GB2581354A

GB2581354A - A wall panel

Info

Publication number: GB2581354A
Application number: GB1901957.9A
Authority: GB
Inventors: Cinga Edvinas
Original assignee: Individual
Current assignee: Individual
Priority date: 2019-02-13
Filing date: 2019-02-13
Publication date: 2020-08-19
Also published as: GB201901957D0

Abstract

A pre-fabricated multi-layer wall panel 10 comprises an inner layer 1 co-facing with a first intermediate layer 2, the first intermediate layer comprising a first insulating material and co-facing with a second intermediate layer 3, the second intermediate layer comprising a load bearing material and co-facing with a third intermediate layer 4, the third intermediate layer comprising at least two structural support posts defining one or more cavities and a second insulation material 9 in the cavity, and a mechanically resistant fourth layer 5 co-facing and co-extensive with the third intermediate layer. The insulating materials are rigid and not subject to sag. The layers are fixed such that they provide an impervious barrier through which air cannot pass. The first and second insulating materials may comprise a graphite polystyrene. Co-facing a surface of the fourth layer be a cement render 6 comprising a silicone resin plaster layer 7. The inner layer may be plasterboard. The second intermediate layer may be oriented strand board (OSB). The support posts may be glue laminated timber or glulam. The fourth layer may comprise cementitious fiber board. Cross-beams may interconnect the support posts. The panel may define an aperture to receive a door or window frame.

Description

Intellectual Property Office Application No. GII1901957.9 RTM Date:21 Jule 2019 The following terms are registered trade marks and should be read as such wherever they occur in this document: Neopor (page 5) BASF (page 5) Kingspan (page 8) Intellectual Property Office is an operating name of the Patent Office www.gov.uk /ipo Title

A Wall Panel Field

The present application relates to wall panels, and in particular to pre-fabricated panels.

Background Of The Invention

An increased awareness of the need for more sustainable living coupled with national legislation, for example, the passive housing standards in Germany, (Passivhaus) have led to a surge in the development of energy efficient structures and new construction methods to support this field of technology.

Traditional methods of wall manufacture such as that of Figure 1, generally comprise structural supports (1) or a structural support layer, a layer of insulation, an inner layer (2) which can have many functions such as fire protection, aesthetic design, vapour check etc., an outer sheathing layer (3) for mechanical protection, an outer rendering layer (4) and a fixing means (5).

These layers may be constructed independently or several of the layers may be preassembled together, such as for example insulation backed plasterboard (combination of insulation layers and inner layer (2)) or Structural Insulated Panels (SIPs) (combination of structural support layer and insulation layer).

Due to the heat differential between the warm interior of the structure and the cool exterior of the structure, it is well recognised in the prior art that moisture laden air from within the interior of the structure will permeate through the various layers of the wall and when the moisture laden air is cooled to the dew point temperature of the air or below, condensation will occur. Thus, condensation typically occurs within the layers of the wall and the wall must be specifically designed in order to take the condensation process into account. If neglected, condensation can lead to a variety of problems such as material degradation, growth of moulds etc. A typical approach in tackling in-wall condensation is to provide a space between the condensation surface and the adjacent layer along with a means of venting the water which is generated. Various other approaches to the condensation problem include "breathable walls" (wherein the materials which make up the layers of the wall are arranged by their respective vapour permeability, with the least permeable layer being towards the interior of the structure and the most permeable layer being towards the exterior of the structure). Thus, the industry is moving towards new means of mitigating the effect of in-wall condensation rather than removing the cause of the in-wall condensation at its source.

It is therefore the object of the present invention to overcome some of the above mentioned problems of the prior art.

Summary

According to the present invention, there is provided a wall panel according to claim 1.

Embodiments provide a multi-layer structure, wherein at least one layer of the structure provides an impervious layer preventing air passing between opposite external surfaces of the wall panel.

The elimination of air cavities within intermediate layers of the wall panel has the advantage of providing a panel which in use is condensate free.

The wall panel can be completely pre-assembled off-site with multiple wall panels being readily and reliably connected together on site to form an exterior wall of a house or similar structure.

Brief Description of The Drawings

The present invention will now be described, by way of example, with reference to the accompanying drawings in which: Figure 1 illustrates a sectional view of a building including a typical wall panel; Figure 2 illustrates a sectional view of a wall panel according to an embodiment of the present invention; and Figure 3 illustrates thermal gradients through the wall panel of Figure 2. Detailed Description of The Drawings Referring now to Figure 2 of the accompanying drawings, there is illustrated a cross-section of a wall panel, generally indicated as (10), according to an embodiment of the present invention.

The wall panel (10) comprises several individual layers which are fixed together, some using mechanical fixtures and others using bonding techniques as will be described in detail below. These layers extend from an inner layer (1), which is adapted to be disposed in use towards the interior of a structure incorporating the wall panel (10), to an outer layer (7) which is adapted to be disposed in use towards the exterior of the structure.

The inner layer (1) can comprise, but is not limited to, a gypsum fiber board.

This inner layer may provide a range of functions such as water resistance, impermeability to air or water, fire protection, sound insulation or suitability as a base for a further layer, for example, a plaster or other decorative finish. It will be appreciated that the list of functions is not limited to those listed above. An exemplary thickness for the inner layer (1) is approximately 12.5mm.

In addition, the panel comprises a first intermediate layer (2), which is positioned between the inner layer (1) and a second intermediate layer (3) where the first intermediate layer (2) is an insulating material such as, but not limited to, expanded polystyrene. The first intermediate layer (2) may provide a range of functions such as water resistance, impermeability to air or water, fire protection, sound insulation, but in particular, the layer provides thermal resistance between the inside and outside surfaces of the wall panel (10). It will be appreciated that the list of functions is not limited to those listed above. An exemplary thickness for the first intermediate layer (2) is approximately 60mm.

In addition, the panel comprises the second intermediate layer (3), which is positioned between the first intermediate layer (2) and a third intermediate layer (4) where the second intermediate layer (3) is a load bearing material such as, but not limited to, Oriented Strand Board (OSB). The OSB is impervious to air and water. An exemplary thickness for the second intermediate layer (3) is approximately 12mm.

A third intermediate layer (4) incorporates a number of support posts (8) -only two of which are shown -which extend through the body of the wall panel (10) between the second intermediate layer (3) and a fourth intermediate layer (5).

The support posts (8) can be fixed to the second (3) and fourth (5) layers in any suitable manner for example, using mechanical fixings such as screws or nails and/or bonding techniques.

The posts (8) may be formed from glue laminated timber (glulam), such as spruce, or any other type of structural support materials as would be known by a person skilled in the art. The posts (8) are approximately 150mm deep and 50mm thick and the spaces between the posts (8) and the facing surfaces of the second (3) and fourth (5) intermediate layers define at least one cavity.

Typically, a wall panel will comprise a number of support posts (8) arranged to be vertically oriented when the wall panel is located within a building structure. It can be desirable to ensure that support posts are located at each end of the wall panel so that the side surfaces of the panels can be readily fixed to other structural members including other wall panels. Wall panels may also include a number of cross-beams (not shown) spanning between the vertical support posts (8). These may be formed from the same or different material to the support posts (8) and depending on the remaining assembly techniques, some of such cross-beams, may have an equal thickness through the wall panel or a lesser thickness than the posts (8).

Depending on the size and shape of wall panel, the spacing between support posts (8) within a panel can vary, but for a typical floor to ceiling height of wall panel, an average spacing of approximately 1200mm between support posts (8) can be sufficient.

As with the support posts (8), it can be useful to provide cross-beams running along an upper and lower surface of the wall panel when located within a building structure, so that again panels can be readily fixed to other structural 10 members located above or below a given wall panel.

Depending on the order of assembly of the layers, before one or other of the second (3) or fourth (5) intermediate layers are fixed to the support posts (8), the at least one cavity is filled with an insulation material (9) such that there are no air cavities within the wall panel. Again, suitable insulation materials can comprise polystyrene, but in particularly advantageous embodiments, graphite polystyrene materials such as, Neopor ® WLG 032 from BASF can be used.

Note that in each case, the insulating material of intermediate layers (2) and (4) is rigid and so not subject to sag and so breakdown of thermal resistance in the same manner as rockwool commonly using in partially pre-fabricated wall panels.

The elimination of air cavities can be achieved in a variety of ways such as, for example, by inserting a respective pre-cut solid section of insulation (9) into each cavity along with a suitable surface bonding or sealing material such that an airless bond / seal is formed between the adjacent interior surfaces of the second (3) and fourth (5) intermediate layers, the support posts (8) and the cross-beams and the insulation material (9). In this case, the cross-beams would either need to have the same thickness as the support posts or the insulation would need to be especially shaped to span the cross-beams without leaving any air within the cavity.

Alternatively, the or each cavity could be filled through a continuous or semi continuous line process wherein insulation material is dispensed into the cavity in a substantially liquid form and thereafter cured, as required, to solidify and fill the cavities. In this case, cross-beams within the body of the wall panel might not need to have the same thickness as the support posts as the insulation material could flow around the cross-beams as it cured.

In either case, once the other of the second (3) or fourth (5) intermediate layer is fixed to the support posts and the insulation (9), the third intermediate layer (4) is then sealed and airless.

The fourth intermediate layer (5) is a layer which provides mechanical resistance and protection for the other layers, and an example of a material suitable for use as the fourth layer (5) includes but is not limited to, cement bonded particle board. Whilst this fourth layer (5) is not necessarily impermeable to water, high water resistance is preferable.

At least one further adjacent layer (6, 7) may be applied to the fourth intermediate layer (5) at the time of manufacture i.e. before the panel is transported to a construction site for assembly within a structure. These additional layers (6,7) may provide either a function such as further sealing of the wall panel or they may provide an aesthetic finish, or both.

The additional layers may comprise for example a cement render (6) to a depth of approximately 4mm, followed by a sealant, for example, a silicone resin plaster layer (7) to a depth of approximately 2mm providing an external surface for the wall panel.

It will be appreciated that the wall panel may include additional layers between or adjacent the layers (1) to (7), as long as the sealed integrity of the wall panel is not affected by the inclusion of such an additional layer.

As each wall panel (10) is pre-assembled, on-site installation can be quicker and easier and thus more cost effective than using traditional house building methods which, even if they employ partly pre-assembled panels, still require further finishes to be applied to complete wall sections of a structure. As the wall panels (10) are pre-assembled, the assembly process can be optimised within a factory/manufacturing setting thus resulting in less waste and a more streamlined process.

The quality of such pre-assembled wall panels (10) can be verified through use of quality assurance procedures. Specific functionality (such as thermal performance, water-tightness etc.) can be guaranteed for the wall panels (10) as there need not be any post manufacturing intervention. Also, the quality of the installed product is less vulnerable to fluctuations in workmanship than that of more traditional methods of construction.

As the interior of the wall panel (10) is completely condensate free, moisture does not develop between layers and thus there is no need for a complex in wall moisture ventilation or breathable barrier layers, which can be subject to material degradation and/or mould growth.

While the above example has been described as a simple solid panel, it will be seen that in variants of the above example, apertures for windows and/or doors can be pre-defined within any given panel and even populated with doors or windows before transportation from a factory to a construction site to again facilitate high quality efficient construction.

In still further variations, supply conduits can be incorporated within any wall panel for facilitating distribution of electrical, mains or heated water or other utilities within a structure. Such conduits can extend through one, or both, of the layers (2) or (4) of the panel (10). So for example, such conduits could extend through the first intermediate layer (2) from a side, upper or lower edge of the wall panel to an aperture in the inner layer (1) so avoiding the need to cut out such channels on site and again to facilitate high quality efficient construction, while still maintaining a seal within the layers and so not negatively impacting the permeability of the wall panel (10).

Referring now to Figure 3, there is shown a temperature profile for the above described embodiment of wall panel. The panel provides an excellent heat transfer coefficient U = 0,14 W/(m2K) and it will be seen that a dew point within the panel remains below the temperature gradient shown from the outside surface of the panel to the inside surface so that no condensation can occur within the panel.

Similarly, it will be appreciated that the wall panel can protect the interior of a structure from large fluctuations in external temperature to maintain a relatively constant temperature within a structure formed by these wall panels.

While the above described embodiments have been described as having certain dimensions, it will be appreciated that these can be scaled as required in accordance with the size and demands for the structure in which the wall panel is to be incorporated.

The wall panel (10) of the above described embodiment is particularly suitable for pre-assembly and the order of fixing layers to one another can be varied as indicated above. Thus, in one example, layers (1) and (2) could be procured pre-assembled, such as the foam backed plasterboard products available from Kingspan. This can be fixed to the OSB layer (3) which may in turn have already been assembled to layers (4) up to (5), (6) or (7); or alternatively, the sub-assembly of layers (1) to (3) can form a base for the subsequent assembly of layers (4) to (7).

Claims

Claims A pre-fabricated multi-layer wall panel comprising: an inner layer (1) having a major surface which is adapted to be disposed in use towards an interior of a structure and an obverse surface, the obverse surface being in co-facing arrangement with a first major surface of a first intermediate layer (2); the first intermediate layer comprising a first insulating material and having an obverse surface in co-facing arrangement with a first major surface of a second intermediate layer (3); the second intermediate layer comprising a load bearing material and having an obverse surface in co-facing arrangement with a third intermediate layer (4); the third intermediate layer comprising: at least two structural support members fixed to and extending from the obverse surface of the adjacent second intermediate layer and defining one or more cavities within said third intermediate layer; and a second insulation material (9) having external surfaces co-facing and co-extensive with the cavity facing surfaces of said at least two structural support members and said obverse surface of said second intermediate layer, the first and second insulating materials being rigid and not subject to sag; and a fourth layer (5) comprising a mechanically resistant material co-facing and co-extensive with said third intermediate layer; wherein the layers are fixed together such that at least the combined second intermediate layer, third intermediate layer and fourth layer provide an impervious barrier through which air cannot pass from a major surface of the 25 panel to an obverse major surface of the panel.
2. A wall panel according claim 1 wherein said first and second insulating materials comprise different materials.
3. A wall panel according to claim 1 wherein said first and second insulating materials comprise a polystyrene.
4. A wall panel according to claim 3 wherein said second insulating material comprises a graphite polystyrene.
5. A wall panel according to claim 1 further comprising a cement render layer (6) co-facing a surface of the fourth layer opposite said third intermediate layer.
6. A wall panel according to claim 5 further comprising a silicone resin plaster layer (7) applied to said cement render layer (6).
7. A wall panel according to claim 1 wherein said inner layer comprises plasterboard.
8. A wall panel according to claim 1 wherein said second intermediate layer comprises oriented strand board.
9. A wall panel according to claim 1 wherein at least some of said support members comprise glue laminated timber.
10. A wall panel according to claim 1 wherein said fourth layer comprises cementitious fiber board.
11. A wall panel according to claim 1 wherein said support members comprises a plurality of parallel spaced support posts and a plurality of cross-beams interconnecting said support posts.
12. A wall panel according to claim 11 wherein at least some of said support members are disposed at respective minor surfaces of said wall panel.
13. A wall panel according to claim 1 in which at least one aperture arranged to receive a respective door frame or window frame is defined.