WO2006070280A1 - Improved prefabricated wall panel and the method of manufacture - Google Patents

Improved prefabricated wall panel and the method of manufacture Download PDF

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Publication number
WO2006070280A1
WO2006070280A1 PCT/IB2005/003963 IB2005003963W WO2006070280A1 WO 2006070280 A1 WO2006070280 A1 WO 2006070280A1 IB 2005003963 W IB2005003963 W IB 2005003963W WO 2006070280 A1 WO2006070280 A1 WO 2006070280A1
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WO
WIPO (PCT)
Prior art keywords
wall panel
external
sheets
corner
resin material
Prior art date
Application number
PCT/IB2005/003963
Other languages
French (fr)
Inventor
Kian Seng Choy
Original Assignee
Sandwich Panel Construction Sdn. Bhd
Choy, Kien, Choong
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from MYPI20045439 external-priority patent/MY138017A/en
Priority claimed from MYPI20045441A external-priority patent/MY153282A/en
Application filed by Sandwich Panel Construction Sdn. Bhd, Choy, Kien, Choong filed Critical Sandwich Panel Construction Sdn. Bhd
Publication of WO2006070280A1 publication Critical patent/WO2006070280A1/en

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/10—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of wood or with an outer layer of wood
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/095—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0875—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having a basic insulating layer and at least one covering layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/44—Number of layers variable across the laminate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof

Definitions

  • the present invention relates to a prefabricated multi-layered wall panel comprising of polyurethane or polyisocyanurate that is sandwiched between two external hard surface sheets, characterised in that the hard surface sheets are fibreboards.
  • Plywood is a common material used in construction today. At the time of its appearance, it was discovered that the layers of different woods that make up a sheet of plywood increased its durability when compared to a similarly sized piece of wood.
  • the invention builds upon the idea of using layered material for added strength.
  • a prefabricated wall panel is used to improve upon existing methods of building walls as compared to methods such as utilising brick and mortar, and by large pieces of material such as that used to construct cubicles in an office.
  • durability that durability is usually the result of using heavy materials that are not easily moved or removed.
  • This invention seeks to provide an alternative with a design comprising light and durable material that can be easily moved about and disassembled.
  • the present invention when compared to light materials used for building walls for example plywood and regular fibreboards, the present invention is stronger and is insulated by means of the polyurethane or polyisocyanurate sandwiched between the sheets of fibreboards.
  • a further objective of this invention is that the plurality of adjoining wall panels by means of the male and female coupling interlocking mechanism, is it can be selectively disassembled when necessary.
  • the stability of the assembly of this wall panel is in the piece of metal that runs along the upper and lower parts of the wall and is between the two fibreboard sheets and held strongly in place by the polyurethane and polyisocyanurate material. This reinforces the strength of the tongue and groove interlocking mechanism when the walls are interlocked and slid onto the C-channels and a rivet can be run through the C-channel and metal piece inside for added reinforcement.
  • a prefabricated multi-layered wall panel comprising a layer of resin material such as polyurethane or polyisocyanurate sandwiched between two external sheets such as fibreboards.
  • the wall panel has a male and female coupling mechanism at its opposing sides to facilitate the attachment of a plurality of wall panels by matching the male section of one wall panel to the corresponding female section of another wall panel.
  • the wall panel further comprising at least one reinforcement means running through from the upper to the lower section of the wall panel and are kept sturdy by the resin material in between the external sheets.
  • the wall panel can be a standard wall panel or a corner wall panel.
  • the corner wall panel has its external L-shaped sheets added with stiffener pieces at the reverse sides of the corners, which extend longitudinally from the top of the corner to the bottom of the corner of the L-shaped sheets to strengthen the structure.
  • a method of manufacturing a wall panel comprising the steps of holding two external sheets of fibreboards spaced apart according to the thickness of the wall to be manufactured and to form a mold, pouring the resin material substance in between the two external sheets, and compressing the two external sheets against one another as not to allow any variable to its thickness when the resin material substance is harden.
  • Figure 1 shows a plan view of a standard prefabricated wall panel joint to other wall panels using the tongue and groove interlocking mechanism of the present invention.
  • Figure 2 depicts a plan view of the prefabricated wall panels joint to a partition to form wall panel unit.
  • Figure 3 shows a plan view of the prefabricated wall panel with a second variation of the joining interlocking mechanism.
  • Figure 4 shows a plan view of the prefabricated wall panel with a third variation of the joining interlocking mechanism.
  • Figure 5 illustrates a plan view of a prefabricated corner wall panel joint to other wall panels by using tongue and groove interlocking mechanism of the present invention.
  • Figure 6a depicts a plan view of the standard prefabricated wall panel of figure 1 with added reinforcement.
  • Figure 6b depicts a plan view of the L-shaped prefabricated wall panel of figure 5 with added reinforcement.
  • a prefabricated wall panel (10) of the present invention comprised of a layer of resin material (11) sandwiched between two external sheets (12) characterized in that the resin material (11) used in the present invention is the polyurethane or polyisocyanurate material and the external sheets (12) are fibreboards as shown in figure 1.
  • a plurality of wall panels (10) may be adjoined together by means of a male and female coupling mechanism (13) and the wall panels (10) can be selectively disassembled when necessary.
  • a male section (13a) is provided at one end of the wall panel (10) and a female section (13b) of the coupling mechanism (13) is provided at the opposing end of the wall panel (10).
  • the male (13 a) is a metal piece formed in opened channel to form a tongue interlocking and fitted at one end of the wall panel (10) and the female section (13b) can be a metal piece configured to receive the male section (13a) at the other end or a corresponding opened receiving area to form a groove interlocking provided at the opposite end of the wall panel
  • the male (13a) and female (13b) sections in the first variation are formed generally in U-shaped.
  • the female section (13b) of this second variation of coupling mechanism is a metal piece is fitted at the opposite end of the wall panel (10) and is shaped as a groove to allow the male section (13 a) to slide in.
  • the female section (13b) also has dimples (17a) in the inner part of the shoulder (17) to lock into place at a neck portion (18) of the male section (13a).
  • the tongue extension has a raised step (19) to be fitted into a corresponding shape of groove (20) of the female section (13b) provided at the opposite end of the wall panel (10) as shown in figure 4.
  • two external L-shaped sheets (22) are spaced apart with a layer of resin material (11) therebetween.
  • the resin material (11) used for the corner wall panel (21) is also preferably the polyurethane or polyisocyanurate material and the external L-shaped sheets (22) are fibreboards.
  • Other wall panels (10) may be adjoined to the corner wall panel (21) by means of the male and female coupling mechanism (13).
  • a stiffener piece (23) is attached at the reverse side of the corner of each L-shaped sheet (22). The stiffener piece (23) extends longitudinally from the top of the corner to the bottom of the corner of the corner wall panel (21) to strengthen the structure.
  • Additional reinforcement means (24) maybe added to the wall panel (10) and the corner wall panel (21) for stability of the assembly as shown in figures 6a and 6b.
  • the reinforcement means (24) is in a piece of hollowed metal that runs along from the upper to the lower part of the wall panels (10, 21) and is between the two external sheets (12, 22) and held strongly in place by the resin material layer (11). This reinforces the strength of the male and female coupling mechanism when the wall panels (10, 21) are interlocked and slid onto the opened channels and a rivet (not shown) can be run through the channel.
  • the variation of the male and female coupling mechanism (13) as described in the first wall panel (10) may also be utilised in the corner wall panel (21).
  • resin material (11) there can be more than one layer of resin material (11) in the centre of the prefabricated wall panels (10, 21).
  • other kinds of material may be added to the prefabricated wall panels (10, 21) to increase its structural durability or to enable the prefabricated wall panels (10, 21) to take on characteristics of the material used.
  • soundproofing foam may be added to the wall panels (10, 21) if it is desired that the assembled plurality of wall panels forms a sound-dampening, sound-resisting, soundproof or a room with some characteristic acoustic requirements.
  • fireproof materials such as calcium silicate board may be used inside the prefabricated wall panels (10, 21) to resist burning or heat. It may also be possible to add cooling or heating coils to the prefabricated wall panels (10, 21) as necessary, and to connect these coils to a suitable apparatus for use in places where it is necessary to control the temperature of the space within the plurality of prefabricated wall panels (10, 21).
  • the two external sheets (12) of the fibreboards are first held in place to make the mold for the resin material layer (11). These two external sheets (12) are spaced apart according to the thickness of the wall to be manufactured.
  • Reinforcement means (24) maybe added in between the two external sheets (12) before the resin material (11) solution is poured in between the sheets (12).
  • the reinforcement means (24) is rested at one side of the sheets (12) to prevent slanting of the reinforcement means (24) during the solution pouring.
  • the sheets (12) are then compressed against one another as to not to allow any variable to its thickness when the resin material (11) substance which is the polyurethane or polysiocyanurate is poured in and allowed to harden.
  • the metal pieces of the male (13a) and female (13b) sections are partially inserted at the opposing ends in between the two external sheets (12) before the resin material (11) substance is poured.
  • the metal piece of the female section (13b) is then removed to form the groove interlocking.
  • two metal plates are added to the reverse side of the external sheets (12) when the sheets being held in place to form the mold. These two metal plates run the full length of the fibreboards in a horizontal position where one metal plate is placed near the top edge of the fibreboard and the other at near the bottom edge.
  • the two external L-shaped sheets (12) of the fibreboards are placed parallel and spaced with each other.
  • stiffener pieces (23) taped to their reverse side of the corner of the L-shaped sheets (22). These stiffener pieces run the full length of the fibreboards in a vertical position. In another embodiment, the stiffener pieces are placed near the top edge of the fibreboard and the other at the bottom edge respectively. Then the two L-shaped sheets (22) of fibreboards are held in place to make the mold for the resin material layer (11). These two external sheets (22) are spaced apart according to the thickness of the wall to be manufactured. Reinforcement means (24) maybe added in between the two external L-shaped sheets (22) before the resin material (11) solution is poured in between the sheets (22).
  • the reinforcement means (24) is rested at one side of the sheets (22) to prevent slanting of the reinforcement means (24) during the solution pouring.
  • the metal pieces of the male (13a) and female (13b) sections are partially inserted at the opposing ends in between the two external L-shaped sheets (22) before the resin material (11) substance is poured.
  • the metal piece of the female section (13b) is then removed to form the groove interlocking.
  • the sheets (22) are then compressed against one another as to not to allow any variable to its thickness when the resin material (11) solution which is the polyurethane or polysiocyanurate is poured in and allowed to harden.

Abstract

A wall panel (10) comprising a layer of resin material such as polyurethane or polyisocyanurate (11) sandwiched between two external sheets such as fibreboards (12). The wall panel (10) has a male and female coupling mechanism (13a, 13b) at its opposing sides to facilitate the attachment of a plurality of wall panels. The wall panel can be a standard wall panel or a corner wall panel.

Description

Improved Prefabricated Wall Panel and the Method of Manufacture
Field of Invention
The present invention relates to a prefabricated multi-layered wall panel comprising of polyurethane or polyisocyanurate that is sandwiched between two external hard surface sheets, characterised in that the hard surface sheets are fibreboards.
Background of the Invention
An earlier patent application by the present inventor relates to a Polyurethane material sandwiched between two metal pieces (PPGI Pre-Painted Galvanized Iron), and which has a tongue and groove mechanism to interlock panels. The shortcoming of this product is that it lacked aesthetic value. Therefore, the present invention utilises fibreboards instead which can be decorated as one would a conventional wall by painting or wall-paper.
Plywood is a common material used in construction today. At the time of its appearance, it was discovered that the layers of different woods that make up a sheet of plywood increased its durability when compared to a similarly sized piece of wood.
The invention builds upon the idea of using layered material for added strength. In this case, a prefabricated wall panel is used to improve upon existing methods of building walls as compared to methods such as utilising brick and mortar, and by large pieces of material such as that used to construct cubicles in an office. Generally, it is observed that although one requirement of construction is durability, that durability is usually the result of using heavy materials that are not easily moved or removed. This invention seeks to provide an alternative with a design comprising light and durable material that can be easily moved about and disassembled.
Furthermore, when compared to light materials used for building walls for example plywood and regular fibreboards, the present invention is stronger and is insulated by means of the polyurethane or polyisocyanurate sandwiched between the sheets of fibreboards.
A further objective of this invention is that the plurality of adjoining wall panels by means of the male and female coupling interlocking mechanism, is it can be selectively disassembled when necessary. The stability of the assembly of this wall panel is in the piece of metal that runs along the upper and lower parts of the wall and is between the two fibreboard sheets and held strongly in place by the polyurethane and polyisocyanurate material. This reinforces the strength of the tongue and groove interlocking mechanism when the walls are interlocked and slid onto the C-channels and a rivet can be run through the C-channel and metal piece inside for added reinforcement.
Summary of the Invention
A prefabricated multi-layered wall panel comprising a layer of resin material such as polyurethane or polyisocyanurate sandwiched between two external sheets such as fibreboards. The wall panel has a male and female coupling mechanism at its opposing sides to facilitate the attachment of a plurality of wall panels by matching the male section of one wall panel to the corresponding female section of another wall panel. The wall panel further comprising at least one reinforcement means running through from the upper to the lower section of the wall panel and are kept sturdy by the resin material in between the external sheets. The wall panel can be a standard wall panel or a corner wall panel.
The corner wall panel has its external L-shaped sheets added with stiffener pieces at the reverse sides of the corners, which extend longitudinally from the top of the corner to the bottom of the corner of the L-shaped sheets to strengthen the structure.
A method of manufacturing a wall panel comprising the steps of holding two external sheets of fibreboards spaced apart according to the thickness of the wall to be manufactured and to form a mold, pouring the resin material substance in between the two external sheets, and compressing the two external sheets against one another as not to allow any variable to its thickness when the resin material substance is harden.
Brief Description of the Drawings
Figure 1 shows a plan view of a standard prefabricated wall panel joint to other wall panels using the tongue and groove interlocking mechanism of the present invention.
Figure 2 depicts a plan view of the prefabricated wall panels joint to a partition to form wall panel unit.
Figure 3 shows a plan view of the prefabricated wall panel with a second variation of the joining interlocking mechanism. Figure 4 shows a plan view of the prefabricated wall panel with a third variation of the joining interlocking mechanism.
Figure 5 illustrates a plan view of a prefabricated corner wall panel joint to other wall panels by using tongue and groove interlocking mechanism of the present invention.
Figure 6a depicts a plan view of the standard prefabricated wall panel of figure 1 with added reinforcement.
Figure 6b depicts a plan view of the L-shaped prefabricated wall panel of figure 5 with added reinforcement.
Detailed Description of the Preferred Embodiments
A prefabricated wall panel (10) of the present invention comprised of a layer of resin material (11) sandwiched between two external sheets (12) characterized in that the resin material (11) used in the present invention is the polyurethane or polyisocyanurate material and the external sheets (12) are fibreboards as shown in figure 1. A plurality of wall panels (10) may be adjoined together by means of a male and female coupling mechanism (13) and the wall panels (10) can be selectively disassembled when necessary.
In relation to the illustration of the prefabricated wall panel (10) of the present invention as shown in Figure 1, it clearly illustrates for the location of the male and female coupling mechanism (13) is situated. A male section (13a) is provided at one end of the wall panel (10) and a female section (13b) of the coupling mechanism (13) is provided at the opposing end of the wall panel (10).
The male (13 a) is a metal piece formed in opened channel to form a tongue interlocking and fitted at one end of the wall panel (10) and the female section (13b) can be a metal piece configured to receive the male section (13a) at the other end or a corresponding opened receiving area to form a groove interlocking provided at the opposite end of the wall panel
(10). To form a wall panel unit (14) with a partition (15) as shown in figure 2, the partition
(15) is mounted transversely between two wall panels (10). A channel (16) is added to one of the external sheets (12) of the wall panel (10) for the partition (15) to secure thereon. The male (13a) and female (13b) sections in the first variation are formed generally in U-shaped.
In a second variation of the male (13a) and female (13b) sections, there are formed with shoulder (17) and neck (18) structure as shown in figure 3. The female section (13b) of this second variation of coupling mechanism is a metal piece is fitted at the opposite end of the wall panel (10) and is shaped as a groove to allow the male section (13 a) to slide in. The female section (13b) also has dimples (17a) in the inner part of the shoulder (17) to lock into place at a neck portion (18) of the male section (13a). In a third variation of the male (13a) section, the tongue extension has a raised step (19) to be fitted into a corresponding shape of groove (20) of the female section (13b) provided at the opposite end of the wall panel (10) as shown in figure 4.
For a comer wall panel (21) as shown in figure 5, two external L-shaped sheets (22) are spaced apart with a layer of resin material (11) therebetween. The resin material (11) used for the corner wall panel (21) is also preferably the polyurethane or polyisocyanurate material and the external L-shaped sheets (22) are fibreboards. Other wall panels (10) may be adjoined to the corner wall panel (21) by means of the male and female coupling mechanism (13). A stiffener piece (23) is attached at the reverse side of the corner of each L-shaped sheet (22). The stiffener piece (23) extends longitudinally from the top of the corner to the bottom of the corner of the corner wall panel (21) to strengthen the structure.
Additional reinforcement means (24) maybe added to the wall panel (10) and the corner wall panel (21) for stability of the assembly as shown in figures 6a and 6b. The reinforcement means (24) is in a piece of hollowed metal that runs along from the upper to the lower part of the wall panels (10, 21) and is between the two external sheets (12, 22) and held strongly in place by the resin material layer (11). This reinforces the strength of the male and female coupling mechanism when the wall panels (10, 21) are interlocked and slid onto the opened channels and a rivet (not shown) can be run through the channel. The variation of the male and female coupling mechanism (13) as described in the first wall panel (10) may also be utilised in the corner wall panel (21).
There can be more than one layer of resin material (11) in the centre of the prefabricated wall panels (10, 21). For various reasons, other kinds of material may be added to the prefabricated wall panels (10, 21) to increase its structural durability or to enable the prefabricated wall panels (10, 21) to take on characteristics of the material used.
For example, soundproofing foam may be added to the wall panels (10, 21) if it is desired that the assembled plurality of wall panels forms a sound-dampening, sound-resisting, soundproof or a room with some characteristic acoustic requirements. In another example, fireproof materials such as calcium silicate board may be used inside the prefabricated wall panels (10, 21) to resist burning or heat. It may also be possible to add cooling or heating coils to the prefabricated wall panels (10, 21) as necessary, and to connect these coils to a suitable apparatus for use in places where it is necessary to control the temperature of the space within the plurality of prefabricated wall panels (10, 21).
For the method of manufacture of wall panel (10), the two external sheets (12) of the fibreboards are first held in place to make the mold for the resin material layer (11). These two external sheets (12) are spaced apart according to the thickness of the wall to be manufactured. Reinforcement means (24) maybe added in between the two external sheets (12) before the resin material (11) solution is poured in between the sheets (12). In a preferred embodiment, the reinforcement means (24) is rested at one side of the sheets (12) to prevent slanting of the reinforcement means (24) during the solution pouring. The sheets (12) are then compressed against one another as to not to allow any variable to its thickness when the resin material (11) substance which is the polyurethane or polysiocyanurate is poured in and allowed to harden.
The metal pieces of the male (13a) and female (13b) sections are partially inserted at the opposing ends in between the two external sheets (12) before the resin material (11) substance is poured. The metal piece of the female section (13b) is then removed to form the groove interlocking. Optionally, two metal plates (not shown) are added to the reverse side of the external sheets (12) when the sheets being held in place to form the mold. These two metal plates run the full length of the fibreboards in a horizontal position where one metal plate is placed near the top edge of the fibreboard and the other at near the bottom edge. For the method of manufacture of the corner wall panel (21), the two external L-shaped sheets (12) of the fibreboards are placed parallel and spaced with each other. There are two stiffener pieces (23) taped to their reverse side of the corner of the L-shaped sheets (22). These stiffener pieces run the full length of the fibreboards in a vertical position. In another embodiment, the stiffener pieces are placed near the top edge of the fibreboard and the other at the bottom edge respectively. Then the two L-shaped sheets (22) of fibreboards are held in place to make the mold for the resin material layer (11). These two external sheets (22) are spaced apart according to the thickness of the wall to be manufactured. Reinforcement means (24) maybe added in between the two external L-shaped sheets (22) before the resin material (11) solution is poured in between the sheets (22). In a preferred embodiment, the reinforcement means (24) is rested at one side of the sheets (22) to prevent slanting of the reinforcement means (24) during the solution pouring. The metal pieces of the male (13a) and female (13b) sections are partially inserted at the opposing ends in between the two external L-shaped sheets (22) before the resin material (11) substance is poured. The metal piece of the female section (13b) is then removed to form the groove interlocking. The sheets (22) are then compressed against one another as to not to allow any variable to its thickness when the resin material (11) solution which is the polyurethane or polysiocyanurate is poured in and allowed to harden.
As will be readily apparent to those skilled in the art, the present invention may easily be produced in other specific forms without departing from its spirit or essential characteristics. The present embodiments is, therefore, to be considered as merely illustrative and not restrictive, the scope of the invention being indicated by the claims rather than the foregoing description, and all changes which come within therefore intended to be embraced therein.

Claims

Claims
1. A wall panel comprising a layer of resin material such as polyurethane or polyisocyanurate sandwiched between two external sheets characterised in that said external sheets are fibreboards.
2. The wall panel as claimed in claim I5 wherein said wall panel has a male and female coupling mechanism at its opposing sides to facilitate the attachment of a plurality of wall panels.
3. The wall panel as claimed in claim 2, wherein said male section has its edge extended from one side of said wall panel to form a tongue interlocking which conforms to said female section having an opened end facing outwardly from the other side of another wall panel to form a groove interlocking, whereby said male and female sections are coupled to form a unitary like structure.
4. The wall panel as claimed in claim 3, wherein said wall panel may be added with a channel to one of said external sheets for receiving a partition to form a wall panel, unit.
5. The wall panel as claimed in claim 3, wherein said wall panel may be added with two metal plates at the reverse side of the external sheets which run the full length in a horizontal position where one metal plate is placed near the top edge of the external sheet and the other at near the bottom edge.
6. The wall panel as claimed in claim 3, wherein said wall panel further comprising at least one reinforcement means running through from the upper to the lower section of said wall panel and are kept sturdy by said resin material in between the external sheets.
7. The wall panel as claimed in claim 6, wherein said wall panel is added with additional layer of material to increase its structural durability such as but not limited to soundproofing foam, fireproof material and cooling or heating coils.
8. A corner wall panel comprising a layer of resin material such as polyurethane or polyisocyanurate sandwiched between two external L-shaped sheets characterised in that said external L-shaped sheets are fibreboards.
9. The corner wall panel as claimed in claim 8, wherein said corner wall panel has a male and female coupling mechanism at its opposing sides to facilitate the attachment of a plurality of wall panels.
10. The corner wall panel as claimed in claim 9, wherein said corner wall panel has its external L-shaped sheets added with stiffener pieces at the reverse sides of the corners, which extend longitudinally from the top of said corner to the bottom of the corner of said L-shaped sheets to strengthen the structure.
11. The corner wall panel as claimed in claim 10, wherein said corner wall panel further comprising at least one reinforcement means running through from the upper to the lower section of said corner wall panel and are kept sturdy by said resin material in between the external L-shaped sheets.
12. A method of manufacturing a wall panel comprising the steps of: holding two external sheets of fibreboards spaced apart according to the thickness of the wall to be manufactured and to form a mold; pouring the resin material substance in between said two external sheets; and compressing said two external sheets against one another as not to allow any variable to its thickness when said resin material substance is harden.
13. The method of manufacturing a wall panel as claim 12, wherein said steps further comprising of fitting at least one reinforcement means in between said external sheets prior to the pouring of resin material substance.
14. The method of manufacturing a wall panel as claim 13, wherein said reinforcement means is rested at one reverse side of said external sheets to prevent slanting of said reinforcement means during said substance pouring.
15. The method of manufacturing a wall panel as claim 12, wherein said wall panel is a standard wall panel as claimed in claim 1.
16. The method of manufacturing the standard wall panel as claim 15, further comprising the step of adding two metal plates at the reverse sides of the external sheets, where one metal plate is placed near a top edge of said external sheet and the other at a bottom edge.
17. The method of manufacturing a wall panel as claim 12, wherein said wall panel is a corner wall panel having two external L-shaped sheets as claimed in claim 8.
18. The method of manufacturing the corner wall panel as claim 17, further comprising the step of adding two stiffener pieces at the reverse sides of the corner of said external L-shaped sheets, where said stiffener pieces run the full length of the external L-shaped sheets in a vertical position.
PCT/IB2005/003963 2004-12-31 2005-12-29 Improved prefabricated wall panel and the method of manufacture WO2006070280A1 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
MYPI20045439 2004-12-31
MYPI20045441 2004-12-31
MYPI20045439 MY138017A (en) 2004-12-31 2004-12-31 An improved prefabricated corner l shaped wall panel and method of manufacture
MYPI20045441A MY153282A (en) 2004-12-31 2004-12-31 An improved prefabricated wall panel and method of manufacture

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WO2006070280A1 true WO2006070280A1 (en) 2006-07-06

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AU2009100337B4 (en) * 2009-04-10 2009-10-29 Allan Charles Hockley Prefabricated interlocking wall construction panel
WO2012112110A1 (en) 2011-02-14 2012-08-23 P Lindberg Förvaltning Ab Edge strip for mounting of a wall board
US8733046B2 (en) 2010-10-11 2014-05-27 Fbm Licence Limited Building panel, building system and method of constructing a building
US9771718B1 (en) * 2016-10-07 2017-09-26 Tate Access Floors Leasing, Inc. Strut with non-structural infill
US10961707B2 (en) * 2017-04-20 2021-03-30 Charles Bree Building formed of encapsulated structural foam panels

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JPH10159248A (en) * 1996-11-28 1998-06-16 Matsushita Electric Works Ltd Board for architecture
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU2009100337B4 (en) * 2009-04-10 2009-10-29 Allan Charles Hockley Prefabricated interlocking wall construction panel
US8733046B2 (en) 2010-10-11 2014-05-27 Fbm Licence Limited Building panel, building system and method of constructing a building
US9340972B2 (en) 2010-10-11 2016-05-17 Fbm Licence Limited Building panel, building system and method of constructing a building
WO2012112110A1 (en) 2011-02-14 2012-08-23 P Lindberg Förvaltning Ab Edge strip for mounting of a wall board
US8789336B2 (en) 2011-02-14 2014-07-29 Oneday Wall Ab Edge strip for mounting of a wall board
US9771718B1 (en) * 2016-10-07 2017-09-26 Tate Access Floors Leasing, Inc. Strut with non-structural infill
US10961707B2 (en) * 2017-04-20 2021-03-30 Charles Bree Building formed of encapsulated structural foam panels

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