AU2010201628B1

AU2010201628B1 - The unique walls panel

Info

Publication number: AU2010201628B1
Application number: AU2010201628A
Authority: AU
Inventors: Oleg Falb
Original assignee: Individual
Current assignee: Individual
Priority date: 2010-04-22
Filing date: 2010-04-22
Publication date: 2011-08-25
Anticipated expiration: 2030-04-22

Abstract

Abstract The invention relates to a building containing a number of walls each assembled from a number of prefabricated wall panels, each of the number of walls is supported by a framework which is constructed by filling unused 5 internal pipes of the wall, which are not used for the installation of a utility of the building, with a settable material to form the framework.

Description

Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT APPLICANT: FALB, Oleg INVENTION TITLE: THE UNIQUE WALLS PANEL The following statement is a full description of this invention, including the best method of performing it known to me: - -2 THE UNIQUE WALLS PANEL Field of the Invention The invention generally relates a building panel and more particularly is concerned with a building panel used to construct a wall. 5 Background to the Invention For many years people have been building a range of constructions with bricks and all sorts of alternative materials. The look, strength, and finishing of these structures are dependent on available skills, resources and budgets. Once the basic structures are up, then there are the range of building methods and costs 10 for finishing both the interior and exteriors around the walls, making the expenditure on the frame and exterior only a part of the needs for the completed walls. The Unique Walls Panel brings together all of the needs of a completed building and minimizes the steps required to achieve an excellent finish inside 15 and out. This product is essentially an invaluable component in an emerging construction reality that fully reduces environmental waste on so many levels and facilitates usage with really low environmental impacts especially with power and water consumption. 20 Summary of the Invention The invention provides in one example for a building wall panel for constructing at least one building wall having a number of internal pipes, the building wall panel includes a building wall panel body including a number of sections of pipes at predetermined positions; wherein the number of sections of pipes are 25 adapted to allow, during the construction of the at least one building wall, the mating of a number of sections of pipes of one building wall panel body with a number of sections of pipes of an adjacent building wall panel body thereby to form the number of internal pipes of the assembled at least one building wall; -3 wherein the number of internal pipes allows one or more utilities to be installed in the at least one building wall through a pipe selected from the number of internal pipes; and wherein each unused pipe of the number of internal pipes are able to be filled with a settable material thereby to form the framework 5 which provides support to the at least one building wall when assembled. In a further example the invention provides for a building wall which includes a building wall body which is constructed from one or more prefabricated panels which are positioned relative to each other to form the building wall body; wherein the building wall body includes a number of internal pipes, which are 10 assembled through the fitment of the one or more prefabricated panels relative to each other to construct the at least one wall, and each of which extends from a bottom end of the building wall body to a top end thereof and which allows one or more utilities to be installed in the building wall body through a pipe selected from the number of internal pipes; and wherein each unused 15 pipe of the number of internal pipes are filled with a settable material thereby to form the framework which provide support to the building wall body. In another example, the invention provides a building which includes at least one wall, which is constructed from one or more prefabricated panels, and a framework which, when constructed, provides support to the at least one wall; 20 wherein the at least one wall includes a number of internal pipes, which are assembled through the fitment of the one or more panels relative to each other to construct the at least one wall, and each of which extends from a bottom end of the at least one wall to a top end thereof and which allows one or more utilities to be installed in the at least one wall through a pipe selected from the 25 number of internal pipes; and wherein each unused pipe of the number of internal pipes are filled with a settable material thereby to form the framework. Each panel of the one or more prefabricated panels has a first outer surface, a second, opposed outer surface, and a cavity which is formed between the first and second outer surfaces; -4 and wherein the number of internal pipes are located inside the internal cavity and are enclosed with a filler material which is used to fill the cavity. 5 The building may include a plurality of walls each of which is constructed from a number of prefabricated panels; wherein the number of internal pipes are divided into sections of piping; and wherein the sections of piping making up the number of internal pipes are embedded in the filler material filled cavities of the number of 10 prefabricated panels to allow the number of internal pipes to be assembled once the plurality of walls are constructed through stacking of the number of prefabricated panels. The number of internal pipes includes a first group of joining pipes which are 15 embedded at spaced apart, predetermined positions inside the plurality of walls thereby to form a number of framework support members of the framework which support the plurality of walls; wherein the number of internal pipes further includes at least a second group of joining pipes which allows the utilities to be installed in the plurality of 20 walls; and wherein each unused internal pipe of the second group of joining pipes are filled with a settable material thereby to form additional framework support members for the framework thereby to strengthen the framework. 25 The number of prefabricated panels are arranged in at least two rows so that each of the plurality of walls are constructed from at least two rows of stacked prefabricated panels of the number of prefabricated panels; wherein the sections of piping are arranged so that, for each of the number of internal pipes, a lower end of a section of piping embedded in an upper prefabricated 30 panel is inserted into an upper end of a section of piping embedded in a lower prefabricated panel positioned below the upper prefabricated panel; whereby the flow of a liquid downwards through a pipe of the number of internal pipes is guided towards an internal passage extending longitudinally inside the pipe.

-5 The building may include a slab from which the plurality of walls extends; and wherein the framework is connected to the slab through each of the first group of joining pipes. 5 The slab is also connected to each of the unused internal pipe of the second group of joining pipes which is filled with a settable material. A method of constructing at least one wall of a building; the at least one wall 10 having a framework and is constructed from a number of prefabricated panels; the method including the steps of fabricating a prefabricated panel which allows the at least one wall to be constructed from a number of the prefabricated panels so that the at least one wall includes a number of internal pipes each of which extends from the bottom 15 end of the at least one wall to a top end thereof thereby allowing one or more utilities to be installed in the at least one wall through a pipe selected from the number of internal pipes and thereby allowing each unused pipe of the number of internal pipes to be filled with a suitable material to form the framework. 20 A building of which at least one wall is constructed from a number of prefabricated panels as substantially hereinbefore described with reference to the accompanying representations. 25 A method of constructing at least one wall of a building from a number of prefabricated panels as substantially hereinbefore described with reference to any one of the company representations. In a further form, the invention provides a building wall panel for constructing at least one building wall having a number of internal pipes, the building wall 30 panel includes a building wall panel body including a number of sections of pipes at predetermined positions; -6 each of the number of sections of pipes including a flange at one end and a joining portion at an opposed end with one of which protruding from the building wall panel body; the number of sections of pipes are adapted to allow, during the 5 construction of the at least one building wall, the mating of a number of sections of pipes of one building wall panel body with a number of sections of pipes of an adjacent building wall panel body thereby to form the number of internal pipes of the assembled at least one building wall; mating of the number of sections of pipes to form the number of 10 internal pipes causes each of the sections of pipes to be sealingly fitted to adjacent sections of pipes by fitment of a flange into a joining portion thereby to form a pipe joint which allows each of the number of internal pipes being used as a sealed pipe to channel flow of liquid downwards through the respective internal pipe 15 wherein the number of internal pipes allows one or more utilities to be installed in the at least one building wall through a pipe selected from the number of internal pipes; and wherein each unused pipe of the number of internal pipes are able to be filled with a settable material thereby to form a framework 20 which provides support to the at least one building wall when assembled. In another form, the invention also provides a building wall which includes a building wall body which is constructed from one or more prefabricated building 25 wall panels which are positioned relative to each other to form the building wall body; the building wall body includes a number of internal pipes, which are assembled through the fitment of the one or more prefabricated building wall panels relative to each other to construct the building wall 30 body, and each of which extends from a bottom end of the building wall body to a top end thereof thereby to allow one or more utilities to be installed in the building wall body through a pipe selected from the number of internal pipes; -7 each of the one or more prefabricated building wall panels including a building wall panel body which includes a number of sections of pipes at predetermined positions each of which including a flange at one end and a joining portion at an opposed end with one of which 5 protruding from the building wall panel body; and each of the number of internal pipes is assembled from a number of sections of pipe so that in an assembled configuration the sections of pipes are sealingly fitted through fitment of a flange into a joining portion thereby to form a pipe joint which allows each of the 10 number of internal pipes to be configured for use as a sealed pipe to channel flow of liquid downwards through the respective internal pipe. In another form, the invention provides a building which includes at least one building wall, which is constructed from one or more prefabricated building wall 15 panels; the at least one building wall includes a number of internal pipes, which are assembled through the fitment of the one or more building wall panels relative to each other to construct the at least one building wall; 20 each of the number of internal pipes are divided into sections of piping and extends from a bottom end of the at least one building wall to a top end thereof and allows one or more utilities to be installed in the at least one building wall through a pipe selected from the number of internal pipes; 25 each of the one or more prefabricated building wall panels including a building wall panel body which includes a predetermined number of sections of pipes at predetermined positions each of which including a flange at one end and a joining portion at an opposed end with the joining portion protruding from a lower end of the building wall 30 panelbody; the number of prefabricated building wall panels when used are arranged in at least two rows so that each of the plurality of building -8 walls are constructed from at least two rows of stacked prefabricated building wall panels of the number of prefabricated building wall panels; wherein the sections of piping are arranged so that, for each of the number of internal pipes, a joining portion of a section of piping, 5 embedded in an upper row prefabricated building wall panel, is sealingly inserted into a flange of a section of piping embedded in a lower row prefabricated building wall panel and which is positioned below the upper prefabricated building wall panel; and wherein the sealingly insertion of the ends of the sections of 10 piping of the upper and lower prefabricated building wall panels to each other causes the number of internal pipes to be sealed thereby allowing each of the number of internal pipes to be used as a sealed pipe to channel the flow of a liquid downwards through the number of internal pipes; 15 and wherein each unused pipe of the number of internal pipes are filled with a settable material thereby to form a framework which, when constructed, provides support to the at least one building wall. In another form, the invention provides a method of constructing at least one 20 wall of a building; the at least one wall having a framework and is constructed from a number of prefabricated building wall panels; each of the one or more prefabricated building wall panels including a building wall panel body which includes a number of sections of pipes at predetermined positions each of which including a flange at one end and a joining portion at an opposed end 25 with one of which protruding from the building wall panel body; the method including the steps of constructing the at least one wall using at least two prefabricated building wall panels by stacking the prefabricated building wall panels on top of each other so that a number of internal pipes are formed within 30 the at least one wall by sealingly connecting a flange with a joining portion of adjacent sections of pipe, used to construct the number of internal pipes, to each other; -9 wherein each of the number of internal pipes form a sealed pipe to channel flow of liquid downwards through the respective internal pipe and is capable of allowing one or more utilities to be installed in the at least one building wall through a pipe selected from the number of internal pipes and allowing each 5 unused pipe of the number of internal pipes to be filled with a suitable material to form the framework. Brief Description of the Drawings 'The Unique Walls Panel' - pictures of small section for conceptual representation 10 Please note: All of these pictures are upside down as it gives a better view. Picture #1 View looking at the inner wall side Picture #2 View looking at the outer wall side Picture #3 View from above and from the outer wall side Picture #4 View from above and from the inner wall side 15 Picture #5 View of the inner walls panel showing the special filling material Picture #6 View of a corner panel Picture #7 View of a strait panel Description of Illustrated Embodiment of the Invention The photos show: 20 1. Inner Panel - showing 2 options for finish - plaster / villa board 2. Outer Panel - in this case finished with weatherproof cement sheet 3. Joining Pipe - between the inner and outer wall - most of these later to be filled with concrete - these are positioned every 500-600mm according to design and plan 25 4. Power / Electrical cables conduit pipe - sized and positioned according to needs 5. Plumbing pipe(s) according to plan 6. The space between the inner and outer face of the walls, around the pipes is -10 then filled with a special filling material. Qualities beyond joining the walls and securing the pipes include soundproofing and insulation. The interior & exterior walls for a nominated area of a construction will be provided as an assembled module to the site of the building / construction. 5 This building module has an inner space of 110mm or 200mm (standard sizes), however can be customized for any build requirement. Within this space are several key features: The internal housing of all essential pipes and conduits for water, gas, electricity, PC networks etc. The walls module in short, has within its structure, 10 all requirements for the finished building in regard to its position. Also of key importance to the overall strength and structural properties the joining system for the segments is also based on pipes housed internally between the walls - most of these later to be filled with concrete. The building segments or 'unique walls' are designed to combine with other 15 standard products such as door jams, windows etc. The walls, once finalized with all specified / required internal aspects, are then filled with a special filling material which also has insulating properties. The external wall and internal walls can be made of / finished with metal, wood or plaster or other materials as considered appropriate. 20 The combination holds many efficiencies and areas of savings and quality benefits: - No nails / screws needed - No damage to materials via attachment - Pest control - no termites, ants, mosquitoes, flies, birds nests etc 25 Size / Dimensions As mentioned, the inner space is an option of either 110mm or 200mm. The - 11 outer width can vary a little depending on the application or decoration / render selected. The inner width can also vary a little depending on plaster / wood finish etc. The ready wall has structural strength and properties which is designed for easy customization of interior and exterior surfaces as desired. 5 The length of a panel is anything up to 6M. The section perpendicular in case of a corner module can be up to 2M. There are left and right corner prefabrication set ups. The height of the 'unique walls' building segment is an option of either 1.2M or 1.35M. The connected, completed building is completely sealable and can use either 10 automatic / manual approach to climate control. PICTURE 6 - CORNER PANEL 1. Stopping End - covered by cement sheet or plasterboard, which will be 15 glued prior to placement alongside of neighbouring panels. This design of the sides to the wall panels also facilitates the placement of windows/doors etc. 2. Outside wall - covered by cement sheet or metal (e.g. corrugated), or alternative appropriate building material. 20 3. Internal PVC pipe - size from 20 mm 150 mm (or any size appropriate to the construction at hand). This internal 'wall panel' component facilitates the structural (concrete filled) design aspect. In addition, other required pipes such as stormwater, sewage, air ventilation system (in some construction projects) will be placed between the walls with this 25 same positional method. 4. The tops (and bottoms) of each panel, at assembly point in the process of manufacture, are fitted with a 'holding structure'. The holding -12 structure fixes the correct and precise position of the internal components prior to the use of the insulating / fixing foam which when set, permanently supports the exact location and ability to join perfectly from panel to panel (originally mapped out with computer software). 5 The holding structure will also facilitate the join between base panels and the slab or construction footing. 5. Conduit - joining between panels similar to internal piping, however specifically of a nature to safely housed electrical requirements. These conduits are not necessarily required to run vertically, and will be placed 10 by design within the wall panels to achieve construction application requirements. 6. Gas piping - housed inside PVC piping. 7. Second 'outside wall' in corner panel. Identical in properties to number '2'. 15 8. Second 'side of panel'. Identical in properties to number '1'. 9. Inner panel - similar to outer panel in assembly aspect he different immaterial use. This panel is most likely to be of a plasterboard nature, yet there are many options for the customer in selecting both inside and outside wall finishes. 20 10. Power points and other wall installation interfaces are placed into the 'wall panels' at assembly stage prior to panel delivery at the construction site. 11. Example of a smaller PVC type pipe for additional specific plumbing / other needs. 25 12. Prior to closing of the wall panel with either top / bottom 'holding structures' or the sides getting closed with the 'stopping' ends, inner corner reinforcement is placed within the structure.

-13 PICTURE 2 - STANDARD MODULE / WALL PANEL 1. Outside face of wall panel. 2. The flange at top of internal pipe - which facilitates a solid and clean join. 5 3. Inside face of wall panel. 4. Protruding base of 'structural pipe', utilised in joining with either the top of the pipe in a low wall panel or with their footing as part of the structural technology of this invention. 5. Internal pipe - structural. 10 6. Internal pipe - additional, for example to be utilised by stormwater / sewage or gas for domestic appliances. 7. Internal pipe - additional, for example to utilise by electrical cabling. Note: The wall panel in this diagram would typically be of length up to 6 m. The 15 standard proposed height of each panel is up to 1.2 meters and 1.35 meters. The dimensions do not form a fundamental constraint in the flexible potential of the panel design. BUILDING WITH THE UNIQUE WALL SYSTEM The Unique Wall System is a building method in which the completed structure 20 is achieved by combining modules called 'Unique Walls' in order to meet design outcomes as defined. All features of the building plan are integrated in computer 3D simulation software. First, a slab is constructed around the 'under-slab' preparations and set 25 founding pieces for the pipes joining system in precisely calculated positions.

-14 Then the walls modules are delivered to site and positioned according to computer allocation, having been constructed in the factory with all features as required. Windows, doors and other 'below-roof' features are all integrated according to 5 the plan. The ceiling is constructed. Roofing and floors are compatible with conventional and modern approaches. THE STANDARD UNIQUE WALL & VARIATIONS Aside from the different inner width options of the unique wall structure 10 (110mm / 200mm and proposed 400mm for industrial constructions), there are only 2 different components to the wall assembly. These are simply a 'left' and 'right' structure when handling corners with regard to inner and outer walls. MANUFACTURE AND COMPONENTS The Unique Walls panel is made of an inner and outer wall, fixed by an 15 insulating filler and housing vertical pipes that join when modules are connected. The materials for the outer and inner will be cut in their own production areas and provided as needed for assembly. The pipes for joining and additional pipes as per project design for plumbing and conduits for electricity etc are all inserted prior to the filling with fixing (and insulating) 20 material. The module is then coded for positional use on site. Materials to be used in the construction (wood, plaster, pvc pipes, other pipes, concrete and special filling material) will all be quality tested and reliable in all required properties. All materials used in the manufacture will be fully certified and approved by the appropriate standards and regulatory bodies. 25 BENEFITS FOR THE GREATER COMMUNITY There is great potential for this complete construction resource and method to greatly assist current needs in the building industry for efficient and viable -15 options amidst great housing demand. The Unique Wall System will help eliminate most pollution, industrial waste and rubbish associated with the building process. The basic manufacture of The Unique Wall is in itself better in minimizing harm to the environment than in 5 many other cases of building resource manufacture. The Unique Wall System building method also reduces waste due to efficient relationship between building process and prior calculations. With this product homes and other constructions can be achieved in much quicker build times than currently experienced. 10 The building will be completely economic and efficient in its regulation of the inner temperature via qualities that do not depend on power consumption. Additionally of great importance, the strength of the finished building as described, will be able to withstand much greater natural 'disaster' type forces than most other building methods currently being applied. 15

Claims

1. A building wall panel for constructing at least one building wall having a number of internal pipes, the building wall panel includes a building wall panel body including a number of sections of pipes at predetermined 5 positions; each of the number of sections of pipes including a flange at one end and a joining portion at an opposed end with one of which protruding from the building wall panel body; the number of sections of pipes are adapted to allow, during the 10 construction of the at least one building wall, the mating of a number of sections of pipes of one building wall panel body with a number of sections of pipes of an adjacent building wall panel body thereby to form the number of internal pipes of the assembled at least one building wall; mating of the number of sections of pipes to form the number of 15 internal pipes causes each of the sections of pipes to be sealingly fitted to adjacent sections of pipes by fitment of a flange into a joining portion thereby to form a pipe joint which allows each of the number of internal pipes being used as a sealed pipe to channel flow of liquid downwards through the respective internal pipe 20 wherein the number of internal pipes allows one or more utilities to be installed in the at least one building wall through a pipe selected from the number of internal pipes; and wherein each unused pipe of the number of internal pipes are able to be filled with a settable material thereby to form a framework 25 which provides support to the at least one building wall when assembled.

2. The building wall panel according to claim 1 in which the building wall panel body has a first outer panel, a second, opposed outer panel, and 30 a cavity which is formed between the first and second outer panels; - 17 wherein the number of sections of pipes are located inside the internal cavity and are enclosed with a filler material which is used to fill the cavity; wherein the filler material is used to join the first and second 5 panels to each other without require any additional fastening mechanisms.

3. A building wall which includes a building wall body which is constructed from one or more prefabricated building wall panels which are 10 positioned relative to each other to form the building wall body; the building wall body includes a number of internal pipes, which are assembled through the fitment of the one or more prefabricated building wall panels relative to each other to construct the building wall body, and each of which extends from a bottom end of the building wall 15 body to a top end thereof thereby to allow one or more utilities to be installed in the building wall body through a pipe selected from the number of internal pipes; each of the one or more prefabricated building wall panels including a building wall panel body which includes a number of sections 20 of pipes at predetermined positions each of which including a flange at one end and a joining portion at an opposed end with one of which protruding from the building wall panel body; and each of the number of internal pipes is assembled from a number of sections of pipe so that in an assembled configuration the 25 sections of pipes are sealingly fitted through fitment of a flange into a joining portion thereby to form a pipe joint which allows each of the number of internal pipes to be configured for use as a sealed pipe to channel flow of liquid downwards through the respective internal pipe. 30

4. The building wall according to claim 3 in which each panel of the one or more prefabricated building wall panels has a first outer panel, a second, opposed outer panel, and a cavity which is formed between the first and second outer panels; -18 wherein the number of internal pipes are located inside the internal cavity and are enclosed with a filler material which is used to fill the cavity; wherein the filler material is used to join the first and second 5 panels to each other without require any additional fastening mechanisms.

5. A building which includes at least one building wall, which is constructed from one or more prefabricated building wall panels; 10 the at least one building wall includes a number of internal pipes, which are assembled through the fitment of the one or more building wall panels relative to each other to construct the at least one building wall; each of the number of internal pipes are divided into sections of 15 piping and extends from a bottom end of the at least one building wall to a top end thereof and allows one or more utilities to be installed in the at least one building wall through a pipe selected from the number of internal pipes; each of the one or more prefabricated building wall panels 20 including a building wall panel body which includes a predetermined number of sections of pipes at predetermined positions each of which including a flange at one end and a joining portion at an opposed end with the joining portion protruding from a lower end of the building wall panel body; 25 the number of prefabricated building wall panels when used are arranged in at least two rows so that each of the plurality of building walls are constructed from at least two rows of stacked prefabricated building wall panels of the number of prefabricated building wall panels; wherein the sections of piping are arranged so that, for each of 30 the number of internal pipes, a joining portion of a section of piping, embedded in an upper row prefabricated building wall panel, is sealingly inserted into a flange of a section of piping embedded in a lower row -19 prefabricated building wall panel and which is positioned below the upper prefabricated building wall panel; and wherein the sealingly insertion of the ends of the sections of piping of the upper and lower prefabricated building wall panels to each 5 other causes the number of internal pipes to be sealed thereby allowing each of the number of internal pipes to be used as a sealed pipe to channel the flow of a liquid downwards through the number of internal pipes; and wherein each unused pipe of the number of internal pipes 10 are filled with a settable material thereby to form a framework which, when constructed, provides support to the at least one building wall.

6. The building according to claim 5 which includes a plurality of building walls each of which is constructed from a number of prefabricated 15 building wall panels; the sections of piping making up the number of internal pipes are embedded in cavities of the number of prefabricated building panel panels each of which are filled with a filler material; wherein the number of internal pipes are assembled once the 20 plurality of building walls are constructed through stacking of the number of prefabricated building wall panels.

7. The building according to claim 6 wherein the number of internal pipes includes a first group of joining pipes which are embedded at spaced 25 apart, predetermined positions inside the plurality of building walls thereby to form a number of framework support members of the framework which support the plurality of building walls; wherein the number of internal pipes further includes at least a second group of joining pipes which allows the utilities to be installed in 30 the plurality of walls.

8. The building according to claim 7 wherein each unused internal pipe of the second group of joining pipes are filled with a settable material -20 thereby to form additional framework support members for the framework thereby to strengthen the framework.

9. The building according to claim 7 which includes a slab from which the 5 plurality of building walls extends; and wherein the framework is connected to the slab through each of the first group of joining pipes.

10.The building according to claim 9 wherein the slab is also connected to each unused internal pipe of the second group of joining pipes which is 10 filled with a settable material.

11.A method of constructing at least one wall of a building; the at least one wall having a framework and is constructed from a number of prefabricated building wall panels; each of the one or more 15 prefabricated building wall panels including a building wall panel body which includes a number of sections of pipes at predetermined positions each of which including a flange at one end and a joining portion at an opposed end with one of which protruding from the building wall panel body; the method including the steps of 20 constructing the at least one wall using at least two prefabricated building wall panels by stacking the prefabricated building wall panels on top of each other so that a number of internal pipes are formed within the at least one wall by sealingly connecting a flange with a joining portion of adjacent sections of pipe, used to construct the number of 25 internal pipes, to each other; wherein each of the number of internal pipes form a sealed pipe to channel flow of liquid downwards through the respective internal pipe and is capable of allowing one or more utilities to be installed in the at least one building wall through a pipe selected from the number of 30 internal pipes and allowing each unused pipe of the number of internal pipes to be filled with a suitable material to form the framework.