Prefabricated wall panels and a method for manufacturing the same

Abstract

A multi-layer prefabricated wall panel for modular building and a method for manufacturing the same. The panel comprises a load-bearing and vapor barrier core layer; an interior insulating and utility installation layer bonded to the inner face of the core layer; an exterior sheet of a first rigid building material bonded to the interior insulating layer; and an interior sheet of a second building material bonded to the outer face of said core layer. The method for manufacturing the wall panel comprises the steps of forming a stack of the panel layers with adhesive coating between successive layers and bonding the layers to each other by uniform compressing forces.

Description

BACKGROUND OF THE INVENTION[0001]1. Field of the Invention[0002]The present invention generally relates to modular construction and more specifically to prefabricated wall panels for use in modular buildings, to a method for fabricating the panels and to building components including the same.[0003]2. Discussion of the Related Art[0004]Industrialized building methods are becoming more popular over the last decades in the construction industry for both domestic and public buildings, Also referred to as large-panel construction, such methods utilize high degree of factory prefabrication in order to reduce site work and improve the quality and speed of construction. The large prefabricated panels are transported from the factory to the construction site where they are assembled in a modular manner to form walls, ceiling and / or floors. Optionally, the panels may be assembled, at least partially, at the factory site to form larger building components, where limitation to the size of pre-...

AI Technical Summary

Benefits of technology

[0008]A further object of the invention is to provide a building panel having the above features which allows for easy installation of utility lines such as electricity wi

Problems solved by technology

Optionally, the panels may be assembled, at least partially, at the factory site to form larger building components, where limitation to the size of pre-assembled components is mainly due to transportation possibilities.

However, available building panels and the manufacturing methods for fabricating such panels still suffer from a number of drawbacks.

Thus, not only the assembling of the panels to form larger building components walls requires manual work, but in many cases the fabrication of the panel themselves require manual work which slows down the manufacturing and increase costs.

Furthermore, the panels so produced may suffer from uneven fastening and consequently from insufficient flatness and from weak points or seaming lines susceptible to instabilities.

Moreover, many times known prefabricated panels do no provide all the properties required from building components in terms of stability, insulation, easiness of utility installation, etc.

Images