A PREFABRICATED PANEL BUILDING SYSTEM

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.

Claims

1. 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 adapted to receive 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 having complementary profiles wherein opposite edge members of abutting panels are joined to form integrated studs and/or cross members of the frame.

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

3. The system of claim 1 wherein the top and bottom portions of the panel 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 against and on top of each other.

4. The system of claim 1 wherein there are edge members on all sides of the panel.

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

6. The system of claim 1, wherein one or more panels 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.

7. The system of claim 1, wherein the panel includes: an inner wall 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 external cladding of prefinished metal coil skin.

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

10. The system of claim 1, wherein the panels are fabricated or manufactured on site in a moveable or relocatable factory or plant from raw and component materials.

11. The system of claim 1, 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 1, wherein there are passages along 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 or water pipes.

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

14. The system of claim 1, wherein the interlocked edge members are permanently joined together by rivets or screws.

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

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

17. The system of claim 1, wherein 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.

18. The system of claim 1, wherein the edge members comprising an integrated stud are aluminum extrusions incorporating a tongue profile and a groove profile wherein the tongues and grooves are serrated to lock the panels when pushed and clipped together.

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

20. The system of claim 1, wherein the edge members are channels provided with a connecting groove and a flange

21. The system of claim 1, wherein a thermal-protective layer is provided with a hole.

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

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 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 required.

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 requisite acoustic, thermal and fire ratings.

28. A method of building using panels of the system according to claim 1 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 ( to join together further panels as required.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0052] In order that the invention is better understood and able to be put into practice, reference is made to the accompanying drawings wherein:

[0053] FIG. 1 is a preferred prefabricated panel used in the building system of the invention.

[0054] FIG. 2 shows detail of the top portions of adjacent panels of FIG. 1.

[0055] FIG. 3 shows detail of a pair of complementary serrated longitudinal edge members.

[0056] FIG. 4 shows a panel which includes a window frame and a door frame as structural components of the panel.

[0057] FIG. 5 shows detail of a preferred thermal break fillet strip according to the invention.

[0058] FIG. 6 shows detail of buttons of an anti-friction material whereby the panels are able to be slid.

DETAILED DESCRIPTION OF EMBODIMENTS

[0059] As shown in the following drawings, the invention aims to provide a novel and versatile prefabricated panel building system characterized by fast installation, rapid construction, high fire resistance, high weight capacity, high cost performance and good sound insulation when compared to the prior art. The present invention comprises a plurality of wallboard panels joined together. Each panel 10 as typically shown in FIG. 1 includes specially adapted interlocking edge members 12,14 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 substantial rigidity and integrity to the erected structure.

[0060] The preferred panel includes an inner waif decoration layer, a fiber calcium silicate board, a thermal-protective layer and an external wallboard 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 hoard 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 (not shown) whereby adjacent panels are able to be slid into position against each other.

[0061] FIG. 2 shows partial detail of adjacent panels 16, 18 about to be joined by clipping together their respective complementary serrated longitudinal edge members 12, 14.

[0062] 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 or buttons of an anti-friction material such as Teflon may be used.

[0063] FIG. 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 profile 26a wherein the grooves are serrated to lock the panels (not 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 for 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, trunkings or other ornaments. Their use to attach removable wall cladding panels also makes the panel system more versatile.

[0064] FIG. 4 shows panels 32, 34 which includes a window 36 and a door 38 as structural components of panels 32, 34 which 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 moveable or re-locatable factory or plant from raw and component materials. Openings can therefore be cut into the panels and prefabricated windows and doorways from suppliers installed on site thereby eliminating the need for separate window frame and door joinery.

[0065] FIG. 5 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 preferably of a magnesium oxide and fiber glass construction which is affixed by mastic based adhesive over the intersecting edge members.

[0066] FIG. 6 shows 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 shown) into position against and on top of other panels.

[0067] It will be apparent to the skilled addressee that, in addition to the embodiments mentioned above, other equivalent technical solutions are also within the scope of the invention.