GB1573452A - Modular building system - Google Patents

Description

(54) MODULAR BUILDING SYSTEM (71) We, BLUE LINE DESIGN AND DEVELOPMENT LTD., formerly known as Blue Line Canal Carriers Limited, a British Company, of Hightrees, The Bailey, Skipton, Yorkshire, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: This invention relates to a wall panel for a modular building system.

A known wall panel used in modular building system consists of a generally rectangular timber frame sandwiched between outer metal skins. When assembling such panels to form a room, an architrave is generally used whenever an opening is required for a door into the room. In accordance with the present invention, one of the frame members of such a panel includes a rebate for hanging a door, at least one of the metal skins being folded to conform to the shape of the rebate. The resulting joint between the wall and the door thus appears smoothly finished and it is no longer necessary to provide an architrave.

One example of a wall panel embodying the invention is illustrated in the accompanying drawing in which the sole figure is a cross-section through the wall panel and showing a door hung in the rebate.

Referring to this drawing the wall panel consists of a mass of hardened thermal insulating foam material 40 sandwiched between a pair of steel skins 41 having a protective acrylic coating 42. The foam material is surrounded by a solid rectangular timber frame 43 which maintains the skins a fixed distance apart. Two opposed frame members 43a, 43b are shown in the drawing.

In assembling the panel, the two metal skins 41 are initially folded to the desired shape and then bonded to the insulating foam and to the timber frame by an adhesive, a vacuum being used to sustain the necessary pressure over the curing cycle.

One of the frame members 43b includes a rebate 48 cut into the timber to leave a projecting flange 44. The two metal skins 41 are folded inwardly around the frame member 43b to conform to the shape of the rebate.

Alternatively only one of the skins is folded, the folded portion being of sufficient length to extend completely around the rebate.

A door 47 is hung in the rebate 48 by means of hinges 49 (one of which is shown in the drawing), the hinges being secured to the opposing surfaces 45 and 50 of the frame member 43b and the door 47 respectively.

A channel section gasket 46 is inserted with a push-fit over the flange 44. The gasket is formed of a plastics material such as neoprene.

The width of the door 47 is less than the width of the wall panel so that the projecting flange 44 with its gasket 46 may also act as a door stop if the door is hinged at its other side to another wall panel. In this case the surface 51 of the door 47 may be provided with a magnetic catch for engaging a magnet attached to the flange 44.

WHAT WE CLAIM IS:- 1. A wall panel comprising a generally rectangular timber frame sandwiched between outer metal skins, one of the frame members including a rebate for hanging a door, and at least one of the metal skins being folded to conform to the shape of the rebate.

2. A panel according to claim 1 in which the metal skins are provided with a nonmetallic protective coating.

3. A panel according to claim 2 in which the said coating is an acrylic coating.

4. A panel according to any one of the preceding claims in which a mass of thermal insulating material is sandwiched between the opposing metal skins.

5. A panel according to claim 4 in which the insulating material comprises hardened foam material bonded to the metal skins.

**WARNING** end of DESC field may overlap start of CLMS **.

Claims (7)

**WARNING** start of CLMS field may overlap end of DESC **. (54) MODULAR BUILDING SYSTEM (71) We, BLUE LINE DESIGN AND DEVELOPMENT LTD., formerly known as Blue Line Canal Carriers Limited, a British Company, of Hightrees, The Bailey, Skipton, Yorkshire, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: This invention relates to a wall panel for a modular building system. A known wall panel used in modular building system consists of a generally rectangular timber frame sandwiched between outer metal skins. When assembling such panels to form a room, an architrave is generally used whenever an opening is required for a door into the room. In accordance with the present invention, one of the frame members of such a panel includes a rebate for hanging a door, at least one of the metal skins being folded to conform to the shape of the rebate. The resulting joint between the wall and the door thus appears smoothly finished and it is no longer necessary to provide an architrave. One example of a wall panel embodying the invention is illustrated in the accompanying drawing in which the sole figure is a cross-section through the wall panel and showing a door hung in the rebate. Referring to this drawing the wall panel consists of a mass of hardened thermal insulating foam material 40 sandwiched between a pair of steel skins 41 having a protective acrylic coating 42. The foam material is surrounded by a solid rectangular timber frame 43 which maintains the skins a fixed distance apart. Two opposed frame members 43a, 43b are shown in the drawing. In assembling the panel, the two metal skins 41 are initially folded to the desired shape and then bonded to the insulating foam and to the timber frame by an adhesive, a vacuum being used to sustain the necessary pressure over the curing cycle. One of the frame members 43b includes a rebate 48 cut into the timber to leave a projecting flange 44. The two metal skins 41 are folded inwardly around the frame member 43b to conform to the shape of the rebate. Alternatively only one of the skins is folded, the folded portion being of sufficient length to extend completely around the rebate. A door 47 is hung in the rebate 48 by means of hinges 49 (one of which is shown in the drawing), the hinges being secured to the opposing surfaces 45 and 50 of the frame member 43b and the door 47 respectively. A channel section gasket 46 is inserted with a push-fit over the flange 44. The gasket is formed of a plastics material such as neoprene. The width of the door 47 is less than the width of the wall panel so that the projecting flange 44 with its gasket 46 may also act as a door stop if the door is hinged at its other side to another wall panel. In this case the surface 51 of the door 47 may be provided with a magnetic catch for engaging a magnet attached to the flange 44. WHAT WE CLAIM IS:-

1. A wall panel comprising a generally rectangular timber frame sandwiched between outer metal skins, one of the frame members including a rebate for hanging a door, and at least one of the metal skins being folded to conform to the shape of the rebate.

2. A panel according to claim 1 in which the metal skins are provided with a nonmetallic protective coating.

3. A panel according to claim 2 in which the said coating is an acrylic coating.

4. A panel according to any one of the preceding claims in which a mass of thermal insulating material is sandwiched between the opposing metal skins.

5. A panel according to claim 4 in which the insulating material comprises hardened foam material bonded to the metal skins.

6. A panel according to any one of the preceding claims in which a channel section gasket is inserted over the projecting flange formed by the rebate.

7. A panel according to claim 1 and substantially as herein described with reference to the accompanying drawing.