WALL PANEL

Abstract

A prefabricated wall panel is described, said panel comprising: a rear board; a front board forming an internal face for a room, said front board spaced away from said rear board to form a cavity; and a first side stud and a second side stud, each side stud connected to the front and rear boards on opposing sides of the cavity; and a wireway disposed within the cavity, wherein the wireway runs substantially from a base of the wall panel to a top of the wall panel to allow services to pass through the panel, and wherein the wireway constrains cabling of the services therein; and wherein the first side stud comprises a male mating means and the second side stud comprises a female mating means such that the prefabricated wall panel can mate with an adjacent prefabricated wall panel to form a continuous internal wall surface.

Claims

1. A prefabricated wall panel comprising: a rear board; a front board forming an internal face for a room, said front board spaced away from said rear board to form a cavity; and a first side stud and a second side stud, each side stud connected to the front and rear boards on opposing sides of the cavity; and a wireway disposed within the cavity, wherein the wireway runs substantially from a base of the wall panel to a top of the wall panel to allow services to pass through the panel, and wherein the wireway constrains cabling of the services therein; and wherein the first side stud comprises a male mating means and the second side stud comprises a female mating means such that the prefabricated wall panel can mate with an adjacent prefabricated wall panel to form a continuous internal wall surface.

2. The panel of claim 1, wherein the wireway comprises one or more channels that run substantially through the wireway.

3. The panel of claim 1, wherein the panel further comprises: one or more steel support rails connected across said side studs and between the rear board and the wireway for supporting the wireway.

4. The panel of claim 3, wherein the side studs comprise a plurality of tabs, said tabs extendable away from the side studs into the void and providing a fixing point for the support rails.

5. The panel of claim 4, wherein the side studs comprise a metal profile, and wherein the tabs are punched into the profile.

6. The panel of claim 5, wherein the tabs are configured to fold away from the profile to provide the fixing point.

7. A prefabricated wall system for creating internal building walls, said system comprising: one or more panels according to any preceding claim; and a guide rail provided on a floor of a building, wherein said guide rail comprises a raised profile configured to be received within a correspondingly shaped recessed portion in a base track of the panel.

8. The system of claim 7, wherein the raised portion comprises a substantially frustoconical cross-section, said raised portion provided along the length of the guide rail.

9. The system of claim 8, wherein the recessed portion extends less than the height of the raised portion, such that a gap is formed between the wall panel and the floor when the recessed portion receives the raised portion.

10. The system of claim 7, wherein multiple panels are provided, each panel secured to an adjacent panel via the mating means and received in the guide rail.

11. The system of claim 7, wherein first and second wall panels are arranged parallel to each other on separate guide rails to form a party wall.

12. The system of claim 11, wherein an insulated sheet is provided between the guiderails to lie between the first wall panel and the second wall panel.

13. The system of claim 7, wherein the front board sits in front of the side studs and tracks to hide the side studs and tracks behind the front board.

14. A method for installing services in a prefabricated wall panel, said method comprising the steps of: forming a wall comprising at least two wall panels according to any preceding panel claim, said wall panels mated together to form a unitary wall; creating an cutaway through said front board of at least one of said panels to access the wireway therein, said cutaway located solely within the wireway; installing a backbox within said cutaway; and feeding services cabling through the one channel to the backbox through the or an opening in a top portion of the front board.

15. A method for installing a wall with services, said method comprising the steps of: installing a guide rail on a floor beneath the intended wall position, said guide rail comprising a raised profile extending away from the floor; providing a first wall panels from a plurality of wall panels, each wall panel comprising: a rear board; a front board forming an internal face of the wall, said front board spaced away from said rear board to form a cavity; and a first side stud and a second side stud, each side stud connected to the front and rear boards on opposing sides of the cavity; and a head track and a base track, each track connected to the of the front and rear board and the first and second side stud at a top and bottom of said panels and studs respectively; aligning a recessed profile in the base track of the first wall panel on the raised profile, wherein the raised profile has a substantially identical negative cross-section to the raised profile; aligning a second wall panel on the guide rail adjacent to said first wall panel, wherein a male mating means on the first side stud of one wall panel with a female mating means on the second side stud of the other wall panel; and installing services according to claim 14.

16. A method of installing a party wall, said method comprising the steps of: installing a first wall according to claim 15; providing a second guide rail on the floor parallel to the guide rail; and installing a second wall on the second guide rail.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0045] The invention is described in further detail below by way of example and with reference to the accompanying drawings, in which:

[0046] FIG. 1 shows an exploded view of a prefabricated internal wall panel for use with a system according to an embodiment of the present invention;

[0047] FIG. 2a shows the wall panel of FIG. 1 when connected but with the front and rear board removed;

[0048] FIG. 2b shows a close-up view of side studs of FIG. 2a FIG. 2c shows a close-up view of the top of the wireway shown in FIG. 2a;

[0049] FIG. 3a shows a lower portion of the wall panel of FIG. 1 with the front board removed and with a back box connected;

[0050] FIG. 3b shows an upper portion of the wall panel of FIG. 3a; and FIG. 4 shows an upper portion of an installed system;

[0051] FIG. 5 shows a bottom portion of the wall panel;

[0052] FIG. 6a shows a top portion of the wall panel;

[0053] FIG. 6b shows a cross sectional view of FIG. 6a;

[0054] FIG. 7 shows an exploded view of the system used for a party wall;

[0055] FIG. 8 shows a lower portion of the mounting system used for the party wall; and

[0056] FIG. 9 shows a cross-sectional view of a party wall with the system of FIG. 7.

[0057] It should be noted that the Figures are diagrammatic and not drawn to scale. Relative dimensions and proportions of parts of the Figures have been shown exaggerated or reduced in size, for the sake of clarity and convenience in the drawings. The same reference signs are generally used to refer to corresponding or similar feature in modified and different embodiments.

DETAILED DESCRIPTION

[0058] FIG. 1 shows an exploded view of a prefabricated internal wall panel 10 according to an embodiment of the present invention. The panel broadly comprises a front gypsum based board 12, rear gypsum based board 14, head track 22 and base track 24. The front board 12 forms an internal face of a room and can be finished accordingly. However, it is typically supplied as a plasterboard finish ready for decorating.

[0059] The front board is spaced away from the rear board. The rear board may either form a corresponding internal wall, or may form part of a party wall as will be described below. The rear board is also typically plasterboard, or may be an alternative backboard surface such as cardboard or the like when the panel is used as a party wall, depending on the intended finish or use of the panel.

[0060] The front and back boards are connected to a head track 22 and a base track 24 and side studs 26 and 28 such that it provides a void or cavity therebetween. It can be appreciated that this cavity within the panel may be filled with an insulation product, such as Rockwool insulation slabs, or the like.

[0061] In the embodiment shown, the panel is an internal wall panel such that the front board and the rear board are gypsum based boards and form an internal face of a room. When used as a party wall, the rear board does not need to be gypsum based and can be cardboard as described above. In a party wall arrangement two panels may be arranged side by side, separated by a void that can be filled with insulation. Each panel is sealed to the floor and a soffit using intumescent fire sealant to provide resistance to fire to prevent fire from spreading from one dwelling or one side of the internal wall to the other dwelling or other side of the internal wall. This also acts to improve the acoustic properties of the panel.

[0062] Side studs 26 and 28 are provided, said side studs are shown in greater detail in FIG. 2c. The side studs receive the head track 22 and the base track 24 to form a frame for the wall panel. The head track, base track and the side studs are typically metal, generally formed from sheet steel or aluminium. This forms a metal framework around the panel, which provides further fire resistance and again improves the acoustic properties of the panel.

[0063] In addition, a wireway 30 is provided that is provided within the cavity behind the front gypsum based board 12, although it can be appreciated that a similar wireway may be provided within the cavity behind the rear gypsum based board 14 when the panel is used as an internal wall. The wireway 30 runs along the height of the front board from a lower point adjacent to the base track to an upper point adjacent to the head track. The wireway typically comprises a number of channels or passages through which cabling for services can be passed therethrough. In the example shown, 3 passages are used, each running parallel to each other. The wireway is typically made of cardboard or the like to provide some degree of structural rigidity and resistance to piercing by the cables. In some embodiments the cardboard may be treated to be smooth with a lower coefficient of friction to aid passage of the cables through the channels.

[0064] Also shown in FIG. 1 are support rails 42 that are attached to the side studs and support the wireway 30. The support rails further act to support service backboxes and the like that are placed within the panel. Similarly pattress plates 44 may be provided in front of the wireway between the wireway and the front board to support fixtures and fittings such as TV wall frames or the like.

[0065] FIG. 2a is a schematic rear view and representation of an assembled wall panel, with the rear board removed. The wireway 30 is shown, supported on support rails 42 that are secured to the side studs 26, 28. The side studs 26, 28 are typically formed of folded metal, such as plate steel or aluminium or the like. As is further shown in FIG. 2b, the side struts has a series of pressed tabs 29 that face inwardly towards the cavity. The pressed tab 29a is shown in a folded out position to form a fixing point against which the support rails 42 can be fixed. In the example shown in FIG. 2a, each support rail 42 forms a brace against which the wireway 30 can be secured. By providing a series of tabs 29 along the length of the side studs 26, 28 the support rail 42 can be secured at any position along the height of the panel.

[0066] FIG. 2c shows a top portion of the wall panel 10. The side stud 26, 28 are secured by the head track 22 that brace to form a top part of the frame. The head track 22 is typically of metal construction and comprises a channel 23 configured to engage with a guide rail 65 as described below. The head track 22 in an embodiment is the same as the base track 24. This allows the panel to be inverted as required, which aids installation. As shown, the wireway 30 is secured in slots or grooves that run along the side struts. One side stud 26 has a male engagement portion 26a, which is configured to be received by a correspondingly shaped female engagement portion 28a in the opposite side stud 28. This allows the wall panel to be aligned against a corresponding adjacent wall panel to form a wall. The interlocking of the male and female engagement portions act to secure the wall against lateral movement. The interlocking is typically a friction-fit.

[0067] Also shown in FIG. 2c are channels or passage 32 in the wireway. The wireway channels 32 run along the length of the wireway 30 and therefore along a substantial portion of the panel. Each channel 32 provides a separate passageway in which service cabling can run and be constrained. The wireway is typically formed of cardboard or the like, that is lightweight and substantially rigid enough to constrain fed cabling. The cardboard also acts to resist piercing through the channels to prevent the cabling being lost in the void. The cardboard may also be substantially smooth (such as with a coating) that acts to reduce friction between cabling and assist in passing cabling through the channels and from a top portion of the panel to a lower part of the panel.

[0068] FIG. 3a shows the panel in use. A cutaway 50 has been made or chased out in the panel, through the plasterboard surface of the front board and through the cardboard of the wireway. As can be seen, the cutaway can be confined to a single channel, which the tradesperson knows lies within this broad location within the panel. A backbox 52 has been installed in the cutaway and a service cable 54 running through the channel. The service block is secured to the support rail 42 to provide structural rigidity.

[0069] The service cable 54 is fed through to the service block 52 through an opening 56 in the top portion of the panel as shown in FIG. 3b. The opening is either cut or chased through the panel and the wireway into the channel and provides an entry point at which the cabling can be fed to the backbox 52. FIG. 4 shows how services pass through walls. Typically panel 12a is installed, and where openings are required a shorter prefabricated panel 12b is formed and positioned, then a prefabricated opening panel 60 is installed. This panel 60 is formed to the correct size appropriate to services passing through with the gypsum based boards cut out 62. The next typical panel 12c can then be installed and the deflection head profile 64 is then installed at the head. Deflection profiles 64 are fixed to the soffit above which hold the panel in position whilst allowing for deflection in the building and maintaining acoustic and fire resistance performance.

[0070] Given the provision of a prefabricated wall panel having the wireway, internal walls can be assembled easily be an installation team, rather than being constructed on site. This reduces the time taken on site and the number of people required on site.

[0071] FIG. 4a shows the system with a panel installed. In the example shown, the system is installed between a floor 52 and a soffit 54. The panel 10 is aligned on a guide rail 60 installed on the floor 52. A deflection head rail profile 70 is used against which the panel 10 is installed.

[0072] FIG. 4b shows an internal wall with four panelsfront boards 12a, 12b and 12c form an internal wall surface. Panel 12b is shorter and allows for a service opening panel 60 to be installed. Typically panel 12a is installed, and where openings are required a shorter prefabricated panel 12b is formed and positioned, then a prefabricated opening panel 60 is installed. This panel 60 is formed to the correct size appropriate to services passing through with the gypsum based boards cut out 62. The next panel 12c can then be installed and the deflection head rail 70 is then installed at the head to secure all panels into position.

[0073] One or more cutaways 62 may then be made through said front board 60 and one or more cutouts can be made for backboxes in said wireways. As noted above, advantageously the cutaway is located solely within one channel. A backbox may then be installed within said cutaway, secured to the support rail. Services cabling may then be fed through the one channel to the backbox through an opening in a top portion of the front board, which may be made by the services installer.

[0074] FIG. 5 shows the lower section of the installed system of FIG. 3. The female profile of the side stud 28a is shown. Also shown is the guide rail 60. The guide rail has a substantially frustoconical or trapezoidal cross-section that runs along the length of the guide rail. This provides a protruding substantially trapezoidal (isosceles trapezoid) raised surface that is configured to be received within a correspondingly shaped recess in the base track 24.

[0075] FIG. 6a shows the corresponding top section of the installed system of FIG. 3. The panel is secured by deflection profile head rails 70a, 70b. The deflection profile head rails 70a, 70b provide rigidity to system and further add to the overall fire resistance of the system. The head rails 70a, 70b also act to provide acoustic sealing for the panels and the overall system. FIG. 6b shows a cross-section, with insulation provided within the cavity of the panel between the front and rear panels, and also above the panels behind the head rails 70a, 70b.

[0076] FIG. 7 shows an exploded view of the system as applied to a party wall 100. As shown, the party wall system is made from 2 party wall panels 100 and comprises front board 112a, 112b that form internal faces for adjacent walls on either side of the party wall system 100. The system 100 further comprises rear panels 114a, 114b. Given these are not providing a finished wall face to a room then these can be a lightweight material, such as cardboard liners 114a, 114b. The use of cardboard provides structural rigidity without the weight of gypsum or metal. The rear boards 114a, 114b and corresponding front board 112a, 112b for cavity panels as described above. In the party wall system there is further provided head tracks 122a, 122b and base tracks 124a, 124b. Corresponding side struts 126a, 128a, 126b, 128b are also shown.

[0077] In the party wall system shown, a wireway 130 is shown, together with steel support plates 142 and pattresses 144. These elements are only shown on one side of the party wallthe other side is a panel wall without such wireway.

[0078] As can be seen, the 2 party wall panels lie adjacent to each other on either side of an insulation slab 120 that sits between the two wall panels. The front boards face away from each other to form opposing internal walls. A mounting system 160 provided on floor 152 is used to mount the panels. An example is shown in FIG. 8. Similarly, deflection profiles 170a, 170b are also provided and are shown in more detail in FIG. 9.

[0079] FIG. 8 shows an exemplary mounting system 160 which in the present embodiment comprises two parallel guide rails 160a, 160b separated by an insulation slab 120. The slab may be rockwool insulation or the like. It can be appreciated that the guide rails 160a, 160b may be a unitary piecethis ensures that the rails are parallel and eases installation.

[0080] FIG. 9 shows a cross-section of the party wall system on FIG. 7 after installation (the centre of the system is omitted for clarity). For ease, only one panel is labelled, which in the example shown has two gypsum boards 112 forming the front board. In addition to the elements already described, there is provided a fire sealant 172, such as an intumescent sealant, in the gap between the base of the panel and the floor. This acts to resist fire and smoke ingress through the internal wall by, in the case of an intumescent sealant, expanding when heated to ensure no smoke ingress through the panels and through the party wall. The insulation slab 120 is fitted between the rear board cardboard liners 114 on the back of each panel. The cavity 178 of the panels are filled with acoustic damping material, such as Isover partition roll. This aids in sound proofing the room to prevent sound escape through the party wall.

[0081] In addition to the deflection profiles 170a, 170b, against which the panels are secured, is a central deflection profile 180. This acts to brace the panels and prevent them from moving inward when subject to a lateral force. Final parts of note include insulation 182 within the head strut and intumescent fireproof sealant 184 between the deflection profile 170a and the soffit and also between the floor and the guide rails 160 (on the side of the front board 112 at least) to again improve performance in case of fire.

[0082] The above described invention provides a prefabricated wall panel system for internal walls that allow walls to be constructed easily with panels interconnected. The system also includes a wireway that aids installation of services, in particular by constraining cabling in defined channels. In this way the cables are more easily fed through the wall panels from a supply in the ceiling to supply boxes at floor level without getting entangled or snagged within the panel. Furthermore, by having cabling within defined channels, the risk to service installers of later service cabling is reduced.

[0083] It can be appreciated that the various embodiments described above contain complimentary features that may be combined depending upon the need of the wall installer. Accordingly, the method and systems described herein therefore provide a way of installing an internal wall and a party wall using prefabricated pane Is.

[0084] From reading the present disclosure, other variations and modifications will be apparent to the skilled person. Such variations and modifications may involve equivalent and other features which are already known in the art of construction and which may be used instead of, or in addition to, features already described herein.

[0085] Although the appended claims are directed to particular combinations of features, it should be understood that the scope of the disclosure of the present invention also includes any novel feature or any novel combination of features disclosed herein either explicitly or implicitly or any generalisation thereof, whether or not it relates to the same invention as presently claimed in any claim and whether or not it mitigates any or all of the same technical problems as does the present invention.

[0086] Features which are described in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, various features which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination. The applicant hereby gives notice that new claims may be formulated to such features and/or combinations of such features during the prosecution of the present application or of any further application derived therefrom.

[0087] For the sake of completeness it is also stated that the term comprising does not exclude other elements or steps, the term a or an does not exclude a plurality, a single panel or other unit may fulfil the functions of several means recited in the claims and reference signs in the claims shall not be construed as limiting the scope of the claims.