A building system for assembling load-bearing walls

Abstract

This invention proposes a building system for assembling load-bearing walls, integrating prefabricated components to improve efficiency and structural integrity. The system consists of prefabricated columns formed by interlocking flanges and webs into a hollow rectangular profile, with alkali-resistant mesh wrapped at the interlocking points. Outer panels are attached to these columns, forming prefabricated hollow wall units with specific cavities, which serve as permanent wall formwork during on-site assembly. Filling materials selected based on their thermal insulation performance and structural strength are introduced into these cavities, thereby completing the construction of the load-bearing wall.

Description

Technical Field

[0001] This utility model relates to the field of construction, and in particular to a system for constructing load-bearing walls. The system uses prefabricated hollow wall units and panels, designed for rapid assembly and enhanced structural integrity. Background Technology

[0002] The field of construction, particularly the development and implementation of load-bearing walls, has long been a subject of continuous innovation and improvement. Traditional construction methods have laid the foundation for building practices, utilizing techniques such as brick block walls, lightweight framed walls with wooden or metal columns, precast wall panel construction, and concrete walls with temporary or permanent formwork. While these methods each have their advantages, they also have inherent limitations and drawbacks, prompting the search for more efficient, versatile, and cost-effective solutions.

[0003] For example, while bricklaying is a time-tested method, it is labor-intensive and inefficient in terms of materials due to the extensive use of mortar joints. This traditional method also requires a large skilled workforce, further increasing construction costs. Similarly, lightweight framed walls, whether built with timber or metal columns, face challenges in terms of on-site installation speed, the need for skilled workers, and achieving an airtight structure. Timber columns, in particular, have additional drawbacks related to fire resistance and susceptibility to moisture damage. While metal columns overcome some of these problems, they also present their own challenges, including higher thermal conductivity and the need to effectively transmit sound vibrations.

[0004] Precast wall panel construction methods attempt to address some of these issues by prefabricating walls in a controlled factory environment. However, this approach typically requires custom-made panels for each specific project, limiting the scalability and flexibility of the construction work. Furthermore, both timber-based and metal-column-based solutions encounter difficulties in suspending objects on the walls and ensuring the airtight integrity of the structure.

[0005] Using concrete walls with permanent formwork has emerged as a promising alternative that can improve structural integrity and efficiency. Proprietary systems such as the Logical Wall System, the Ritek Permanent Formwork Wall System, and the Fastform Wall System have made significant progress. However, these systems typically require custom-made formwork panels, complex reinforcement works, and handling of heavy materials, which complicates the construction process and limits flexibility.

[0006] To address these challenges, the construction industry has been committed to developing innovative construction methods that seek to balance efficiency, structural performance, and versatility. This pursuit of solutions has deepened the exploration of lightweight prefabricated units and panels that can be easily assembled on-site, offering an alternative to traditional construction methods. This innovative approach aims to address the multifaceted limitations of existing systems by reducing labor requirements, simplifying the construction process, and providing enhanced thermal and acoustic performance. The pursuit of these advancements underscores a broader effort across construction practice and reflects the industry's ongoing commitment to innovation and improvement.

[0007] EP1660734B1 describes a building system using panels and columns specifically designed for constructing concrete-filled walls, where columns equipped with heads and flanges are attached to the outer panels and spacers are fixed for assembly. This disclosure focuses on creating solid walls, requiring manual assembly of components to achieve the desired structural, thermal, and acoustic properties. It relies on the complex assembly of concrete infill and spacers with columns for wall construction, rather than minimizing construction complexity and potential material waste through modular design.

[0008] WO2020098618A1 outlines a frame-type precast wall panel system for constructing prefabricated houses, with particular emphasis on the ease of manual transport and assembly of wall panels and column modules in remote areas. The system consists of a hollow, monolithic frame structure including L-shaped, T-shaped, and cross-shaped columns, designed for on-site bolting. The method includes the option of filling the frame voids with insulation material. However, deficiencies in the structural integrity of the precast wall system lead to problems with load-bearing capacity and insulation performance.

[0009] It is against this backdrop that this utility model was proposed. Utility Model Content

[0010] This utility model relates to a building system for assembling load-bearing walls, comprising prefabricated panel columns, outer panels, and infill material. The panel columns consist of interlocking flanges and webs, the webs and flanges being wrapped with alkali-resistant mesh to form a hollow rectangular profile. Outlined outer panels attached to these columns form a cavity between the columns, creating a prefabricated hollow wall unit that serves as a permanent wall formwork. Introducing a selected infill material into this cavity provides insulation and structural integrity to the formwork, facilitating the construction of load-bearing walls with greater efficiency and durability.

[0011] In some embodiments, the flanges and webs are made of materials such as cement fiberboard, moisture-proof gypsum board, and calcium silicate board, which improves durability and enhances resistance to environmental factors.

[0012] A further embodiment includes one or more steel profiles disposed within the plate column, connected to the inner surface of the hollow rectangular profile, thereby enhancing the structural integrity and load-bearing capacity of the wall unit.

[0013] In some embodiments, an adhesive material selected from building adhesives and polymer-modified mortars is used to secure the outer panel to the column, ensuring a strong and durable bond between components.

[0014] Some embodiments also include one or more alignment guide members that help to precisely assemble multiple prefabricated hollow wall units into a coherent and straight wall template.

[0015] In another embodiment, the infill material includes foamed concrete, which is known for its thermal insulation and structural integrity, helping to improve the overall energy efficiency and strength of the constructed wall.

[0016] Some further embodiments are characterized by prefabricated hollow wall unit B specifically designed for corners and T-joints, including extended flanges and end plates, facilitating seamless integration of wall units at building joints.

[0017] Other embodiments include prefabricated exterior wall units equipped with support for facade components, which include insulation layers and outer panels designed for facade connections, thereby enhancing the aesthetics and functionality of the exterior walls.

[0018] In addition, door and window frame columns are configured to be integrated into the wall template at the locations corresponding to door and / or window openings, ensuring structural support and alignment of the building openings.

[0019] In addition, the embodiment includes a lintel unit consisting of a column and an outer panel, reinforced with structural steel, and equipped with fins for secure connection to the door frame panel keel, providing robust support for top loads.

[0020] In some embodiments, the prefabricated hollow wall unit is configured to include embedded boxes for switches and sockets, facilitating the integration of electrical services within the wall structure.

[0021] Finally, in some embodiments, the alkali-resistant mesh covering the interlocking device between the flange and the web is made of glass fiber, which has enhanced durability and resistance to alkali-related degradation.

[0022] A building system for assembling load-bearing walls includes: a plurality of prefabricated columns configured to form a hollow rectangular profile, each column including interlocking flanges and webs, wherein the interlocking portion between the flanges and webs is wrapped with alkali-resistant mesh;

[0023] Multiple outer panels are configured to be attached to precast columns, one pair of which are attached to the parallel edges of a corresponding pair of precast columns, thereby defining a cavity between the pair of precast columns to form one or more precast hollow wall units, which serve as permanent wall formwork for the building structure; and infill material is used to fill the cavities of the one or more precast hollow wall units to form a load-bearing wall, the infill material being selected to provide thermal insulation and structural integrity to the load-bearing wall.

[0024] The flange and web are selected from cement fiberboard, cement particleboard or calcium silicate board.

[0025] It also includes one or more steel profiles disposed within the plurality of said columns, the steel profiles being connected to the inner surface of the hollow rectangular profile.

[0026] The outer panel is attached to the column by an adhesive material selected from building adhesives and polymer-modified mortars.

[0027] It also includes one or more alignment guide members configured to facilitate the assembly of multiple prefabricated hollow wall units.

[0028] The filling material is selected from foamed concrete and hemp concrete.

[0029] It also includes one or more prefabricated hollow wall units B specifically designed for corners and T-joints, the hollow wall unit B including extended flanges and end plates to alter its rectangular profile.

[0030] It also includes one or more prefabricated exterior wall units equipped to provide support for the facade components, the prefabricated exterior wall units including an insulation layer and an outer panel B for facade attachment.

[0031] It also includes one or more door and window frame posts, which are configured to be used at openings corresponding to doors and / or windows and integrated into the wall formwork.

[0032] It also includes one or more lintel units, each comprising a column and an outer panel, reinforced with steel sections, the lintel unit being adapted to be positioned on the lintel of the door frame panel and including fins for connection.

[0033] One or more of the prefabricated hollow wall units are configured to contain embedded boxes for switches and sockets.

[0034] The alkali-resistant mesh mentioned therein is a glass fiber mesh. Attached Figure Description

[0035] Various embodiments of this utility model are disclosed in the following description and drawings.

[0036] Figure 1An exploded view of the components of a plate column is shown, with the web and flanges separated.

[0037] Figure 2 An example top view of an assembled plate column is shown, in which the steel profile is installed with screws.

[0038] Figure 3 An example isometric view of a plate column in an assembled state is shown, where a mesh enclosure holds the flange and web together.

[0039] Figure 4 An example top view of an assembled precast wall unit is shown, which includes an outer panel that is coupled together by connecting to the opposing parallel edges of two standard panel posts.

[0040] Figure 5 An example isometric view of a precast wall unit is shown, illustrating the cavity between the coupled slab columns.

[0041] Figure 6 An example exploded view of a plate column component designed for connecting corners and T-joints in a template is shown.

[0042] Figure 7 An example isometric view of a connecting plate column designed for corners and T-joints is shown.

[0043] Figure 8 An example isometric view of the wall is shown, illustrating the assembly of multiple prefabricated wall units aligned along one edge by guide members.

[0044] Figure 9 An example isometric view is shown, illustrating subsequent steps in wall construction, showing the outer panel being installed onto a prefabricated wall unit.

[0045] Figure 10 An example isometric view of a constructed wall in an assembled state is shown, with infill material sealing the hollow sections.

[0046] Figure 11 An example top view of an assembled exterior wall unit is shown, which has facade support components such as thermal insulation filling material.

[0047] Figure 12 An example isometric view of an exterior wall unit with exterior facade support members is shown.

[0048] Figure 13 An example front view of an exterior door / window frame post is shown, which is fitted with fins and an outer panel to reach the required height for the door / window.

[0049] Figure 14 An example top view of the exterior wall door and window frame columns is shown.

[0050] Figure 15 An example isometric view of the exterior door / window frame pillars is shown, which are fitted with fins and outer panels to reach the required height for the doors / windows.

[0051] Figure 16 An example top view of a prefabricated exterior wall lintel unit is shown, which has horizontal steel sections and an outer panel including the lintel.

[0052] Figure 17 An example side view of a prefabricated exterior wall lintel unit is shown.

[0053] Figure 18 An example isometric view shows an exterior wall lintel assembled with a set of exterior door and window frame columns to form a doorway.

[0054] Figure 19 An example cross-sectional view of the assembled doorway is shown, illustrating the connection between the steel profile and the fin.

[0055] Common reference numerals are used throughout the accompanying drawings and detailed description to denote the same elements. Those skilled in the art will readily recognize that the above drawings are exemplary and that other architectures, modes of operation, sequences of operation, and elements / functions may be provided and implemented without departing from the features and characteristics of the invention as set forth in the claims. Detailed Implementation

[0056] The following is a detailed description of exemplary embodiments to illustrate the principles of the present invention. The embodiments are provided to illustrate the present invention, but the present invention is not limited to any particular embodiment. The scope of the present invention includes many alternatives, modifications, and equivalents; it is limited only by the claims.

[0057] To facilitate a thorough understanding of this invention, numerous specific details are set forth in the following description. However, this invention may be practiced without some or all of these specific details, as per the claims. For clarity, known technical materials in the art related to this invention have not been described in detail to avoid unnecessarily obscuring the invention.

[0058] definition:

[0059] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the invention.

[0060] As used herein, the term “and / or” includes any combination of one or more of the related listed items.

[0061] It is further understood that when the terms “comprising” and / or “including” are used in this specification, the presence of the said feature, step, operation, element and / or component is specified, but the presence or addition of one or more other features, steps, operations, elements, components and / or combinations thereof is not excluded.

[0062] When a feature or element is described as being "on" or "directly on" another feature or element, there may or may not be an intermediate feature or element. Similarly, when a feature or element is described as being "connected," "attached," or "coupled" to another feature or element, there may or may not be an intermediate feature or element. The features and elements described with respect to one embodiment may be applied to other embodiments.

[0063] For ease of explanation, spatial terms such as "below," "lower," "above," and "upper" are used to describe the relationships between elements when the device is in the correct orientation.

[0064] The terms “first,” “second,” etc., are used to distinguish different elements or features, but these elements or features should not be limited by these terms. Without departing from the teachings of this disclosure, a first element or feature described may be referred to as a second element or feature, and vice versa.

[0065] For the purposes of this patent, precast slab columns are understood to include any assembly comprising interlocking flanges and webs, regardless of the specific locking mechanism employed. The term "interlocking" should be interpreted broadly to include any form of engagement between the flanges and webs that allows for the formation of a stable hollow rectangular profile. Examples of materials suitable for constructing these components include, but are not limited to, cement fiberboard, gypsum board, and any composite materials known to those skilled in the art that provide similar structural properties.

[0066] The term "alkali-resistant mesh" as used herein is intended to encompass any mesh material that resists degradation under alkaline conditions common in built environments. This includes fiberglass mesh, carbon fiber mesh, and any synthetic polymer mesh that provides similar resistance.

[0067] When the terms "connection" or "fixture" are used with respect to the outer panels and panel posts, they include a range of connection mechanisms, including but not limited to adhesive bonding, mechanical fastening (such as screws, nails, rivets), and interlocking mechanisms. The selection of adhesive materials used to connect the outer panels to the panel posts includes construction adhesives, polymer-modified mortars, and any other adhesives known to those skilled in the art suitable for construction applications.

[0068] The filling material used for inserting into the cavity of the wall unit may include, but is not limited to, foamed concrete, hemp concrete, insulating foam, or any material cured to provide structural integrity and insulation. For example, foamed concrete may be specified to have a density range suitable for the expected load-bearing requirements and insulation properties.

[0069] In addition, the building system may include "guide components," which are understood as any structural element or tool used to assist in the alignment and assembly of prefabricated hollow wall units. This may include temporary supports, alignment clamps, or laser guidance systems.

[0070] Description of the attached figures

[0071] This utility model generally relates to the field of construction, and more specifically, to a building system and method for assembling load-bearing walls. This innovative method utilizes prefabricated components, including columns and exterior panels, designed for easy on-site assembly to form the structural walls of a building. The system aims to simplify the construction process, providing a method that is not only efficient but also enhances the structural integrity and thermal insulation performance of the final load-bearing walls.

[0072] This invention comprises a set of prefabricated columns formed by interlocking flanges and webs to create a hollow rectangular profile. These columns are then wrapped with alkali-resistant mesh at their interlocking points to ensure durability and resistance to environmental factors common in the built environment. Outer panels are attached to these columns to form prefabricated hollow wall units. During on-site assembly, these units form a template into which a selected infill material is introduced. The infill material cures within the template, completing the construction of the load-bearing wall and ensuring its thermal insulation performance and structural integrity.

[0073] A set of example configurations of various aspects of the present invention will now be described with reference to the accompanying drawings.

[0074] Figure 1 An exploded view of the components forming the column 100 is provided. The column 100 consists of a web 104 and flanges 102, and a set of steel profiles 106 connected by screws 107. The web 104 and flanges 102 are designed to interlock to form a hollow rectangular profile. This configuration not only facilitates assembly but also contributes to the structural integrity of the wall system. The modular nature of the column 100 allows for customization in size and shape to meet various building requirements.

[0075] Figure 2 A top view of the assembled column 100 is shown, in which steel profiles 106 are mounted using screws. These steel profiles 106 are optional components that can be incorporated into the column 100 to provide additional support, particularly in applications requiring enhanced load-bearing capacity.

[0076] Figure 3This is an isometric view of the column 100 in its assembled state, wherein alkali-resistant fiberglass mesh 108 wraps around the joint where the flange plate 102 and the web plate 104 intersect. The alkali-resistant fiberglass mesh 108 serves a dual purpose: it holds the sheets together, enhancing the structural integrity of the column, and provides resistance to environmental degradation, especially in the alkaline environments common in building environments.

[0077] Figure 4 A top view of an assembled prefabricated hollow wall unit 110 is shown. This unit includes an outer panel 112 that is attached to the opposing parallel edges of two standard columns 100, connecting the two columns together. Notably, the outer panel 112 only covers half of the edge of each column 100. This strategy allows space for additional outer panels to be attached to the exposed portions of the edges when multiple prefabricated hollow wall units 110 are assembled side-by-side, thus facilitating the creation of a continuous wall structure.

[0078] Figure 5 Provided Figure 4 The figure shows an isometric view of the precast hollow wall unit 110. The figure further illustrates the spatial relationship between the columns 100 and the outer panel 112, and the cavity 114 formed between the columns 100 within the unit. The cavity 114 is designed to be filled with a selected infill material, such as foamed concrete, to provide insulation and additional structural support after the hollow wall unit 110 is installed.

[0079] Figure 6 An exploded view of the components of a modified column B150 is depicted, which is specifically designed for connecting corners and T-joints within wall formwork. This variant of column B includes elongated flange plates 152 and end plates 154, as well as a standard web plate 104.

[0080] Figure 7 Provided Figure 6 An isometric view of the assembled connecting plate column 150. This view shows how the elongated flange plate 152 and end plate 154 interlock with the web plate 104 to form a robust and coherent structure. Alkali-resistant fiberglass mesh 108 wraps around the assembled joint, reinforcing the connection while providing a resilient environment. The connecting plate column 150 helps maintain the structural continuity of the wall system at corners and T-junctions.

[0081] Figure 8 An isometric view of the wall assembly is shown, in which multiple prefabricated wall units 110 are aligned and connected along one edge by guide members 160. The guide members 160 ensure the vertical and horizontal alignment of the prefabricated wall units 110, guaranteeing the accuracy of the wall template and the straightness of the construction, achieving uniformity and structural integrity during assembly.

[0082] Figure 9An isometric view is shown illustrating subsequent steps in the wall construction, where the outer panel 162 is installed. Figure 8 The outer panel 162 is attached to the edge of the column 100 within each precast wall unit 110, effectively sealing the wall formwork and preparing the structure for the introduction of infill material. This step helps to seal the wall units, improving the overall stability and insulation of the wall system.

[0083] Figure 10 The image shows the assembled wall after the outer panel 162 is installed and the infill material 164 is introduced into the hollow portion of the wall formwork. The infill material 164 cures within the cavity, providing insulation and additional structural support to the wall.

[0084] Figure 11 The diagram presents a top view of the assembled facade unit 170, which incorporates facade support elements such as insulation layer 172. This unit is designed to facilitate the connection of various facade elements, enhancing the thermal insulation performance and aesthetic appeal of the facade.

[0085] Figure 12 Provided Figure 11 The isometric view of the exterior wall unit 170 shown in the figure further details the arrangement of the facade support elements, including the placement of the insulation layer 172.

[0086] Figure 13 The image shows a front view of the exterior door and window frame posts 174 equipped with fins 176. The outer panel 178 extends to a predetermined height suitable for accommodating door or window openings.

[0087] Figure 14 Provided Figure 13 The diagram shows a top view of the exterior door and window frame posts 174. This view shows the construction of the fin 176 relative to the outer panel 178, demonstrating how the door and window frame posts support the structural integrity around the opening.

[0088] Figure 15 This is an isometric view of the exterior wall door and window frame posts 174, further showing the assembly with fins 176 and outer panels 178 that reach the required height for the doors and windows. From this angle, a comprehensive understanding can be gained of how the door and window frame posts are integrated into the wall formwork, supporting openings and reinforcing the structural framework of the wall.

[0089] Figure 16 A top view of the prefabricated exterior wall lintel unit 180 is shown, revealing the horizontal steel section 182 and the inner and outer panels 183 that form the lintel. This assembly provides robust support above the opening, ensuring that the load is adequately transferred and distributed.

[0090] Figure 17 Provided Figure 16The side view of the precast exterior wall lintel unit 180 shows the vertical steel section 186, the horizontal steel section 182, and the outer panel 184. The side of the precast exterior wall lintel unit opposite to the steel section is used for the facade.

[0091] Figure 18 An isometric view shows the assembly process of a prefabricated exterior wall lintel unit 180 having a pair of exterior wall door and window frame columns 174 forming a doorway frame.

[0092] Figure 19 A sectional view of the assembled doorway structure is provided, in which the outer panel 184 and inner panel 183 of the prefabricated exterior wall lintel unit are partially removed to show the connection between the vertical steel section 186 and the horizontal steel section 182 and the fin plate 176, as well as the internal columns.

[0093] in conclusion

[0094] Unless otherwise defined, all terms (including technical terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. It should also be understood that terms, as defined in commonly used dictionaries, should be interpreted as having the same meaning as they have in the context of the relevant technology and this disclosure, and should not be interpreted in an idealized or overly formal sense unless explicitly defined herein.

[0095] The disclosed embodiments are illustrative and not restrictive. While specific configurations of the systems and methods of this invention have been described in a particular manner with reference to the illustrated embodiments, it should be understood that this invention can be applied to various solutions that conform to the scope and spirit of the claims. Many alternative methods of implementing this invention exist.

[0096] It should be understood that the embodiments of the present invention described herein are merely illustrative of the application of the principles of the present invention. Reference to the details of the illustrated embodiments herein is not intended to limit the scope of the claims, which themselves list those features considered essential to the present invention.

Claims

1. A building system for assembling load-bearing walls, characterized in that, include: Multiple prefabricated columns are configured to form a hollow rectangular profile. Each column includes an interlocking flange and a web, wherein the interlocking portion between the flange and the web is wrapped with an alkali-resistant mesh. Multiple outer panels are configured to be attached to precast columns, one pair of which are attached to the parallel edges of a corresponding pair of precast columns, thereby defining a cavity between the pair of precast columns to form one or more precast hollow wall units, which serve as permanent wall formwork for the building structure. and A filler material is used to fill the cavities of the one or more prefabricated hollow wall units to form a load-bearing wall, the filler material being selected to provide thermal insulation and structural integrity to the load-bearing wall.

2. The building system according to claim 1, wherein the flange and web are selected from cement fiberboard, cement particleboard or calcium silicate board.

3. The building system according to claim 1, characterized in that, It also includes one or more steel profiles disposed within the plurality of said columns, the steel profiles being connected to the inner surface of the hollow rectangular profile.

4. The building system of claim 1, wherein the outer panel is attached to the column by an adhesive material selected from building adhesives and polymer-modified mortars.

5. The building system according to claim 1, characterized in that, It also includes one or more alignment guide members configured to facilitate the assembly of multiple prefabricated hollow wall units.

6. The building system of claim 1, wherein the infill material is selected from foamed concrete and hemp concrete.

7. The building system according to claim 1, characterized in that, It also includes one or more prefabricated hollow wall units B specifically designed for corners and T-joints, the hollow wall unit B including extended flanges and end plates to alter its rectangular profile.

8. The building system according to claim 1, characterized in that, It also includes one or more prefabricated exterior wall units equipped to provide support for the facade components, the prefabricated exterior wall units including an insulation layer and an outer panel B for facade attachment.

9. The building system according to claim 1, characterized in that, It also includes one or more door and window frame posts, which are configured to be used at openings corresponding to doors and / or windows and integrated into the wall formwork.

10. The building system according to claim 1, characterized in that, It also includes one or more lintel units, each comprising a column and an outer panel, reinforced with steel sections, the lintel unit being adapted to be positioned on the lintel of the door frame panel and including fins for connection.

11. The building system of claim 1, wherein one or more prefabricated hollow wall units are configured to include embedded boxes for switches and sockets.

12. The building system according to claim 1, wherein the alkali-resistant mesh is a glass fiber mesh.

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