WO2024261754A1

WO2024261754A1 - Industrial panel for cladding

Info

Publication number: WO2024261754A1
Application number: PCT/IL2024/050598
Authority: WO
Inventors: Doron GESHURI
Original assignee: Prima Advanced Building Solution Ltd
Current assignee: Prima Advanced Building Solution Ltd
Priority date: 2023-06-20
Filing date: 2024-06-19
Publication date: 2024-12-26
Anticipated expiration: 2025-12-20
Also published as: IL303897B2; IL303897B1; IL303897A

Abstract

The present invention relates to the construction of a skeleton of a building using ready-made panels having a decoration on their outer side and vertical and horizontal anchors on their inner side. The panels serve as the external mold of the building and also as the decoration of the building.

Description

INDUSTRIAL PANEL FOR CLADDING

FIELD OF THE INVENTION

[Para 1 ] The present invention relates to the construction site, and more particularly, to constructing a skeleton of a building without using an external mold and the panels serving also as the external mold and decoration of the structure.

5

BACKGROUND OF THE INVENTION AND PRIOR ART

[Para 2] There are several main methods for building the skeleton of a residential building:

[Para 3] The conventional method - constructing the skeleton and then0 cladding/finishing works, using a scaffolding system on the outside walls.

The molds are a simple metal frame that allows contractors to adjust its dimensions and is reusable (can be used, very easily, in many different projects), the duration of the project is longer. Good opacity ability. External insulation can be incorporated. 5 [Para 4] The industrialized method on site - while casting the building's skeleton, the cladding system is integrated and prevents prolonged cladding works and significant loss of time.

[Para 5] The molds used to build the project are "custom" made for each project individually. This method has a lot of drawbacks. [Para 6] The method requires an organizing area for arranging and installing stone in a mold. There is no control over the planarity of the stone mold. This method is designed for usage with small panels (slabs) only.

[Para 7] There is a high risk of slabs breaking off and falling. Low-quality castings may prevent concrete from reaching around the anchors and fix them.

[Para 8] Low opacity, water penetration into the building occurs mainly due to the settling of water in those areas of "low-quality casting". Inability to release water vapors and slow seepage into the apartment. Many interspaces between the panels, meaning areas with a high chance of water penetration.

[Para 9] Most of the material that constitutes the finishing of the building is natural stone. Low range of options for use and constitutes a large environmental nuisance (quarries in sensitive areas). External insulation cannot be incorporated.

[Para 10] Prefabricated construction - casting of the foundations of the building on site and construction of walls in the factory with a readymade cladding system on top. The method shortens the amount of work in constructing the skeleton and therefore shortening the project time. This method also has a lot of drawbacks.

[Para 1 1] The walls are constructive and bear force of the building's weights.

Low quality sealing capability. The need to trust simple site workers to assemble all parts of the sealing details and not miss out. The flatness of the walls is compromised due to poor installation and external insulation cannot be incorporated. Also mainly using natural stone.

[Para 12] In the new system hereunder introduced, when casting the skeleton, the cladding system integrates large size panels, thus gaining a lot of work time, avoiding casing and scaffolding installations.

[Para 13] The panel serves as an external mold and comes ready in its dimensions for the project (like the conventional method).

[Para 14] The dimensions of the panels are large in size therefore allowing a variety of architectural possibilities that are usually possible only in high- budget buildings.

[Para 15] High quality sealing ability, minimum interspaces/joints which decrease the chance of water penetration and gives confidence in panel fixation.

[Para 16] The use of large dimensions "floor to ceiling" panels creates a better grip and connection between all the anchors on the back of the panel, even in the event of casting failure, due to low quality concrete.

[Para 17] There is no need for a large organizing area. The panels are immediately placed in the center of the floor upon delivery to the site, for assembly.

[Para 18] To control the homogeneity surface level of the panels, there is a "Plug and lock" mechanisms confirming consecutiveness of the panels and having visual ability to diagnose malfunctions even before casting the wall. [Para 19] Further advantages of the method are, being a green construction, ability to combine external insulation, reducing the energy consumption of the building, and using an industrialized product that can be recycled thus preventing environmental waste.

[Para 20] The main raw materials come from quarries whose location does not constitute a major environmental nuisance.

[Para 21] The panels are not part of the constructive static calculations of the building. The system shortens the project times by integration project time between the casting process, the skeleton, and the assembling of the cladding works.

SUMMARY OF THE INVENTION

[Para 22] A system for constructing a skeleton of a building using panels with thickness of at least 2-5 cm serving also as the external mold and decoration of the structure, comprising: vertical profile anchors comprising screw points being scattered throughout the breadth of the panels; connection screws; horizontal profiles having a U shape mounted on and fixed to an anchor; a profile having an L shape and at least two grooves, placed at the bottom and at the top of each panel and fixed to it at least in four points; another element attached to each panel with several screws; bended perforated metal angles and other metal angles.

[Para 23] In one embodiment, the vertical anchors are attached to the panel by being submerged into a notch carved into the panel along the anchor . The notch may be filled with a suitable filling material with or without epoxy, obtaining a full contact area between the anchor and the panel.

[Para 24] In another embodiment, the vertical profile anchors, having a U shape, are scattered throughout the breadth of the panel, and are fixed to the panel on the flat side of the anchor with connection screws mounted inside the U shape.

[Para 25] The grooves serve as a fixation and stopper for placing the next panel in line, creating a continuous horizontal building joint and a uniform plane between the two meeting panels.

[Para 26] An element seals the vertical joint that connects two plates and the profile seals the horizontal joint connecting the panel at the bottom with a sealing strip between the profile and the concrete floor.

[Para 27] The perforated metal sheet is reinforced by welding an extra metal angle to the panels in the corners.

BRIEF DESCRIPTION OF THE FIGURES

[Para 28] Fig. 1 shows a schematic outside view of a two-story building. Panels 100 on one of elevation facade in the structure.

[Para 29] Fig. 2 shows a general schematic overview of the system according to one embodiment, presenting the inner side of panels 100 and the binding and supporting system between two panels 100.

[Para 30] Fig. 3A-3E show the parts of an anchor system according to one embodiment as mounted on panel 100. [Para 31] Fig. 4 shows a general schematic overview of the system according to another embodiment.

[Para 32] Fig. 5A-5B show the parts of an anchor according to another embodiment as mounted on panel 100.

[Para 33] Fig. 6 shows a detailed section of the special connection screws 1 50.

[Para 34] Fig. 7 shows the use of a continuity mechanism for the panels to ensure the continuity of connection (horizontal seam(joint)) between the panels and the entire building.

[Para 35] Fig. 8 - shows the use of a leveling and opacity mechanism between panels throughout the building (vertical seam(joint)).

[Para 36] Fig. 9 - shows how the system maintains opacity in the vertical and horizontal seams (joints).

[Para 37] Fig. 10 - shows a corner accessory for internal concealing of the fixation between two meeting panels.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[Para 38] An embodiment is an example or implementation of the inventions. The various appearances of "one embodiment," "an embodiment" or "some embodiments" do not necessarily all refer to the same embodiments. Although various features of the invention may be described in the context of a single embodiment, the features may also be provided separately or in any suitable combination. Conversely, although the invention may be described herein in the context of separate embodiments for clarity, the invention may also be implemented in a single embodiment.

[Para 39] Reference in the specification to "one embodiment", "an embodiment", "some embodiments" or "other embodiments" means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least one embodiment, but not necessarily all embodiments, of the inventions. It is understood that the phraseology and terminology employed herein is not to be construed as limiting and are for descriptive purpose only.

[Para 40] The present invention discloses a system of constructing a skeleton of building (hereinafter "skeleton") without using external molds but using panels 100 serving also as the external decoration of the structure (see fig. l ).

[Para 41] The system comprises panels 100 with thickness of at least 2-5 cm, serving as an external mold and can withstand the loads of the construction and casting process of the skeleton.

[Para 42] In one embodiment of the system, (as shown in figs.2 & fig. 3), panel 100 comprises vertical profile anchors 1 20 (hereinafter "first anchors 120"), being scattered throughout the breadth of panel 100 for a continuous grip of entire panell 00. To connect first anchors 1 20 to panel 100, a notch 180 of at least 2-5cm is cut along panel 100 and first anchorl 20 is immersed into the slot. [Para 43] For fixing first anchors 1 20 to panel 100 as shown in fig. 3A special connection screws 1 50 are used (see fig. 3B & fig. 6). Notch 180 may be filled with a suitable filling material with or without epoxy 1 70, thus obtaining a full contact area between first anchor 120 and panel 100. In order to avoid confusion, all profiles 1 20 shown in fig. 3 are designated with a U cross-section, even if it is not clearly shown.

[Para 44] In another embodiment of the system, (as shown in figs.4 & fig. 5), panel 100 comprises second anchors 200 having a U shape (hereinafter "second anchors 200"), being scattered throughout the breadth of panel 100 for a continuous grip of the entire panell OO. As shown in fig. 5B, anchors 200 is attached to panel 100 with its flat side and special connection screws 1 50 are mounted inside the U shape 200a, as shown in fig 4, thus obtaining a full contact area between second anchor 200 and panel 100.

[Para 45] In fig. 6 first Anchor 1 20 & second anchor 200 comprise screw points 160 for connecting horizontal profilesl 10. Horizontal profilesl 10 having a U shape are mounted on and fixed to first anchor 1 20 & second anchor 200. Horizontal profilel 10 passes through inner side of panel 100 (Fig. 2).To avoid misunderstanding, fig. 6 shows no casting.

[Para 46] In every system of building, temporary rods 210 are used when assembling and casting the skeleton construction for stabilizing the skeleton before actual building or casting. The combination of First anchor 1 20 and/or second anchor 200 can distribute the efforts to panel 100 and the screw points 160 attaching horizontal profiles! 10, enable the use of a minimum number of temporary rod 210 when assembling and casting the skeleton construction.

[Para 47] Profiles 1 30 having an L shape and at least two grooves 140, are placed at the bottom and at the top of panel 100. Profile 1 30 is fixed to panel 100 in four points.

[Para 48] Grooves 140a/b serve only as a fixation and stopper for placing the next panel in line creating a continuous horizontal building joint and a uniform plane between the two meeting panelsl OO.

[Para 49] As shown in Figure 7, the system uses a plug and lock mechanism for continuous connection of panels 100 one on top of the other. When panels 100 are brought to the construction site, they are installed directly from the transport truck on the previous installed panels 100, using the "plug and lock" mechanisms in grooves 140. This saves operations on the construction site. As may be seen in fig. 4, groove 140b on the upper side of the panels are the entry of the next panel from above (see ' ' and signs in fig. 7 showing the entry points of upper and lower panels using the "plug and lock" mechanisms. The horizontal lower profile 1 30 is connected by several screws to panel 100 and several screws to a concrete floor. Profile 1 10 has nothing to do with the connection between panels.

[Para 50] As may be seen in fig. 8 and fig. 9 at the vertical joint between panels 100, on their inner side, a sealing strip 240 is mounted glued or screwed between panels 100 on the back side. Sealing strip 240 is added for hermetically sealing the two panels.

[Para 51 ] The sealing strip 240 is of a certain thickness for the entire panell 00 and may be attached to each panel 100 with several screws, thus maintaining a uniform plane, fixation, and opacity between panels 100 when they are installed.

[Para 52] The lower profile 1 30 is connected by several screws to panel 100 and several screws to the concrete floor.

[Para 53] The system provides a solution for connecting panels 100 in the corners by using metal sheet 250, where there is the highest load accumulation when casting skeletal walls, and an extra metal angle 260 is reinforced by welding to a bended perforated metal sheet 250 (where each two panels 100 meet in one corner) (see fig 9),

[Para 54] Other goals of the disclosed invention are to present a system that:

1 . Includes an anchor connecting to panel 100 and allowing load distribution to the entire building.

2. Uses same anchor to fix a concealed accessory on the back of the panel, connecting the concealed profiles by using minimal connections.

3. Uses a continuity mechanism for panelsl OO for continually connecting the panels to the building.

4. Uses a leveling mechanism for panels 100 throughout the building for uniform plane.

5. Maintains opacity in the vertical and horizontal seams(joints). 6. A corner accessory (stiffener) for internal fixation at the meeting point of two panels.

Claims

Claims:

1 . A system for constructing a skeleton of a building comprising;

• panels with thickness of at least 2-5 cm comprising an external mold serving also as the outer decoration of the building;

• first anchors 120 scattered throughout the breadth of panel 100; wherein first anchors 1 20 are attached to panel 100 with screws

1 50 being partially submerged into notch 1 80, and; wherein notch 1 80 is filled with filling material 1 70, obtaining a full contact area between first anchors 120 and panel 100; and

• second anchors 200 having a U shape are scattered throughout the breadth of panel 100, and attached to panel 100 on their flat side by connection screws 160, obtaining a full contact area between second anchors 200 and panel 100;

• horizontal profiles 1 10 are scattered throughout the length of panel 100 having a U shape and mounted on and fixed to first anchors 1 20 or to second anchors 200 by screws;

• L shape profiles 1 30 having at least two groovesl 40 are fixed on the bottom and on the top of each panel 100;

• the skeleton is built by mounting each panel 100 on top of the previous panel 100 attaching the top profile 1 30 of one panel 100 to the bottom profile 1 30 of the next panel 100 through grooves 140 by a "plug and lock" mechanism;

• A sealing strip 240 is glued, screwed or both along the back side of any two panels 100 in their meeting point for complete opacity; • The bottom of the panels is sealed to a floor with profile 1 30 and perforated metal sheet 250, reinforced by welding an extra metal angle 260.

2. The system of claim 1 wherein grooves 140 serve as a fixation and stopper for placing panels 100 in line, creating a continuous horizontal building joint and a uniform plane between the two meeting panels.

3. The system of claim 1 wherein sealing strip 240 connects two panels

100 on their vertical side.