WO2018007910A1

WO2018007910A1 - Wall module

Info

Publication number: WO2018007910A1
Application number: PCT/IB2017/053919
Authority: WO
Inventors: Stéphane Roger G REUMERS
Original assignee: Btdims Nv
Priority date: 2016-07-04
Filing date: 2017-06-29
Publication date: 2018-01-11
Also published as: BE1023413B1

Abstract

This invention relates to a wall module (3) for constructing a wall for a building, wherein the wall module (3) comprises a plurality of spaced upright pillars (1, 10) which are formed in one part, wherein said pillars (11, 12) comprise a plurality of first connecting means which are disposed at a distance from each other and which have been made integral with the pillar (1, 10) and which are provided to cooperate with corresponding second connecting means (27, 24) on an upper edge of one or more wall panels (21, 22) for connecting the one or more wall panels (21, 22) to the spaced apart pillars (1, 10), the second connecting means being arranged on a side facing the pillar (20) of the one or more wall panels. The invention further relates to a housing containing one or more of such wall modules, and roof profiles for mounting a roof.

Description

Wall module.

This invention relates to a wall module wall module for constructing a wall for a building, wherein the wall module comprises a plurality of spaced upright pillars extending in the height direction of the wall module, according to the preamble of the first claim.

This invention also relates to a building containing two or more such wall modules.

Amongst others, areas where a natural disaster has occurred and in developing countries, may present a sudden need for affordable housing for a large group of people which must be available in the shortest possible time. In such situations there is often also a need for buildings that can be built and furnished in the shortest possible time as a school or as a hospital or as a pavilion. But in other situations there may also be a need for pavilions and the like. In addition, it is important that these buildings can be set up in a relatively simple manner and ready for use at a cost which is not too high and within a shortest possible timeframe.

In order to make this possible and to keep costs related to transport of parts for these buildings as low as possible, modular buildings have been developed, of which the separate parts can be produced in industrialized countries and then transported to the destination where the buildings are assembled.

Numerous such projects are known, including those which make use of wood skeleton construction, composite materials and the like.

It will be clear that in practice divergent situations may occur where there is a need for budget-friendly, modular constructionable buildings that can be relatively easily assembled, require as short an assembly time as possible and can be constructed as easily as possible from their individual parts.

FR1,563,525 discloses a panel for casing a flat or curved surface, for example for hiding heating radiators, for making false ceilings or for decoration purposes. The panel includes a lower and an upper edge which are both pleated in such a way that the panel can be clamped into a recess in the upright edges of an upright U-shaped profile. Consecutive panels are arranged at a distance from each other in height direction of the U-shaped profile, with an opening between consecutive panels. A material located behind the panels may be removed through the gap between consecutive panels. In addition, the casing disclosed in

FR1,563,525 does not constitute a standalone wall.

GB 1,489, 422 also discloses a surface casing assembly. The assembly includes a plurality of pillars, each pillar comprising multiple protrusions formed integral with the pillar for clamping a top and bottom edge of a panel.

Alternatively, a panel is attached to the protrusions, and a panel is held between the edges of two adjacent panels. The casing described in GB1, 489,422 can not stand alone and does not form a self standing wall.

From US3.363.371 a wall panel is known which is provided for cooperation with a framework. The framework comprises two longitudinal and two transverse end profiles, which form a rectangular frame and contribute to the mechanical structure of the wall panel. Transverse reinforcement profiles are mounted between the transverse end profiles. The opposing faces of the framework are lined with a metal mesh and a water repellent cloth.

None of the above cited prior art discloses a standalone modular wall that can be mounted in a relatively easily manner and is suitable for

manufacturing a building that requires as short a possible assembly time as possible and may be assembled from its parts in a manner which is as simple as possible.

Therefore, it is an object of this invention to provide a wall module suitable for use as a wall for building such modular buildings, with an assembly time as short as possible and an assembly procedure as simple as possible.

This is achieved according to the invention with a wall module which shows the technical features of the first claim.

To this end, this invention relates to a wall module wall module for constructing a wall for a building, wherein the wall module 3 comprises a plurality of spaced upright pillars 1, 10 extending in height direction of the wall module. The wall module of this invention is characterized in that said pillars 11, 12 are formed in one part, in that a first upright side of said pillars 11, 12 comprises a plurality of first connecting means arranged at a distance from each other in height direction, which first connecting means are integrally formed with the pillar 1, 10 and are provided for cooperating with corresponding second connecting means 27, 24 on an upper edge of one or more wall panels 21, 22 for connecting the one or more wall panels 21, 22 with the spaced apart pillars 1, 10, the second connecting means being located on a side of the one ore more wall panels facing the pillar 20, with successive wall panels arranged adjacent with respect to each other in height and longitudinal direction of the wall module, so that said pillars and said wall panels disposed on opposite sides of said pillars define an inner space 5 suitable for receiving a filling material 2, said pillars having at least one upright wall which is at least partly open in the direction of the inner space 5.

Because the pillars are formed as one part and the connecting means for connecting a panel with a pillar in the upright sides of the pillar are also integral with the pillar, the panels can be attached to the pillars without requiring further prior assembly of any other possible components. As a result, significant time gains may be realised not only when assembling wall panels and pillars into a wall module, but also when joining two or more wall modules with the purpose of building a wall and/or a building. This also makes it possible to significantly improve the mechanical strength at the position of the suspension, as the suspension is not compromised by the loose connection of the connecting means to the pillar. The inventors have realized that this invention makes it possible to minimize the number of components needed to build a wall module, without this adversely affecting the mechanical firmness and horizontal stability of the wall module.

Because successive wall panels are disposed in an adjacent manner in the height and longitudinal direction of the wall module, successive pillars and wall panels positioned on opposite sides of said pillars cooperate to define a space suitable for receiving a filling material so that a wall module can be provided which also meets the requirements of insulation properties. A wall panel will usually be mounted to a pillar in such a way that at least a part of the second connecting means are positioned adjacently to an upright wall of the pillar.

The use of pillars with at least one upright wall, which is at least partially open in the direction of the inner space results in a wall module, with the open space in the pillar joining the open space between the wall panels, as a result of which the pillars contribute to increasing the mechanical stability of the wall module and to reducing the risk of the formation of cold bridges by the pillars to a minimum.

Forming of the connecting means and the pillar in one part further offers the advantage that both assembly time and assembly costs can be reduced, that the mechanical strength of the connection between the pillar and the connecting means is improved and that the connecting means always take the intended position, have the desired dimensions and extend in the desired manner relative to the pillar. Especially this latter is an important advantage as it positively affects the wall module stability, and construction defects can be reduced to a minimum. Forming of the connecting means in one part with the pillar can be accomplished in various ways known to the person skilled in the art, for example by punching or punching the connecting means in the pillars.

The wall module of this invention offers the advantage that the panels not only fulfil a constructive function - in which they define, together with the pillars, the volume for receiving the filling material, function as connecting means for the pillars and provide horizontal and mechanical firmness to the wall module - but at the same time also provide a finishing for the walls of the wall module, both for the inner walls and the outside walls. Due to the fact that the mechanical strength and aesthetic finishing are provided by one and the same component, significant time gain may be realised in building a wall module and assembling two or more wall modules to a building. The wall module of this invention offers the additional advantage that the components can be manufactured separately so that the wall module can be transported in its components in unmounted state to the location where the wall module will be built.

Between the pillars and the wall panels, a hollow space is formed which can be filled with a filling material, preferably an insulating material, for example polyurethane, glass wool, sand, earth, bricks, lightweight insulating concrete or any other insulating material considered suitable by the skilled artisan. Such modules are suitable for use in a wide range of climatologic conditions, because of the presence of the filling material. Indeed, the inventors have found that the temperature of the filling material changes over a limited thickness only throughout the day, even under extreme temperature conditions, the filling material thus fulfilling an excellent insulating function. Such a wall module can be used in various applications. In a first possible application, the wall module is provided for connection with a further wall or an existing wall. The space formed between the wall on one side and the wall module on the other side can be filled with a filling material. For example, such a wall module may find application as an insulation module for mounting against an existing wall.

Preferably, the panels are also formed in one part and the second connecting means provided on the panels are formed in one part with the panels. This also contributes to minimize assembly time and handling. The forming of the connecting means and the pillar in one part further offers the advantage that assembly costs can be reduced, that the mechanical strength of the connection between a panel and the second connecting means is improved, that the connecting means always have the same size and shape. Especially this latter is an important advantage as it positively influences the stability of the wall module and minimizes structural defects.

In a preferred embodiment, connecting means for connecting the one or more wall panels to the spaced apart upright pillars are provided on opposing upright sides of said pillars, and said wall panels are disposed on opposite sides of said pillars, said wall panels and said pillars thereby defining a space for receiving a filling material.

The oppositely positioned wall panels create a hollow space that can be filled with an insulating material as described above. Such modules are suitable for use in a wide range of climatic conditions, due to the presence of the filling material. Indeed, the inventors have found that the filling material present in the cavity only warms or cools over a limited thickness, even in extreme climatic conditions, and thus shows an excellent insulating function.

Preferably the pillars have a substantially U-shaped profile. This offers the advantage that the inner space of the pillars is also available to be filled with filling material, so that the pillars contribute to increasing the stability of the wall and the risk of forming heat conducting bridges decreases.

The mechanical firmness of the pillar of this invention is promoted in that the opposite upright sides of the pillar are provided with facing upright flanges, which extend transversely of the pillar and preferably extend transversely of the wall module over a part of the pillar opening. On the other hand, the presence of the flanges offers the possibility of reducing the layer thickness of the material from which the pillars are manufactured, which will benefit both the material cost and the transport cost. Due to the presence of the inwardly directed flanges, the pillars are preferably substantially sigma shaped.

If desired, the wall panels can be additionally attached to the pillars via additional connecting means, for example by means of screws, staples, nails, blind rivets and the like, to provide additional firmness to the whole. This connection is preferably made such that it is not visible from the outside.

The wall panel is preferably configured such that the wall panel has an upper and a lower panel edge, the upper panel edge being configured to provide the connecting means for attaching the wall panel to corresponding connecting means on the pillar and wherein the upper and lower panel edges of consecutive wall panels have complementary engaging shapes. The complementary shape of the upper and lower edges allows for a smooth transition of consecutive panels in height direction of the wall module. This not only provides for a reinforcement at the location of adjacent wall panels but also ensures a sealing of the inner space of wall module, so that the risk of water penetration can be reduced to a minimum, for example in case of impinging precipitation. The connecting means on the wall panel may for example comprise suspension means for suspending the wall panel on corresponding suspension means, for example substantially square brackets on the pillar.

In a further preferred embodiment, a centre upright side of a pillar of a first wall module and a centre upright side of an adjacent pillar of a second wall module are connectable by a first connecting profile adjacent to and connectable to the centre upright side of a first terminal pillar of the first wall module, wherein the first centre upright side extends in thickness or transverse direction of the wall module, and to a second connecting profile positioned adjacent to and connectable to the centre upright side of a second terminal pillar of the second wall module, wherein the second centre upright side extends in thickness or transverse direction of the wall module, wherein the first and second connecting profiles extend in upright direction of the first and second pillars and are connectable to each other. By means of such connecting profiles, two or more wall modules can be connected in longitudinal direction to build walls of a desired length. Preferably, the centre or central upright side of the upright pillar and an adjacent upright side of the joint connecting profile contain cooperating positioning means for fixing the position of the pillar relative to the connecting profile. This allows for a simple, unambiguous positioning of a first and second wall module relative to each other and benefits the stability of the connection.

In another preferred embodiment, a first wall module is connectable to a second wall module extending transversely to the first wall module to form an angle connection, by means of a second connecting profile which is substantially L- shaped and extends in the upright direction of the first and second wall module, wherein a first side of the L-shaped profile is provided to be connected to a first upright side of a pillar extending along the wall of the first wall module, i.e.

longitudinally or transverse to the wall module, and a second side of the L-shaped profile is provided to be connected to a second upright side of a pillar of the second wall module, the pillar being generally a terminal pillar, and the second upright side being a centre upright side which extends in transverse or thickness direction of the wall module or an upright side which extends in longitudinal direction of the wall module. By means of such transverse connecting profiles, walls can be made which extend circumferentially around a room and which delimit a space.

The finishing of the transverse joints thus formed is ensured by specially designed profiles.

The invention also relates to a housing comprising at least one wall module as described above.

The invention further relates to a method of manufacturing a wall module as described above, wherein a plurality of upright pillars are arranged at a distance from one another, wherein a plurality of wall panels are mounted in the height direction of the pillars such that between successive pillars and panels suspended thereto form a closed space, after which the closed space is filled with a filling material.

The invention will be further explained with reference to the attached figures and figure description.

Figure 1 shows a view to a part of an exterior and an inner volume of a wall module. Figure 2a shows a vertical section through part of a wall module at the position of a pillar. Figure 2b shows a detail of Figure 2a, at the position of the brackets.

Figure 3a shows a horizontal section through a part of two wall modules connected in longitudinal direction. Figure 3b shows a detail of the connection between adjacent wall modules, Figure 3c shows a further enlarged detail of the positioning means.

Figure 4 shows a horizontal section through a part of two wall modules in a transverse connection along the outside of the connection.

Figure 5 shows a horizontal section through a part of two wall modules in a transverse connection along the inside of the connection.

Figure 6 shows a horizontal section through a terminal profile.

Figure 7 shows a cross-sectional view of a wall panel in height direction thereof.

Figure 8 shows a cross-sectional view of a part of a wall module provided with a profile for a roof.

Figure 9 shows a connection profile for a corner joint as shown in Figure

4.

Figure 10 shows a horizontal section of a wall module provided with a finishing profile.

Figure 11 shows a vertical section of a housing comprising a wall on which a roof is mounted.

Figure 11a shows a cross-sectional view in height direction of the profile of a support profile for a ceiling and roof, figure 1 lb shows a cross-sectional view in height direction of a profile for connecting ceiling profiles with lacquer profiles.

A preferred embodiment of a wall module 3 shown in Figures 1, 3a and 4 comprises a plurality of spaced apart pillars 1, 10 provided to be arranged on a support surface. The pillar 1, 10 extends in an upright direction, preferably in a height direction. A plurality of first wall panels 21 are connected to a first upright side 11 of the pillars. This first upright side extends in height and longitudinal direction of the wall module.

A wall module in which wall panels are disposed exclusively on one side of successive pillars forms a kind of front wall suitable for being placed alongside, possibly against or at a distance from, and connected to, an existing wall. Between the existing wall and the wall panels, a plurality of adjacent empty inner spaces 5 are defined, which are provided for receiving filling material. Such a wall module can be used, for example, for the renovation of existing walls by using wall panels with an aesthetic character, or for providing an insulating function to an existing wall.

In an alternate preferred embodiment, the second upright side 12 of the pillar 1, which is located on one side of the pillar opposite the first upright side 11, is also connected to a plurality of second wall panels 22. In this manner, between the wall panels, which are attached to the first upright sides 11 of spaced apart pillars 1, 10, and the wall panels which are attached to the second side 12 of the pillars opposite the first side 11, a plurality of consecutive open spaces 5 is defined which are provided to be filled with filling material, at least in part but preferably fully filled. Within the scope of this invention it is possible not to insert filling material in any of the inner spaces 5, to insert filling material in all of the spaces 5, or to fill part of the inner spaces 5 with filling material. It is possible to fill the entire volume of the interior spaces 5 with filling material or to partially fill the interior spaces 5.

Within the scope of this invention, various types of filling material may be used, for example, polymeric foam, for example polyurethane foam, polymeric granules, for example granules of polyurethane, polyethylene, polypropylene and the like, glass wool or other mineral wool, sand, earth, bricks, lightweight insulating concrete or any other material considered suitable by the skilled person. The filling material has an insulating function, whereby the wall module of this invention is suitable for use in a wide range of climatic conditions. Indeed, the inventors have found that the temperature of the filling material changes only over a limited thickness throughout the day, even under extreme temperature conditions, the filling material thus fulfilling an excellent insulating function.

The wall module 3, 30 preferably further comprises a first and second floor profile 28, 29 which extends longitudinally of the wall module parallel to the wall panels, the first floor profile being connectable to a first upright side of the pillar 11, and the second floor profile being connectable to a second upright side of the pillar 12 opposite the first upright side of the pillar, with the aim of providing towards the support surface 4, to which the wall module will be mounted, an aesthetically acceptable finishing of the wall and prevent an optional loss of filling material through a lower part of the wall module.

With a pillar 1, 10 is meant within the scope of this invention a pillar, profile or tube which extends in upright or height direction of wall module 3 and which substantially has the form of an upright column with a hollow inner space 14. The Pillar 1, 10 may be of any form considered suitable by the skilled person, and may, for example, have a substantially angular cross-section, for example square or rectangular, or 6- or 8-angular. In the wall module of this invention, preferably pillars are used which have a substantially rectangular or square cross- section, since in that way an optimal support surface is provided to the wall panels to be attached to the pillars. The pillars 1, 10 can have widely varying dimensions. The height of the pillars will usually be adjusted to the height of the building unit to be built, and it can range from a few tens of centimetres to a few meters, typically 2.5 meters or 3 meters or more. The remaining dimensions will usually be chosen by the person skilled in such a manner that an optimal compromise may be achieved between the mechanical stability required by the wall module, the weight of the pillar and the transportation costs.

The pillar 1, 10 can be manufactured from a wide range of materials known to the person skilled in the art, for example, from steel, for example cold rolled steel, aluminium, plastic, composite material of a plastic material containing a fibrous reinforcing material and other materials considered suitable by the person skilled in the art.

The pillar 1, 10 of this invention preferably has a substantially U- shaped cross-section and includes a centre upright side 13, 13'. This centre upright side 13, 13' generally extends in transverse or in thickness direction of the wall module. Along opposed upright edges of the centre upright side 13, 13', a first and second opposing upright side 11, 12 are present which extend in height direction of the pillar 1, 10. The first and second opposing upright sides 11, 12 generally extend longitudinally of the wall module and provide an abutment surface for the wall panels. Between upright centre side 13 and first and second opposing upright sides 11, 12 an upright opening 14 is defined. Along the edges of opposite opposed sides 11, 12 along the edges 14 of the pillar 1, 10, over at least a portion of the height, preferably a first and second upright flange 16, 17 is provided. The first and second upright flanges 16, 17 point towards each other and extend over a portion of the opening 14 in transverse direction of the pillar 1, 10. The presence of the flanges increases the mechanical strength and stability of the pillar 1, 10. On the other hand, the presence of the flanges 16, 17 allows the pillar to be made of a sheet with a lower layer thickness without having to give in on mechanical strength and stability. The pillar of this invention will in that case be substantially sigma shaped.

On the first and second opposing upright sides 11, 12 of the pillar 1, 10, connecting means 15 are provided for connecting the pillar 1, 10 with a wall panel 21, 22, 23. These connecting means are integrally formed with the pillar 1, 10, and are executed in a way to enable as simple as possible automated production of the pillars. Making the connecting means integrally with the upright side 11, 12 of the pillar increases the stability at the position of the attachment of the connecting means to the pillar, ensures that the connecting means are located at the desired positions, have the desired shape and dimensions, and allows the assembling time of the wall module to be kept as short as possible and simplifies assembly.

The connecting means 15 on the pillar 1, 10 may take any form considered suitable by the person skilled in the art and a wide variety of connecting means may be used. Preferably, the connecting means on the pillar comprise a plurality of spaced apart bracket-shaped suspension means 15, arranged in the height direction of the pillar, which are provided to cooperate with corresponding connecting means on the wall panel, in particular on the upper panel edge 27 In a particular embodiment, the connecting means are in the form of substantially square suspending brackets 40 as shown in Figs. 2a and 2b (encircled), the opening of the bracket pointing towards an upper part of the wall module, and providing an opening 47 between an upright part of the bracket and the upright side 11, 12 of the pillar 1, 10.

More particularly, the substantially square suspension bracket 40 includes an upper side extending at an angle with respect to the upright side of the pillar, and an upstanding inner side which extends parallel to the pillar and is spaced from the pillar, in such a way that an open space is formed for receiving a portion of the upper edge of an underlying panel and a portion of the lower edge of an upper panel. Thus, there is provided a connection between an underlying and upper panel and the pillar, which shows a minimal risk to water dragging over.

The connecting means may be provided on one single upright side 11, 13 of the pillar. In that case, the wall module will be primarily suitable for use as an extension module for an existing wall as described above. Preferably, however, the connecting means are arranged on opposite sides 11, 13 of the pillar 1, 10. More preferably, the connecting means are provided by punching because this allows for automated production. Connecting means or the substantially square brackets 15 may be provided in corresponding positions on the opposite sides 11, 13, but it is also possible to arrange connecting means or substantially square brackets on a first side 11 with respect to connecting means on a second side 12 of pillar 1, 10 in a staggered manner, for stability reasons. Connecting means 15 on opposite sides 11, 13 may be provided at the same distance from each other or at a different distance. Preferably, however, the connecting means 15 are arranged on opposite sides 11, 13 at corresponding positions and at the same distance from each other as this simplifies automated production. The connecting means 15 can be arranged at regular intervals on the opposite sides 11, 13 or at a distance, which may vary in height direction of the pillar. Preferably, however, the connecting means 15 are arranged at a regular distance from each other to enable automated production at the lowest possible cost and to ensure uniform load distribution in height direction of pillar 1, 10. The dimensions of the connecting means may vary within wide limits and may be adjusted by the skilled person taking into account the expected load.

The centre upright side 13 of a pillar of the first wall module 3 may comprise first connecting means 51 for connecting a first pillar 13 of a first wall module 3 with corresponding third connecting means 53 on the centre upright side 13' of a second pillar of a second wall module 30. Similarly, the centre upright side 13' of a pillar of the second wall module 30 may comprise second connecting means 52 for connecting to corresponding fourth connecting means 54 on the centre upright side 13 of a pillar of the first wall module 3, wherein respectively, the first and second connecting means and the third and fourth connecting means are arranged in a staggered manner. In a preferred embodiment of this invention, the first, second, third and fourth connecting means provide circular openings for receiving a screw or equivalent connecting.

Further, in the centre upright side 13 of the pillar, one or more recesses 49 may be provided, the shape and dimensions of which may be tuned by the skilled person taking into account the function to be performed. These recesses 49 preferably serve to pass through pipes or cabling provided in the wall panel towards electrical facilities or water supply or the like arranged on the wall. In this manner, pipes and cabling can be hidden within the wall.

The centre upright side 13, 13'of a pillar may comprise positioning means 50 which allow to fix the position of two adjacently arranged pillars via their adjacent centre sides 13. A detail hereof is shown in Figures 3a and 3b. Due to the presence of these positioning means, a displacement of a wall module relative to an adjacent wall module is counteracted, and the stability of the connection is increased.

In order to connect adjacent wall modules in longitudinal direction it is possible to connect a first and second pillar via connecting means provided in the centre upright sides 13, 13'. In addition, the centre upright sides 13 and 13' are positioned adjacent to each other. In this embodiment, the centre upright sides 13, 13' preferably comprise cooperating interlocking positioning means, which allow to fix the position of two pillars whose centre sides 13, 13' are disposed adjacent to each other. In this embodiment, the positioning means on the upright side 13 of a first pillar preferably has a shape which is complementary to the shape of the positioning means on the centre upright side 13' of a second pillar. For example, use can be made of a tooth and groove joint, or a co-operating groove and protrusion. However, any other shape considered suitable by the skilled person may be used. This embodiment requires that at least two types of pillars be provided.

In order to enable only one type of upright pillars 13 to be used and to permit the production of the pillars to be automated as much as possible, use can be made of a connecting profile 31 which is provided to be positioned between two upright pillars 13, 13', for example a profile as shown in figures 3a and 3b. The connecting profile shown comprises an upright side 56 in which second positioning means 55 are provided which are provided to cooperate with corresponding first positioning means 50 on the centre side 13, 13' of the pillar 1, 10.

The connection between a pillar 1, 10 and a connecting profile 1, 10 is accomplished by positioning a first pillar 1 adjacent to the upright side 56 of a first connecting profile and connecting it therewith, and by positioning a second pillar 10 adjacent to an upright side 56' of a second connecting profile and connecting it thereto, and to connect the upright sides of the pillars and connecting profiles.

The connecting profile 31 preferably includes first and second upright sides 61, 62, positioned on opposing upright sides of the centre side 13, which upright sides are provided to extend along at least a portion of the side 60 pointing towards the outside of the wall panel. The first and second upright sides 61, 62 preferably exert a clamping force on the wall panel to ensure optimum closure of the inner hollow space.

To provide a more aesthetically attractive finish of for example, windows or doors openings, the centre upright side 13 of the pillar can be covered in upright direction with a finishing profile, or an upper part of a wall module may be covered with a finishing profile. A finishing profile has first and second opposing upright sides disposed on opposite sides of a centre upright side. In the centre upright side, positioning means are provided as described above for the connecting profile. An example of a finishing profile 63 is shown in figure 10. A finishing profile also ensures closing of the hollow inner space between opposing pillars and wall panels suspended thereon.

A cross-section of a wall panel 21 in height direction of the wall panel suitable for use in this invention is shown in Figure 7.

A wall panel for use in this invention may be produced in a wide range of materials, for example in wood, plastic, a composite material comprising fibrous reinforced plastic, cast in concrete, or in metal, for example aluminium, zinc, steel, or any other material considered suitable by the skilled person. Preferably wall panels are used which are made of metal or composite material because of the possibility to form these materials in a desired shape. If the wall panels are made of metal, the metal can be used as such or may be coated with a resin or granulate to provide corrosion protection, provide sound insulating properties or give the material the desired appearance and the desired colour. Such a panel

simultaneously provides an aesthetic finish.

In a preferred embodiment, a wall panel includes a surface 36 having an upper edge 27 and a lower edge 24. The lower edge 24 has a portion formed to extend along the upright centre side 13 of the pillar. The upper edge 27 is formed in such a way to provide connection means suitable for cooperating with the corresponding connecting means 15 on the pillar.

The upper edge 27 of a wall panel 23 is further preferably formed in such a way that some space is left between the connecting means 15 on the pillar, the upper edge 27 and a front or visible side of the wall panel. This space is suitable for accommodating a portion of the lower edge 24 of an adjacent wall panel 21. In this manner, the position of the lower edge 24 of the wall panels is fixed and a framework of interconnected parts is provided with an increased structural firmness. This is shown in detail in Figures 1 and 2. The upper edge 27 of a wall panel 23 may, for example, in a preferred embodiment be substantially bracket or hook shaped. For example, the lower edge 24 of a wall panel 23 may be in the form of a zigzag. Such connectors in the edge of the wall panel can be formed in one piece with the wall panel, in automated production, for example by roll forming. However, any other production technique can be used. Also any other suitable design of the panel edges may be used to provide the connecting means.

The upper edge 27 of a wall panel 23 preferably has a shape suitable for cooperating with the suspension means 15 on the pillar 13, 13'. To this end, the upper edge 27 of the wall panel is preferably folded several times such that a substantially bracket-shaped profile is provided, more preferably a profile substantially in the shape of a square bracket. The bracket-shaped profile has a first side, which is provided for engaging the space 47 between the upright side 11, 12 of the pillar and the suspension means 48 on the pillar. The bracket-shaped profile has a second side 59 connected to the first side 58, which is provided for resting on and extending parallel to an upper side of the suspension means 48. The second side is connected to the face 60 of the panel.

The dimensions of the wall panels in height and transverse direction can be varied within wide limits. Preferably, standard sizes will be chosen to allow automated production. However, it is also possible to adjust the dimensions of the wall panels to the dimensions of the intended module.

In the wall module of this invention it is possible to connect a wall panel exclusively to its opposite transverse ends with a pillar but it is also possible to connect a wall panel with one or more pillars as shown in Figure 1, at a position between its transverse ends. This can improve the stability of the wall module.

Figure 2a shows a cross-section of a wall module of this invention in height direction. To a pillar 1, between a top of the pillar 1 and the supporting surface 4 at the bottom of the pillar 1, a first, third and fifth wall panel 21, 23, 45 are connected to a first upright side 11 of the pillar. A second, fourth and sixth wall panel 22, 24, 46 are connected to a second side 12 of the pillar 1 opposite the first side. The number of wall panels mounted in height to the pillar 1 can vary within wide limits and is amongst others determined by the intended height of the wall module 3, the height of the pillar 1, 10, the height of the wall panels in height direction of the pillar, the distance between successive connecting means on the pillar and the presence of windows, doors or other openings in the wall.

In order to allow for the construction of a space or a dwelling unit, two or more wall modules as described above will usually be connected to each other by means of appropriate connecting means.

Figure 3a shows two adjacent wall modules connected to each other in longitudinal direction. This is accomplished by positioning two pillars 1, 10 adjacent to each other along their respective centre upright walls 13 and connecting the pillars through connecting profiles 31, 32 as described above.

Figure 5 shows a connection of three wall modules for connecting a wall module extending transversely, to two wall modules that have been interconnected in longitudinal direction, for example for forming an inner wall. This is

accomplished by connecting two adjacent pillars 1, 10 via their adjacent centre upright side 13 using an intermediate profile T which is positioned adjacent to the centre upright side of opposite upright pillars 1, 10 via its opposite upright sides, and is connected therewith. The profile T provides the connection for connecting to a transversely positioned module 40.

Figure 4 shows a preferred embodiment of an outer corner connection for two wall modules. This outer corner joint includes an end profile 41, 42 as shown in Figure 6, which is provided to be disposed along the upright side of wall module 3. This outer corner joint further comprises a corner profile 43 of which a first side is provided for engaging a first end profile 41 of a first wall module and a second side is provided for engaging a second end profile 42 disposed on one end of a second wall module. The hollow corner space thus formed may be filled with filling material as described above.

To mount a roof on an upper edge of a wall module, use is made of a roof connecting part 65 similar to the wall panel 1, 10 of which a cross-section is shown in Figure 7. A lower edge 54 of the roof connecting part 65 is provided to engage an upper edge 27 of an adjacent wall panel, and an upper edge 53 of the roof connection panel is provided with connecting means which engage an adjacent roof panel 55.

When building a wall module 3 of this invention, as shown in figure 4 and 5, a plurality of pillars 1, 10 are positioned in a spaced apart manner. Pillars 1, 10 positioned in each others vicinity are interconnected by connecting wall panels 21, 23, 45 to a first upright side 11 of adjacent arranged pillars as shown in Figs. 4 and 5, and by connecting wall panels 22, 44 and 46 to the second side 12 opposite the first side of the pillar 11. Successive pillars are preferably arranged such that the openings of the substantially U or sigma-shaped pillars all point in the same direction, except for the pillars arranged at the ends of the wall module, whose opening always points towards the wall module. A panel is suspended with its upper edge 27 over the bracket-shaped suspension means 48 on one or more pillars. The lower edge of the panel engages the space remaining between the upper edge of a next panel and the upright side of the pillar as shown in Figure 2. This construction ensures a minimum risk of the formation of openings along which filling material could leave the inner space.

As shown in Figure 1, panels and pillars define a closed space filled with a filling material.

Walls of desired length are obtained by connecting two or more of the wall modules 3 described above along their upright sides as shown in Figure 3.

This invention also relates to a housing comprising at least one wall module as described above. The housing of this invention is manufactured by connecting two or more wall modules 3, 30 in longitudinal direction as shown in Figure 3, when building two or more walls of the desired length, and positioning a wall of the desired length on a supporting base and connecting the wall therewith. Thereafter, walls of the desired length are connected in transverse direction, to provide a housing which may, for example be square or rectangular, by connecting one end of a first wall module 3 as described above with an end of a second wall module 30 which extends in transverse direction with respect tot eh first wall module. To effectuate the connection, use is preferably made of a corner joint profile 43. Inner walls of the housing can be provided by connecting a wall module 3, 30 at the position of a pillar, with a wall module 40 as shown in figure 5, using a

substantially L shaped transverse connecting profile as shown in Figure 9. The inner corner can then be finished with a cover profile 47. After having positioned the wall modules forming the housing, the hollow spaces in the wall modules are filled with a filling material as described above. The modules can all be filled with the same filling material, or with different fillings. Additionally, the pillars 43 that form the corner connecting profile are also filled with filling material.

In the walls, between adjacent wall modules, one or more spaces can be left for use as door or window or the like. It is also possible to leave one or more spaces in a wall module for use as a window or door or the like. The raised sides and upper edge and lower edge of a window and/or door can be finished with a finishing profile 63 as described above.

For mounting a roof on an upper edge of a wall module as shown in Fig. 8, use is made of a roof connecting member 66. A roof connecting member 66 is connected to an upper wall panel 21 in such a way that the lower edge 54 of the roof connecting member 65 engages an upper edge 27 of an adjacent wall panel, and an upper edge 53 of the roof connecting panel engages an adjacent roof panel 55. Such a connection is usually provided on two opposing walls but can also be provided along the four walls of the housing.

A roof can be made by connecting an upper part of pillars of a wall module to one end of a ceiling profile 64, the ceiling profile thereby extending perpendicular to the wall module. In such a construction there a framework is provided to which a roofing can be applied and a substantially flat roof is obtained. This construction can also be used as a bearing construction for a ceiling.

If it is intended to provide a sloping roof, the ends of one or more ceiling profiles 64 are connected to one end of a roof profile 55 which extends at an angle with respect to the ceiling profile, the angle preferably being less than 60°, and wherein the roof profile 55 is provided for supporting one or more roof plates.

To support the roof profiles, a ceiling profile and roof profile are connected via at least one upright connecting roof profile.

In this way a housing can be provided that is provided with a roof, which has not been possible until now.

The wall module of this invention may be arranged on any support surface deemed suitable by the skilled person, for example earth or a hard surface such as concrete, a polymer surface, floorboards and the like. Preferably, a support surface is chosen which offers some mechanical stability and is not too easily distorted so that the stability of a building constructed from modules according to this invention can be guaranteed.

The wall module of this invention is suitable for use in a wide range of applications, for example for building homes, schools, pavilions, hospitals and the like, pool houses, garages, garden rooms in a more or less luxurious embodiment. Given the simple assembly and the limited number of connections that need to be made, it is possible to set up a building in a period of several hours.

Claims

1. A wall module (3) for constructing a wall for a building, wherein the wall module (3) comprises a plurality of spaced upright pillars (1, 10) extending in the height direction of the wall module, characterized in that said pillars (11, 12) are formed in one part, in that a first upright side of said pillars (11, 12) comprises a plurality of first connecting means arranged at a distance from each other in height direction, which first connecting means are integrally formed with the pillar (1, 10) and are provided for cooperating with corresponding second connecting means (27, 24) on an upper edge of one or more wall panels (21, 22) for connecting the one or more wall panels (21, 22) with the spaced apart pillars (1, 10), the second connecting means being located on a side of the one ore more wall panels facing the pillar (20), with successive wall panels arranged adjacent with respect to each other in height and longitudinal direction of the wall module, so that said pillars and said wall panels disposed on opposite sides of said pillars define an inner space (5) suitable for receiving a filling material (2), said pillars having at least one upright wall which is at least partly open in the direction of the inner space (5).

2. A wall module according to claim 1, wherein the connecting means for connecting the one or more wall panels (21, 22) to the spaced apart pillars (1, 10) are provided on opposing upright sides of said pillars (11, 12), which upright sides also extend longitudinally of the wall module so that said pillars and said wall panels disposed on opposite sides of said pillars define an inner space (5) suitable for receiving a filling material (2).

3. A wall module according to claim 1 or 2, wherein said pillars (1, 10) have a substantially U-shaped profile.

4. A wall module according to claim 3, wherein two opposite upright sides (11, 12) of the pillar define an upright pillar opening (14), the opposed upright sides (11, 12) being provided with upright flanges (16, 17) which face one another and extend transversely of the pillar over a part of the pillar opening.

5. A wall module according to any one of the preceding claims, wherein the connecting means in the opposite upright sides of said pillars (11, 12) are made using punching.

6. A wall module according to any one of the preceding claims, wherein the wall panel (21, 22) has an upper (27) and a lower (24) panel edge, the upper panel edge (27) being configured in such a way that it provides the connecting means for attaching the panel to the corresponding connecting means (15) on the pillar.

7. A wall module according to any one of the preceding claims, wherein the panels are integrally formed in one part and the second connecting means provided on the panels are formed in one part with the panels.

8. A wall module according to claim 7, wherein the connecting means on the pillar comprise a plurality of spaced apart, substantially square brackets (15) with an upwardly pointing bracket opening, and the connecting means on the wall panel comprise a correspondingly shaped upper panel edge (27) which is provided for being suspended on the brackets (15) present on the pillar and for at least partially being supported by an upper portion of the square bracket (15).

9. A wall module according to claim 8, wherein a side of the substantially square brackets (15) provided on the pillar for carrying the upper panel edge (27) includes an upper side, and wherein the panel edge comprises a corresponding side which in the connected position, is provided to extend parallel to and be support by said upper side of the square bracket for supporting the panel edge.

10. A wall module according to any one of the preceding claims, wherein a lower edge (24) of the panel has a portion formed to extend along the upright side of the pillar, which upright side extends longitudinally of the wall module.

11. A wall module according to any one of the preceding claims, wherein a centre upright side (13) of a pillar of the first wall module (3) is connectable to a centre upright side (13') of an adjacent pillar of the second wall module (30) by means of a first connecting profile (31) positioned adjacent to and connectable to the centre upright side (13) of a first terminal pillar of the first wall module (3), and a second connecting profile positioned adjacent to and connected to the centre upright side (13') of a second terminal pillar of the second wall module (30), wherein the first and second connecting profiles (31, 31') extend in upright direction of the pillars (13, 13') and are connectable to each other.

12. A wall module according to claim 11, wherein the connecting profile and the pillar of the first and second wall modules contain cooperating positioning means for fixing the position of the pillar of the first and second wall modules relative to each other.

13. A wall module according to claim 11 or 12, wherein the centre upright side (13) of a pillar of the first wall module (3) comprises first connecting means for connecting to corresponding third connecting means on the centre upright side (13') of a pillar of the second wall module (30), and the centre upright side (13') of a second wall module (30) contains second connecting means for connecting to corresponding fourth connecting means on the centre upright side (13) of a pillar of the first wall module (3), wherein respectively the first and second connecting means and the third and fourth connecting means are arranged in a staggered arrangement.

14. A wall module according to any one of the preceding claims, wherein a first wall module (3) is connectable to a third wall module (40) extending transversely with respect to the first wall module (3) through a second, essentially L-shaped connecting profile (32), wherein a first side (34) of the L-shaped profile is provided to be connected to the first wall module (3), and a second side of the L- shaped profile (35) is provided for connection to the third wall module (40).

15. A housing comprising at least one wall module according to any one of claims 1 to 14.

16. A housing according to claim 15, wherein an upper part of a pillar is connected to an end part of a further pillar for providing a ceiling profile

(64) which extends at an angle relative to the wall module, preferably an angle smaller than 60°, more preferably smaller than 45°, most preferably smaller than 30°, especially 0°.

17. A housing according to claim 16, wherein the ceiling profile is provided for carrying one or more ceiling panels.

18. A housing according to claim 17, wherein an end part of the ceiling profile is connected to an end part of a roof profile (64) which extends at an angle relative to the ceiling profile, the angle preferably being smaller than 60° and wherein the roof profile (64) is provided for supporting one or more roof panels.

19. A housing according to claim 18, wherein a ceiling profile and a roof profile are connected to each other in longitudinal direction of the ceiling profile and roof profile, via one or more upright connecting roof profiles (65) with the purpose of providing mechanical stability to the roof.

20. A method of manufacturing a wall module according to any one of claims 1 to 14, wherein a plurality of upright pillars (1, 10) are spaced apart, wherein a plurality of consecutive wall panels are mounted to the pillars in height direction of the pillars (1, 10), wherein longitudinally of the wall module a plurality of wall panels are positioned adjacently in such a way that a closed space is formed between successive pillars and wall panels mounted thereon, after which the closed space is filled with a filling material.