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WO2020109871A1 - A prefabricated building system, a prefabricated wall panel and a prefabricated floor panel thereof - Google Patents

A prefabricated building system, a prefabricated wall panel and a prefabricated floor panel thereof Download PDF

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Publication number
WO2020109871A1
WO2020109871A1 PCT/IB2019/050508 IB2019050508W WO2020109871A1 WO 2020109871 A1 WO2020109871 A1 WO 2020109871A1 IB 2019050508 W IB2019050508 W IB 2019050508W WO 2020109871 A1 WO2020109871 A1 WO 2020109871A1
Authority
WO
WIPO (PCT)
Prior art keywords
prefabricated
frame
panel
wall panel
framing members
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/IB2019/050508
Other languages
French (fr)
Inventor
Chee Keong TEY
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Gibs Building Tech Pty Ltd
Original Assignee
Gibs Building Tech Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Gibs Building Tech Pty Ltd filed Critical Gibs Building Tech Pty Ltd
Publication of WO2020109871A1 publication Critical patent/WO2020109871A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
    • E04B1/6108—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
    • E04B1/612—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces
    • E04B1/6125—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with protrusions on the one frontal surface co-operating with recesses in the other frontal surface
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • E04B1/34315—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts
    • E04B1/34326—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts mainly constituted by longitudinal elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B1/2403—Connection details of the elongated load-supporting parts
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
    • E04B1/6108—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
    • E04B1/612—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces
    • E04B1/6125—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with protrusions on the one frontal surface co-operating with recesses in the other frontal surface
    • E04B1/6141—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with protrusions on the one frontal surface co-operating with recesses in the other frontal surface the connection made by an additional locking key
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/16—Load-carrying floor structures wholly or partly cast or similarly formed in situ
    • E04B5/32—Floor structures wholly cast in situ with or without form units or reinforcements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
    • E04C2/388—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a frame of other materials, e.g. fibres, plastics
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/78—Heat insulating elements
    • E04B1/80—Heat insulating elements slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B2001/2481—Details of wall panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B2001/2484—Details of floor panels or slabs
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2002/001—Mechanical features of panels
    • E04C2002/004—Panels with profiled edges, e.g. stepped, serrated
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
    • E04G21/14—Conveying or assembling building elements
    • E04G21/16—Tools or apparatus
    • E04G21/167—Tools or apparatus specially adapted for working-up plates, panels or slab shaped building elements

Definitions

  • This invention generally relates to a prefabricated building system and more particularly to a prefabricated building system having a cast-in formwork and a complementary interlocking and/or overlapping configurations for on-site rapid assembly yet strong sustainability.
  • Formwork is used as a temporary or permanent mould for the process of forming concrete or the like material in-situ.
  • the universal formwork built out of prefabricated modules is often used by the modern construction industry for walls, foundations, columns and slabs formation.
  • the permanent formwork which remains in place after concrete casting is preferred for the modern formwork as it offers minimal environmental impact of the construction process on the site.
  • prefabricated building is manufactured and constructed using prefabrication that consists of factory-made components or units that are transported and assembled on-site to form a complete building. Work is done at a remote location for increasing construction speed and quality while minimizing the amount of site work required. Hence, it has attracted much interest in the construction industry.
  • the major challenges that could possibly affect the application of prefabricated building are structural complexity, strength performance and lightweight materials.
  • Ul 2014701500 discloses a prefabricated lightweight concrete panel, wherein the panel comprises tongue and groove configuration for connecting and reinforcing the lightweight concrete panels.
  • the panel provides a ready-to-use concrete panel that is easily cast in a stay-in-place formwork.
  • US 3,604,174 discloses a lightweight structural panel that is fireproof and has good insulating properties.
  • the panel is a rectangular concrete slab bounded by or contained within a structural steel frame that is formed of angle or channel iron members. This frame serves as a form when the concrete is poured and as a convenient connecting means when the panel is being incorporated in a building.
  • a lightweight aggregate is used for the concrete which also contributes to the good insulating properties.
  • the rigid panel has a complex joining which render inefficient building construction.
  • CN203022215(U) discloses a bearing split mounting type light plate that uses integral foaming cement material as an inner core, and a frame body as a supporting skeleton for a strong supporting and bearing capability.
  • the integral foaming cement material is injected via the hole of the frame body.
  • the configuration has space limitation for assembly.
  • W01998050646 and CN202644824U disclose a sandwiched panel that comprises tongue and groove to facilitate the interconnection between the panels.
  • the actual assembly may have limitation particularly at the end joining point.
  • the strength of the panel may not strong due to the current configurations.
  • the structural building system comprises building panel with an interlocking system may also found in W02006095266, WO20131 51494, and US20020100242A1 .
  • W02006095266 discloses wall panel made of insulated material that is sandwiched between two sheets of fiber boards. While WO2013151494 and US20020100242A1 relate to locking means between panels for a firm joining between adjoining panels.
  • None of the aforementioned examples disclose a perfect end joining of the panels to form a complete unit, whereby the existing panels comprises an end joining that may be seen with brackets for coupling the unit to the frame structure, which render a poor finishing to the unit.
  • the panel configuration and material choice as infill and outer layers may affect the strength and sustainability of the panel.
  • At least preferred embodiments of the present invention provide a prefabricated building system that offers high flexibility for panels assembly. It would also be advantageous if at least preferred embodiments of the present invention provide a prefabricated building system which has perfect joining with concealed joints for a smooth appearance that is more aesthetically pleasing.
  • the present invention relates to a prefabricated building system, wherein the prefabricated building system comprising a frame structure having a plurality of beams and columns; a plurality of prefabricated panels including wall panels and floor panels; wherein each of the prefabricated panels comprising a plurality of framing members and a composite cast therein; the framing members of the prefabricated wall panels comprising a tongue frame, a groove frame or a L-profile frame for connecting the prefabricated panel to the adjacent panel or to the frame structure via a plurality of supplementary brackets; the framing members of the prefabricated floor panels comprising a L-like frame, an inverted L-like frame, or a C-profile side frame; wherein the plurality of supplementary brackets comprising a complementary profile for receiving the groove frame or the L-profile top frame of the framing member; whereby the framing members and the supplementary brackets are concealed within the prefabricated building system.
  • a prefabricated wall panel for a prefabricated building system comprises: a plurality of framing members as a formwork; a lightweight composite cast therein; characterized by the plurality of framing members comprising a tongue frame, a groove frame, or a L-profile frame for interconnecting means; wherein the lightweight composite comprising a coating layer on top and bottom surfaces to form the prefabricated wall panel.
  • a prefabricated floor panel for a prefabricated building system comprises: a plurality of framing members forming a structure as a formwork; a lightweight composite cast therein; characterized by: the plurality of framing members (310) comprising a L-like frame (312), an inverted L-like frame (313), or a C-profile side frame (314); the lightweight composite (120) comprising a coating layer (140) on top and bottom surfaces to form the prefabricated floor panel (300).
  • Fig. 1 is an exploded view of a prefabricated wall panel of an embodiment of the present invention
  • Fig. 2a illustrates a cross-sectional view of a prefabricated wall panel in accordance to an embodiment of the present invention
  • Fig. 2b illustrates the prefabricated wall panel having an internal frame therein
  • Fig. 2c illustrates the interconnecting joint of the tongue frame and groove frame of two adjacent prefabricated wall panels
  • Fig. 3 is a cross-sectional view of an erected prefabricated wall panel according to one of the preferred embodiments
  • Fig. 3a is an enlarged view of Fig. 3 illustrating the top installation of the prefabricated wall panel to a frame structure
  • Fig. 3b is an enlarged view of Fig. 3 illustrating the bottom installation of the prefabricated wall panel to a floor or a frame structure
  • Fig. 4a shows an installation of a T-shaped guide rail to a frame structure
  • Figs. 4b and Fig. 4c are two different views showing an installation at the side of the prefabricated wall panel to the T-shaped guide rail;
  • Figs. 5a and 5b are two different views showing an installation at the bottom of the prefabricated wall panel to the T-shaped guide rail;
  • Figs. 6a and 6b are two different views showing an installation at the top of the prefabricated wall panel to the frame structure by L-shaped mounting bracket;
  • Fig. 7 is a perspective view of a prefabricated floor panel of an embodiment of the present invention.
  • Fig. 8 illustrates a cross-sectional view of a prefabricated floor panel in accordance to an embodiment of the present invention
  • Fig. 9 illustrates the interconnection of a L-like frame and an inverted L-like frame of two adjacent prefabricated floor panels which form a lap joint;
  • Fig. 9a is an enlarged view of Fig, 10;
  • Fig. 10 illustrates a site installation where the frame structure is constructed;
  • Fig. 1 1 illustrates the installation of prefabricated floor panel on the frame structure;
  • Figs. 1 1 (a) - (c) further illustrate each connection of the end piece of prefabricated floor panel to the frame structure and the adjacent prefabricated floor panel;
  • Fig. 12 illustrates the installation of prefabricated floor panel on the frame structure
  • Figs. 12(a) - (d) further illustrate interconnection of the of prefabricated floor panels to the frame structure and the adjacent prefabricated floor panel;
  • Fig. 13 illustrates the floor screeding upon complete installation of the prefabricated floor panels
  • Fig. 14 is a cross-sectional view of the prefabricated floor panel with the floor screed as finishing. Detailed Description of the Invention
  • the words “include,” “including,” and “includes” mean including, but not limited to. Further, the words “a” or “an” mean “at least one” and the word “plurality” means one or more, unless otherwise mentioned. Where the abbreviations or technical terms are used, these indicate the commonly accepted meanings as known in the technical field.
  • the present invention relates to a prefabricated building system (100) which configured to have a combination of permanent cast-in formwork, interlocking features, and overlapping features, thereby giving a perfect finishing and flexibility while enable rapid assembly and good sustainability.
  • the prefabricated building system (100) of the present invention comprises of:
  • a frame structure (1 10) comprising a plurality of beams (1 12) and a plurality of columns (1 14);
  • each of the prefabricated wall panels (200) and prefabricated floor panels (300) comprising a plurality of framing members (210, 310) forming a panel structure and a lightweight composite (120) cast therein;
  • the plurality of framing members (210) of the prefabricated wall panels (200) comprising a tongue frame (212) and a groove frame (213) that form a joint for interconnecting the prefabricated wall panels (200), and the groove frame (213) and a L-profile frame (214) for interconnecting to the frame structure (1 10);
  • the plurality of framing members (310) of the prefabricated floor panels (300) comprising a L-like frame (312) and an inverted L-like frame (313) that form a lap joint for overlapping the prefabricated floor panels (300), and a C-profile side frame (314) as an end joint;
  • the plurality of prefabricated panels (200, 300) are configured to firmly interconnect or overlap with the adjacent prefabricated panels (200, 300) and the supplementary brackets (400) by inserting or laying; whereby the framing members (210, 310) and the supplementary brackets (400) are concealed within the prefabricated building system (100).
  • the lightweight composite (120) is a lightweight cement. Any equivalent materials such as lightweight aggregate concrete, foamed concrete or autoclaved aerated concrete for construction that possesses lightweight property may also use as the composite.
  • the lightweight cement can be obtained by any ways such as water extended, injection of gas for foamed cement, or by adding low-specific-gravity microspheres or other enhancing additives which are known in the construction industry.
  • the lightweight composite (120) is casted within the plurality of framing members (210, 310) that forms as a panel structure. As such, the prefabricated panels (200, 300) are light in weight to facilitate transportation of the prefabricated panels (200, 300) to the construction site.
  • the tongue frame (212) and the groove frame (213) form an interlocking joint between the prefabricated wall panels (200) during assembly, as seen in Fig. 2c.
  • the prefabricated wall panels (200) are erected to install on a floor or the frame structure (1 10) via the groove frame (213) on the bottom part and the L-profile frame (214) on the top part of the prefabricated wall panel (200), whereby the groove frame (213) and the L-profile frame (214) are interlocked with the respective supplementary brackets (400), as seen in Fig. 3, Fig. 3a and Fig. 3b.
  • the supplementary brackets (400) comprises a T-shaped guide rail (410) for receiving the prefabricated wall panel (200) at the groove frame (213) of the framing member (210).
  • the T-shaped guide rail (310) is mounted on a base such as floor or the frame structure (1 10) by fastening means (800).
  • the fastening means (800) can be any type of fasteners that use for building construction, particularly structure installation such as beam, column, frame and et cetera.
  • the fastening means (800) is a screw.
  • the T-shaped guide rail (410) is laid flat on the floor to form an inverted-T and is fastened with fastening means (800) on both sides of the T-shaped guide rail (410), leaving the T projection in upright position for receiving the bottom groove frame (213) of the prefabricated wall panel (200).
  • Said installation can be seen in Fig. 3 which shows the erected prefabricated wall panel (200) well installed on a base with the T-shaped guide rail (410).
  • Fig. 3c further illustrates the mounting of the prefabricated wall panel (200) to the T-shaped guide rail (410).
  • the first side installation of the prefabricated wall panel (200) comprises of coupling the T-shaped guide rail (410) on the frame structure (1 10), particularly the column (1 14), leaving the T projection in a right angle for receiving the side groove frame (213) of the prefabricated wall panel (200).
  • the supplementary brackets (400) comprises a L-shaped mounting bracket (420) for coupling the prefabricated wall panel (200) at the L-profile frame (214) to the frame structure (1 10), particularly the beam (1 12), as seen in Fig. 3.
  • the L-shaped mounting bracket (420) may be any L brackets that commonly used in the building construction, such as but not limited to L anchor bar.
  • the L-shaped mounting bracket (420) is mounted to the beam (1 12) or soffit of the building and the prefabricated wall panel (200) by any fastening means (800).
  • the L-shaped mounting bracket (420) may first mounts on the beam (1 12) of the frame structure (1 10) in a right angle, whereby the extended leg receives the L-profile frame (214) of the prefabricated wall panel (200) to complete the installation of the prefabricated wall panel (200), as shown in Fig. 3a.
  • the second side installation of the prefabricated wall panel (200) to the frame structure (1 10), particularly the column (1 14 comprises of mounting the L-shaped mounting bracket (420) to the column (1 14).
  • the L-shaped mounting bracket (420) is fastened to the L-profile frame (214) of the prefabricated wall panel (200) for completing the installation of wall unit.
  • the installation becomes easy and flexible without any space limitation for completion.
  • the joining is hidden by resting the L-profile frame (214) of the prefabricated wall panel (200) to the L-shaped mounting bracket (420), whereby both profiles are complementary to each other giving a perfect attachment and fixation.
  • the L-shaped mounting bracket (420) comprises a pair of extended legs having different lengths extended in a right angle.
  • the length differences offer a flexibility such as during mounting the prefabricated wall panel (200) at an uneven floor.
  • the floor unevenness may lead to a gap between the connection of the prefabricated wall panel (200) and the frame structure (1 10), whereby the L-shaped mounting bracket (420) may adjust accordingly by interchanging the extended legs to affix the connection.
  • the L-like frame (312) and inverted L-like frame (313) form a lap joint for overlapping the prefabricated floor panels (300) during assembly, as seen in Fig. 8 and Fig. 9.
  • the prefabricated floor panels (300) are laid on the frame structure (1 10), particularly on the beam (1 12), whereby the C-profile side frame (314) forms as a side end of the floor panels (300).
  • the prefabricated floor panels (300) may be connected by the fastening means (800).
  • the fastening means (800) may include but not limited to a spot welding or a screw. In a most preferred embodiment, the fastening means comprises a minimum length of 75mm.
  • a floor screed (160) is necessary as a floor finishing or to level a slightly uneven floor and smoothen the floor surface.
  • a concrete top up screeding with steel wire mesh laid therein is performed for flatness and levelness of the prefabricated floor panels (300), as depicted in Fig. 13 and Fig. 14.
  • the plurality of prefabricated wall panels (200) are interconnected via the tongue frame (212) and groove frame (213) to form a complete wall unit of the prefabricated building system (100), and the plurality of prefabricated floor panels (300) are overlapped via the L-like frame (312) and inverted L-like frame (313) to form a complete floor unit.
  • the plurality of prefabricated wall panels (200) and the plurality of floor panels (300) can be mass produced at the factory and transport to the site for installation. The prefabrication saves time and hassle free, yet assure quality and reduce manpower at the site.
  • the present invention further discloses a prefabricated wall panel (200) for the prefabricated building system (100).
  • the prefabricated wall panel (200) comprises of:
  • the plurality of framing members (210) comprising a tongue frame (212), a groove frame (213), or an L-profile frame (214) for connecting means;
  • the lightweight composite (120) comprising a coating layer (140) on top and bottom surfaces to form the prefabricated wall panel (200).
  • the lightweight composite (120) comprising a lightweight infill and the coating layer (140) comprising a concrete, cement fiber board, aluminium, timber, equivalent material that deemed fit or any combination thereof to form a sandwiched panel.
  • the coating layer (140) is replaceable with any construction material that deem practical and well fit the purpose and does not limit to the aforesaid options.
  • concrete is selected as the coating layer (230) as concrete is rigid and harder, thereby acting as a protecting layer to the lightweight infill from crack.
  • Figs. 2a-c illustrate the sandwiched panel having three layers with the lightweight composite (120) in between.
  • the prefabricated wall panel (200) further comprising a pair of corner beads (700) coupled to each of the framing members (210).
  • the pair of corner beads (700) are each welded to the top and bottom of the framing member (210) forming a frame on top and bottom of the prefabricated wall panel (210), thereby holding the coating layer (140) casted therein, particularly for any liquid form coating layer (140) such as but not limited to concrete in an exemplary embodiment, the concrete is casted within the bottom frame as a bottom coating layer (140), follow by casting the lightweight infill within the framing members (210) as formwork and lastly casting the concrete on top of the lightweight infill within the corner beads (700) as the top coating layer (140).
  • the coating layer (140) of the prefabricated wall panel (200) comprising a chamfer (220) for touch up joining, as seen in Fig. 2c.
  • Said chamfer (220) allows finishing on the wall panel with a smooth surface.
  • the prefabricated wall panel (200) further comprising an internal frame (215) mounted within the prefabricated wall panel (200).
  • the prefabricated wall panel (200) comprises a multiple internal frame (215) integrated with the framing members (210) and form within the lightweight composite, as showed in Fig. 1 .
  • the integration of internal frame (215) improves strength of the prefabricated wall panel (200).
  • the internal frame (215) may be a C-channel frame but not limited to other shapes or frame that well fit to the use.
  • the prefabricated wall panel (200) comprising a thickness of 10 mm of coating layer (140) and 102 mm of lightweight composite (120), wherein the chamfer (220) is 2.5 mm at the coating layer (140).
  • the chamfer (220) may forms at each sides of the coating layer (140) whenever deem necessary for touch up joining.
  • the present invention also discloses a prefabricated floor panel (300) for the prefabricated building system (100).
  • the prefabricated floor panel (300) comprises of:
  • the plurality of framing members (310) comprising a L-like frame (312), an inverted L-like frame (313), or a C-profile side frame (314);
  • the lightweight composite (120) comprising a coating layer (140) on top and bottom surfaces to form the prefabricated floor panel (300).
  • the lightweight composite (120) comprising a lightweight infill and the coating layer (140) is selected from concrete, cement fiber board, aluminium, timber, equivalent material that deemed fit or a combination thereof to form a sandwiched panel.
  • concrete is selected as the coating layers (140).
  • cement fiber board may be used as one of the coating layers (140), such as but not limited to top coating layer (140).
  • a combination of cement fiber board and concrete may be used to form the coating layer (140).
  • the coating layer (140) may be replaced with any construction material that deem practical and well fit to the purpose.
  • the prefabricated floor panel (300) comprising the lightweight composite (120) and the bottom coating layer (140) casted within the framing members (310).
  • the lightweight composite (120) and the bottom coating layer (140) are in equal thickness. More particularly, the lightweight composite (120) and the coating layer (140) each comprises 50 mm thickness within the framing members (310).
  • the top coating layer (140) is formed on top of the framing members (310).
  • the top coating layer (140) comprises 50 mm thickness of concrete or cement screed.
  • the top coating layer (140) comprises 6-9 mm thickness of cement fiber board.
  • the prefabricated floor panel (300) further comprises a mesh (600) embedded within each of the concrete coating layer (140).
  • the use of mesh (600) is eliminated if cement fiber board, aluminium or wood is selected as the coating layer (140).
  • the mesh (600) reinforce the coating layer (140), preferably liquid form of coating layer (140), to sustain higher load.
  • the mesh is preferably but not limited to, a steel wire mesh.
  • the framing member (210) comprises a pair of inverted legs (31 1 ) for holding the mesh (600) in place. The inverted legs (31 1 ) extended upright from the framing member (210).
  • the mesh (600) of the bottom coating layer (140) is held in place by the inverted leg (31 1 ) of the framing members (310); whereby the mesh (600) of the top coating layer (140) is laid on top of the framing members (310).
  • Fig. 7 illustrates the preferred embodiment of the prefabricated floor panel (300).
  • the method of installing the prefabricated wall panel (200) comprises the steps of: setting the frame structure (1 10) of the building; mounting the T-shaped guide rail (410) on a base; inserting the first prefabricated wall panel (200) having the groove frame (213) onto the T-shaped guide rail (410) at the base; mounting the T-shaped guide rail (410) on the column (1 14) and attaching the first prefabricated wall panel (200) to the T-shaped guide rail (410) at the column (1 14); mounting the first prefabricated wall panel (200) at the L-profile frame (214) to the beam (1 12) on top via a L-shaped mounting bracket (420) for installing the first prefabricated wall panel (200).
  • the installation of the prefabricated floor panel (300) may be performed before or after the installation of the prefabricated wall panel (200) upon setting of the building frame structure (1 10).
  • the method of installing the prefabricated floor panel (300) comprises the steps of: laying a first prefabricated floor panel (300) on the beam (1 12), subsequently laying a second prefabricated floor panel (300) on the first prefabricated floor panel (300), whereby the inverted L-like frame (313) of the second prefabricated floor panel (300) rest on the L-like frame (312) of the first prefabricated floor panel (300) to form a lap joint for overlapping.
  • the installation is repeated until the last piece of the prefabricated floor panel (300), wherein the side end of the prefabricated floor panels (300) having the C-profile side frame (314) forms a flat end.
  • a further disclosure of the present invention includes a method of producing the prefabricated panels (200, 300). The method comprises the steps of:
  • top coating layer (140) as a topping of the composite (120).
  • the method further comprising the step of welding the pair of corner beads (700) to the framing members (210) for forming the coating layer (140) therein, particularly liquid form coating layer (140), to form a prefabricated wall panel (200).
  • the method further comprising the step of resting the mesh (600) before forming the bottom coating layer (140) to form the prefabricated floor panel (300), whereby the bottom coating layer (140) is concrete or equivalent materials in liquid form.
  • the prefabricated building system (100) of the present invention provides flexibility and tolerance for installation. Particularly, the unique features and arrangement of the prefabricated panels (200, 300) ensures an efficient and quality installation, whereby the fabrication of panels are done in an off-site location and transported to the actual site for installation. While the lightweight cement offers a light weight panels to ease for transportation and installation. In addition, the structure of the building system is simple and easy to assemble, therefore reduces involvement of manpower and skilful labour.

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Abstract

A prefabricated building system (100) comprises: a frame structure (110) having a plurality of beams (112) and a plurality of columns (114); a plurality of prefabricated wall panels (200) and a plurality of floor panels (300); characterized in that each of the prefabricated wall panels (200) and prefabricated floor panels (300) comprising a plurality of framing members (210, 310) forming a panel structure, and a lightweight composite (120) cast therein; the framing members (210) of the prefabricated wall panels (200) comprising a tongue frame (212), a groove frame (213) or a L -profile frame (214); the framing members (310) of the prefabricated floor panel (300) comprising a L-like frame (312), an inverted L-like frame(313) or a C -profile side frame (314); a plurality of supplementary brackets (400); wherein the plurality of prefabricated panels (200, 300) are configured to interconnect or overlap by inserting or laying. The building system (100) provides a rapid assembly and concealed joints that offer a prefect installation. The construction of prefabricated wall panel (200) and prefabricated floor panel (300), including the method of producing the prefabricated panels (200, 300) also disclosed herein.

Description

A PREFABRICATED BUILDING SYSTEM, A PREFABRICATED WALL PANEL AND A PREFABRICATED FLOOR PANEL THEREOF
Technical Field
This invention generally relates to a prefabricated building system and more particularly to a prefabricated building system having a cast-in formwork and a complementary interlocking and/or overlapping configurations for on-site rapid assembly yet strong sustainability.
Background Art
Formwork is used as a temporary or permanent mould for the process of forming concrete or the like material in-situ. The universal formwork built out of prefabricated modules is often used by the modern construction industry for walls, foundations, columns and slabs formation. The permanent formwork which remains in place after concrete casting is preferred for the modern formwork as it offers minimal environmental impact of the construction process on the site.
Whilst prefabricated building is manufactured and constructed using prefabrication that consists of factory-made components or units that are transported and assembled on-site to form a complete building. Work is done at a remote location for increasing construction speed and quality while minimizing the amount of site work required. Hence, it has attracted much interest in the construction industry. The major challenges that could possibly affect the application of prefabricated building are structural complexity, strength performance and lightweight materials.
There are many efforts made in improving the quality of prefabricated building and overcoming the existing challenges, some of the examples are discussed below. Ul 2014701500 discloses a prefabricated lightweight concrete panel, wherein the panel comprises tongue and groove configuration for connecting and reinforcing the lightweight concrete panels. The panel provides a ready-to-use concrete panel that is easily cast in a stay-in-place formwork.
US 3,604,174 discloses a lightweight structural panel that is fireproof and has good insulating properties. The panel is a rectangular concrete slab bounded by or contained within a structural steel frame that is formed of angle or channel iron members. This frame serves as a form when the concrete is poured and as a convenient connecting means when the panel is being incorporated in a building. A lightweight aggregate is used for the concrete which also contributes to the good insulating properties. However, the rigid panel has a complex joining which render inefficient building construction.
CN203022215(U) discloses a bearing split mounting type light plate that uses integral foaming cement material as an inner core, and a frame body as a supporting skeleton for a strong supporting and bearing capability. The integral foaming cement material is injected via the hole of the frame body. The configuration has space limitation for assembly.
The other examples such as W01998050646 and CN202644824U disclose a sandwiched panel that comprises tongue and groove to facilitate the interconnection between the panels. However, the actual assembly may have limitation particularly at the end joining point. Furthermore, the strength of the panel may not strong due to the current configurations.
The structural building system comprises building panel with an interlocking system may also found in W02006095266, WO20131 51494, and US20020100242A1 . W02006095266 discloses wall panel made of insulated material that is sandwiched between two sheets of fiber boards. While WO2013151494 and US20020100242A1 relate to locking means between panels for a firm joining between adjoining panels.
None of the aforementioned examples disclose a perfect end joining of the panels to form a complete unit, whereby the existing panels comprises an end joining that may be seen with brackets for coupling the unit to the frame structure, which render a poor finishing to the unit. In addition, the panel configuration and material choice as infill and outer layers may affect the strength and sustainability of the panel.
Accordingly, it can be seen in the prior arts that there exists a need to provide a prefabricated building system that provides flexibility for assembly while meeting standard requirements in sustainability. There is also a need to provide a building panels that is easy to fabricate and less accessories required for installation.
Summary of the Invention
The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.
It would be advantageous if at least preferred embodiments of the present invention provide a prefabricated building system which comprises of a plurality of prefabricated panels having interconnecting joints.
It would also be advantageous if at least preferred embodiments of the present invention provide a prefabricated building system that offers high flexibility for panels assembly. It would also be advantageous if at least preferred embodiments of the present invention provide a prefabricated building system which has perfect joining with concealed joints for a smooth appearance that is more aesthetically pleasing.
It would also be advantageous if at least preferred embodiments of the present invention provide a prefabricated panel having a unique configuration for high sustainability and improved strength.
It would also be advantageous if at least preferred embodiments of the present invention provide a prefabricated building system with cast-in formwork as a permanent mould.
Such advantages may be achieved by following the teachings of the present invention. The present invention relates to a prefabricated building system, wherein the prefabricated building system comprising a frame structure having a plurality of beams and columns; a plurality of prefabricated panels including wall panels and floor panels; wherein each of the prefabricated panels comprising a plurality of framing members and a composite cast therein; the framing members of the prefabricated wall panels comprising a tongue frame, a groove frame or a L-profile frame for connecting the prefabricated panel to the adjacent panel or to the frame structure via a plurality of supplementary brackets; the framing members of the prefabricated floor panels comprising a L-like frame, an inverted L-like frame, or a C-profile side frame; wherein the plurality of supplementary brackets comprising a complementary profile for receiving the groove frame or the L-profile top frame of the framing member; whereby the framing members and the supplementary brackets are concealed within the prefabricated building system.
Also disclosed herein a prefabricated wall panel for a prefabricated building system, the prefabricated wall panel comprises: a plurality of framing members as a formwork; a lightweight composite cast therein; characterized by the plurality of framing members comprising a tongue frame, a groove frame, or a L-profile frame for interconnecting means; wherein the lightweight composite comprising a coating layer on top and bottom surfaces to form the prefabricated wall panel.
Further disclosed herein a prefabricated floor panel for a prefabricated building system, the prefabricated floor panel comprises: a plurality of framing members forming a structure as a formwork; a lightweight composite cast therein; characterized by: the plurality of framing members (310) comprising a L-like frame (312), an inverted L-like frame (313), or a C-profile side frame (314); the lightweight composite (120) comprising a coating layer (140) on top and bottom surfaces to form the prefabricated floor panel (300).
A method of producing the prefabricated wall panel (200) and the prefabricated floor panel (300) also disclosed herein.
Brief Description of the Drawings
The features of the invention will be more readily understood and appreciated from the following detailed description when read in conjunction with the accompanying drawings of the preferred embodiment of the present invention, in which:
Fig. 1 is an exploded view of a prefabricated wall panel of an embodiment of the present invention;
Fig. 2a illustrates a cross-sectional view of a prefabricated wall panel in accordance to an embodiment of the present invention;
Fig. 2b illustrates the prefabricated wall panel having an internal frame therein; Fig. 2c illustrates the interconnecting joint of the tongue frame and groove frame of two adjacent prefabricated wall panels;
Fig. 3 is a cross-sectional view of an erected prefabricated wall panel according to one of the preferred embodiments;
Fig. 3a is an enlarged view of Fig. 3 illustrating the top installation of the prefabricated wall panel to a frame structure; Fig. 3b is an enlarged view of Fig. 3 illustrating the bottom installation of the prefabricated wall panel to a floor or a frame structure;
Fig. 4a shows an installation of a T-shaped guide rail to a frame structure;
Figs. 4b and Fig. 4c are two different views showing an installation at the side of the prefabricated wall panel to the T-shaped guide rail;
Figs. 5a and 5b are two different views showing an installation at the bottom of the prefabricated wall panel to the T-shaped guide rail;
Figs. 6a and 6b are two different views showing an installation at the top of the prefabricated wall panel to the frame structure by L-shaped mounting bracket;
Fig. 7 is a perspective view of a prefabricated floor panel of an embodiment of the present invention;
Fig. 8 illustrates a cross-sectional view of a prefabricated floor panel in accordance to an embodiment of the present invention;
Fig. 9 illustrates the interconnection of a L-like frame and an inverted L-like frame of two adjacent prefabricated floor panels which form a lap joint;
Fig. 9a is an enlarged view of Fig, 10;
Fig. 10 illustrates a site installation where the frame structure is constructed; Fig. 1 1 illustrates the installation of prefabricated floor panel on the frame structure; Figs. 1 1 (a) - (c) further illustrate each connection of the end piece of prefabricated floor panel to the frame structure and the adjacent prefabricated floor panel;
Fig. 12 illustrates the installation of prefabricated floor panel on the frame structure;
Figs. 12(a) - (d) further illustrate interconnection of the of prefabricated floor panels to the frame structure and the adjacent prefabricated floor panel;
Fig. 13 illustrates the floor screeding upon complete installation of the prefabricated floor panels; and
Fig. 14 is a cross-sectional view of the prefabricated floor panel with the floor screed as finishing. Detailed Description of the Invention
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting but merely as a basis for claims. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents and alternatives falling within the scope of the present invention as defined by the appended claims. As used throughout this application, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words "include," "including," and "includes" mean including, but not limited to. Further, the words "a" or "an" mean "at least one” and the word "plurality" means one or more, unless otherwise mentioned. Where the abbreviations or technical terms are used, these indicate the commonly accepted meanings as known in the technical field.
The present invention is described hereinafter by various embodiments with reference to the accompanying drawing, wherein reference numerals used in the accompanying drawing correspond to the like elements throughout the description. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following detailed description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only, and are not intended to limit the scope of the claims. In addition, a number of materials are identified as suitable for various facets of the implementations. These materials are to be treated as exemplary, and are not intended to limit the scope of the invention. The present invention will now be described in details with reference to Figs.
1 -14.
The present invention relates to a prefabricated building system (100) which configured to have a combination of permanent cast-in formwork, interlocking features, and overlapping features, thereby giving a perfect finishing and flexibility while enable rapid assembly and good sustainability. The prefabricated building system (100) of the present invention comprises of:
a frame structure (1 10) comprising a plurality of beams (1 12) and a plurality of columns (1 14);
a plurality of prefabricated wall panels (200); and
a plurality of prefabricated floor panels (300);
characterized in that:
each of the prefabricated wall panels (200) and prefabricated floor panels (300) comprising a plurality of framing members (210, 310) forming a panel structure and a lightweight composite (120) cast therein;
the plurality of framing members (210) of the prefabricated wall panels (200) comprising a tongue frame (212) and a groove frame (213) that form a joint for interconnecting the prefabricated wall panels (200), and the groove frame (213) and a L-profile frame (214) for interconnecting to the frame structure (1 10);
the plurality of framing members (310) of the prefabricated floor panels (300) comprising a L-like frame (312) and an inverted L-like frame (313) that form a lap joint for overlapping the prefabricated floor panels (300), and a C-profile side frame (314) as an end joint;
a plurality of supplementary brackets (400), each comprising a complementary profile to the plurality of framing members (210) for engaging the framing members (210) of the prefabricated wall panels (200) to the frame structure (1 10);
wherein the plurality of prefabricated panels (200, 300) are configured to firmly interconnect or overlap with the adjacent prefabricated panels (200, 300) and the supplementary brackets (400) by inserting or laying; whereby the framing members (210, 310) and the supplementary brackets (400) are concealed within the prefabricated building system (100).
In accordance with an embodiment of the present invention, the lightweight composite (120) is a lightweight cement. Any equivalent materials such as lightweight aggregate concrete, foamed concrete or autoclaved aerated concrete for construction that possesses lightweight property may also use as the composite. The lightweight cement can be obtained by any ways such as water extended, injection of gas for foamed cement, or by adding low-specific-gravity microspheres or other enhancing additives which are known in the construction industry. The lightweight composite (120) is casted within the plurality of framing members (210, 310) that forms as a panel structure. As such, the prefabricated panels (200, 300) are light in weight to facilitate transportation of the prefabricated panels (200, 300) to the construction site.
In accordance with a preferred embodiment of the prefabricated wall panel (200), the tongue frame (212) and the groove frame (213) form an interlocking joint between the prefabricated wall panels (200) during assembly, as seen in Fig. 2c. The prefabricated wall panels (200) are erected to install on a floor or the frame structure (1 10) via the groove frame (213) on the bottom part and the L-profile frame (214) on the top part of the prefabricated wall panel (200), whereby the groove frame (213) and the L-profile frame (214) are interlocked with the respective supplementary brackets (400), as seen in Fig. 3, Fig. 3a and Fig. 3b.
In accordance with an embodiment of the present invention, the supplementary brackets (400) comprises a T-shaped guide rail (410) for receiving the prefabricated wall panel (200) at the groove frame (213) of the framing member (210). Preferably, the T-shaped guide rail (310) is mounted on a base such as floor or the frame structure (1 10) by fastening means (800). The fastening means (800) can be any type of fasteners that use for building construction, particularly structure installation such as beam, column, frame and et cetera. In an exemplary embodiment, the fastening means (800) is a screw. For bottom installation of the prefabricated wall panel (200), the T-shaped guide rail (410) is laid flat on the floor to form an inverted-T and is fastened with fastening means (800) on both sides of the T-shaped guide rail (410), leaving the T projection in upright position for receiving the bottom groove frame (213) of the prefabricated wall panel (200). Said installation can be seen in Fig. 3 which shows the erected prefabricated wall panel (200) well installed on a base with the T-shaped guide rail (410). Fig. 3c further illustrates the mounting of the prefabricated wall panel (200) to the T-shaped guide rail (410). Once the T-shaped guide rail (310) is securely screwed to the floor, the wall panel can be slowly lifted and rigged to its designated location.
Likewise, the first side installation of the prefabricated wall panel (200) comprises of coupling the T-shaped guide rail (410) on the frame structure (1 10), particularly the column (1 14), leaving the T projection in a right angle for receiving the side groove frame (213) of the prefabricated wall panel (200).
In accordance with an embodiment of the present invention, the supplementary brackets (400) comprises a L-shaped mounting bracket (420) for coupling the prefabricated wall panel (200) at the L-profile frame (214) to the frame structure (1 10), particularly the beam (1 12), as seen in Fig. 3. The L-shaped mounting bracket (420) may be any L brackets that commonly used in the building construction, such as but not limited to L anchor bar.
According to a preferred embodiment for top installation of the prefabricated wall panel (200), the L-shaped mounting bracket (420) is mounted to the beam (1 12) or soffit of the building and the prefabricated wall panel (200) by any fastening means (800). The L-shaped mounting bracket (420) may first mounts on the beam (1 12) of the frame structure (1 10) in a right angle, whereby the extended leg receives the L-profile frame (214) of the prefabricated wall panel (200) to complete the installation of the prefabricated wall panel (200), as shown in Fig. 3a. Likewise, the second side installation of the prefabricated wall panel (200) to the frame structure (1 10), particularly the column (1 14), comprises of mounting the L-shaped mounting bracket (420) to the column (1 14). Then, the L-shaped mounting bracket (420) is fastened to the L-profile frame (214) of the prefabricated wall panel (200) for completing the installation of wall unit. By having the L-profile frame (214) at the ending of the prefabricated wall panel (200), the installation becomes easy and flexible without any space limitation for completion. Furthermore, the joining is hidden by resting the L-profile frame (214) of the prefabricated wall panel (200) to the L-shaped mounting bracket (420), whereby both profiles are complementary to each other giving a perfect attachment and fixation.
In accordance to a more preferred embodiment, the L-shaped mounting bracket (420) comprises a pair of extended legs having different lengths extended in a right angle. The length differences offer a flexibility such as during mounting the prefabricated wall panel (200) at an uneven floor. Particularly, the floor unevenness may lead to a gap between the connection of the prefabricated wall panel (200) and the frame structure (1 10), whereby the L-shaped mounting bracket (420) may adjust accordingly by interchanging the extended legs to affix the connection.
In accordance with a preferred embodiment of the prefabricated floor panel (300), the L-like frame (312) and inverted L-like frame (313) form a lap joint for overlapping the prefabricated floor panels (300) during assembly, as seen in Fig. 8 and Fig. 9. The prefabricated floor panels (300) are laid on the frame structure (1 10), particularly on the beam (1 12), whereby the C-profile side frame (314) forms as a side end of the floor panels (300). In an embodiment, the prefabricated floor panels (300) may be connected by the fastening means (800). The fastening means (800) may include but not limited to a spot welding or a screw. In a most preferred embodiment, the fastening means comprises a minimum length of 75mm. Upon a complete installation of the prefabricated floor panels (300), it is commonly known in the construction industry that a floor screed (160) is necessary as a floor finishing or to level a slightly uneven floor and smoothen the floor surface. In an exemplary embodiment of the present invention, a concrete top up screeding with steel wire mesh laid therein is performed for flatness and levelness of the prefabricated floor panels (300), as depicted in Fig. 13 and Fig. 14.
In accordance with an embodiment of the present invention, the plurality of prefabricated wall panels (200) are interconnected via the tongue frame (212) and groove frame (213) to form a complete wall unit of the prefabricated building system (100), and the plurality of prefabricated floor panels (300) are overlapped via the L-like frame (312) and inverted L-like frame (313) to form a complete floor unit. Flence, the plurality of prefabricated wall panels (200) and the plurality of floor panels (300) can be mass produced at the factory and transport to the site for installation. The prefabrication saves time and hassle free, yet assure quality and reduce manpower at the site.
The present invention further discloses a prefabricated wall panel (200) for the prefabricated building system (100). The prefabricated wall panel (200) comprises of:
a plurality of framing members (210) forming a structure as a formwork; and a lightweight composite (120) cast therein;
characterized by
the plurality of framing members (210) comprising a tongue frame (212), a groove frame (213), or an L-profile frame (214) for connecting means;
wherein the lightweight composite (120) comprising a coating layer (140) on top and bottom surfaces to form the prefabricated wall panel (200).
In accordance with an embodiment of the prefabricated wall panel (200), the lightweight composite (120) comprising a lightweight infill and the coating layer (140) comprising a concrete, cement fiber board, aluminium, timber, equivalent material that deemed fit or any combination thereof to form a sandwiched panel. The coating layer (140) is replaceable with any construction material that deem practical and well fit the purpose and does not limit to the aforesaid options. In an exemplary embodiment, concrete is selected as the coating layer (230) as concrete is rigid and harder, thereby acting as a protecting layer to the lightweight infill from crack. Figs. 2a-c illustrate the sandwiched panel having three layers with the lightweight composite (120) in between.
In accordance with an embodiment of the present invention, the prefabricated wall panel (200) further comprising a pair of corner beads (700) coupled to each of the framing members (210). Preferably, the pair of corner beads (700) are each welded to the top and bottom of the framing member (210) forming a frame on top and bottom of the prefabricated wall panel (210), thereby holding the coating layer (140) casted therein, particularly for any liquid form coating layer (140) such as but not limited to concrete in an exemplary embodiment, the concrete is casted within the bottom frame as a bottom coating layer (140), follow by casting the lightweight infill within the framing members (210) as formwork and lastly casting the concrete on top of the lightweight infill within the corner beads (700) as the top coating layer (140).
In accordance with an embodiment of the present invention, the coating layer (140) of the prefabricated wall panel (200) comprising a chamfer (220) for touch up joining, as seen in Fig. 2c. Said chamfer (220) allows finishing on the wall panel with a smooth surface.
In accordance with an embodiment of the present invention, the prefabricated wall panel (200) further comprising an internal frame (215) mounted within the prefabricated wall panel (200). Preferably, the prefabricated wall panel (200) comprises a multiple internal frame (215) integrated with the framing members (210) and form within the lightweight composite, as showed in Fig. 1 . The integration of internal frame (215) improves strength of the prefabricated wall panel (200). The internal frame (215) may be a C-channel frame but not limited to other shapes or frame that well fit to the use.
In accordance with a preferred embodiment of the present invention, the prefabricated wall panel (200) comprising a thickness of 10 mm of coating layer (140) and 102 mm of lightweight composite (120), wherein the chamfer (220) is 2.5 mm at the coating layer (140). The chamfer (220) may forms at each sides of the coating layer (140) whenever deem necessary for touch up joining.
The present invention also discloses a prefabricated floor panel (300) for the prefabricated building system (100). The prefabricated floor panel (300) comprises of:
a plurality of framing members (310) forming a structure as a formwork; a lightweight composite (120) cast therein;
characterized by:
the plurality of framing members (310) comprising a L-like frame (312), an inverted L-like frame (313), or a C-profile side frame (314);
the lightweight composite (120) comprising a coating layer (140) on top and bottom surfaces to form the prefabricated floor panel (300).
In accordance with an embodiment of the prefabricated floor panel (300), the lightweight composite (120) comprising a lightweight infill and the coating layer (140) is selected from concrete, cement fiber board, aluminium, timber, equivalent material that deemed fit or a combination thereof to form a sandwiched panel. In one of the embodiments, concrete is selected as the coating layers (140). Alternatively, cement fiber board may be used as one of the coating layers (140), such as but not limited to top coating layer (140). In a further embodiment, a combination of cement fiber board and concrete may be used to form the coating layer (140). The coating layer (140) may be replaced with any construction material that deem practical and well fit to the purpose.
In a preferred embodiment, the prefabricated floor panel (300) comprising the lightweight composite (120) and the bottom coating layer (140) casted within the framing members (310). The lightweight composite (120) and the bottom coating layer (140) are in equal thickness. More particularly, the lightweight composite (120) and the coating layer (140) each comprises 50 mm thickness within the framing members (310).
In accordance with an embodiment of the present invention, the top coating layer (140) is formed on top of the framing members (310). In an exemplary embodiment, the top coating layer (140) comprises 50 mm thickness of concrete or cement screed. In another exemplary embodiment, the top coating layer (140) comprises 6-9 mm thickness of cement fiber board.
In accordance with an embodiment of the present invention, the prefabricated floor panel (300) further comprises a mesh (600) embedded within each of the concrete coating layer (140). The use of mesh (600) is eliminated if cement fiber board, aluminium or wood is selected as the coating layer (140). The mesh (600) reinforce the coating layer (140), preferably liquid form of coating layer (140), to sustain higher load. The mesh is preferably but not limited to, a steel wire mesh. In a further embodiment, the framing member (210) comprises a pair of inverted legs (31 1 ) for holding the mesh (600) in place. The inverted legs (31 1 ) extended upright from the framing member (210). Preferably, the mesh (600) of the bottom coating layer (140) is held in place by the inverted leg (31 1 ) of the framing members (310); whereby the mesh (600) of the top coating layer (140) is laid on top of the framing members (310). Fig. 7 illustrates the preferred embodiment of the prefabricated floor panel (300).
Accordingly, a method of installing the prefabricated building system (100) of the present invention is disclosed herein. The method of installing the prefabricated wall panel (200) comprises the steps of: setting the frame structure (1 10) of the building; mounting the T-shaped guide rail (410) on a base; inserting the first prefabricated wall panel (200) having the groove frame (213) onto the T-shaped guide rail (410) at the base; mounting the T-shaped guide rail (410) on the column (1 14) and attaching the first prefabricated wall panel (200) to the T-shaped guide rail (410) at the column (1 14); mounting the first prefabricated wall panel (200) at the L-profile frame (214) to the beam (1 12) on top via a L-shaped mounting bracket (420) for installing the first prefabricated wall panel (200). Subsequently, inserting the second prefabricated wall panel (200) onto the T-shaped guide rail (410) at the base and interconnecting the groove frame (213) of the second prefabricated wall panel (200) with the tongue frame (212) of the first prefabricated wall panel (200); mounting the L-shaped mounting bracket (420) on the beam (1 12) and attaching the top of the second prefabricated wall panel (200) having the L-profile frame (214) to the L-shaped mounting bracket (420) for installing the second prefabricated wall panel (200); repeating the installation until a last piece of prefabricated wall panel (200) is interconnected to form the wall unit; whereby the installation of the unit is completed by mounting the L-shaped mounting bracket (420) to the L-profile frame (214) of the last prefabricated wall panel (200) and the column (1 14).
The installation of the prefabricated floor panel (300) may be performed before or after the installation of the prefabricated wall panel (200) upon setting of the building frame structure (1 10). The method of installing the prefabricated floor panel (300) comprises the steps of: laying a first prefabricated floor panel (300) on the beam (1 12), subsequently laying a second prefabricated floor panel (300) on the first prefabricated floor panel (300), whereby the inverted L-like frame (313) of the second prefabricated floor panel (300) rest on the L-like frame (312) of the first prefabricated floor panel (300) to form a lap joint for overlapping. The installation is repeated until the last piece of the prefabricated floor panel (300), wherein the side end of the prefabricated floor panels (300) having the C-profile side frame (314) forms a flat end.
A further disclosure of the present invention includes a method of producing the prefabricated panels (200, 300). The method comprises the steps of:
coupling the framing members (210) to form a structure as a formwork; forming the bottom coating layer (140) as a base; pouring the lightweight composite (120) within the frame structure on top of the bottom coating layer (140);
forming the top coating layer (140) as a topping of the composite (120).
In accordance with the method of producing the prefabricated panels (200, 300), the method further comprising the step of welding the pair of corner beads (700) to the framing members (210) for forming the coating layer (140) therein, particularly liquid form coating layer (140), to form a prefabricated wall panel (200).
In accordance with the method of producing the prefabricated panels (200, 300), the method further comprising the step of resting the mesh (600) before forming the bottom coating layer (140) to form the prefabricated floor panel (300), whereby the bottom coating layer (140) is concrete or equivalent materials in liquid form.
The prefabricated building system (100) of the present invention provides flexibility and tolerance for installation. Particularly, the unique features and arrangement of the prefabricated panels (200, 300) ensures an efficient and quality installation, whereby the fabrication of panels are done in an off-site location and transported to the actual site for installation. While the lightweight cement offers a light weight panels to ease for transportation and installation. In addition, the structure of the building system is simple and easy to assemble, therefore reduces involvement of manpower and skilful labour.
The exemplary implementation described above is illustrated with specific shapes, dimensions, and other characteristics, but the scope of the invention includes various other shapes, dimensions, and characteristics.
Various modifications to these embodiments are apparent to those skilled in the art from the description and the accompanying drawings. The principles associated with the various embodiments described herein may be applied to other embodiments. Therefore, the description is not intended to be limited to the embodiments shown along with the accompanying drawings but is to be providing broadest scope of consistent with the principles and the novel and inventive features disclosed or suggested herein. Accordingly, the invention is anticipated to hold on to all other such alternatives, modifications, and variations that fall within the scope of the present invention and appended claim.
It is to be understood that any prior art publication referred to herein does not constitute an admission that the publication forms part of the common general knowledge in the art.
In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word“comprise” or variations such as“comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
Description of the reference numerals used in the accompanying drawings according to the present invention:
Figure imgf000021_0001

Claims

CLAIMS:
1. A prefabricated building system (100) comprising:
a frame structure (110) comprising a plurality of beams (1 12) and a plurality of columns (114);
a plurality of prefabricated wall panels (200); and
a plurality of prefabricated floor panels (300);
characterized in that
each of the prefabricated wall panels (200) and prefabricated floor panels (300) comprising a plurality of framing members (210, 310) forming a panel structure and a lightweight composite (120) cast therein;
the plurality of framing members (210) of the prefabricated wall panels (200) comprising a tongue frame (212) and a groove frame (213) that form a joint for interconnecting the prefabricated wall panels (200), and the groove frame (213) and a L-profile frame (214) for interconnecting to the frame structure (1 10);
the plurality of framing members (310) of the prefabricated floor panels (300) comprising a L-like frame (312) and an inverted L-like frame (313) that form a lap joint for overlapping the prefabricated floor panels (300), and a C-profile side frame (314) as an end joint;
a plurality of supplementary brackets (400), each comprising a complementary profile to the plurality of framing members (210) for engaging the framing members (210) of the prefabricated wall panels (200) to the frame structure (1 10);
wherein the plurality of prefabricated panels (200, 300) are configured to firmly interconnect and/or overlap with the adjacent prefabricated panels (200, 300) and the supplementary brackets (400) by inserting or laying;
whereby the framing members (210, 310) and the supplementary brackets (400) are concealed within the prefabricated building system (100).
2. The prefabricated building system (100) as claimed in claim 1 , wherein the supplementary brackets (400) comprising a T-shaped guide rail (410) for receiving the prefabricated wall panel (200) at the groove frame (213).
3. The prefabricated building system (100) as claimed in claim 2, wherein the T-shaped guide rail (410) is mounted on a base or the column (1 14) of the frame structure (1 10) by fastening means (800).
4. The prefabricated building system (100) as claimed in claim 1 , wherein the supplementary brackets (400) comprising a L-shaped mounting bracket (420) for coupling the prefabricated wall panel (200) at the L-profile frame (214) to the beam (1 12) or the column (1 14) of the frame structure (1 10).
5. The prefabricated building system (100) as claimed in claim 4, wherein the L-shaped mounting bracket (420) is mounted to the frame structure (1 10) and the prefabricated wall panel (200) by fastening means. (800)
6. The prefabricated building system (100) as claimed in claim 1 , wherein the plurality of prefabricated wall panels (200) are interconnected via the tongue frame (212) and groove frame (213) to form a wall unit of the prefabricated building system (100).
7. The prefabricated building system (100) as claimed in claim 1 , wherein the plurality of prefabricated floor panels (300) are interconnected via the L-like frame (312) and the inverted L-like frame (313) to form a floor unit of the prefabricated building system (100).
8. A prefabricated wall panel (200) comprising:
a plurality of framing members (210) forming a structure as a formwork; and
a lightweight composite (120) cast therein;
characterized by: the plurality of framing members (210) comprising a tongue frame (212), a groove frame (213) or a L-profile frame (214);
the lightweight composite (120) comprising a coating layer (140) on top and bottom surfaces to form the prefabricated wall panel (200).
9. The prefabricated wall panel (200) as claimed in claim 8, wherein the coating layers (140) are selected from cement fiber board, concrete, aluminium, timber or a combination thereof to form a sandwiched panel.
10. The prefabricated wall panel (200) as claimed in claim 8, wherein the prefabricated wall panel (200) further comprising a pair of corner beads (700) coupled to each of the framing members (210).
1 1. The prefabricated wall panel (200) as claimed in claim 10, wherein the pair of corner beads (700) are welded to top and bottom of the framing member (210) forming a frame on top and bottom of the prefabricated wall panel (210).
12. The prefabricated wall panel (200) as claimed in claim 9 and claim 1 1 , wherein the concrete coating layer (140) is formed within the frame.
13. The prefabricated wall panel (200) as claimed in claim 8, wherein the prefabricated wall panel (200) comprising a chamfer (220) at the coating layer (140) for touch up joining.
14. The prefabricated wall panel (200) as claimed in claim 8, wherein the prefabricated wall panel (200) further comprising an internal frame (215) mounted within the prefabricated wall panel (200).
15. A prefabricated floor panel (300) comprising:
a plurality of framing members (310) forming a structure as a formwork;
a lightweight composite (120) cast therein; characterized by:
the plurality of framing members (310) comprising a L-like frame (312), an inverted L-like frame (313), or a C-profile side frame (314);
the lightweight composite (120) comprising a coating layer (140) on top and bottom surfaces to form the prefabricated floor panel (300).
16. The prefabricated floor panel (300) as claimed in claim 15, wherein the coating layers (140) are selected from concrete, cement fiber board, aluminium, timber or a combination thereof to form a sandwiched panel.
17. The prefabricated floor panel (300) as claimed in claim 15, wherein the bottom coating layer (140) is formed within the framing members (310).
18. The prefabricated floor panel (300) as claimed in claim 15 and claim 17, wherein the lightweight composite (120) and the bottom coating layer (140) are in equal thickness.
19. The prefabricated floor panel (300) as claimed in claim 15, wherein the top coating layer (140) is formed on top of the framing members (310).
20. The prefabricated floor panel (300) as claimed in claim 15, wherein each of the framing members (310) comprising a pair of inverted legs (311 ).
21. The prefabricated floor panel (300) as claimed in claim 15 and claim 16, wherein the prefabricated floor panel (300) further comprising a mesh (600) embedded within each of the concrete coating layer (140).
22. The prefabricated floor panel (300) as claimed in claim 20 and claim 21 , wherein the mesh (600) of the bottom coating layer (140) is held in place by the inverted leg (31 1 ) of the framing members (310).
23. The prefabricated floor panel (300) as claimed in claim 16, claim 20 and claim 21 , wherein the mesh (600) of the top concrete coating layer (140) is laid on top of the framing members (310).
24. A method of producing the prefabricated wall panel (200) and prefabricated floor panel (300), the method comprising the steps of:
coupling the framing members (210, 310) to form a structure as a formwork;
forming the bottom coating layer (140) as a base;
pouring the lightweight composite (120) within the frame structure on top of the bottom coating layer (140);
forming the top coating layer (140) as a topping of the composite
(120).
25. The method as claimed in claim 24, wherein the method further comprising of welding the pair of corner bead (700) to each of the framing members (210) for forming the concrete coating layer (140) therein to form a prefabricated wall panel (200).
26. The method as claimed in claim 24, wherein the method further comprising the step of resting the mesh (600) before forming the bottom concrete coating layer (140) to form the prefabricated floor panel (300).
PCT/IB2019/050508 2018-11-27 2019-01-22 A prefabricated building system, a prefabricated wall panel and a prefabricated floor panel thereof Ceased WO2020109871A1 (en)

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