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WO2023146388A1 - An industrialised building system wall panel system - Google Patents

An industrialised building system wall panel system Download PDF

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Publication number
WO2023146388A1
WO2023146388A1 PCT/MY2023/050002 MY2023050002W WO2023146388A1 WO 2023146388 A1 WO2023146388 A1 WO 2023146388A1 MY 2023050002 W MY2023050002 W MY 2023050002W WO 2023146388 A1 WO2023146388 A1 WO 2023146388A1
Authority
WO
WIPO (PCT)
Prior art keywords
wall panel
profile
panel system
female
male
Prior art date
Application number
PCT/MY2023/050002
Other languages
French (fr)
Inventor
Tze Nen CHUA
Original Assignee
Chua Tze Nen
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 Chua Tze Nen filed Critical Chua Tze Nen
Publication of WO2023146388A1 publication Critical patent/WO2023146388A1/en

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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
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/74—Removable non-load-bearing partitions; Partitions with a free upper edge
    • E04B2/7407—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts
    • E04B2/7448—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts with separate framed panels without intermediary posts, extending from floor to ceiling
    • E04B2/7451—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts with separate framed panels without intermediary posts, extending from floor to ceiling with false tongue joints
    • 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
    • E04C2/34—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 composed of two or more spaced sheet-like parts
    • E04C2/36—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 composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
    • E04C2/365—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 composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels by honeycomb structures
    • 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
    • E04B1/541—Joints substantially without separate connecting elements, e.g. jointing by inter-engagement
    • 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
    • E04B1/7608—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 comprising a prefabricated insulating layer, disposed between two other layers or 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
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • 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
    • E04C2/384—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 metal frame
    • 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
    • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
    • E04C2/46—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose specially adapted for making walls
    • 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
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2002/0202—Details of connections
    • E04B2002/0204—Non-undercut connections, e.g. tongue and groove connections
    • 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
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2002/0202—Details of connections
    • E04B2002/0204—Non-undercut connections, e.g. tongue and groove connections
    • E04B2002/023—Non-undercut connections, e.g. tongue and groove connections with rabbets, e.g. stepped
    • 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
    • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
    • E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits

Definitions

  • This invention relates to building constructions. More particularly, the invention concerns a wall panel system in building constructions with an Industrialised Building System (IBS).
  • IBS Industrialised Building System
  • US Patent No. 9, 115, 504 B2 discloses a system for modular building construction that comprises interconnectible prefabricated modular volumetric units, each of the unit having a steel frame shaped as a rectangular parallelepiped and comprised of framing members and a plurality of nodes, each node situated at a corner of the frame for selective interconnection with other units.
  • the issue of structural strength versus weight or eco- friendly insulation have not been considered in the design of the prefabricated modular units of this prior US patent.
  • US Patent No. US 3, 683, 100 A discloses a modular wall and ceiling system that comprises a modular system of interchangeable and demountable solid wall panels.
  • the wall panels are connectable to and detachable from a ceiling grid system.
  • this prior US patent discloses connectors that enable the panels to be placed in position or moved to different locations on the ceiling grid to form the desired floor plan arrangement of rooms, halls, alcoves and the like.
  • the modularity of the wall system of this prior US patent hinges on its detachable connectivity with a ceiling grid system. This raises the cost of construction and is undesirably limiting in the construction of an Industrialised Building System.
  • the modular wall system of this prior US patent also does not consider the issue of structural strength versus weight or eco-friendly insulation.
  • US Patent No. 7, 993, 719 B2 discloses an assembled structure of a sandwich panel and a connecting member attached together by way of an adhesive. Specifically, it discloses two fiber reinforced resin sheets sandwiching a core material. The side wall portions of the panel can be connected to rails.
  • the fiber reinforced resin sheets have disadvantages such as low mechanical strength. Further, the design of components made from fiber reinforced resin is complex and the manufacturing and testing of such components is highly specialized.
  • the core material comprises pultruded fiber reinforced plastic which is commonly known as fiber reinforced polymer.
  • the sandwich panel of this prior US patent does not provide for insulation much less eco-friendly insulation.
  • US Patent No. 7, 964, 272 B2 discloses lightweight compositions that comprises a lightweight cementitious (LWC) composition set in the form of concrete masonry units (CMUs), construction articles, pre-cast/pre-stressed construction articles, construction panels, or roadbeds.
  • LWC lightweight cementitious
  • CMUs concrete masonry units
  • the LWC units of this prior US patent were not designed with interconnectibility, design adaptability nor ease of construction, in mind.
  • This invention thus aims to alleviate some or all of the problems of the prior art.
  • an Industrialised Building System wall panel system comprising: a plurality of wall panels, whereby each of the wall panel comprises: at least two sheathing boards; a porous material sandwiched between the sheathing boards; an expandable adhesive material surrounding the porous material; and a frame that surrounds and defines the mating edges of the wall panel; wherein each mating edge is provided with a suitable male or female connecting profile, such that a wall panel frame edge with a male profile can be removably mated with a wall panel frame edge having a corresponding female profile during assembly of the wall panel system.
  • the present invention seeks to provide a strong, lightweight and modular wall panel system that eases the assembly process of the wall panel system of an Industrialised Building System (IBS).
  • IBS Industrialised Building System
  • the object of this invention is to revolutionize the construction of walls in building construction industry with an IBS lightweight sandwich wall panel system (IBSLSWPS) that is uniquely designed to fit each member with precision while requiring the use of minimum adhesives to securely join them together to form a permanent wall structure or even a temporary wall.
  • IBSLSWPS IBS lightweight sandwich wall panel system
  • a sandwich layout panel offers huge advantages over a solid composite panel. This is mainly because sandwich panels offer a higher strength-to-weight ratio than solid composite laminates.
  • the wall panel comprises two sheathing boards and a porous material sandwiched between the sheathing boards (i.e. a sandwich layout wall panel).
  • a thick solid panel will be stiffer, but it might not be lightweight.
  • a sandwich layout panel offers a solution to that problem. When a panel bends, the outermost layers take a majority of the load. Both major faces of the panel will experience stress with one in compression and one in tension. However, the center of a bending panel sees a minimal to no stress at all. The center layers of a panel do not contribute much in absorbing stress, and, hence, can be eliminated and replaced with a porous material such as foam or a suitable honeycomb-shaped structure.
  • the present invention relates to building constructions and, more particularly, to wall construction in IBS constructions with a lightweight sandwich wall panel system.
  • the main embodiment mainly comprises several wall panels connected to each other via correspondingly profiled mating edges. This allows the wall panels to be modular.
  • the sheathing boards are made of fiber boards. [0021] In another embodiment, the sheathing boards are made of compressed mineral fiber boards.
  • each wall panel comprises multiple sheathing boards to form the wall panel.
  • the porous material has a honeycomb-shaped structure.
  • a honeycomb-shaped structure is a high-strength but lightweight structure that enables efficient mechanical performance. It is an excellent alternative to monolithic materials like solid aluminum, wood and steel, and as well as panels with traditional core materials such as plywood, balsa, and foam.
  • Honeycomb-shaped structure can be used in many situations that require elevated core shear, compression, and adhesion performance. Due to the nature of a honeycomb-shaped structure, it requires less material to manufacture, hence, resulting in a general weight reduction relative to conventional solid single sheet material. The stiffness of a honeycomb-shaped structure increases exponentially against its weight, which makes its strength to weight ratio higher compared to a single sheet material.
  • honeycomb-shape structure can result in a dramatic increase in stiffness with very little weight gain.
  • the pores or air pocket in the honeycomb-shaped structure also creates an insulation for the wall panel.
  • the porous material is made of either fiberglass, fire retarded paper or aluminum or any equivalent type of material.
  • the expandable materials are made of polyurethane foam.
  • Polyurethane is regarded as an affordable, versatile, durable, excellent insulator, and a safe way of reducing carbon emissions that contribute to global warming. Thus, it offers many solutions to the challenges of energy conservation and eco-design.
  • Polyurethane has insulation properties that can dramatically reduce heat loss in homes and offices in cold weather. During the summer months, it plays an important role in keeping buildings cool, which means air conditioning is needed less and therefore reduces harmful impact on the environment.
  • Use of an expandable adhesive material surrounding the porous material core reinforces the structure of the IBS wall panel of this invention while maintaining its lightweight and high strength properties. Additionally, this unique design of the core (expandable adhesive material surrounding a porous material) in one embodiment of the wall panel of this invention enables the application of energy-efficient insulation without compromise as to the mechanical strength or adding to the weight of the panel itself.
  • the mating edges of the wall panel have homogenous connecting profiles where all the mating edges have female connecting profiles or all the mating edges have male connecting profiles.
  • the mating edges of the wall panel have heterogenous connecting profiles where the mating edges can be: i) Three sides male profiles and one side female profile ii) Two sides male profiles and two sides female profiles iii) One side male profile and three sides female profiles
  • the male and female connecting profiles are tongue and groove profiles, respectively.
  • These male and female profiles mating edges provide modularity to the wall panels.
  • the user may determine the number of wall panels to be used in a wall panel system depending on the overall size requirement of the wall to be assembled.
  • a wall panel frame edge with a female connecting profile is mated with a capping profile to create a flush surface effect.
  • a female connecting profile is installed backwards onto a wall panel, such that its groove portion is concealed to create a flush surface effect.
  • the wall panel frame edge further comprises openings for accommodating utility items such as electrical utility wires, gas pipes, water pipes and cables and the like.
  • the wall panel system further comprises a railing, the wall panels being slidable along the railing to form a series of wall panels. More than one unit of railing can be affixed together.
  • the railing further comprises openings for accommodating utility items such as electrical utility wires, gas pipes, water pipes, cables and the like.
  • the railing may further comprise at least one hump for reducing friction when wall panels are slid along the railing.
  • an IBS wall panel comprises: at least two sheathing boards; a porous material sandwiched between the sheathing boards; an expandable adhesive material surrounding the porous material; and a frame that surrounds and defines the mating edges of the wall panel; wherein each mating edge is provided with a suitable male or female connecting profile, such that a wall panel frame edge with a male profile can be removably mated with a wall panel frame edge having a corresponding female profile during assembly of the wall panel system.
  • an IBS wall panel system comprising: a plurality of wall panels, whereby each of the wall panel comprises: at least two sheathing boards; an expandable adhesive material sandwiched between the sheathing boards; and a frame that surrounds and defines the mating edges of the wall panel; wherein each mating edge is provided with a suitable male or female connecting profile, such that a wall panel frame edge with a male profile can be removably mated with a wall panel frame edge having a corresponding female profile during assembly of the wall panel system.
  • an IBS wall panel comprising: at least two sheathing boards; an expandable adhesive material sandwiched between the sheathing boards; and a frame that surrounds and defines the mating edges of the wall panel; wherein each mating edge is provided with a suitable male or female connecting profile, such that a wall panel frame edge with a male profile can be removably mated with a wall panel frame edge having a corresponding female profile during assembly of the wall panel system.
  • Figure 1 illustrates a perspective view of an embodiment of a wall panel system.
  • Figure 2 illustrates a second perspective view of the embodiment of Figure 1.
  • Figure 3 illustrates the cross-sectional view of a female profile mating edge.
  • Figure 4 illustrates the cross-sectional view of a male profile mating edge.
  • Figure 5 illustrates the cross-sectional view of the connection between a female profile mating edge and a male profile mating edge.
  • Figure 6 illustrates the cross-sectional view of a capping profile mating edge which is similar with the female profile mating edge.
  • Figure 7 illustrates the cross-sectional view of the connection between a female profile mating edge and a capping profile mating edge.
  • Figure 8 illustrates the cross-sectional view of a railing.
  • Figure 9A illustrates the cross-sectional view of a railing
  • Figure 9B illustrates a cross- sectional view of a grating clamp
  • Figure 9C illustrates a railing anchored to a surface using a sleeve anchor bolt
  • Figure 9D illustrates two railings bolted back-to-back.
  • Figure 10 illustrates the side view of the alignment of a single wall panel on a railing before assembly.
  • Figure 11 illustrates the side view of a single wall panel assembled onto a railing.
  • Figure 12 illustrates the cross-sectional view of the connection between a female profile mating edge and a railing.
  • Figure 13 illustrates an embodiment of an assembled wall panel system with an empty slot for installation of a window frame.
  • Figure 14 illustrates a disassembled view of the embodiment of Figure 13.
  • Figure 15 illustrates an embodiment of an assembled wall panel system with an empty slot for installation of a door frame.
  • Figure 16 illustrates a disassembled view of the embodiment of Figure 15.
  • Figure 17 illustrates the mating edges and railing having openings to accommodate utility services.
  • Figure 18 illustrates the cross-sectional view of the assembly of wall panels on each side of the railings that are bolted back-to-back.
  • Figure 19 illustrates an embodiment of an assembled wall panel system with a two- level wall panel system assembly.
  • Figure 20 illustrates an embodiment of two series of wall panels assembled to form a corner.
  • Figure 21 illustrates a fully assembled cubicle with window and door using the corner forming method shown in Figure 20.
  • Figure 22 illustrates a female profile mating edge installed such that the groove portion is concealed.
  • Figure 23 illustrates a disassembled view of the embodiment of Figure 22.
  • Figure 24 illustrates the top view of the embodiment of Figure 23.
  • Figure 25 illustrates an example of the corner forming method of Figure 20 having a female profile mating edge installed as per Figure 22.
  • Figure 26 illustrates a disassembled view of the example of Figure 25.
  • Figure 27A illustrates a front view of a fully assembled two-level panel system
  • Figure 27B illustrates a front view of a disassembled two-level panel system.
  • Figure 28A illustrates another front view of a fully assembled two-level panel system and Figure 28B illustrates another front view of a disassembled two-level panel system.
  • Figure 29 illustrates a perspective view of another embodiment of a wall panel.
  • Figure 30 illustrates a two-dimensional view of the embodiment of Figure 29. DETAILED DESCRIPTION OF THE EMBODIMENTS
  • the industrialised building system wall panel system of this invention mainly comprises: a plurality of wall panels 1.
  • Each of the wall panel 1 can generally be of different sizes and comprises: at least two sheathing boards 2, a porous material layer 3 sandwiched between the sheathing boards 2, an expandable adhesive material 4 surrounding the porous material 3, and a frame 5 that surrounds and defines the mating edges of the wall panel 1.
  • One of the sheathing boards 2 is firstly attached to the frame 5 using a suitable adhesive such as epoxy.
  • the porous material layer 3 is then attached to the sheathing board 2 and enclosed within the frame 5.
  • another sheathing board 2 is attached on the other side of the porous material layer 3, enclosing the porous material layer within, and forming a sandwich layout wall panel 1.
  • the expandable adhesive material 4 is injected into the sandwich layout wall panel 1 filling in any gaps within the sandwich layout wall panel 1 and reinforcing the joint between the sheathing boards 2, the frame 5 and the porous material layer 3.
  • Each mating edge of the frame 5 is provided with a suitable male 5c or female 5a connecting profile, such that a wall panel frame edge with a male profile 5c can be removably mated with a wall panel frame edge having a corresponding female profile 5a during assembly of the wall panel system.
  • Figure 1 illustrates a wall panel 1 that comprises a pair of sheathing boards 2, a porous material layer 3, expandable adhesive material 4 enclosing the porous material layer 3, and a frame 5.
  • each of the sheathing boards 2 can be compressed mineral fiber boards.
  • the sheathing boards can be of any suitable shape.
  • the sheathing board 2 is a rectangular shaped board having a range of length of between 100 to 5000 mm, a range of width between 100 to 5000 mm, a range of thickness of between 3 to 25 mm and a range of density of between 800 to 1500 kg/m 3 .
  • the length, width, thickness and density of each board is generally dependent on the structural requirements of the wall to be formed from the wall panels of this invention.
  • each mineral fiber board 2 has a length of 2400 mm, a width of 600 mm, a thickness of 12 mm and a density of 1000 kg/m 3 .
  • the porous material layer 3 is suitably a lightweight material and its pores can be of any shape.
  • the porous material can be made of fiber glass, fire retarded paper or aluminum or any equivalent type of material.
  • the porous material layer 3 has a honeycomb-shaped structure.
  • the porous material layer 3 can be rectangular and have a range of length of between 50 to 5000 mm, a range of width between 50 to 5000 mm, and a range of thickness of between 12 to 300 mm.
  • the honeycomb-shaped structure layer 3 has a height of 2232 mm, a width of 450 mm and a thickness of 76 mm.
  • the porous material layer 3 (core of the wall panel) functions like the vertical element of an I-shaped Beam (or I-Beam), and the major faces/surface of the wall panel 1 are akin to the flanges of an I-Beam, working together to create a high shear strength structure. Similar to an I-beam, the greater the distance between the pair of sheathing boards 2 creates a higher overall strength for the wall panel 1, which reduces the risk of tensile failure, buckling failure and shear failure of the wall panel 1.
  • the expandable adhesive material 4 can be any suitable material and is preferably, a polyurethane foam material.
  • the polyurethane foam material used can be a closed cell or opened cell polyurethane foam.
  • the polyurethane foam material 4 is applied so as to fully enclose the porous material layer 3 and forms a secure bond around the edges of the porous material layer 3.
  • the expandable adhesive material 4 acts as an adhesive to securely join the porous material layer 3, sheathing boards 2 and the frame 5 together and further strengthens and reinforces the wall panel 1.
  • the frame 5 that surrounds the wall panel and defines its mating edges can be made of suitable materials such as fiber glass, plastic or metal. Preferably, the frame is made of metal.
  • the frame is a quadrilateral with each side defining a mating edge. Each mating edge is suitably profiled as either a male 5c or female 5a profile that enables removable connection between wall panels.
  • a wall panel 1 of this invention comprises: at least two sheathing boards 2, an expandable adhesive material 4 sandwiched between the sheathing boards 2, and a frame 5 that surrounds and defines the mating edges of the wall panel 1. This embodiment is particularly advantageous when the wall panel 1 of the invention is used for construction in environments where greater heat insulation is required as it enables the application of a higher volume of expandable adhesive material 4 between the sheathing boards 2.
  • a wall panel 1 of this invention is not limited to having only a pair of sheathing boards 2. Multiple layers of sheathing boards 2 can be arranged and stacked on top of each other on both opposing sides to form a new wall panel. On each opposing side of the new wall panel, the multiple layers of sheathing boards 2 are joined to each successive sheathing boards by way of suitable adhesives such as epoxy, glue or any other equivalent adhesive materials.
  • Figure 2 illustrates a perspective view of a disassembled wall panel 1 of this invention.
  • Figure 3 shows a general cross-sectional profile of a female profile mating edge 5a of the frame.
  • This female profile mating edge 5a is a groove profile mating edge that has a groove width matching the combined thickness of the porous material layer 3 enclosed within the expandable adhesive material 4 of the wall panel.
  • the female profile mating edge 5a has a thickness of 0.4 mm and ranges between 0.2 to 1.5 mm.
  • each wall panel comprises four mating edges.
  • This female profile mating edge 5a of a wall panel 1 can removably mate or connect with a male profile mating edge 5c of another wall panel 1.
  • the mating connection between two mating edges of adjacent wall panels establishes a removable connection assembly between wall panels 1 to form a series of wall panels.
  • the mating edges of the wall panel 1 can be either a female profile mating edge 5a or a male profile mating edge 5c.
  • Figure 4 shows a general cross-sectional profile of a male profile mating edge 5c.
  • This male profile mating edge 5c is also a tongue profile mating edge.
  • the male profile mating edge 5c has a thickness of 0.4 mm and ranges between 0.2 to 1.5 mm.
  • This male profile mating edge 5c can form a mating connection with a female profile mating edge 5a to establish a removable connection assembly between two adjacent wall panels 1.
  • Figure 5 shows the connectivity between a male profile mating edge 5c and a female profile mating edge 5a.
  • the wall panels 1 are removably connected to each other by way of the corresponding-shaped mating between the male profile 5c and the female profile 5a mating edges 5.
  • the first wall panel 1 with a male profile 5c is connected and secured to a second wall panel 1 with a female profile 5a.
  • the subsequent wall panels 1 can be joined in the same manner and secured to other wall panels 1 to form a wall panel system.
  • the mating edges 5 hold an entire series of wall panels 1 together during assembly and provides precise fitting when joining the wall panels 1. This minimizes the need for adhesives to connect adjacent wall panels 1 together.
  • additional adhesive may be used to reinforce the connections between the wall panels 1.
  • Screws can also be used instead of adhesive to reinforce such connections between adjacent panels.
  • screws are meant for creating a temporary connection between the wall panels, for example, when the wall panel 1 of this invention is used to create a temporary wall panel system.
  • the temporary wall panel system is easily disassembled by having the user unscrew the screws securing the connections between the successive wall panels 1 when it is no longer in use. Once disassembled, the wall panels can be easily relocated and reassembled for other applications.
  • each wall panel 1 can have different combinations of male and female profile mating edges. The precise combination is dependent on end-use assembly requirements. The following are the possible combinations of male and female profile mating edges of a wall panel 1 of this invention. i) Four sides of male profiles 5c ii) Four sides of female profiles 5a iii) Any three sides of male profiles 5c and remaining one of side female profile 5a iv) Any two sides of male profiles 5c and remaining two sides of female profiles 5a v) Any one side of male profile 5c and remaining three sides of female profiles 5a [0089]
  • An example of the different combinations of the types of mating edges 5 is a first wall panel 1 comprising four sides of female profile mating edges 5a, a second wall panel 1 that will be connected to the right side of the first wall panel which has at least one male profile mating edge 5c so that it can be securely joined with the female profile mating edge 5a of the first wall panel 1.
  • Figure 6 shows a general cross-sectional profile of a capping profile mating edge 5b.
  • This capping profile mating edge 5b has a smaller profile than the female profile mating edge 5a.
  • the capping profile mating edge 5b can be fitted together with a female profile mating edge 5a to create a flush surface.
  • adhesive such as epoxy can be used to be applied on the surface between the female profile mating edge 5a and the capping profile 5b to reinforce the joint.
  • Figure 7 illustrates how a capping profile mating edge 5b is used to fit in an opposite facing direction into a female profile mating edge 5a, such that they are in a groove-meets- groove position. By doing so, it creates a flush and flat surface wall panel edge.
  • the flush and flat edge is used to accommodate the installation of other building structures such as a window frame 10, a door frame 11 or the like.
  • Figure 8 shows a general cross-sectional profile of a railing 6.
  • the railing 6 is a uniquely designed profile track that can be used to guide the alignment and to accommodate the assembly of the plurality of wall panels 1.
  • the wall panels 1 are slidable along the railing 6 to form a series of wall panels 1.
  • the railing 6 is provided to anchor the assembly of the wall panels 1 to permanent fixtures such as a floor, wall or ceiling, as show in Figure 9C, or to an existing wall panel 1 using a sleeve anchor bolt 7 and grating clamp 8.
  • the wall panel system of this invention can be directly fixed to existing floor, wall, ceiling fixtures or the like that have a suitable profile for accommodating either the male or female mating edges 5a, 5b, 5c of the wall panel 1.
  • the railing 6 has a thickness of between 0.2 to 2 mm and can be of any length necessary to accommodate the series of wall panels.
  • Each railing 6 can optionally be provided with at least one hump 6a to reduce friction between the railing 6 and the female profile mating edge 5a when a wall panel 1 is being slid along the railing 6.
  • Figure 9D illustrates two railings 6 that are bolted back-to-back using a sleeve anchor bolt 7 and a nut, and two grating clamps 8.
  • the series of joined railings 6 are further used as a form of support for the wall panel system, such as a stiffener, a beam and a column.
  • the joined railings 6 are able to accommodate the installation of a series of wall panels by sliding the wall panels 1 along the joined railings 6.
  • Figures 10 and 11 illustrate how the wall panel 1 is joined to the railing 6.
  • the wall panel 1 is slidable onto the railing 6.
  • the mating edges 5 on the wall panels 1 provide connectivity between the wall panels 1 and the railing 6.
  • the side of the wall panel 1 that is intended to be slid onto the railing 6 must be of a female profile mating edge 5a.
  • the female profile 5a of the wall panel 1 engages with the railing 6 to form a secure connection as seen in Figure 11.
  • Figure 12 illustrates how the female profile mating edge 5a engages with the railing 6 to form a secure connection.
  • Figure 13 illustrates a perspective view of an embodiment of an assembled wall panel system utilizing a plurality of wall panels 1.
  • an opening 12 is formed in the center of the wall panel system which allows a window frame 10 to be inserted.
  • the opening 12 has four sides consisting of flush surfaces formed by joining a female profile mating edge 5a with a capping profile mating edge 5b, as mentioned in paragraph [0086] and seen in Figure 7.
  • Figure 14 illustrates a perspective view of the disassembled wall panel system shown in Figure 13.
  • a railing 6 is positioned and/or anchored to a fixed surface.
  • a first wall panel la that is positioned vertically is slid and inserted onto the railing, followed by installation of a capping profile mating edge 5b onto the first wall panel la.
  • a second wall panel lb that is positioned horizontally is installed on the side of the first wall panel la and below the capping profile mating edge 5b, and subsequently a third wall panel lc that is positioned horizontally is installed on the same side of the first wall panel la and above the capping profile mating edge 5b, forming a C-shape structure.
  • a fourth wall panel Id that is already installed with a capping profile mating edge and is positioned vertically is slid in to close the C-shape, forming an O-shape structure with an opening 12 in the middle.
  • the four sides of the opening 12 are each installed with a capping profile mating edge 5b to form flush surface edges of the opening 12.
  • a window frame 10 can then be installed into this opening 12 in this embodiment.
  • the wall panels la, lb, lc, Id are slid onto the railing 6 via a female profile mating edge 5a and are connected to each other using the male profile edge 5c and female profile edge 5a.
  • Figure 15 illustrates a perspective view of another embodiment of an assembled wall panel system utilizing a plurality of wall panels 1.
  • an opening 12 is formed in the center of the wall panel system which allows a door frame 11 to be inserted.
  • the opening 12 has four sides flush surfaces form by joining a female profile mating edge 5a with a capping profile mating edge 5b.
  • Figure 16 illustrates a perspective view of a disassembled wall panel system shown in Figure 15. Similar to Figure 14, a first wall panel la that is positioned vertically is slid and inserted onto the railing, followed by installation of a capping profile mating edge 5b onto the first wall panel la. A second wall panel lb that is positioned horizontally is installed on the side of the first wall panel la and above the capping profile mating edge 5b. Lastly a third wall panel lc that is already installed with a capping profile mating edge 5b and is positioned vertically is slid on to the other side of the second wall panel lb, forming a U- shape structure with an opening 12 in the middle. The three sides of the opening 12 are each installed with a capping profile mating edge 5b to form flush surface edges of the opening 12. A door frame 11 can then be installed into this opening 12 in this embodiment.
  • Figure 17 shows an example of a mating edge 5 having perforations or openings 9. All mating edges 5 and railings 6 can be provided with perforations or openings 9 for the sake of utilities such as electrical utility wires, gas pipes, water pipes, cables and the like to be accommodated within the wall panel system. Using appropriately-sized drill bits, the porous material 3 sandwiched inside the wall panel 1 can be drilled to provide openings to easily accommodate such utilities as well. [0103] The following examples illustrate various aspects of a wall panel system of this invention. These examples do not limit the invention, the scope of which is set out in the appended claims.
  • a pair of railings 6 can be bolted back-to-back and accommodate wall panels 1 on both sides of the pair.
  • Figure 18 shows an example where a wall panel 1 is installed onto each side of the pair of railings 6 that are bolted back-to-back. Therefore, other than being used as a form of support for the wall panel system, it may also be used as a bridge between a first level of wall panels 1 and a second level of wall panels 1.
  • the pair of railings 6 is however, not limited to being a bridge between two vertical levels of wall panels 1. It may also bridge between two wall panels 1 that are horizontally aligned side by side.
  • Figure 19 shows a general example of an assembly of a two-level wall panel system joined by bolted back-to-back pair of railings.
  • a railing 6 is firstly positioned and/or anchored onto a surface.
  • a series of wall panels 1 are then slid onto the railing 6 and are connected with one another via the male profile edges 5c and the female profile edges 5a.
  • a pair of railings 6 that is bolted back-to-back is slid into the top of the series of wall panels.
  • a second series of wall panels 1 may be slid onto the other side of the pair of railings 6 to form a second level of wall panels.
  • This configuration is, however, not limited to only two levels of wall panels. It may accommodate more level of wall panels, should the building assembly require so.
  • Figure 20 shows an example where two series of wall panels 1 are joined together so as to form a corner.
  • a railing 6 can be anchored by being bolted to an existing wall panel 1 and accommodate another wall panel 1 on its other side. This allows the two series of wall panels 1 to be perpendicularly joined together, ultimately forming a corner.
  • Figure 21 shows an example of a complete assembly of four series of wall panels 1 that are joined together by anchoring a railing 6 onto one end of each wall panel series to form four corners, as mentioned in paragraph [0101]. This enables the formation of walls for a building structure.
  • Figure 22 shows an assembled view of a female profile mating edge 5a installed in a manner such that the groove portion is concealed.
  • a female profile mating edge 5a can optionally be installed backwards, same as a capping profile mating edge 5b, using a suitable adhesive such as epoxy in order to create a flush and flat wall panel edge to accommodate installation of a single or multiple sheathing boards 2 onto the flush and flat surface using a suitable adhesive such as epoxy.
  • the sheathing board 2 has a thickness of between 2 to 50 mm.
  • a disassembled view of Figure 22 is shown in Figure 23 to clearly illustrate the alignment of components.
  • Figure 24 shows the top view of the disassembled view in Figure 23.
  • Figure 25 shows an example of a complete assembly where two series of wall panels 1 are joined together so as to form a corner.
  • a female profile mating edge 5a in a backwards manner and subsequently installing the sheathing board 2 onto the flush surface formed by the female profile mating edge 5a, the sheathing board 2 forms a flush corner piece when the assembly is configured using the corner forming method mentioned in paragraphs [0101] and [0102] and shown in Figure 20.
  • the perforations or openings 9 are aligned with each other vertically and horizontally such that they create a tunnel effect across a series of wall panels to easily accommodate utilities.
  • Figure 26 shows the disassembled view of Figure 25.
  • Figure 27 shows an example of a complete assembly of a two-level wall panel system together with the installation of window frames 10 and a door frame 11.
  • Figure 28 shows another example of a complete assembly of a two-level wall panel system together with the installation of window frames 10 and a door frame 11.

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Abstract

There is provided an industrialised building system wall panel system comprising a plurality of wall panels (1). Each of the wall panel (1) comprises at least two sheathing boards (2), a porous material (3) sandwiched between the sheathing boards (2), an expandable adhesive material (4) surrounding the porous material (3) and a frame (5) that surrounds and defines the mating edges of the wall panel (1). Each mating edge of the frame (5) is provided with a suitable male (5c) or female (5a) connecting profile, such that a wall panel frame edge with a male profile (5c) can be removably mated with a wall panel frame edge having a corresponding female profile (5a) during assembly of the wall panel system.

Description

AN INDUSTRIALISED BUILDING SYSTEM WALL PANEL SYSTEM
TECHNICAL FIELD
[0001] This invention relates to building constructions. More particularly, the invention concerns a wall panel system in building constructions with an Industrialised Building System (IBS).
BACKGROUND OF THE INVENTION
[0002] Brick, lightweight block, lightweight precast panels and lightweight sandwich panels of different materials are often used for the construction of building walls. It involves a lot of skilled workers to lay and join these modules together, making it a very time consuming and messy job. Often, heavy equipment is needed to lift the panels together in order to build a wall structure. A lot of cleaning is required at the end of such building projects. Excess and waste materials will need to be removed and transported away from the site and this creates wastes and is not environmentally friendly.
[0003] Labour costs can be expensive in construction of building walls since it involves skilled workers to lay and join these modular wall panels together. The material costs can be costly as well as the materials used to manufacture the wall panels may be expensive to manufacture.
[0004] Furthermore, frequent maintenance may be required due to the poor durability of the materials used to manufacture the wall panels. The materials used may also lack insulation properties and does not provide for moisture-resistant and energy-efficient properties.
[0005] US Patent No. 9, 115, 504 B2 discloses a system for modular building construction that comprises interconnectible prefabricated modular volumetric units, each of the unit having a steel frame shaped as a rectangular parallelepiped and comprised of framing members and a plurality of nodes, each node situated at a corner of the frame for selective interconnection with other units. The issue of structural strength versus weight or eco- friendly insulation have not been considered in the design of the prefabricated modular units of this prior US patent.
[0006] US Patent No. US 3, 683, 100 A discloses a modular wall and ceiling system that comprises a modular system of interchangeable and demountable solid wall panels. The wall panels are connectable to and detachable from a ceiling grid system. Specifically, this prior US patent discloses connectors that enable the panels to be placed in position or moved to different locations on the ceiling grid to form the desired floor plan arrangement of rooms, halls, alcoves and the like. The modularity of the wall system of this prior US patent hinges on its detachable connectivity with a ceiling grid system. This raises the cost of construction and is undesirably limiting in the construction of an Industrialised Building System. Furthermore, much like US Patent No. 9, 115, 504 B2, the modular wall system of this prior US patent also does not consider the issue of structural strength versus weight or eco-friendly insulation.
[0007] US Patent No. 7, 993, 719 B2 discloses an assembled structure of a sandwich panel and a connecting member attached together by way of an adhesive. Specifically, it discloses two fiber reinforced resin sheets sandwiching a core material. The side wall portions of the panel can be connected to rails. The fiber reinforced resin sheets have disadvantages such as low mechanical strength. Further, the design of components made from fiber reinforced resin is complex and the manufacturing and testing of such components is highly specialized. The core material comprises pultruded fiber reinforced plastic which is commonly known as fiber reinforced polymer. The sandwich panel of this prior US patent does not provide for insulation much less eco-friendly insulation.
[0008] US Patent No. 7, 964, 272 B2 discloses lightweight compositions that comprises a lightweight cementitious (LWC) composition set in the form of concrete masonry units (CMUs), construction articles, pre-cast/pre-stressed construction articles, construction panels, or roadbeds. The LWC units of this prior US patent were not designed with interconnectibility, design adaptability nor ease of construction, in mind.
[0009] This invention thus aims to alleviate some or all of the problems of the prior art. SUMMARY OF THE INVENTION
[0010] In a first aspect of the invention, there is provided an Industrialised Building System wall panel system, the wall panel system comprising: a plurality of wall panels, whereby each of the wall panel comprises: at least two sheathing boards; a porous material sandwiched between the sheathing boards; an expandable adhesive material surrounding the porous material; and a frame that surrounds and defines the mating edges of the wall panel; wherein each mating edge is provided with a suitable male or female connecting profile, such that a wall panel frame edge with a male profile can be removably mated with a wall panel frame edge having a corresponding female profile during assembly of the wall panel system.
[0011] The present invention seeks to provide a strong, lightweight and modular wall panel system that eases the assembly process of the wall panel system of an Industrialised Building System (IBS).
[0012] The object of this invention is to revolutionize the construction of walls in building construction industry with an IBS lightweight sandwich wall panel system (IBSLSWPS) that is uniquely designed to fit each member with precision while requiring the use of minimum adhesives to securely join them together to form a permanent wall structure or even a temporary wall.
[0013] It is a further object of this invention to provide a "green building" construction system by minimizing the wastage of materials and incorporating effective insulation, therefore saving energy, while the materials of the components used to manufacture the IBSLSWPS are eco-friendly. Construction of building walls erected with IBSLSWPS can be relatively low cost and structural costs can also be decreased by incorporating the IBSLSWPS at the beginning of the design stage. Further, the invention of this application can increase the speed of construction with less consumption of labour. [0014] An IBS incorporating the Wall Panel System of this invention comprises several member panels that can be connected together by way of precisely profiled mating edges.
[0015] When weight saving is critical and strength is a requirement, a sandwich layout panel offers huge advantages over a solid composite panel. This is mainly because sandwich panels offer a higher strength-to-weight ratio than solid composite laminates.
[0016] In the first aspect of the invention, the wall panel comprises two sheathing boards and a porous material sandwiched between the sheathing boards (i.e. a sandwich layout wall panel).
[0017] The main theory behind the high strength-to-weight ratios of a sandwich layout panel is the concept of mass moment of inertia. Increasing the mass moment of inertia directly increases the stiffness. Taking a solid panel into consideration, thicker panels will be stiffer but not just because there is more material. When layers are further from the center (commonly called the neutral axis) they contribute more stiffness. For example, if there are two tubes of different diameter, the large diameter tube will be stiffer than the small diameter tube, even if the amount of materials in them is equal. This is because the larger diameter tube has more material further from its center.
[0018] Therefore, a thick solid panel will be stiffer, but it might not be lightweight. A sandwich layout panel offers a solution to that problem. When a panel bends, the outermost layers take a majority of the load. Both major faces of the panel will experience stress with one in compression and one in tension. However, the center of a bending panel sees a minimal to no stress at all. The center layers of a panel do not contribute much in absorbing stress, and, hence, can be eliminated and replaced with a porous material such as foam or a suitable honeycomb-shaped structure.
[0019] The present invention relates to building constructions and, more particularly, to wall construction in IBS constructions with a lightweight sandwich wall panel system. The main embodiment mainly comprises several wall panels connected to each other via correspondingly profiled mating edges. This allows the wall panels to be modular.
[0020] In an embodiment, the sheathing boards are made of fiber boards. [0021] In another embodiment, the sheathing boards are made of compressed mineral fiber boards.
[0022] In another embodiment, each wall panel comprises multiple sheathing boards to form the wall panel.
[0023] In another embodiment, the porous material has a honeycomb-shaped structure. A honeycomb-shaped structure is a high-strength but lightweight structure that enables efficient mechanical performance. It is an excellent alternative to monolithic materials like solid aluminum, wood and steel, and as well as panels with traditional core materials such as plywood, balsa, and foam. Honeycomb-shaped structure can be used in many situations that require elevated core shear, compression, and adhesion performance. Due to the nature of a honeycomb-shaped structure, it requires less material to manufacture, hence, resulting in a general weight reduction relative to conventional solid single sheet material. The stiffness of a honeycomb-shaped structure increases exponentially against its weight, which makes its strength to weight ratio higher compared to a single sheet material. The use of a honeycomb-shape structure can result in a dramatic increase in stiffness with very little weight gain. Thus, it is a crucial component for this invention to achieve a high strength-to-weight ratio structure. The pores or air pocket in the honeycomb-shaped structure also creates an insulation for the wall panel.
[0024] In another embodiment, the porous material is made of either fiberglass, fire retarded paper or aluminum or any equivalent type of material.
[0025] In another embodiment, the expandable materials are made of polyurethane foam. Polyurethane is regarded as an affordable, versatile, durable, excellent insulator, and a safe way of reducing carbon emissions that contribute to global warming. Thus, it offers many solutions to the challenges of energy conservation and eco-design. Polyurethane has insulation properties that can dramatically reduce heat loss in homes and offices in cold weather. During the summer months, it plays an important role in keeping buildings cool, which means air conditioning is needed less and therefore reduces harmful impact on the environment. [0026] Use of an expandable adhesive material surrounding the porous material core reinforces the structure of the IBS wall panel of this invention while maintaining its lightweight and high strength properties. Additionally, this unique design of the core (expandable adhesive material surrounding a porous material) in one embodiment of the wall panel of this invention enables the application of energy-efficient insulation without compromise as to the mechanical strength or adding to the weight of the panel itself.
[0027] In another embodiment, the mating edges of the wall panel have homogenous connecting profiles where all the mating edges have female connecting profiles or all the mating edges have male connecting profiles.
[0028] In another embodiment, the mating edges of the wall panel have heterogenous connecting profiles where the mating edges can be: i) Three sides male profiles and one side female profile ii) Two sides male profiles and two sides female profiles iii) One side male profile and three sides female profiles
[0029] In another embodiment, the male and female connecting profiles are tongue and groove profiles, respectively.
[0030] These male and female profiles mating edges provide modularity to the wall panels. The user may determine the number of wall panels to be used in a wall panel system depending on the overall size requirement of the wall to be assembled.
[0031] In another embodiment, a wall panel frame edge with a female connecting profile is mated with a capping profile to create a flush surface effect.
[0032] In another embodiment a female connecting profile is installed backwards onto a wall panel, such that its groove portion is concealed to create a flush surface effect.
[0033] In another embodiment, the wall panel frame edge further comprises openings for accommodating utility items such as electrical utility wires, gas pipes, water pipes and cables and the like. [0034] In another embodiment, the wall panel system further comprises a railing, the wall panels being slidable along the railing to form a series of wall panels. More than one unit of railing can be affixed together. The railing further comprises openings for accommodating utility items such as electrical utility wires, gas pipes, water pipes, cables and the like. The railing may further comprise at least one hump for reducing friction when wall panels are slid along the railing.
[0035] In a second aspect of the invention, there is provided an IBS wall panel, the wall panel comprises: at least two sheathing boards; a porous material sandwiched between the sheathing boards; an expandable adhesive material surrounding the porous material; and a frame that surrounds and defines the mating edges of the wall panel; wherein each mating edge is provided with a suitable male or female connecting profile, such that a wall panel frame edge with a male profile can be removably mated with a wall panel frame edge having a corresponding female profile during assembly of the wall panel system.
[0036] In a third aspect of the invention, there is provided an IBS wall panel system, the wall panel system comprising: a plurality of wall panels, whereby each of the wall panel comprises: at least two sheathing boards; an expandable adhesive material sandwiched between the sheathing boards; and a frame that surrounds and defines the mating edges of the wall panel; wherein each mating edge is provided with a suitable male or female connecting profile, such that a wall panel frame edge with a male profile can be removably mated with a wall panel frame edge having a corresponding female profile during assembly of the wall panel system.
[0037] In a fourth aspect of the invention, there is provided an IBS wall panel, the wall panel comprising: at least two sheathing boards; an expandable adhesive material sandwiched between the sheathing boards; and a frame that surrounds and defines the mating edges of the wall panel; wherein each mating edge is provided with a suitable male or female connecting profile, such that a wall panel frame edge with a male profile can be removably mated with a wall panel frame edge having a corresponding female profile during assembly of the wall panel system.
[0038] The advantages of the wall panel system and wall panel of this invention will be further elaborated in the following pages.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] The present invention will become more clearly understood from the following description of the embodiments thereof, when taken in conjunction with the accompanying drawings. However, the embodiments and the drawings are given only for the purpose of illustration and explanation and are not to be taken as limiting the scope of the present invention, the scope of which is to be determined by the appended claims.
[0040] In the accompanying drawings, like reference numerals are used to denote like parts throughout several views. The features of the described embodiments are generic to all embodiments unless specifically stated otherwise or required by the context.
[0041] Figure 1 illustrates a perspective view of an embodiment of a wall panel system.
[0042] Figure 2 illustrates a second perspective view of the embodiment of Figure 1.
[0043] Figure 3 illustrates the cross-sectional view of a female profile mating edge.
[0044] Figure 4 illustrates the cross-sectional view of a male profile mating edge.
[0045] Figure 5 illustrates the cross-sectional view of the connection between a female profile mating edge and a male profile mating edge. [0046] Figure 6 illustrates the cross-sectional view of a capping profile mating edge which is similar with the female profile mating edge.
[0047] Figure 7 illustrates the cross-sectional view of the connection between a female profile mating edge and a capping profile mating edge.
[0048] Figure 8 illustrates the cross-sectional view of a railing.
[0049] Figure 9A illustrates the cross-sectional view of a railing, Figure 9B illustrates a cross- sectional view of a grating clamp, Figure 9C illustrates a railing anchored to a surface using a sleeve anchor bolt, and Figure 9D illustrates two railings bolted back-to-back.
[0050] Figure 10 illustrates the side view of the alignment of a single wall panel on a railing before assembly.
[0051] Figure 11 illustrates the side view of a single wall panel assembled onto a railing.
[0052] Figure 12 illustrates the cross-sectional view of the connection between a female profile mating edge and a railing.
[0053] Figure 13 illustrates an embodiment of an assembled wall panel system with an empty slot for installation of a window frame.
[0054] Figure 14 illustrates a disassembled view of the embodiment of Figure 13.
[0055] Figure 15 illustrates an embodiment of an assembled wall panel system with an empty slot for installation of a door frame.
[0056] Figure 16 illustrates a disassembled view of the embodiment of Figure 15.
[0057] Figure 17 illustrates the mating edges and railing having openings to accommodate utility services. [0058] Figure 18 illustrates the cross-sectional view of the assembly of wall panels on each side of the railings that are bolted back-to-back.
[0059] Figure 19 illustrates an embodiment of an assembled wall panel system with a two- level wall panel system assembly.
[0060] Figure 20 illustrates an embodiment of two series of wall panels assembled to form a corner.
[0061] Figure 21 illustrates a fully assembled cubicle with window and door using the corner forming method shown in Figure 20.
[0062] Figure 22 illustrates a female profile mating edge installed such that the groove portion is concealed.
[0063] Figure 23 illustrates a disassembled view of the embodiment of Figure 22.
[0064] Figure 24 illustrates the top view of the embodiment of Figure 23.
[0065] Figure 25 illustrates an example of the corner forming method of Figure 20 having a female profile mating edge installed as per Figure 22.
[0066] Figure 26 illustrates a disassembled view of the example of Figure 25.
[0067] Figure 27A illustrates a front view of a fully assembled two-level panel system and Figure 27B illustrates a front view of a disassembled two-level panel system.
[0068] Figure 28A illustrates another front view of a fully assembled two-level panel system and Figure 28B illustrates another front view of a disassembled two-level panel system.
[0069] Figure 29 illustrates a perspective view of another embodiment of a wall panel.
[0070] Figure 30 illustrates a two-dimensional view of the embodiment of Figure 29. DETAILED DESCRIPTION OF THE EMBODIMENTS
[0071] The industrialised building system wall panel system of this invention mainly comprises: a plurality of wall panels 1.
[0072] Each of the wall panel 1 can generally be of different sizes and comprises: at least two sheathing boards 2, a porous material layer 3 sandwiched between the sheathing boards 2, an expandable adhesive material 4 surrounding the porous material 3, and a frame 5 that surrounds and defines the mating edges of the wall panel 1.
[0073] One of the sheathing boards 2 is firstly attached to the frame 5 using a suitable adhesive such as epoxy. The porous material layer 3 is then attached to the sheathing board 2 and enclosed within the frame 5. After that, another sheathing board 2 is attached on the other side of the porous material layer 3, enclosing the porous material layer within, and forming a sandwich layout wall panel 1. Lastly, the expandable adhesive material 4 is injected into the sandwich layout wall panel 1 filling in any gaps within the sandwich layout wall panel 1 and reinforcing the joint between the sheathing boards 2, the frame 5 and the porous material layer 3.
[0074] Each mating edge of the frame 5 is provided with a suitable male 5c or female 5a connecting profile, such that a wall panel frame edge with a male profile 5c can be removably mated with a wall panel frame edge having a corresponding female profile 5a during assembly of the wall panel system.
[0075] Figure 1 illustrates a wall panel 1 that comprises a pair of sheathing boards 2, a porous material layer 3, expandable adhesive material 4 enclosing the porous material layer 3, and a frame 5.
[0076] Each of the sheathing boards 2 can be compressed mineral fiber boards. The sheathing boards can be of any suitable shape. In the embodiment of Figure 1, the sheathing board 2 is a rectangular shaped board having a range of length of between 100 to 5000 mm, a range of width between 100 to 5000 mm, a range of thickness of between 3 to 25 mm and a range of density of between 800 to 1500 kg/m3. The length, width, thickness and density of each board is generally dependent on the structural requirements of the wall to be formed from the wall panels of this invention. In the embodiment of Figure 1, each mineral fiber board 2 has a length of 2400 mm, a width of 600 mm, a thickness of 12 mm and a density of 1000 kg/m3.
[0077] The porous material layer 3 is suitably a lightweight material and its pores can be of any shape. The porous material can be made of fiber glass, fire retarded paper or aluminum or any equivalent type of material. In the embodiment of Figure 1, for example, the porous material layer 3 has a honeycomb-shaped structure. The porous material layer 3 can be rectangular and have a range of length of between 50 to 5000 mm, a range of width between 50 to 5000 mm, and a range of thickness of between 12 to 300 mm. In the embodiment of Figure 1, the honeycomb-shaped structure layer 3 has a height of 2232 mm, a width of 450 mm and a thickness of 76 mm.
[0078] The porous material layer 3 (core of the wall panel) functions like the vertical element of an I-shaped Beam (or I-Beam), and the major faces/surface of the wall panel 1 are akin to the flanges of an I-Beam, working together to create a high shear strength structure. Similar to an I-beam, the greater the distance between the pair of sheathing boards 2 creates a higher overall strength for the wall panel 1, which reduces the risk of tensile failure, buckling failure and shear failure of the wall panel 1.
[0079] The expandable adhesive material 4 can be any suitable material and is preferably, a polyurethane foam material. For example, the polyurethane foam material used can be a closed cell or opened cell polyurethane foam. The polyurethane foam material 4 is applied so as to fully enclose the porous material layer 3 and forms a secure bond around the edges of the porous material layer 3. The expandable adhesive material 4 acts as an adhesive to securely join the porous material layer 3, sheathing boards 2 and the frame 5 together and further strengthens and reinforces the wall panel 1.
[0080] The frame 5 that surrounds the wall panel and defines its mating edges can be made of suitable materials such as fiber glass, plastic or metal. Preferably, the frame is made of metal. The frame is a quadrilateral with each side defining a mating edge. Each mating edge is suitably profiled as either a male 5c or female 5a profile that enables removable connection between wall panels. [0081] In an alternative embodiment, as illustrated in Figures 29 and 30, a wall panel 1 of this invention comprises: at least two sheathing boards 2, an expandable adhesive material 4 sandwiched between the sheathing boards 2, and a frame 5 that surrounds and defines the mating edges of the wall panel 1. This embodiment is particularly advantageous when the wall panel 1 of the invention is used for construction in environments where greater heat insulation is required as it enables the application of a higher volume of expandable adhesive material 4 between the sheathing boards 2.
[0082] In another alternative embodiment, a wall panel 1 of this invention is not limited to having only a pair of sheathing boards 2. Multiple layers of sheathing boards 2 can be arranged and stacked on top of each other on both opposing sides to form a new wall panel. On each opposing side of the new wall panel, the multiple layers of sheathing boards 2 are joined to each successive sheathing boards by way of suitable adhesives such as epoxy, glue or any other equivalent adhesive materials.
[0083] Figure 2 illustrates a perspective view of a disassembled wall panel 1 of this invention.
[0084] Figure 3 shows a general cross-sectional profile of a female profile mating edge 5a of the frame. This female profile mating edge 5a is a groove profile mating edge that has a groove width matching the combined thickness of the porous material layer 3 enclosed within the expandable adhesive material 4 of the wall panel. In the embodiment of Figure 3, the female profile mating edge 5a has a thickness of 0.4 mm and ranges between 0.2 to 1.5 mm. As mentioned, each wall panel comprises four mating edges. This female profile mating edge 5a of a wall panel 1 can removably mate or connect with a male profile mating edge 5c of another wall panel 1. The mating connection between two mating edges of adjacent wall panels establishes a removable connection assembly between wall panels 1 to form a series of wall panels. As seen in Figure 2, the mating edges of the wall panel 1 can be either a female profile mating edge 5a or a male profile mating edge 5c.
[0085] Figure 4 shows a general cross-sectional profile of a male profile mating edge 5c. This male profile mating edge 5c is also a tongue profile mating edge. In the embodiment of Figure 4, the male profile mating edge 5c has a thickness of 0.4 mm and ranges between 0.2 to 1.5 mm. This male profile mating edge 5c can form a mating connection with a female profile mating edge 5a to establish a removable connection assembly between two adjacent wall panels 1.
[0086] Figure 5 shows the connectivity between a male profile mating edge 5c and a female profile mating edge 5a. The wall panels 1 are removably connected to each other by way of the corresponding-shaped mating between the male profile 5c and the female profile 5a mating edges 5. For example, the first wall panel 1 with a male profile 5c is connected and secured to a second wall panel 1 with a female profile 5a. The subsequent wall panels 1 can be joined in the same manner and secured to other wall panels 1 to form a wall panel system. In this way, the mating edges 5 hold an entire series of wall panels 1 together during assembly and provides precise fitting when joining the wall panels 1. This minimizes the need for adhesives to connect adjacent wall panels 1 together.
[0087] Optionally, additional adhesive may be used to reinforce the connections between the wall panels 1. Screws can also be used instead of adhesive to reinforce such connections between adjacent panels. However, screws are meant for creating a temporary connection between the wall panels, for example, when the wall panel 1 of this invention is used to create a temporary wall panel system. The temporary wall panel system is easily disassembled by having the user unscrew the screws securing the connections between the successive wall panels 1 when it is no longer in use. Once disassembled, the wall panels can be easily relocated and reassembled for other applications.
[0088] In this wall panel system, each wall panel 1 can have different combinations of male and female profile mating edges. The precise combination is dependent on end-use assembly requirements. The following are the possible combinations of male and female profile mating edges of a wall panel 1 of this invention. i) Four sides of male profiles 5c ii) Four sides of female profiles 5a iii) Any three sides of male profiles 5c and remaining one of side female profile 5a iv) Any two sides of male profiles 5c and remaining two sides of female profiles 5a v) Any one side of male profile 5c and remaining three sides of female profiles 5a [0089] An example of the different combinations of the types of mating edges 5 is a first wall panel 1 comprising four sides of female profile mating edges 5a, a second wall panel 1 that will be connected to the right side of the first wall panel which has at least one male profile mating edge 5c so that it can be securely joined with the female profile mating edge 5a of the first wall panel 1.
[0090] Figure 6 shows a general cross-sectional profile of a capping profile mating edge 5b. This capping profile mating edge 5b has a smaller profile than the female profile mating edge 5a. The capping profile mating edge 5b can be fitted together with a female profile mating edge 5a to create a flush surface. Optionally, adhesive such as epoxy can be used to be applied on the surface between the female profile mating edge 5a and the capping profile 5b to reinforce the joint.
[0091] Figure 7 illustrates how a capping profile mating edge 5b is used to fit in an opposite facing direction into a female profile mating edge 5a, such that they are in a groove-meets- groove position. By doing so, it creates a flush and flat surface wall panel edge. The flush and flat edge is used to accommodate the installation of other building structures such as a window frame 10, a door frame 11 or the like.
[0092] Figure 8 shows a general cross-sectional profile of a railing 6. The railing 6 is a uniquely designed profile track that can be used to guide the alignment and to accommodate the assembly of the plurality of wall panels 1. The wall panels 1 are slidable along the railing 6 to form a series of wall panels 1. Ideally, the railing 6 is provided to anchor the assembly of the wall panels 1 to permanent fixtures such as a floor, wall or ceiling, as show in Figure 9C, or to an existing wall panel 1 using a sleeve anchor bolt 7 and grating clamp 8. However, it is also possible for the wall panel system of this invention to be directly fixed to existing floor, wall, ceiling fixtures or the like that have a suitable profile for accommodating either the male or female mating edges 5a, 5b, 5c of the wall panel 1. In the embodiment of Figure 8, the railing 6 has a thickness of between 0.2 to 2 mm and can be of any length necessary to accommodate the series of wall panels. Each railing 6 can optionally be provided with at least one hump 6a to reduce friction between the railing 6 and the female profile mating edge 5a when a wall panel 1 is being slid along the railing 6. [0093] Figure 9D illustrates two railings 6 that are bolted back-to-back using a sleeve anchor bolt 7 and a nut, and two grating clamps 8. The series of joined railings 6 are further used as a form of support for the wall panel system, such as a stiffener, a beam and a column. The joined railings 6 are able to accommodate the installation of a series of wall panels by sliding the wall panels 1 along the joined railings 6.
[0094] Figures 10 and 11 illustrate how the wall panel 1 is joined to the railing 6. As seen in Figure 10, during the assembly of a wall panel system, the wall panel 1 is slidable onto the railing 6. The mating edges 5 on the wall panels 1 provide connectivity between the wall panels 1 and the railing 6. The side of the wall panel 1 that is intended to be slid onto the railing 6 must be of a female profile mating edge 5a. The female profile 5a of the wall panel 1 engages with the railing 6 to form a secure connection as seen in Figure 11.
[0095] Figure 12 illustrates how the female profile mating edge 5a engages with the railing 6 to form a secure connection.
[0096] Figure 13 illustrates a perspective view of an embodiment of an assembled wall panel system utilizing a plurality of wall panels 1. In this assembled wall panel system, an opening 12 is formed in the center of the wall panel system which allows a window frame 10 to be inserted.
[0097] The opening 12 has four sides consisting of flush surfaces formed by joining a female profile mating edge 5a with a capping profile mating edge 5b, as mentioned in paragraph [0086] and seen in Figure 7.
[0098] Figure 14 illustrates a perspective view of the disassembled wall panel system shown in Figure 13. Firstly, a railing 6 is positioned and/or anchored to a fixed surface. Then, a first wall panel la that is positioned vertically is slid and inserted onto the railing, followed by installation of a capping profile mating edge 5b onto the first wall panel la. A second wall panel lb that is positioned horizontally is installed on the side of the first wall panel la and below the capping profile mating edge 5b, and subsequently a third wall panel lc that is positioned horizontally is installed on the same side of the first wall panel la and above the capping profile mating edge 5b, forming a C-shape structure. Lastly a fourth wall panel Id that is already installed with a capping profile mating edge and is positioned vertically is slid in to close the C-shape, forming an O-shape structure with an opening 12 in the middle. The four sides of the opening 12 are each installed with a capping profile mating edge 5b to form flush surface edges of the opening 12. A window frame 10 can then be installed into this opening 12 in this embodiment. The wall panels la, lb, lc, Id are slid onto the railing 6 via a female profile mating edge 5a and are connected to each other using the male profile edge 5c and female profile edge 5a.
[0099] Figure 15 illustrates a perspective view of another embodiment of an assembled wall panel system utilizing a plurality of wall panels 1. In this assembled wall panel system, an opening 12 is formed in the center of the wall panel system which allows a door frame 11 to be inserted.
[0100] Similarly, the opening 12 has four sides flush surfaces form by joining a female profile mating edge 5a with a capping profile mating edge 5b.
[0101] Figure 16 illustrates a perspective view of a disassembled wall panel system shown in Figure 15. Similar to Figure 14, a first wall panel la that is positioned vertically is slid and inserted onto the railing, followed by installation of a capping profile mating edge 5b onto the first wall panel la. A second wall panel lb that is positioned horizontally is installed on the side of the first wall panel la and above the capping profile mating edge 5b. Lastly a third wall panel lc that is already installed with a capping profile mating edge 5b and is positioned vertically is slid on to the other side of the second wall panel lb, forming a U- shape structure with an opening 12 in the middle. The three sides of the opening 12 are each installed with a capping profile mating edge 5b to form flush surface edges of the opening 12. A door frame 11 can then be installed into this opening 12 in this embodiment.
[0102] Figure 17 shows an example of a mating edge 5 having perforations or openings 9. All mating edges 5 and railings 6 can be provided with perforations or openings 9 for the sake of utilities such as electrical utility wires, gas pipes, water pipes, cables and the like to be accommodated within the wall panel system. Using appropriately-sized drill bits, the porous material 3 sandwiched inside the wall panel 1 can be drilled to provide openings to easily accommodate such utilities as well. [0103] The following examples illustrate various aspects of a wall panel system of this invention. These examples do not limit the invention, the scope of which is set out in the appended claims.
[0104] As mentioned, a pair of railings 6 can be bolted back-to-back and accommodate wall panels 1 on both sides of the pair. Figure 18 shows an example where a wall panel 1 is installed onto each side of the pair of railings 6 that are bolted back-to-back. Therefore, other than being used as a form of support for the wall panel system, it may also be used as a bridge between a first level of wall panels 1 and a second level of wall panels 1. The pair of railings 6 is however, not limited to being a bridge between two vertical levels of wall panels 1. It may also bridge between two wall panels 1 that are horizontally aligned side by side.
[0105] Figure 19 shows a general example of an assembly of a two-level wall panel system joined by bolted back-to-back pair of railings. A railing 6 is firstly positioned and/or anchored onto a surface. A series of wall panels 1 are then slid onto the railing 6 and are connected with one another via the male profile edges 5c and the female profile edges 5a. Then, a pair of railings 6 that is bolted back-to-back is slid into the top of the series of wall panels. Subsequently, a second series of wall panels 1 may be slid onto the other side of the pair of railings 6 to form a second level of wall panels. This configuration is, however, not limited to only two levels of wall panels. It may accommodate more level of wall panels, should the building assembly require so.
[0106] Figure 20 shows an example where two series of wall panels 1 are joined together so as to form a corner. As mentioned in paragraph [0087], a railing 6 can be anchored by being bolted to an existing wall panel 1 and accommodate another wall panel 1 on its other side. This allows the two series of wall panels 1 to be perpendicularly joined together, ultimately forming a corner.
[0107] Figure 21 shows an example of a complete assembly of four series of wall panels 1 that are joined together by anchoring a railing 6 onto one end of each wall panel series to form four corners, as mentioned in paragraph [0101]. This enables the formation of walls for a building structure. [0108] Figure 22 shows an assembled view of a female profile mating edge 5a installed in a manner such that the groove portion is concealed. A female profile mating edge 5a can optionally be installed backwards, same as a capping profile mating edge 5b, using a suitable adhesive such as epoxy in order to create a flush and flat wall panel edge to accommodate installation of a single or multiple sheathing boards 2 onto the flush and flat surface using a suitable adhesive such as epoxy. In this embodiment, the sheathing board 2 has a thickness of between 2 to 50 mm. A disassembled view of Figure 22 is shown in Figure 23 to clearly illustrate the alignment of components. Figure 24 shows the top view of the disassembled view in Figure 23.
[0109] Figure 25 shows an example of a complete assembly where two series of wall panels 1 are joined together so as to form a corner. By installing a female profile mating edge 5a in a backwards manner and subsequently installing the sheathing board 2 onto the flush surface formed by the female profile mating edge 5a, the sheathing board 2 forms a flush corner piece when the assembly is configured using the corner forming method mentioned in paragraphs [0101] and [0102] and shown in Figure 20. Furthermore, as seen in Figure 25, the perforations or openings 9 are aligned with each other vertically and horizontally such that they create a tunnel effect across a series of wall panels to easily accommodate utilities. Figure 26 shows the disassembled view of Figure 25.
[0110] Figure 27 shows an example of a complete assembly of a two-level wall panel system together with the installation of window frames 10 and a door frame 11.
[0111] Figure 28 shows another example of a complete assembly of a two-level wall panel system together with the installation of window frames 10 and a door frame 11.
[0112] As will be readily apparent to those skilled in the art, the present invention may easily be produced in other specific forms without departing from its scope or essential characteristics. The present embodiments are, therefore, to be considered as merely illustrative and not restrictive, the scope of the invention being indicated by the claims rather than the foregoing description, and all changes which come within therefore intended to be embraced therein.

Claims

1) An industrialised building system wall panel system, said wall panel system comprising: a plurality of wall panels (1), whereby each of the wall panel (1) comprises: at least two sheathing boards (2); a porous material (3) sandwiched between said sheathing boards (2); an expandable adhesive material (4) surrounding said porous material (3); and a frame (5) that surrounds and defines the mating edges of said wall panel (1); wherein each mating edge of said frame (5) is provided with a suitable male (5c) or female (5a) connecting profile, such that a wall panel frame edge with a male profile (5c) can be removably mated with a wall panel frame edge having a corresponding female profile (5a) during assembly of the wall panel system.
2) The wall panel system according to claim 1, wherein the sheathing boards (2) are fiber boards.
3) The wall panel system according to any one of claims 1 or 2, wherein the sheathing boards (2) are compressed mineral fiber boards.
4) The wall panel according to any one of the preceding claims, wherein each wall panel (1) further comprises more than two sheathing boards (2).
5) The wall panel according to claim 1, wherein the porous material (3) is a honeycomb-shaped structure.
6) The wall panel system according to any one of claims 1 or 5, wherein the porous material (3) is made of materials selected from a group comprising of fibreglass, fire retarded paper or aluminium.
7) The wall panel system according to claim 1, wherein the expandable materials (4) are made of polyurethane foam. 8) The wall panel system according to claim 1, wherein all the mating edges (5) of the wall panel (1) have homogenous connecting profiles.
9) The wall panel system according to claim 8, wherein the mating edges (5) have female connecting profiles (5a).
10) The wall panel system according to claim 8, wherein the mating edges (5) have male connecting profiles (5c).
11) The wall panel system according to claim 1, wherein the mating edges (5) of the wall panel (1) have heterogenous connecting profiles.
12) The wall panel system according to claim 11, wherein two of the mating edges (5) are male connecting profiles (5c) and two others are female connecting profiles (5a).
13) The wall panel system according to claim 11, wherein three of the mating edges (5) are male connecting profiles (5c) and one other is a female connecting profile (5a).
14) The wall panel system according to claim 11, wherein one of the mating edges (5) is a male connecting profile (5c) and three others are female connecting profiles (5a).
15) The wall panel system according to any one of claims 1 to 14, wherein the male and female connecting profiles (5c, 5a) are tongue and groove profiles, respectively.
16) The wall panel system according to any one of claims 1 to 15, wherein a wall panel frame edge (5) with a female connecting profile (5a) is mated with a capping profile (5b) to create a flush surface effect.
17) The wall panel system according to any one of claims 1 to 16, wherein a female connecting profile (5a) is installed backwards onto a wall panel (1), such that its groove portion is concealed to create a flush surface effect. 18) The wall panel system according to any one of claims 1 to 17, wherein the wall panel frame edge (5) comprises openings (9) for accommodating utility items such as electrical utility wires, gas pipes, water pipes and cables.
19) The wall panel system according to any one of claims 1 to 18, wherein the system further comprises a railing (6), said wall panels (1) being slidable along the railing (6).
20) The wall panel system according to claim 19, wherein more than one railing (6) can be affixed together.
21) The wall panel system according to claim 19 or claim 20, wherein the railing (6) comprises openings (9) for accommodating utility items such as electrical utility wires, gas pipes, water pipes and cables.
22) The wall panel system according to any one of claims 19 to 21, wherein the railing (6) further comprises at least one hump (6a) for reducing friction when wall panels (1) are slid along the railing (6).
23) A wall panel (1) comprises: at least two sheathing boards (2); a porous material (3) sandwiched between said sheathing boards (2); an expandable adhesive material (4) surrounding said porous material (3); and a frame (5) that surrounds and defines the mating edges of said wall panel (1); wherein each mating edge of said frame (5) is provided with a suitable male (5c) or female (5a) connecting profile, such that a wall panel frame edge with a male profile (5c) can be removably mated with a wall panel frame edge having a corresponding female profile (5a) during assembly of the wall panel system.
24) An industrialised building system wall panel system, said wall panel system comprising: a plurality of wall panels (1), whereby each of the wall panel (1) comprises: at least two sheathing boards (2); an expandable adhesive material (4) sandwiched between said sheathing boards (2); and a frame (5) that surrounds and defines the mating edges of said wall panel (1); wherein each mating edge of said frame (5) is provided with a suitable male (5c) or female (5a) connecting profile, such that a wall panel frame edge with a male profile (5c) can be removably mated with a wall panel frame edge having a corresponding female profile (5a) during assembly of the wall panel system.
25) A wall panel (1) comprising: at least two sheathing boards (2); an expandable adhesive material (4) sandwiched between said sheathing boards (2); and a frame (5) that surrounds and defines the mating edges of said wall panel (1); wherein each mating edge of said frame (5) is provided with a suitable male (5c) or female (5a) connecting profile, such that a wall panel frame edge with a male profile (5c) can be removably mated with a wall panel frame edge having a corresponding female profile (5a) during assembly of the wall panel system.
PCT/MY2023/050002 2022-01-28 2023-01-20 An industrialised building system wall panel system WO2023146388A1 (en)

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GB1269244A (en) * 1968-09-30 1972-04-06 United Plastics Ltd Improvements in composite panels
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CN107882266A (en) * 2017-12-19 2018-04-06 宁占起 A kind of partition plate, wall and room body

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3529394A (en) * 1968-09-30 1970-09-22 Comstruct Inc Modular wall corner connector
GB1269244A (en) * 1968-09-30 1972-04-06 United Plastics Ltd Improvements in composite panels
US6253530B1 (en) * 1995-09-27 2001-07-03 Tracy Price Structural honeycomb panel building system
RO117976B1 (en) * 2001-07-09 2002-11-29 Vasile Moga Process of making a sandwich panel and panel thus obtained
US20110223372A1 (en) * 2006-10-16 2011-09-15 Csp Systems, Inc. Non-Planar Composite Structural Panel
KR20080051248A (en) * 2006-12-05 2008-06-11 채수하 A five-resistent snadwich panel
US20130136886A1 (en) * 2011-11-24 2013-05-30 Rhinokore Composites Manufacturing Partnership Foam Filled Composite Construction Panel with Heating and Cooling Means
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CN107882266A (en) * 2017-12-19 2018-04-06 宁占起 A kind of partition plate, wall and room body

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