US20240084576A1

US20240084576A1 - Apparatus and methods for prefabricated building skin system exterior wall panels

Info

Publication number: US20240084576A1
Application number: US18/467,516
Authority: US
Inventors: Bruce Dennis BEATTY; Andrew Keith LOFF
Original assignee: Hitt Holding Corp
Current assignee: Hitt Holding Corp
Priority date: 2022-09-14
Filing date: 2023-09-14
Publication date: 2024-03-14

Abstract

Apparatus, systems, and methods for a prefabricated building skin system including a composite external wall panel. The external wall panel may include an inner skin forming a first side of the external wall panel and an outer skin forming a second side of the external wall panel. A fiber reinforced polymer is wrapped around a panel edge connecting the inner skin and the outer skin. A foam center may be disposed between the inner skin and the outer skin. A thermoset resin may be infused into the composite external wall panel. At least one steel connector integrated between the inner skin and the outer skin. The steel connector may be connectable to a building column, wherein the steel connector is configured to support a vertical load.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This patent application claims priority to U.S. Provisional Patent Application No. 63/375,578, filed on Sep. 14, 2022, and entitled “APPARATUS AND METHODS FOR PREFABRICATED BUILDING SKIN SYSTEM EXTERNAL WALL PANELS.” The disclosure of the prior application is considered part of and is incorporated by reference into this patent application.

TECHNICAL FIELD

The present disclosure generally relates to apparatus and methods for building skin system external wall panels.

BACKGROUND

Traditional skin systems for buildings, such as veneers or facades, may be limited by various factors including weight, cost, and assembly time. In particular, external wall panels for buildings may need to comply to various design code requirements or standards, which may result in the use of different components to satisfy such requirements. For example, exterior or external wall panels, which may have windows or doors, may not be able to satisfy code requirements without the use of additional parts. Further, conventional wall panels may not be able to react loads experienced during assembly, transportation, installation, or service without additional structural members to support any cladding, thereby increasing the weight of the external skin system. Therefore, there is a need for a prefabricated building skin system which can be lightweight, self-supporting, and able to satisfy building code requirements.

SUMMARY

Disclosed embodiments include systems, methods, and apparatus for a prefabricated building skin system. Some disclosed embodiments involve a composite external wall panel. Some disclosed embodiments include an inner skin forming a first side of the external wall panel. Some disclosed embodiments include an outer skin forming a second side of the external wall panel; wherein a fiber reinforced polymer may be wrapped around a panel edge connecting the inner skin and the outer skin. Some disclosed embodiments include a foam center disposed between the inner skin and the outer skin. Some disclosed embodiments include a thermoset resin infused into the composite external wall panel. Some disclosed embodiments include at least one steel connector integrated between the inner skin and the outer skin, the steel connector connectable to a building column, wherein the steel connector may be configured to support a vertical load.
In some disclosed embodiments, the steel connector may be connectable to the building column by a single point connection on each column. Some disclosed embodiments include a maximum deflection of a span length divided by 400 when subjected to at least one of an erection load, a service load, or a dead load. In some disclosed embodiments, wherein the inner skin and the outer skin comprise fiberglass and thermoset resin. Some disclosed embodiments include a rain screen covering the outer skin. Some disclosed embodiments include a gel finish on the outer skin. Some disclosed embodiments include a painted finish on the outer skin. Some disclosed embodiments include a brick finish on the outer skin. In some disclosed embodiments, the fiber reinforced polymer may be vacuum infused with the thermoset resin. Some disclosed embodiments include at least one inner frame. Some disclosed embodiments include a glazing disposed within the inner frame.
Some disclosed embodiments include a method for assembling a prefabricated building skin system. Some disclosed embodiments include forming, at a first location, an external wall panel by positioning a fiberglass wrapping around a foam core; the foam core disposed between an inner skin and outer skin, integrating a steel connector into the external wall panel, and integrating a thermoset resin into the wall panel by vacuum infusing the resin, wherein an atmospheric pressure differential from the vacuum pushes the resin through a void space in the external wall panel. Some disclosed embodiments include applying, at the first location, a finish to the external wall panel. Some disclosed embodiments include connecting the external wall panel to a building column at a second location.
In some disclosed embodiments, the finish includes a brick finish. In some disclosed embodiments, the finish includes a rain screen. In some disclosed embodiments, the finish includes a paint. Some disclosed embodiments include connecting the steel connector to the building column through an attachment bracket. In some embodiments, the external wall panel may have a maximum deflection of a span length divided by 400 when subjected to at least one of an erection load, a service load, or a dead load. Some disclosed embodiments include an inner frame. Some disclosed embodiments include applying a glazing disposed within the inner frame.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sketch of a front view of a wall panel, consistent with embodiments of the present disclosure.

FIG. 2 is an illustration of a cross section of a wall panel, consistent with embodiments of the present disclosure.

FIG. 3 is an illustration of a perspective view of a wall panel, consistent with embodiments of the present disclosure.

FIG. 4 is an illustration of a cross section of an external wall panel, consistent with embodiments of the present disclosure.

FIG. 5 is an illustration of a column building connection, consistent with embodiments of the present disclosure.

FIG. 6 is an illustration of a panel connection, consistent with embodiments of the present disclosure.

FIG. 7 is an illustration of a building connection, consistent with embodiments of the present disclosure.

FIG. 8 is an illustration of a building skin system, consistent with embodiments of the present disclosure.

FIG. 9 is an illustration of a building skin system, consistent with embodiments of the present disclosure.

FIG. 10 is an illustration of a building skin system, consistent with embodiments of the present disclosure.

FIG. 11 is a flow diagram for a method for assembling a prefabricated building skin system, consistent with embodiments of the present disclosure.

DETAILED DESCRIPTION

All relative terms such as “about,” “substantially,” “approximately,” etc., indicate a possible variation of ±20% (unless noted otherwise or another variation is specified). For example, a feature disclosed as being about “t” units long (wide, thick, etc.) may vary in length from (t−0.2t) to (t+0.2t) units. Similarly, a temperature within a range of about 100-150° C. can be any temperature between (100-20%) and (150+20%). In some cases, the specification also provides context to some of the relative terms used. For example, a structure described as being substantially circular or substantially cylindrical may deviate slightly (e.g., 20% variation in diameter at different locations, etc.) from being perfectly circular or cylindrical. Further, a range described as varying from 1 to 10 (1-10), or between 1 and 10, includes the endpoints (i.e., includes 1 and 10).
Unless otherwise defined, all terms of art, notations, and other scientific terms or terminology used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this disclosure belongs. Some of the components, structures, and/or processes described or referenced herein are well understood and commonly employed using conventional methodology by those skilled in the art. Therefore, these components, structures, and processes will not be described in detail. All patents, applications, published applications and other publications referred to herein as being incorporated by reference are incorporated by reference in their entirety. If a definition or description set forth in this disclosure is contrary to, or otherwise inconsistent with, a definition and/or description in these references, the definition and/or description set forth in this disclosure controls over those in the references that are incorporated by reference. None of the references described or referenced herein is admitted as prior art to the current disclosure. Furthermore, it should be noted that section headings are used in the description below solely to improve readability. The features described under one section heading are applicable to the description under all section headings. That is, even if it is not expressly described, each described feature can be used interchangeably with other described features.
Disclosed embodiments may involve a building exterior wall panel system including any attachment systems for various cladding systems and to accommodate a glazing and/or fenestration system. The entire panel may be completed off site, and unit or entire panel are transportable to jobsite for erection. In some examples, wall panel systems may span 40 feet column to column.
The panel system may include compliance with building, energy, and sustainable code design requirements including thermal break and/or continuous insulation, moisture and vapor barrier, air infiltration resistance, fire resistance, structural span and deflection, lifespan, and/or sustainability elements in a prefabricated panel.
Some disclosed embodiments involve a prefabricated building skin system. Prefabrication may refer to manufacturing or assembling components of a structure, device, or apparatus before installation of the apparatus. For example, prefabricated systems may be manufactured or assembled in a factory or other manufacturing site and transported to an installation site, such as for a system assembled in a factory and installed at a construction site. A building skin system may refer to an exterior of a building or structure, such as a boundary between an outside environment and the inside of a building. In some examples, a building skin system may refer to an external face or façade, including cladding. It will be recognized that building skins may provide protection, enable structural support, and serve aesthetic purposes.
Some disclosed embodiments involve a composite external wall panel. A wall panel may refer to any external skin or covering for a building, such as covering for a wall. In some examples, a composite wall panel may refer to a wall panel which includes one or more materials or components. For example, a composite wall panel may include multiple different materials or components. A composite panel may also refer to a sandwich panel, including panels with a core layer and an outer layer on one or both sides of the core.
FIG. 1 illustrates a front view of a wall panel, consistent with embodiments of the present disclosure. Wall panel 100 may be a sandwich panel including fiberglass (e.g., knit fiberglass laminate). Wall panel 100 may include a skin 102, which may have an inner or outer surface. In some examples, wall panel 100 may include one or more frames 104, which may represent openings in wall panel 100. Disclosed embodiments of wall panel 100 may involve facesheets having a continuous filament material (CFM) fiberglass, which can be a reinforced material composed of continuous glass fiber strands that are spun to produce a random fiber orientation. A skin may include a facesheet, which may refer to a sheet of material which may serve as an outer face. The CFM fiberglass can also facilitate a closed molding process such as vacuum infusion (resin transfer molding and compression molding). In addition, the facesheets include knit material fiberglass, which can be used for the facesheets' laminate build-up. The thickness and core thickness may be varied according to the specification of an architect design, as such, the laminate may vary in thicknesses and weight, and may have four different layer orientations, such as: 0°, −45°, 90°, and 45°.
The structure and composition of wall panel 100 may allow wall panel 100 to span between columns of a building. It will be appreciated that wall panel 100 may be self-supporting, such that additional structural members or components may not be necessary to support any cladding. Wall panel 100 may be lightweight compared to conventional wall systems (which can weigh in at 100-125 pounds per square foot and/or combination panel systems at 60 psf), as wall panel 100 may weigh 15-30 psf in some examples. This weight difference affects the methods for shipping and/or handling as well as rigging of the panels onto the building façade including equipment differences (quantity as well as size of cranes).
FIG. 2 illustrates a cross section of a wall panel, consistent with embodiments of the present disclosure. Wall panel 200 may include an outer skin 202 and an inner skin 206, which may each represent a side or face of wall panel 200. In some embodiments, inner skin 206 may form a first side of wall panel 200, and outer skin 202 may form a second side of wall panel 200. For example, inner skin 206 may refer to a face or surface of wall panel 200 which can contact a building, and outer skin 202 may refer to a surface of wall panel 200 which may be disposed opposite to the inner skin 206. In some embodiments, wall panel 200 may include reinforced polymer wrapped around a panel edge. Fiber-reinforced polymer may be wrapped around one or more panel edges of wall panel 200, thereby connecting the inner skin 206 and the outer skin 202. In some examples, fiber-reinforced polymer may be wrapped around all panel edges, such as all four edges of a rectangular wall panel, as an exemplary embodiment. For example, fiber-reinforced polymer may be wrapped around an inner frame on the edges of wall panel 200, and the fiber-reinforced polymer may form the inner skin 206 and outer skin 202. In some examples, inner skin 206 and outer skin 202 may have the same thickness or different thickness from each other depending on the configuration of the panel. In some examples, inner skin 206 and outer skin 202 may each have a thickness of 0.25 inches to 0.75 inches.
In some embodiments, a wall panel may include foam. For example, wall panel 200 may include foam 204 disposed between inner skin 206 and outer skin 202. Wall panel 200 may include reinforced polymer on each side of foam 204, such as a foam core, foam stick, or foam center. Fiber-reinforced polymer may be wrapped around one or more sides, or all sides, of a foam center. For example, fiber-reinforced polymer may be wrapped around a foam core, with a polymer thickness of 0.125 inches to 0.5″. In an example, foam 204 may include PET (Polyethylene Terephthalate) foam core (sticks), which can be resin-infused together to form a structural integral shear web within the wall panel. Foam core 204 may also include closed cell foams, such as polyisocyanurate, polyvinyl chloride (PVC), or polyurethanes. In some examples, wall panel 200 may include an integral web, which may refer to a unit of fiber-reinforced polymer wrapped around a foam core. The foam core may be fire retardant, such as to ASTM E84 class 1 standards, and may be a green sustainable product.
FIG. 3 illustrates a perspective view of a wall panel, consistent with embodiments of the present disclosure. Wall panel 300 may include a panel edge 304, which may have a thickness 306. As described herein, wall panel 300 may include an outer skin 302 and an inner skin (not shown in FIG. 3 ). The wall panel 300 may have a frame width 308, which may be a distance or dimension between an edge of wall panel 300 and an inner frame of the panel. As described herein, disclosed embodiments may involve fiber-reinforced polymer wrapped around edges of wall panel 300, including fiber-reinforced polymer wrapped around panel edge 304. In an example, panel edge 304 may connect outer skin 302 and the inner skin. In some examples, wall panel 300 may provide thermal insulation properties, such as a minimum R-value of 2 per inch of thickness. Wall panel 300 may be lightweight and strong, allowing flexibility and creativity of design, offering longevity, and may last up to 100 years. Further, wall panel 300 may offer minimum of upkeep and repair, offer good electrical insulation, offer high impact strength, fire retardant capabilities, and may be low cost due to its use of composite materials.
FIG. 4 illustrates a cross section of an external wall panel, consistent with embodiments of the present disclosure. Wall panel 400 may include an inner frame 404, which may be an opening. For example, windows or doors may be placed within frame 404. In some embodiments, wall panel 400 includes a thermoset resin 402, as well as fiberglass. Thermoset resin 402, which may include phenolic resin, may be infused into wall panel 400. The addition of hardeners may influence the pot life, gel and cure temperature times for the resin. It will be recognized that disclosed embodiments may involve other resins. The viscosity, specific gravity, free formaldehyde, pot life, water, and free phenol may be optimized to ensure that the phenolic resin may be compatible with the infusion process. In some examples, the core of the wall panel may not absorb the phenolic resin because the core may have closed cells. In some examples, the resin may be fire retardant, such as to meet flame propagation standards and/or requirements, including NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) 285 standards (Standard Fire Test Method for the Evaluation of Fire Propagation Characteristics of Exterior Wall Assemblies Containing Combustible Components). The resin infusion process may involve the use of multiple layers of specifically-oriented fiberglass fabric (particular to the design loads and needs of the particular panels) coupled with phenolic fire-resistive resin over a layer of foam cores resin-infused together, forming the structural shear webs within the panels themselves, as described herein. In some examples, the infusion process may involve acrylic, epoxy, vinylester, polyester, or any suitable thermoset resin. In some embodiments, resin 402 may be integrated into wall panel 400 by vacuum infusion. For example, vacuum infusion may involve an atmospheric pressure differential, which may push resin 402 through a void space in wall panel 400. The resin 402 may then fill any void spaces in wall panel 400. As such, it will be appreciated that wall panel 400 may resist moisture, vapor, and air infiltration, as well as enable appropriate temperature transfer (R-value), and resist fire and/or flame propagation. For example, wall panel 400 may limit air infiltration such that it may comply with building codes that have a 0.1 cubic feet per minute (per square foot) at 6.24 pounds per square feet maximum air infiltration.
In some embodiments, wall panel 400 may include at least one steel connector integrated between the inner skin and the outer skin. For example, wall panel 400 may include a steel connector 406, which may be connectable to a building. In some examples, wall panel 400 may be connectable to any structural member of a building. For example, steel connector 406 may be connectable to a floor beam. In another example, steel connector 406 may be connectable to a floor beam and a building column. In some embodiments, steel connector 406 may be connectable to a building column. Wall panel 400 may include any number of connectors. A connector may refer to any component for connecting wall panel 400 to other wall panels or to an external surface. For example, a connector may include a plate or steel profile, which may be made of steel, disposed within panel 400, such as disposed between the inner skin and outer skin of panel 400. For example, external panel 400 may be connected at certain locations to a balcony structure where the panel and joints can be designed to carry vertical shear and compression loads. In some examples, steel connector 406 can be threaded through the fiber-reinforced polymer. Joints in the wall panel 400 may include butt joints with a double caulk joint for the purpose of preventing water intrusion. Caulk joints can be used, and the structural connection may be a steel plate bolted to the panel. Panel 400 may be embedded with steel connector 406, which may be a steel plate, to accommodate the joint connections. Panel 400 may include one or more steel plates which may be placed at certain intervals. For example, joints may be held to wall panel 400 through surface mounted steel plates at certain intervals bolted to panel 400 with embedded threaded steel plate for a positive bolted connection. The embedded threaded steel plates may be installed inside the wall panel, such as between the inner and outer skins, thereby enabling any embedded threaded steel plates to provide a structural connection.
FIG. 5 illustrates an exemplary embodiment of a column building connection, consistent with embodiments of the present disclosure. As discussed herein, wall panel 502 may include steel connectors 506, which may be a steel plate integrated into wall panel 502. In some embodiments, steel connector 506 may be connectable to building column 514. Building columns may refer to structural elements which may transfer loads, including vertically-oriented columns or pillars. Connectable may involve attaching, securing, or fixing. For example, steel connector 506 may be connectable to building column 514 such that wall panel 502 may be secured to building column 514. In an example, steel connector 506 may be connectable to building column 514 through attachment bracket 512. Attachment bracket 512 may be fixed to a building connector 504, such as through screws or bolts 510, and wall panel 502 may be secured to the attachment bracket 512 through bolts 508 which may be driven through steel connector 506. As such, it will be appreciated that steel connector 506 may be configured to support a vertical load. A vertical load may refer to any load applied in a vertical direction, including gravity loads such as a load applied perpendicular to a floor or the ground. For example, the vertical load may include the dead load, such as the intrinsic weight, attached cladding, or glazing, of panel 502. Vertical loads may also include seismic loads and ice loads.
FIG. 6 illustrates a panel connection, consistent with embodiments of the present disclosure. For example, panel connection 600 may include steel connector 602, which may include one or more connection hardware 604. Connection hardware 604 may include any suitable connector or fastener, including steel bolts. Panel connection 600 may include an elevation adjustment shim 606, which may be any shim for adjusting the height of certain connections. It will be appreciated that steel connectors 602 disposed within the panel may enable connection hardware 604 to be connected to the panel, as it may be detrimental to thread hardware such as bolts through fiberglass in the panel. In some embodiments, steel connector 602 may be connectable to the building column by a single point connection on a building column. In some examples, steel connector 602 may be connectable to building columns by a single point connection on each column the panel may cover. For example, steel connectors 602 may be spaced apart within the external panel to be flush or aligned with the columns of a building. In an example, a single point connection may refer to a single bolt per column connection. In some examples, there may be any suitable number of bolts per column connection depending on the configuration of the external panel, including one to six bolts per column connection.
FIG. 7 illustrates a building connection 700, consistent with embodiments of the present disclosure. Building connection 700 may include a building connector 704, which may be attached to building column 702. For example, building connector 704 may be a steel connector connectable to an external wall panel. In some embodiments, the distances between building columns 702 in a structure may be span lengths. Some disclosed embodiments involve a maximum deflection, which may refer to a stiffness or degree of deformation of a component. For example, referring to FIG. 5 , wall panel 502 may have a maximum deflection of a span length divided by 400 when subjected to at least one of an erection load, a service load, or a dead load. In some examples wall panel 502 may have a maximum deflection of span length divided by 400 when experiencing an erection load, a service load, and a dead load. For example, the erection load may refer to loads experienced during assembly and/or construction, and the service load may refer to loads experienced when the wall panel may be used or in service. Thus, it will be appreciated that wall panel 502 may react erection, service, and/or dead loads without requiring additional structural members to support cladding. In some examples, the embedded steel plates and layers of fabric may accommodate generated shear and compression loads of a structure, such as a balcony. The loads can be distributed back to the building structure through dead load column connections and lateral rod connections back to the perimeter of beams, reducing direct concentrated loads applied to the building structure.
FIG. 8 illustrates a skin system 800, consistent with embodiments of the present disclosure. Skin system 800 may include an external wall panel 802 connected to building column 804 by connector 806. It will be recognized that wall panel 802 may be configured in any orientation, including vertical and horizontal orientations. For example, wall panel 802 may represent a vertical orientation of a wall panel.
FIG. 9 illustrates a building skin system, consistent with embodiments of the present disclosure. Skin system 900 may include one or more external wall panels, such as wall panel 902 and wall panel 906. As discussed herein, wall panels may be horizontally or vertically adjacent, and may include caulk between the exteriors of different wall panels. In some embodiments, wall panels may include at least one inner frame. For example, wall panel 902 may include inner frame 904. An inner frame may refer to any frame or outline, including frames disposed within a wall panel. For example, inner frame 904 may be an opening, cutout, or cavity within wall panel 902 such that components may be placed within inner frame 904. Disclosed embodiments may involve one or more inner frames. In some examples, a wall panel may include no inner frames, one inner frame, or multiple inner frames. Components such as doors or windows may represent cladding or finishes which may be applied to wall panel 902. Some disclosed embodiments include a glass finish 910 disposed within the inner frame 904. In some embodiments, skin system 900 may also include a parapet 912 disposed above external wall panel 902. For example, parapet 912 may refer to a barrier or low protective along the top of external wall panel 902. In some examples, wall panel 902 may have any suitable dimension, such as dimensions of 40 feet length by 13.5 feet height. For example, wall panel 902 may span from building column-to-column spaced apart at 40 feet, with panel window openings disposed in an inner frame 904 taking 80% of the panel face area.
It will be appreciated that any suitable finish, façade, or veneer may be applied to the outer skin 908 of external wall panels, such as wall panel 906. In some embodiments, a finish such as glazing may be applied to an external wall panel. For example, glazing may refer to glass, such as the installation of glass in an opening (e.g., a window or door). Glazing may also involve glass included in a wall. In some examples, a rain screen may cover the outer skin 908 of external wall panel 906, thereby providing a cosmetic cladding on the exterior of the wall panel. Some disclosed embodiments involve a gel finish on the outer skin 908. A gel finish or gel coat may be applied to wall panels, including spray gel coat. Some disclosed embodiments involve a brick finish on the outer skin 908. A brick finish may refer to brick cladding, including brick with drainage features including base flashing and weep holes. Brick may include building units which may include materials such as clay, stone, or the like. Some disclosed embodiments may involve a painted finish on outer skin 908. A painted finish may include applying paint coating to the outer skin 908. In some examples, the outer skin 908 can be painted with fluropolymer. It will be recognized that any suitable finish may be applied to a skin, such as an outer skin, of the external wall panels, including any combination of finishes. Further, it will be appreciated that applied finishes may provide one or more functionalities, including protection, and aesthetics. The outer skin of the panel may be designed to allow for the fastening of a finish material. Wall panel 906 may include veneers which can be fastened anywhere on the panel face and maintain a structural connection, which may provide a more simple layout for attachment of panel veneers.
It will be appreciated that wall panels such as panel 906 may offer a complete code-compliant and sustainable building exterior wall system that integrates both the code-required exterior wall panel system with the addition of an aesthetic architectural finishes in one fabrication process, which may be shipped directly to the construction site from the panel prefabrication plant. Panel 906 can also be used with a customized structural design of the fiber layers to satisfy ATFP (Anti-Terrorism Forced Protection) needs by providing an exterior building wall panel system that provides protection from blast and ballistic penetration in accordance with the Unified Facilities Criteria (UFC) DoD (Department of Defense) Minimum Antiterrorism Standards for Buildings.
FIG. 10 illustrates a building skin system 1000, consistent with embodiments of the present disclosure. Skin system 1000 may include a wall panel 1002 which may be connected to building column 1004. In an example, wall panel 1002 may be in a vertical configuration. In some examples, wall panels as described herein may be connectable to a building, including to various structural elements of a building, such as a floor beam or support beam. For example, wall panel 1002 may be connected to a floor beam and/or a building column 1004. Wall panel 1002 may include one or more inner frames, with glazing 1006 disposed within the inner frame. It will be appreciated that wall panels 1002 may provide a moisture barrier, such as a moisture barrier in accordance with AMERICAN ARCHITECTURAL MANUFACTURERS ASSOCIATION and/or ASTM standards. In some examples, wall panel 1002 may enable the complete installation of glazing, such as glazing 1006 (e.g., glass in windows), and/or doors, prior to delivery and installation at the jobsite, thereby reducing the time and manpower on-site.
It will be appreciated that disclosed embodiments provide the ability to satisfy multiple building code design requirements, such as various standards described herein (e.g., NFPA 285), in one panel, such as panel 1002, rather than using a series of different products to comply with design requirements, which may result in higher weight, increased costs, and/or increased construction time.
FIG. 11 illustrates a flow diagram for a method for assembling a prefabricated building skin system. Method 1100 may include a first step 1102 of forming, at a first location, an external wall panel. A first location may refer to a location away from an erection site of a wall panel, such as a different site from where a wall panel may be installed. For example, a first location may include a factory or manufacturing site. Forming the external wall panel may include a step 1104 of positioning a fiberglass wrapping around a foam core. The fiberglass wrapping may refer to the fiber-reinforced polymer, as described herein. For example, fiberglass may be wrapped around a foam core to form a sandwich panel. In some examples, fiberglass may be wrapped around the edges of a wall panel, such that the fiberglass forms the inner skin and outer skin of the wall panel. The foam core may be disposed between the inner skin and outer skin.
Method 1100 may include a step 1106 of integrating a steel connector into the external wall panel. A steel connector, such as a steel plate, may be placed within the inner skin and outer skin such that the fiberglass can be wrapped around the steel connector. For example, a steel connector may be molded into the panel behind the inner or outer skin.
Method 1100 may include a step 1108 of integrating a thermoset resin into the wall panel by vacuum infusing the resin. Vacuum infusing the resin may involve creating a vacuum to generate pressure to drive resin into a laminate. Components of the wall panel, such as steel connectors, foam cores, and fiberglass, may be laid into a mold or frame. The vacuum, such as from a vacuum bag, may create an atmospheric pressure differential which may push the resin through a void space in the external wall panel. For example, the pressure differential may be a difference between the pressure in the vacuum bag and the atmospheric pressure, thereby driving the resin through void spaces in the external wall panel. As a result, the resin may be infused into the wall panel, filling any empty space and joining together various components, such as the steel connectors, fiberglass, and foam cores. In some example, step 1108 may involve a closed molding process such as vacuum infusion (e.g., resin transfer molding).
Method 1100 may include a step 1110 of applying, at the first location, a finish to the external wall panel. In some examples, a finish can be applied to the outer skin of the wall panel, as described herein. The finish can include paint, glazing, brick, ceramic, or any other suitable finish. A rain screen may also be applied to the wall panel at the first location. For example, the finish can be applied at a factory or manufacturing site for the panel before the panel may be transported to a construction site. In some examples, step 1110 includes the installation of glass windows and/or doors prior to delivery and installation at the jobsite, reducing the time and manpower required on-site.
Method 1100 may include a step 1112 of connecting the external wall panel to a building column at a second location. The building column may refer to any column for a structure. The second location may refer to the location of the building, such as a construction site or location where the wall panel may be installed. In some examples, the second location may be different from the first location, such as the location of the manufacturing of the wall panel. In some embodiments, connecting the external wall panel may involve connecting the steel connector to the building column through an attachment bracket, as described herein. Connecting the external wall panel may refer to any method of fastening, attaching, or securing the wall panel to building, including by connecting to one or more building panels. Wall panels may be connected to one or more building columns such that they span between columns. Step 1112 may also involve caulking adjacent wall panels together. Thus, it will be appreciated that disclosed embodiments, including method 1100, may enable the ability to assemble wall panels with finishes such as windows and/or facades at a factory and transport the panels to a jobsite, where the panels may be already assembled and ready to be erected.
In some examples, the structural design of the panel system may include accommodations for the addition of balconies for use on multi-family residential structures. The balcony loads may be accounted for within the structure of the panels and may not rely on a direct tie back to the building structure, thus eliminating penetrations thru the exterior wall barrier into the building structure.
Methods described herein may allow for design-to-fabrication duration including 1-day fabrication versus typical 7-day precast concrete and/or a 6-week typical stick-built on-site installation solution. The installation of the exterior façade of the building (which may be watertight) may allow the interior construction work (mechanical, electrical, partitions, and/or finishes) to begin sooner. Disclosed embodiments may reduce on-site labor hours compared to typical methods, thereby reducing the potential exposure to safety hazards. Disclosed embodiments may reduce overall construction time on-site resulting in earlier occupancy of the building. For example, the use of external wall panel 300 on a 4-story structure saves 3 months in construction and erection time and on a 12-story structure saves 6 months in construction and erection time compared to traditional construction methods. Further, such reduction in time on-site and acceleration of the project schedule saves in construction loan carry costs for the project owner.
Disclosed embodiments may reduce on-site labor, time and associated costs. It will be appreciated that external wall panels, such as wall panel 906, can be customized to specific project needs. The specifics of window opening sizes, spans between columns, and the addition of balconies to the panel design may be enabled by wall panel 906, as referenced in FIG. 9 .
The structural “column-only” building deadload connection of wall panel 906 may be ideal for building recladding and/or refacing applications relying on the predictable existing column load capacity and eliminating and/or discounting the typical floor connection for existing buildings.
The foregoing disclosure provides illustration and description but is not intended to be exhaustive or to limit the implementations to the precise form disclosed. Modifications may be made in light of the above disclosure or may be acquired from practice of the implementations. As used herein, the term “component” is intended to be broadly construed as hardware. As used herein, satisfying a threshold may, depending on the context, refer to a value being greater than the threshold, greater than or equal to the threshold, less than the threshold, less than or equal to the threshold, equal to the threshold, and/or the like, depending on the context. Although particular combinations of features are recited in the claims and/or disclosed in the specification, these combinations are not intended to limit the disclosure of various implementations. In fact, many of these features may be combined in ways not specifically recited in the claims and/or disclosed in the specification.
Although each dependent claim listed below may directly depend on only one claim, the disclosure of various implementations includes each dependent claim in combination with every other claim in the claim set. No element, act, or instruction used herein should be construed as critical or essential unless explicitly described as such. Also, as used herein, the articles “a” and “an” are intended to include one or more items and may be used interchangeably with “one or more.” Further, as used herein, the article “the” is intended to include one or more items referenced in connection with the article “the” and may be used interchangeably with “the one or more.” Furthermore, as used herein, the term “set” is intended to include one or more items (e.g., related items, unrelated items, a combination of related and unrelated items, and/or the like), and may be used interchangeably with “one or more.” Where only one item is intended, the phrase “only one” or similar language is used. Also, as used herein, the terms “has,” “have,” “having,” or the like are intended to be open-ended terms. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. Also, as used herein, the term “or” is intended to be inclusive when used in a series and may be used interchangeably with “and/or,” unless explicitly stated otherwise (e.g., if used in combination with “either” or “only one of”).
Moreover, while illustrative embodiments have been described herein, the scope of any and all embodiments having equivalent elements, modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those skilled in the art based on the present disclosure. The limitations in the claims are to be interpreted broadly based on the language employed in the claims and not limited to examples described in the present specification or during the prosecution of the application. The examples are to be construed as non-exclusive. Furthermore, the steps of the disclosed methods may be modified in any manner, including by reordering steps and/or inserting or deleting steps. It is intended, therefore, that the specification and examples be considered as illustrative only, with a true scope and spirit being indicated by the following claims and their full scope of equivalents.

Claims

What is claimed is:

1. A prefabricated building skin system comprising:

a composite external wall panel including:

an inner skin forming a first side of the external wall panel;

an outer skin forming a second side of the external wall panel; wherein a fiber reinforced polymer is wrapped around a panel edge connecting the inner skin and the outer skin;

a foam center disposed between the inner skin and the outer skin,

a thermoset resin infused into the composite external wall panel; and

at least one steel connector integrated between the inner skin and the outer skin, the steel connector connectable to a building column, wherein the steel connector is configured to support a vertical load.

2. The prefabricated building skin system of claim 1, wherein the steel connector is connectable to the building column by a single point connection on each column.

3. The prefabricated building skin system of claim 1, further comprising a maximum deflection of a span length divided by 400 when subjected to at least one of an erection load, a service load, or a dead load.

4. The prefabricated building skin system of claim 1, wherein the inner skin and the outer skin comprise fiberglass and thermoset resin.

5. The prefabricated building skin system of claim 1, further comprising a rain screen covering the outer skin.

6. The prefabricated building skin system of claim 1, further comprising a gel finish on the outer skin.

7. The prefabricated building skin system of claim 1, further comprising a painted finish on the outer skin.

8. The prefabricated building skin system of claim 1, further comprising a brick finish on the outer skin.

9. The prefabricated building skin system of claim 1, wherein the fiber reinforced polymer is vacuum infused with the thermoset resin.

10. The prefabricated building skin system of claim 1, further comprising at least one inner frame.

11. The prefabricated building skin system of claim 10, further comprising a glazing disposed within the inner frame.

12. A method for assembling a prefabricated building skin system, the method comprising:

forming, at a first location, an external wall panel by:

positioning a fiberglass wrapping around a foam core; the foam core disposed between an inner skin and outer skin;

integrating a steel connector into the external wall panel; and

integrating a thermoset resin into the wall panel by vacuum infusing the resin, wherein an atmospheric pressure differential from the vacuum pushes the resin through a void space in the external wall panel;

applying, at the first location, a finish to the external wall panel; and

connecting the external wall panel to a building column at a second location.

13. The method of claim 12, wherein the finish is applied to the outer skin.

14. The method of claim 12, wherein the finish includes a brick finish.

15. The method of claim 12, wherein the finish includes a rain screen.

16. The method of claim 12, wherein the finish includes a paint.

17. The method of claim 12, further comprising connecting the steel connector to the building column through an attachment bracket.

18. The method of claim 12, wherein the external wall panel has a maximum deflection of a span length divided by 400 when subjected to at least one of an erection load, a service load, or a dead load.

19. The method of claim 12, further comprising an inner frame.

20. The method of claim 19, further comprising applying a glazing disposed within the inner frame.