section can be circular, or any polygon having three or more facets. Additionally, or alternatively cross sections could include, for example hollow thin walled sections.

[0031] As indicated hereinabove, internal and/or external insulation layers (103, 107 respectively, see e.g., FIG. 1), used in the integrated MCP 10 described and claimed herein, can comprise multiple or single insulating layer (in other words, low thermal conductivity, k of, for example, between about 0.6 W/mK and 0.7 W/mK). The thermal insulation can be, for example; mineral wool fibers, rock wool fibers, slag wool fibers, glass wool fibers, polymer based insulation or a composition of thermal and/or acoustic insulation materials comprising one or more of the foregoing.

[0032] Additionally, internal wall section 100 used in the integrated MCP 10 described and claimed herein, can be, for example; particle wood, cement particle, magnesium oxide, calcium silicate, gypsum based board or a composition comprising one or more of the foregoing.

[0033] Turning now to FIGS. 3A-3D, wherein FIG. 3A, illustrates a X-Y Cross section plan view of an embodiment of the construction panel, while FIG. 3B illustrating a modification to increase structural performance of the embodiment illustrated in FIG. 3A, while FIG. 3C illustrating a modification adapted to allow for increased thermal (and acoustic) performance and FIG. 3D, illustrating an even greater thermal (and acoustic) performance. As indicated, using staggered studs' arrays (104.sub.i, 105.sub.j respectively), defining gaps D.sub.1, D.sub.2 insulation 103, 107 (see e.g., FIG. 1), whether in a single or double layers, can be dispersed, poured or layered continuously throughout the panel interior defined between front side 162 or internal wall section 100, and back side 181 of external wall section 108, thus preventing the formation of cold bridges between external wall section 108 and internal wall section 100, without compromising on structural integrity of MCP 10. The interplay between the size and/or periodicity (whether fixed or variable) and/or offset (whether fixed or variable) of the beams forming arrays 104.sub.i, 105.sub.j respectively, as well as gaps D.sub.1, D.sub.2 defined between the distal ends 142, 152 of the beams forming arrays 104.sub.i, 105.sub.j respectively and the choice of insulating material used, it is possible to obtain the required multifunctional performance in terms of structural integrity, thermal and acoustic characteristics, as well as fire resistance performance, without the formation of cold bridges. Integrated MCP 10 can thus be configured such that the distance between the front end of the external wall section and the back end of the internal wall section is between about 89 mm and about 450 mm, for example, between 89 mm and about 198 mm.

[0034] For example, as illustrated in FIG. 3A, using mineral wool for thermal and acoustic insulation, and non-combustible mineral board as the internal and external wall sections, and beams forming arrays 104.sub.i, 105.sub.j respectively having fixed periodicity with each i.sup.th and/or j.sup.th studs in internal and/or external studs' arrays (104.sub.i, 105.sub.j respectively), with W=47 mm, and L=97 mm as well as gaps D.sub.1A, D.sub.2A defined between the distal ends 142, 152 of the beams forming arrays 104.sub.i, 105.sub.j respectively being the same and equal 75 mm, heat transfer coefficient U of 0.23 W/m2.Math.K was obtained.

[0035] In certain embodiments, acoustic insulation can be achieved using a separate absorbing and decoupling material, for example, batts constructed from, glass fibre, and polyesterin addition to the mineral wool. In certain embodiments, the acoustic insulation (in other words, sound adsorbing and decoupling), can comprise a bladder layer of viscoelastic material, such as hydrocolloid gum, for example, gelatin, xanthan, cellulosics and the like.

[0036] The same thickness can be modified to increase structural integrity as illustrated in FIG. 3B. As shown in FIG. 3B, using the same materials as in FIG. 3A, and beams forming arrays 104.sub.i, 105.sub.j respectively having fixed periodicity with each i.sup.th and/or j.sup.th studs in internal and/or external studs' arrays (104.sub.i, 105.sub.j respectively), with W=47 mm, and L=122 mm as well as gaps D.sub.1B, D.sub.2B defined between the distal ends 142, 152 of the beams forming arrays 104.sub.i, 105.sub.j respectively being the same and equal 50 mm, heat transfer coefficient U of 0.24 W/m2.Math.K was obtained.

[0037] Increasing W3 (See e.g. FIG. 1) can result in increased thermal insulation. As illustrated in FIG. 3C, using the same materials as in FIG. 3A and beams forming arrays 104.sub.i, 105.sub.j respectively having fixed periodicity with each i.sup.th and/or j.sup.th studs in internal and/or external studs' arrays (104.sub.i, 105.sub.j respectively), with W=38 mm, and L=89 mm as well as gaps D.sub.1C, D.sub.2C defined between the distal ends 142, 152 of the beams forming arrays 104.sub.i, 105.sub.j respectively being the same and equal 95 mm, heat transfer coefficient U of 0.206 W/m2.Math.K was obtained.

[0038] When necessary, it is possible to increase W3 even further. As illustrated in FIG. 3D, using the same materials as in FIG. 3A and beams forming arrays 104.sub.i, 105.sub.j respectively having fixed periodicity with each i.sup.th and/or j.sup.th studs in internal and/or external studs' arrays (104.sub.i, 105.sub.j respectively), with W=38 mm, and L=89 mm as well as gaps D.sub.1D, D.sub.2D defined between the distal ends 142, 152 of the beams forming arrays 104.sub.i, 105.sub.j respectively being the same and equal 146 mm, heat transfer coefficient U of 0.15 W/m2.Math.K was obtained.

[0039] The term coupled, including its various forms such as operably coupling, coupling or couplable, refers to and comprises any direct or indirect, structural coupling, connection or attachment, or adaptation or capability for such a direct or indirect structural or operational coupling, connection or attachment, including integrally formed components and components which are coupled via or through another component or by the forming process. Indirect coupling may involve coupling through an intermediary member or adhesive, or abutting and otherwise resting against, whether frictionally or by separate means without any physical connection

[0040] The term about, when used in the description of the technology and/or claims means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. In general, an amount, size, formulation, parameter or other quantity or characteristic is about or approximate whether or not expressly stated to be such and may include the end points of any range provided including, for example 25%, or 20%, specifically, 15%, or 10%, more specifically, 5% of the indicated value of the disclosed amounts, sizes, formulations, parameters, and other quantities and characteristics.

[0041] The terms first, second, and the like, herein do not denote any order, quantity, or importance, but rather are used to denote one element from another. The terms a, an and the herein do not denote a limitation of quantity, and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The suffix (s) as used herein is intended to include both the singular and the plural of the term that it modifies, thereby including one or more of that term (e.g., the aggregate(s) includes one or more aggregates). Reference throughout the specification to one embodiment, another embodiment, an embodiment, and so forth, means that a particular element (e.g., feature, structure, and/or characteristic) described in connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments.

[0042] Accordingly and in an embodiment, provided herein is an integrated construction panel comprising: an internal wall section; an internal studs' array operably coupled to the internal wall section, extending externally; a moisture control layer coupled to the internal wall section; an internal thermal insulation layer, an external thermal insulation layer; an external wall section; and an external studs' array operably coupled to the external wall section, extending internally, wherein, the internal studs' array is staggered with respect to the external studs' array, wherein (i) each of the internal wall section and the external wall section consists of a slab having front side and a back side, (ii) each stud in the internal studs' array has a proximal end coupled to the front side of the internal wall section and a distal end opposite the proximal end; and wherein each stud in the external studs' array has a proximal end coupled to the back side of the external wall section and a distal end opposite the proximal end, (iii) the distal end of each of the studs in the internal studs' array defines a gap between the distal end and the back side of the external wall section, wherein (iv) the distal end of each of the studs in the external studs' array defines a gap between the distal end and the front side of the internal wall section, wherein (v) the gap between the distal end of each of the studs in the internal stud's array and the back side of the external wall is no less than about 10 mm, wherein (vi) the gap between the distal end of each of the studs in the external stud's array and the front side of the internal wall is no less than about 10 mm, wherein (vii) the internal and/or external studs' arrays have variable periodicity, wherein (viii) the internal stud's array is out of phase with the external stud's array by a variable distance, wherein (ix) the integrated construction panel defines a quadrilateral prism having a basal facet, an apical facet, a pair of side walls disposed on opposing sides of the basal and apical facets forming a frame and coupled to the front side internal wall section and the back side of the external wall section, (x) wherein each of the studs in the internal and/or external studs' array is a beam defining a longitudinal axis with a rectangular cross-section transverse to the longitudinal axis, (xi) each of the studs in at least one of the internal studs' array and external studs' array is a beam defining a longitudinal axis with a rectangular cross-section transverse to the longitudinal axis, wherein (xii) the cross section is no less than 10 mm by 63 mm, wherein (xiii) the beam spans the length of the panel between basal and the apical facets, wherein (xiv) the internal and/or external insulation layer comprises multiple or single layers, (xv) the insulation is mineral wool fibers, rock wool fibers, slag wool fibers, glass wool fibers, polymer based insulation or a composition comprising one or more of the foregoing, (xvi) the internal wall section is particle wood, cement particle, magnesium oxide, calcium silicate, gypsum based board or a composition comprising one or more of the foregoing, and wherein (xvii) the distance between the front end of the external wall section and the back end of the internal wall section is between about 89 mm and about 450 mm.

[0043] While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended, are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.