Wall panel including a mounting kit, and corresponding method of manufacture

Abstract

In order to be able to manufacture at least the wall stud layer (4) of a solid wall panel (1) from adjacent wooden beam studs (4.1-4.z) with only very little distance in between them in a highly automated fashion and in a continuous process yet being able to integrate a special kit such as a mounting kit (4PInst), the special kit, in particular the mounting kit (4PInst) is pre-fabricated externally and is supplied to the production line for the stud layer (4).

Description

I. Area of ​​application

[0001] The invention relates to a wall structure for buildings whose primary building material is wood, which is chosen because of its low weight, good thermal insulation properties and the sustainability of its production. II. Technical Background

[0002] For buildings that consist primarily of wood, different construction methods are known: In order to reduce the need for wood - e.g. compared to log houses made of wood - and to improve the thermal insulation properties, lightweight timber frame houses are known, in which a wall panel has a frame-like supporting structure made of wood, the cavities of which are filled with insulating material and then an inner and outer closed sheathing, often also made of wood-based materials, is applied to the frame.

[0003] Furthermore, wall panels are also known, for example from DE 102011110918 B4, in which a continuous, load-bearing layer of wood is present, consisting of, for example, virtually gapless vertical, natural wood beams, the so-called timber studs, which may have a horizontal beam-shaped frame or sill running across all timber studs on the top and bottom as an upper and lower termination, and which may additionally be provided with an insulating layer on the outside, with possibly additional cladding for weather protection, fire protection and the like.

[0004] Such wall panels are also prefabricated in the factory to enable rapid construction progress when assembling them on the construction site.

[0005] However, if one wants to use such a wall construction to build multi-story buildings of four to eight floors, a number of additional problems arise regarding not only vertical load transfer, but also stiffness of the panels in their main plane, sufficient fire protection, consideration of the settlement and swelling behavior of the building material wood, economical and rapid production even of larger quantities to solve.

[0006] In particular, fire protection for installation channels to be provided in such wall panels, for example for electrical cables, and its integration into a production process for the wall panels have not yet been satisfactorily resolved.

[0007] Document DE 10 2011 110918 A1, which is considered the closest prior art, discloses a wall panel with a stud layer comprising wooden studs, straps attached to them, and sheathing. Reference is also made to documents DE 299 18 445 U1, US 2018 / 038103 A1, US 9 725 902 B1, and DE 102014 009528 A1. III. Description of the invention a) Technical task

[0008] The object of the invention is therefore to provide an installation channel, a generic wall panel with such an installation channel, and a method for manufacturing it, which solve the aforementioned problems. b) Solution of the task

[0009] This problem is solved by the features of claims 1 and 11. Advantageous embodiments are described in the dependent claims.

[0010] Regarding a Installation channel, which is described separately from the invention, it is proposed that an installation package in cross-section with respect to its longitudinal direction, which is in particular the greatest extension direction of the installation package, has an installation base and an enclosure attached thereto with the installation channel extending, in particular in the longitudinal direction, therein, which is enclosed at least on all sides except for the outside of the installation channel which is flush with the outside of the installation package, by fire-resistant, in particular non-combustible, material of the enclosure.

[0011] The installation base preferably consists of a wood-based material, but usually not of natural wood, but in particular of laminated wood, especially plywood, such as veneer plywood, with in particular at least two layers, wherein the fiber directions of the individual layers intersect.

[0012] As a rule, the installation base and the enclosure made of non-combustible material will extend across the entire width of the installation package. Alternatively, the enclosure made of non-combustible material can be positioned at least partially within an installation recess in the installation base that runs in the direction of the installation channel.

[0013] The enclosure itself can be constructed in different ways. In one variant, it consists of at least one fixed component: The enclosure can be made from a block or a layered structure of one or more layers of gypsum plasterboard – that is, pressed or adhesive-bonded powdered gypsum between two layers of paper or cardboard – and / or gypsum fiberboard. In the case of multiple layers, these are oriented parallel to the main plane (4") of the stud layer (4) or the installation base (7). The installation channel is then usually subsequently integrated into the layered structure or the block, for example, by milling.

[0014] The enclosure can also consist of a prefabricated component, especially a profile, in which the installation channel is included from the beginning, particularly in a U-shaped or box-shaped cross-section.

[0015] A species-appropriate blackboard It comprises, firstly, a stud layer consisting of closely spaced wooden studs, which stand vertically, particularly in the case of a wall panel mounted in a building, and, at the end of the studs, a strap running transversely to the direction of travel, the greatest extension direction of the studs, as well as at least one sheathing arranged on at least one side of the stud layer, which preferably extends over the entire surface of the stud layer.

[0016] Depending on the construction of the wall panel, the support layer consists of in the case of a solid stud wall made of closely spaced, in particular virtually gapless, wooden studs or in the case of a lightweight stud wall made of widely spaced wooden studs with insulation material in between.

[0017] Sheathing, in particular by means of one or more sheathing panels, is understood to be sheathing that additionally stabilizes and / or stiffens the wall panel.

[0018] In addition, cladding can be carried out, in particular by means of at least one cladding panel, where the material properties of the cladding are concerned within the scope of the present application, in particular its, for example, fire-retardant material properties.

[0019] However, sheathing and cladding can also be combined functionally, with the sheathing or cladding providing additional functions such as fire protection, sound insulation, etc., besides its stabilizing function. This is the case, for example, with gypsum fiberboards containing mineral fibers.

[0020] According to the inventionIn the event that the corresponding wall is to have an installation channel, preferably running vertically, for approximately one electrical cable, a special package, according to the invention an installation package, is present in the solid stud layer instead of one or a certain number of successive studs, a so-called stud package.

[0021] In a lightweight stud wall system, the installation package is usually present in addition to the wooden studs and runs parallel to them at the desired position, and, like the wooden studs, is butt-jointed between the two transverse straps and screwed, nailed or clamped to them.

[0022] For the purposes of this application, a fire-protection-effective material is understood to mean, in particular, a fire-retardant or non-combustible material.

[0023] In a solid stud wall panel, the wooden studs are arranged so close together – or even touching each other – that the sum of the distances between the wooden studs, considered over the entire wall panel, is less than 5%, better less than 3%, better less than 2%, better less than 1% of the length of the wall panel in that direction.

[0024] Preferably, all wooden beam uprights should be the same thickness and / or width.

[0025] Wooden beam stands with varying dimensions, especially different widths, can also be used, particularly within the framework of the stand packages described later.

[0026] This includesThe straps are not as thick as the wooden beam uprights, but are significantly thinner in the thickness direction of the upright layer.

[0027] For this purpose, the wooden beam uprights – especially those of special packages such as an installation package – have transverse strap recesses at their ends, the shape and dimensions of which are adapted to the cross-section of the respective strap – the two straps preferably having identical cross-sections. Preferably, the strap recesses are open both towards the end face of the wooden beam upright and / or towards three adjacent longitudinal sides, thereby forming a narrower end tongue at each end of each upright.

[0028] InThe direction of the straps, the transverse direction of the wooden beam posts and also of the post layer - the straps lie in the thickness direction of the post layer both on the same side in the thickness direction of the post layer and preferably with their outer side aligned with the outer side of the post layer, whereby alignment also includes deviations of up to 3 mm, better a maximum of 2 mm, better a maximum of 1 mm.

[0029] Preferably, the thickness of the cross ribs in the thickness direction of the stator layer is a maximum of 40%, better a maximum of 30%, preferably a maximum of 20% of the thickness of the stator layer.

[0030] The cross-section of the belt is therefore larger in the longitudinal direction of the wooden beam uprights, which is also the longitudinal direction of the upright layer, than in the thickness direction of the wooden beam uprights, preferably by a factor of at least 6, better by a factor of at least 8, better by a factor of at least 9.

[0031] This design offers several advantages: Firstly, in terms of production technology – as explained in more detail later – it allows two belts to be arranged parallel and at a distance from each other for the production of a stand layer, so that the wooden beam stands can be placed one after the other between the belts and brought to a small distance from each other or into contact with each other, without the wooden beam stands being able to fall through between the belts, which also significantly facilitates the automated feeding, insertion and connection as well as further transport with the belts.

[0032] The main advantage, however, is that the high load-bearing capacity of the wooden posts in their longitudinal direction - the wooden beam posts are cut so that the primary grain direction coincides with their longitudinal direction - is maintained over most of the thickness of the post layer, regardless of whether and what compressive strength the strap has in this direction.

[0033] For example, in spruce wood the modulus of elasticity for bending is 11,000 N / mm² in the direction of the grain and 370 N / mm² perpendicular to the grain, and the compressive strength is 21 N / mm² in the direction of the grain and 2.5 N / mm² perpendicular to the grain.

[0034] In construction using sills that have the same thickness as the wooden beam posts - the so-called sill and the top plate - the compressive strength is limited to the smaller of the two compressive strengths: the compressive strength in the longitudinal direction of the wooden beam posts and the compressive strength of the sill in its transverse direction.

[0035] Nevertheless, the belts will preferably consist of wood-based materials, preferably laminated wood, in particular plywood, preferably veneer plywood.

[0036] This gives them high dimensional stability, although they usually do not have the same compressive strength in the longitudinal direction of the timber stud layer as the individual timber studs, since wood-based materials or laminated wood generally consist of layers glued crosswise with respect to the grain direction to increase dimensional stability and accuracy, and thus even if the grain direction of one layer is in the longitudinal direction of the timber stud layer, this grain direction and - with the same type of wood - the same compressive strength is only present in every second layer of this laminated strip.

[0037] To ensure that the pressure load primarily acts on the wooden beam uprights, the straps do not extend beyond the ends of the wooden beam uprights in the longitudinal direction, but are flush with them or, if necessary, are set back slightly from their ends, i.e. by one to a few millimeters.

[0038] Preferably, each of the wooden beam uprights is connected to each of the chords by a force-fit or form-fit connection, for example by clamping, nailing, or screwing. For manufacturing reasons, such connecting elements as nails or screws – which may be made of metal or a wood-based material – are also inserted into the end tongues of the wooden beam uprights from the side facing away from the chord and extend into the chord, but preferably also from the chord side.

[0039] At least the first and last wooden beam upright is fixed to the straps, and if not all wooden beam uprights are fixed to the straps, then preferably at least 20%, better at least 30%, better at least 50% of all wooden beam uprights of a wall panel, preferably with the fixings evenly distributed between the unfixed wooden beam uprights.

[0040] Preferably, initial fixing takes place when the straps and uprights are brought together, so that these connecting elements do not extend through the subsequently applied sheathing panel; however, additional fastening elements can be inserted from the outside of the sheathing panel into the uprights and / or into the cross straps and, if necessary, also through them to the end tongues of the uprights.

[0041] The sheathing and / or cladding layers preferably consist of a fire-retardant and / or sound-absorbing material, in particular primarily of gypsum or another non-combustible mineral, for example gypsum cardboard boards or gypsum fiberboards reinforced with non-combustible fibers.

[0042] Especially for external thermal insulation, chipboard and oriented strand boards (OSB) or other wood-based materials can also be used.

[0043] Preferably, the material of the sheathing panels has a specific weight that is at least 50%, or preferably at least 100%, higher than the specific weight of the stud layer in order to achieve good sound insulation.

[0044] Preferably, the straps have positioning recesses along their direction of travel, the transverse direction of the timber stud layer, which are open towards the longitudinal direction of the timber stud layer and the two adjacent main side surfaces of the strap and have a length in the extension direction of the strap such that a stud can be inserted precisely and thereby positioned in a transverse direction, whereby the straps as a whole determine a positioning in the transverse direction for the timber stud layer.

[0045] In the event that the wall in question is to have a door or window, instead of a specific number of consecutive studs, a so-called stud package, a special package of the same width, namely a special door package or window package, is inserted during the production of the stud layer. This package is also prefabricated separately from the production of the stud layer and contains, in addition to the door or window opening and, if applicable, the surrounding jamb timbers, the remaining elements necessary below and / or above it, in particular partial studs that are shorter than a normal stud, in order to achieve the length configuration of the stud package thereby replaced.

[0046] The ends of such special packages can be designed to fit into the positioning recesses of the straps, so that the straps do not need to be individually designed for this purpose, but only the door package or window package.

[0047] Or corresponding package recesses are provided in the belts to precisely position the special package in the transverse direction of the stand layer.

[0048] Regarding the procedure To produce an installation package that is described independently of the invention, it is proposed that On an installation base, in particular a board-shaped one, with a width corresponding to the width of the installation package, non-combustible material is applied and fixed over its entire surface, in particular by gluing, in particular in the form of one or more layers, in particular in the form of gypsum board or gypsum fiberboard, an installation channel is introduced into the non-combustible material, in particular milled into it, such that the installation channel is completely surrounded on all sides except for the outer side opposite the installation base by non-combustible material.

[0049] Alternatively, the fire-resistant, in particular non-combustible, material can be applied as a pasty, hardenable mass to the installation base, especially in several layers, or inserted into the installation recess.

[0050] Especially in the latter case, a shaped body with the dimensions of the installation channel can be inserted into the still pasty, curable mass at the position of the later installation channel, thus avoiding the need for subsequent milling out of the cured material.

[0051] Provided that the form is well-defined and continuous in the direction of the installation channel and is made of a fire-resistant material, it can remain as the wall of the installation channel in the hardened mass; otherwise, it is removed from the mass after it has partially or completely hardened.

[0052] Alternatively, a U-profile can be manufactured from fire-resistant material, in particular fire-retardant or non-combustible material, and used either alone or after fixing it to the connecting leg of the cross-section of the U-profile with an installation base as an installation package.

[0053] This U-profile is manufactured for this purpose. with a defined outer width, in particular corresponding to a simple or an integer multiple of the nominal width of a wooden beam upright and / or with a defined length, in particular the length of an upright or the length of the installation channel to be produced and / or with a defined outer height, in particular corresponding to the thickness of an upright or a thickness reduced by the thickness of an installation base compared to the thickness of an upright.

[0054] Such a U-profile can be produced virtually endlessly, for example in an extrusion process, and the required lengths can be cut off without waste.

[0055] Although it is possible for an installation channel that is only intended to extend over part of the room height, for example from the floor to the usual height of a light switch, to extend over the entire room height in the stud layer, the unused upper part of the U-profile forming the installation channel then represents an unnecessary weak point with regard to sound insulation and thermal insulation, which is why the U-profile should only extend over the length of the installation channel that is actually required.

[0056] Therefore, it is advisable to use an installation base that extends over the entire height of the wall panel, especially made of a wood-based material, on which a wood-based material can then be applied in areas away from the U-profile to fill up to the full cross-section of a stud on the installation base.

[0057] Regarding the procedureFor the production of solid wall panels, as previously described and which contain an installation package, at least their solid stud layers are produced according to the invention in a highly automated and very efficient continuous process by a) Arranging two straps at the correct longitudinal distance between the uprights and with a downward clearance between them, the straps preferably bearing against an end stop with their end faces, b) Inserting a first upright by placing the end tongues of the upright onto the two straps, so that the end of the strap recess then rests as close as possible to or directly against the narrow longitudinal side of the strap, c) Fixing this upright, in particular by screwing it through its end tongues, to the two straps in all three spatial directions, d) Inserting the next upright or - as described later - upright assembly between the straps behind the last upright, in particular one already fixed to the straps, e) Fixing this further upright, in particular by screwing or nailing it through its end tongues to the two straps, f) Repeating steps d) and e),until the entire length of the crossbeams, whose longitudinal spacing between the uprights is filled with wooden beam uprights.

[0058] This allows not only for the production of upright layers of virtually unlimited width – limited only by the length of the belts – but also for the individual uprights to be automatically fed in from above and fixed to the belts.

[0059] For wall panels that are to contain a door, a window and / or electrical or sanitary installation channels, instead of a specific number of studs – referred to as a stud package in the application – a special package can be inserted between the straps when creating the stud layer, particularly in steps d) and e), wherein this preferably has a width that is simple or an integer multiple of the nominal width of studs, in particular the width of the replaced stud package.

[0060] Such a special package is an installation package that contains an installation channel.

[0061] Such a special package can also be a door package with a door opening in it, which may include jamb timbers around the door opening as part of the door package, and / or a window package with a window opening in it, which may include jamb timbers around the door opening as part of the window package.

[0062] Preferably, between steps b) and c), the next stand is pushed close to the previous stand in order to keep the voids in the stand layer to a minimum.

[0063] Preferably, in step c), the fixing is carried out by inserting so-called screw nails, which, due to their external thread, can also be unscrewed again. All other fixings of the uprights to the crossbeams and / or the sheathing to the uprights or crossbeams are preferably carried out by means of clamps, i.e., by inserting U-shaped clamps.

[0064] To ensure that the feed device for the stands and / or the fixing device for fixing the stands to the belts can remain approximately, and in particular exactly, in the same position, the resulting layer of stands is preferably moved forward by the corresponding distance after each or a defined number of stands have been fixed between the belts. This distance is a conveying distance in the form of a single or multiple integer of the target width of a transverse belt, optionally plus a width allowance to compensate for material or manufacturing differences in the width of the stands.

[0065] Due to the manufacturing process, despite a defined very low moisture content, the individual stands do not all have exactly the same width and are not perfectly straight, as they are made of grown wood.

[0066] In order to distribute the stands evenly across the width of the wall panel and to prevent their under-dimensions from adding up in relation to the conveying distance, positioning recesses with a length corresponding to the conveying distance or the target width of a stand can be provided in the two belts in the narrow longitudinal sides facing each other at corresponding longitudinal positions.

[0067] This naturally requires two different types A and B of stands, which are the same length, but whose strap recesses and therefore also their end tongues have different lengths in the longitudinal direction of the stands.

[0068] Then will Between two opposing positioning recesses, stands of type A with the shorter belt recesses and end tongues were inserted; away from the positioning recesses, stands of type B with the longer belt recesses and end tongues were inserted.

[0069] After the stud layer has been constructed, the planking on both sides is carried out by g) Laying at least one layer of sheathing panels on the top of the completed stud layer, h) Fixing, in particular by stapling, screwing or nailing, these sheathing panels to the stud layer, which can also be done in a continuous flow process.

[0070] The planking of the second side of the stud layer is then carried out by i) Turn the upright layer, which is already planked on the top side, 180° around the conveying direction so that the planking panels attached to it are at the bottom and the belts are at the top, ii) if necessary, additionally fix the belts opposite the end tongues, in particular with staples, nails or screws, k) Repeat steps g) and h) on the now top side of the upright layer. c) Examples of implementation

[0071] Embodiments according to the invention are described in more detail below by way of example. The figures show: Figure 1a: a support layer of a solid wall panel in a partially finished state, viewed from above on one of its main surfaces, Figure 1b: a first cut through the stator layer at point B - B in Figure 1a , Figure 1c: a second cut through the stator layer at point C - C in Figure 1a , Figure 1d: a cross-section through the already nailed stud layer, Figure 1e: a cross-section through a stud layer that is already sheathed on one side, Figure 1f: a cross-section through a stud layer that is already sheathed on both sides, Figure 2a: a stud layer of a solid wall panel with a window contained therein in a partially completed state, viewed from above on one of its main surfaces, Figure 2b:a stud layer of a wall panel with a door and windows included, as well as an installation channel, in its finished state in the view according to Figure 2a and Figure 1a from inside the room, Figure 2c: the stratification layer of the Figure 2b , however, without the smaller window, in perspective view, Figure 3: the stratification layer of the Figure 2c in perspective view, already planked on both sides, Figure 4a - d: the manufacturing process of an installation stand, viewed in the direction of the installation channel, Figure 5a, b: the beginning of the production process of the stator layer in different manufacturing stages, viewed from above, Figure 6a, b: the start of the production process in the manufacturing stages according to Figure 5a , b in side view, Figure 7a - c: the storage and assembly process of a stand in detail, Figure 8a, b:a lightweight stud layer with an installation package in plan view on its main plane as well as in sectional view.

[0072] The Figure 1a - f Figure 1 shows the basic structure of the solid stud layer 4 of a solid wall panel 1 according to the invention: This consists of wooden beam studs 4.1, 4.2 etc. arranged in a row in the width direction 11 of the wall panel 1, which preferably all have an identical cross-section, in particular identical width, and an identical length in their direction 4', the stud direction 4', which is thus simultaneously the height direction 10 of the wall panel 1.

[0073] The width direction 11 and the height direction 10 of wall panel 1 span its main plane.

[0074] The wooden beam uprights 4.1, 4.2, etc., each have a shoulder-shaped recess, the strap recess 24a, b, on the same side 4a of their circumference at the end regions of their upright direction 4', so that a board-shaped strap 6a, 6b, extending across the entire width of the wall panel 1 in the width direction 11 and fitting into it with its cross-section, can be inserted into these aligned strap recesses 24a, b when the uprights 4 are placed side by side and can be connected to each individual upright 4.1, 4.2.

[0075] For the vertically standing posts 4.1, 4.2 etc. made of solid wood - when the wall panel 1 is mounted vertically - they are cut in such a way that the grain direction 9 is essentially in the direction 4' of the wooden beam posts 4.1, 4.2 etc., because in the direction of the grain direction 9 solid wood has the least dimensional changes in the future and the highest static load-bearing capacity.

[0076] The straps 6a, 6b can also consist of sawn timber, but are usually made of layers 8 lying parallel to the main plane of the upright layer - as best seen in the magnification of the Figure 1c to be recognized - glued, whereby the grain direction in the individual layers 8 runs crosswise to the adjacent layer 8, so that in every second layer 8 the grain direction can also lie in the stand direction 4', so that the end grain content in the top and bottom is relatively high and thus offers a high resistance to dimensional changes in the vertical direction 20.

[0077] Since the belts 6a, 6b can fulfill these functions all the better the more layers 8 glued together they consist of, they are preferably made of layers of veneer, i.e. as laminated veneer lumber, and not just as plywood.

[0078] In order to prevent dimensional inaccuracies regarding the cross-section, especially the width B, of the uprights from being summed up over the width of the up to 12 m long upright layer 4, according to Figure 1a Positioning recesses 23a, b are provided in the facing narrow sides of the two belts 6a, b at corresponding positions in the width direction 11 at defined intervals, for example for every fifth upright 4.5, 4.10 etc., which - in the overhead view of the Figure 1a - from one main side to the other main side of the cross chords 6a, b and have a length corresponding to the nominal width B of a wooden beam post, resulting in shorter end tongues 25a, b on the posts in the end area in the post direction 4'.

[0079] This defines the position in the width direction 11 of the wooden uprights 4.5, 4.10 etc. inserted in these positioning recesses 23a, b, and between them are - in this case four each - wooden beam uprights 4.6 - 4.9, which fill this space, whereby they may contact each other or, due to manufacturing inaccuracies, may have very small distances to each other in the width direction 11.

[0080] The positioning recesses 23 thus hold stands 4.5 of type 4A according to Figure 1c , whose positioning recesses 24a, b and thus also their end tongues 25a, b in the stand direction 4' are shorter than in the case of type 4B according to Figure 1b , which are provided in the sections between the positioning recesses 23.

[0081] In the frontal view of the Figure 1dThe connection between the individual uprights 4.1 etc. and the straps 6a, 6b is also shown, here by nailing using nails 13, which are driven from the side 4b facing away from the straps (the side facing upwards during manufacturing) through the end tongues 25a, b into the opposite strap 6a, 6b of each upright as an initial fixing. Screw nails, which have a thread on their outer side and can be unscrewed again, are usually used for this purpose.

[0082] To complete the stud layer 4 into a finished wall panel 1, possibly after additional clamping, the following steps are first carried out according to... Figure 1eon one side, preferably again the still upper side 4b, in one or more layers of sheathing panels 5, mostly made of a non-combustible material such as gypsum plasterboard or gypsum fiberboard, in particular over the entire surface, applied to the stud layer 4 and - preferably by means of staples 13, which extend approximately to the middle of the thickness D of the stud layer 4 - nailed or stapled to the studs in their middle area as well as through the flanges 6a, 6b through their end tongues 25 a, b.

[0083] The sheathing 5 serves a dual purpose: firstly, fire resistance, as the sheathing 5 consists of fire-resistant, in particular non-combustible, material, for example primarily gypsum or another stone flour material or calcium silicate; secondly, the sheathing 5 is also intended to improve the load transfer of the stud layer 4 in its main plane.

[0084] For this purpose, the sheathing 5 has a fiber component, preferably again made of a non-combustible or poorly combustible material, for example of mineral materials, which are arranged in irregular directions and thus give the sheathing 5 a high resistance to forces in its main plane, i.e. to shear forces.

[0085] A non-combustible or poorly combustible material can also be achieved by coating or impregnating a combustible material with a fire-retardant material such as calcium silicate or water glass to give it non-combustible or poorly combustible material properties.

[0086] The indirect connection of the individual uprights to each other via nailing to the sheathing panels is also improved.

[0087] The stud layer 4 should also be covered on its vertical narrow sides with such fire-resistant, in particular fire-retardant, cladding 5 in order to prevent the penetration of fire and smoke into the structure.

[0088] Subsequently, after turning over the single-sided planked stud layer 4 so that the chords 6a, b are now on top, planking is usually also carried out on the upper side 4a, which is away from the chords 6a, b, whereby in this case the nails or staples 13 do not reach or even penetrate the chords when nailing.

[0089] The Figures 2b and 2c The figures show, in plan view and in perspective, a stud layer 4 of a solid wall panel 1, in which a door opening T, a window opening F, and an installation channel 21 – the latter on the interior side – are integrated, as in Figure 2cAdditionally, a small window opening.

[0090] Figure 2a Figure 1 shows in detail how such a window opening F or door opening T is provided in such a stud layer 4: For this purpose, instead of a defined number of successive, continuous, i.e. normal, studs at a defined position in the width direction 11 of the wall panel 1, for example a prefabricated window package 4PF or door package 4PT is placed between the two stringers 6a, b, which contains a window opening F or door opening T for inserting a window whose width is less than the width of the window package 4PF.

[0091] The window package 4PF therefore has a width that is preferably an integer multiple of the nominal width B of a stud.

[0092] Above and below the window opening F, perpendicular to the stud direction 4', i.e., usually horizontally in the installed state of the wall panel, runs an upper chord 4PFa or 4PTa as a lintel and a lower chord 4PFb as a parapet in the case of a window opening or 4PTb as a threshold in the case of a door opening, at least over the entire width of the window opening F or door opening T.

[0093] The lintel preferably extends across the entire width of the 4PF or 4PF package. Below the lintel, on both sides of the opening, there is at least one shorter support than the standard-length supports on which the lintel rests, for load transfer.

[0094] Depending on the distance of the lintel, parapet or sill to the adjacent chord 6a, 6b in the stud direction 4', partial studs can again be connected to this upper chord or lower chord, with which the upper chord or lower chord is firmly connected, and in whose end tongues in particular the chord recesses 24a, 24b are incorporated to receive the chord 6a, 6b which continues over the entire width of the wall panel 1 and thus also over the window opening F and the window assembly 4PF.

[0095] Since the upper edge of a window opening F as well as a door opening T is usually only a short distance from the upper chord 6a, partial mullions are generally no longer used there, but the upper chord 4PFa extends as a lintel from the opening to the upper end of the mullion layer 4. Preferably, the upper chord 4PFa also extends across the entire width of the corresponding window assembly 4PF or door assembly 4PT.

[0096] The lower chord 4PFb - as a parapet at the window and as a threshold at the door - in contrast, usually only extends across the width of the opening in the width direction, and is connected at its ends to the partial studs that extend from the lower chord 6b to the lintel.

[0097] For the exact positioning of the window opening F in the width direction 11, the belts 6a, 6b have a package recess 27 analogous to the positioning recesses 23a, b in the facing narrow sides, but with a multiple of the length of the package recesses 23a, b - namely the width of the window package 4PF - and with a different depth in the frame direction 4', usually with a greater depth b than the depth a of the positioning recesses 23a, b.

[0098] The prefabricated window package 4PF is therefore placed at the appropriate position and then inserted between the package recesses 27 when the production of the stud layer begins at one end of the belts 6a, 6b, for example with stud 4.1.

[0099] In order to avoid being bound to the grid dimension of the integer width B of a stud with the width of a window package 4PF or a door package 4PT and thus the window opening F or door opening T contained therein, within such a package - as in Figure 2b In the smaller window shown - a special stand 4* can also be used - which in particular limits the opening e.g. F on one side or each side - which has a width that deviates from the target width B, about 1.5 times or 2 times.

[0100] Such a special stand 4* can have a recess in the area of ​​the opening, e.g. F, whereby the width of the opening, e.g. F, becomes independent of the grid dimension based on the width B of a normal stand.

[0101] Furthermore, in the Figures 2b , 2c - in particular on the main side 4b of the solid stud layer 4 facing away from the straps - an installation channel 21 is provided, through which an electrical cable can be routed from the floor up into the stud layer 4, as shown, to an installation opening 21a provided at the upper end of the installation channel 21 in the sheathing 5, e.g. for a light switch at the upper end of the installation channel 21. The sheathing 5 is then attached to the stud layer 4 according to the Figures 2b , c laid and thus covers installation channel 21, as in Figure 3a evident.

[0102] Alternatively, the installation channel 21 can also run along the entire length of the installation package or installation stand - if the installation package is only the width of a single wooden beam stand - in which it is located.

[0103] Depending on the depth and width, other lines such as a water pipe can also be laid in such an installation channel 21.

[0104] The Figures 4a - 4dFigure 1 shows one way of manufacturing such an installation package: For this purpose, instead of the width B of one or more normal uprights of type 4A or 4B - in the case of an installation channel 21 for only one electrical cable, usually only one upright - an installation package 4PInst is used - which accordingly can only have the width of a single upright or, if necessary, an integer multiple of the target width B - and which is prefabricated externally: In the thickness direction 12, the installation package 4PInst consists of an installation base 7, usually board-shaped, made of a wood-based material - either solid wood or a laminated wood panel - whose extension in the width direction 11 preferably has a multiple of the required width of the installation package 4PInst.

[0105] On this installation base 7, several layers of a non-combustible material, in particular gypsum plasterboard or gypsum fiberboard, are applied and connected to each other and to the installation base 7 over a surface area, usually not by nailing or stapling, but by e.g. gluing, until the total structure has the thickness D of the stud layer and thus of a single stud.

[0106] From such a layer structure, 28 are then cut, for example using a circular saw, according to Figure 4a , Strips with the required width of the installation package, here the width B of a single stand according to Figure 4b , cut off.

[0107] The installation channel 21 to be produced in the longitudinal direction 4' of the installation package 4PInst is constructed according to Figure 4c by passing along the desired length with, for example, a roller cutter 29 in the column direction 4', i.e. the longitudinal direction 10.

[0108] According to Figure 4d The completed installation package 4PInst is installed as a special package during the production of the support layer 4 instead of the corresponding number of normal supports between the belts 6a, b.

[0109] Alternatively, the groove can also be inserted in the stud layer 4 only after the installation package 4PInst has been installed.

[0110] This means that the cross-section of the installation channel 21 is surrounded on three sides by non-combustible material, and for the fourth side of the cross-section this is achieved by the subsequent cladding of the finished stud layer 4 with e.g. gypsum plasterboard.

[0111] Such an installation package 4PInst can be configured according to the Figures 8a , b likewise used and installed in a lightweight stud layer 4: How Figure 8aAs shown, such a lightweight stud layer 4 has a frame consisting of, on the one hand, wooden studs 4a - z arranged parallel to each other at a mostly regular interval, usually of about 60 cm, which stand vertically when the wall panel is installed, and on the other hand, an upper crossbeam 6c running over all upper ends and a lower crossbeam 6d running under all lower ends, to which the wooden studs are butt-jointed and firmly connected, usually by nailing or clamping.

[0112] Measured perpendicular to the main plane of the support frame - see Figure 8b - the wooden beam uprights 4a - z usually all have the same thickness, namely the same thickness as the crossbeams 6c, d.

[0113] At the earliest, after one side of the supporting frame has been covered with a continuous sheathing 5, for example with wood-based panels that are nailed or stapled to the supporting frame, the cavities between the wooden studs 4a - z are filled with insulating material 4a. Before or after filling, the other side of the supporting frame is completely closed off by another layer of sheathing 5.

[0114] If a vertically running installation channel 21 is required in the wall panel when mounted, an installation package 4PInst - which has the same length as a wooden beam stand 4a - z and whose width can be determined as required - is mounted at the desired position between two wooden beam stands and usually parallel to them by attaching the respective crossbeam 6c, d to the end face of the installation package 4PInst, in particular its installation base 7.

[0115] This can – as in Figure 8b As shown, the installation package 4PInst may have a lesser thickness – measured perpendicular to the main plane of the stud layer 4 – than the crossbeams and / or the timber studs, or it may have the same thickness, and the installation package 4PInst with the installation channel 21 is mounted adjacent to one of the main sides of the stud package 4. The remaining gap to the other main side can then be filled with insulation material 4a.

[0116] According to the Figures 5a to 7c The belts with their recesses are designed to enable the production of the stud layer 4, preferably including the sheathing 5, in a largely automated continuous process, resulting in significant cost advantages: As shown in the overview of the Figure 5aAs can be seen, belt supports 18 are arranged at intervals corresponding to the length of the uprights 2 in the conveying direction 11, the width direction of the wall panel to be produced, here in the form of roller tracks 18 consisting of a large number of horizontally arranged rotatable, optionally also controllable, transport rollers 30.

[0117] On each roller track 18 a belt 6a, b is placed with opposing positioning recesses 23a, 23b, whereby the correct distance in the upright direction 4' is ensured by belt guides 32a, b provided on both sides, i.e. on the respective outside of the belt 6a, 6, for the belts as a stop in the height direction of the wall panel 1 to be produced.

[0118] The productionThe process begins on a support layer 4 by placing the two belts 6a, 6b onto their respective belt supports 18a, 18b and pushing or driving them forward in the conveying direction 11 up to activated end stops 31 located at analogous positions in the conveying direction 11, and – usually manually – bringing them outwards into contact with their belt guides 32a, 32b according to Figure 5a and Figure 6a .

[0119] Then, from above, the first wooden beam upright 4.1 is placed, in particular directly, on the end stops 31, 31 onto the beginning of the two straps 6a, 6b - preferably automatically - with its strap recesses 24a, b pointing downwards between the straps 6a, 6b, so that it rests only with each of its end tongues 25a, 25b on the front end of one of the two cross straps 6a, b and is then nailed from above by means of nails 13 through these end tongues 25a, 25b to the strap 6a, b below - preferably automatically.

[0120] Preferably, a supply of uprights of type 4A is located, for example, above the area in front of the end stops 31, from which - preferably automatically - the first upright 4.1 and subsequently the further uprights 4.ff are placed and nailed together.

[0121] At the position of a specific, e.g. the fifth, upright 4.5, the two crossbeams 6a, 6b have - as in Figure 5avisible - each a positioning recess 23a, b facing each other, extending through the entire thickness of the belt, so that at this position in the vertical direction 10 the clear distance between the belts 6a, 6b is greater.

[0122] Accordingly, for insertion at this, for example, fifth position, a stand of type 4B is required, of which there is also a supply, for example, above the area in front of the end stops 31, and whose end tongues 25a, b are somewhat shorter corresponding to the depth of the positioning recesses 23a, b. This is inserted as stand 4.5 between the positioning recesses 23a, b.

[0123] Basically, it is irrelevant at which positions positioning recesses 23a, b are provided for a stand of type 4B, provided that the distance in the conveying direction 11 between the positioning recesses 23a, b of a belt preferably corresponds to a multiple of the nominal width B, possibly plus an allowance for manufacturing inaccuracies.

[0124] As soon as the first stand 4.1 is placed and mounted, i.e. nailed in place, the stops 31 are deactivated, i.e. removed from the path of movement of the cross straps 6a, b and the mounted stands, for example moved downwards between the transport rollers 30.

[0125] The entire started upright layer 4 can then be moved forward in transport direction 11 to the target width B of an upright.

[0126] Theoretically, this is possible by controlled driving of the transport rollers 30. However, since slippage can occur in this process, it is preferable instead to grip the first mounted stand 4.1 and / or the front end of the two cross belts 6a, b by one or, better yet, two grippers 2 spaced apart from each other in the vertical direction 10, preferably clamped, and preferably mounted on a common gripper arm 3.

[0127] By moving the grippers 2, in particular the gripper arm 3, forward in the transport direction 11 by, for example, a target width B of a stand or the width of a special package to be inserted, another stand 4.2ff or a special package can be successively placed on the belts 6a, b and connected to them until the stand layer 4 is completed.

[0128] In this way, automatic placement devices 33a, b for the stands and automatic nailing devices 34 can essentially remain in their longitudinal position in the conveying direction 11 and do not need to be designed to be movable in the conveying direction 11.

[0129] If the placement device - like Figure 7a in the same direction as the Figures 6a , b If a gripper 33 is used to place the individual stands, for example at the front end of a robot arm, the stand will usually be clamped between two gripper prongs 33a, b, which grip the side surfaces of the stand 4x pointing in and against the transport direction 11.

[0130] Then the problem arises that a gripping tine 33b would collide with the previously mounted stand 4x immediately behind it - or with the longitudinal stop 31 in the case of the first stand - when lowering the stand.

[0131] Therefore, the stand to be mounted is placed 4x on a stand support 35 which is height-adjustable by means of an adjusting cylinder 36, at such a storage height that, on the one hand, the gripping prong 33b does not yet collide with the adjacent previously mounted stand and, on the other hand, preferably, the stand 4x is not yet immersed with its middle part between the two straps 6a, b.

[0132] After removing the gripper 33, according to Figure 7c The stand is pressed downwards 4 times from above by means of a pressing device 38 until the end tongues 25 a, b rest on the straps 6a, b, for which of course the stand support 35 must also be lowered further.

[0133] Before pressing between the straps 6a, b, according to Figure 7bThe stand 4x – preferably still at storage height – is pushed with slight resistance in the transport direction 11 against a stand stop 39 or the last previously mounted stand by means of a slider 37. During the downward pushing of the stand until its end tongues rest on the belts 6a, b, the slider 37 does not press against the stand, but is preferably moved slightly backwards away from it.

[0134] The stand stop 39 for the stand 4x held by the gripper 33 serves in the vertical direction as a stop for the gripper tine 33b and in the transport direction 11 as a stop for the held stand 4x.

[0135] Preferably, this stand stop 39 is arranged above the activated end stop 31 and / or the last mounted stand.

[0136] Preferably, this stand stop 39 is arranged with its contact surface pointing against the direction of transport 11 slightly in front of the end stop 31 in the direction of transport 11. REFERENCE MARK LIST

[0137] 1Wall panel 2Gripper 3Gripper arm 4Stand layer 4'Stand direction 4a, bPage 4.1, 4.2 Timber stud 4A, B Type of timber stud 4PS Stud package 4PT Door package 4PF Window package 4PFa Top chord 4PFb Bottom chord 4PInst Installation package 5 Sheathing panel, sheathing 5* Installation sheathing 6a, b Chord 6c, d Crossbeam 7 Installation base 8 Layer 9 Fiber direction 10 Vertical direction of panel 11 Transverse direction, width direction, conveying direction 12 Thickness direction 13 Screw, nail, staple 14 Insulation body 14a Insulation body-wall 15 Weatherproof layer 16 Air gap 17 Rib 18a, b Chord support 19 Horizontal direction 20 Vertical direction 21 Installation channel 21a Installation opening 22 Installation recess 23 Positioning recess 24a, b Cross belt recess 25a, b End tongue 26 Batten 27 Package recess 28 Saw blade 29 Milling cutter 30 Transport roller 31 Face stop 32a, b Belt guide Side stop 33 Placement device, gripper 33a, b Placement device 34 Nail device 35 Height-adjustable stand support 36 Actuating cylinder 37 Slider 38 Press-in device 39 Dispensing stop . 50 Exterior wall 60 floor ceiling 100 buildings aDepth 23 bDepth 27 BTarget width of upright dThickness of belt DThickness of upright and upright layer FWindow opening TDoor opening

Claims

1. Wall panel (1) for constructing a building, having a stud layer (4) comprising timber-beam studs (4.1, 4.2) which, when the wall panel (1) is mounted in the building, run vertically in their stud direction (4'), and which at the top and bottom are connected to one another by a respective rail (6a, b) running transversely to their stud direction (4'), as well as one or more planar sheathings (5), in particular extending over the entire wall panel (1), on at least one side of the stud layer (4), wherein the wall panel (1) has an installation package (4Plnst) in the stud layer (4), wherein the installation package (4Plnst), in cross-section to its longitudinal direction (10), which is in particular the direction in which the installation package (4PInst) extends the most, has an installation base (7) and an enclosure with an installation duct (21) therein, running in particular in the longitudinal direction (10), which is enclosed on all sides by material effective for fire protection, in particular non-combustible material, except for the outer side of the installation duct (21) that is flush with the outer side of the installation package (4PInst), and wherein the stud layer (4) consists of timber-beam studs (4.1, 4.2) arranged close together, in particular virtually without gaps, wherein the rails (6a, b), in the thickness direction (12) of the stud layer (4), have a smaller thickness (d) than the stud layer (4) and both, in the thickness direction (12), are arranged only on one, namely the same side (4a) of the stud layer (4), and with their cross-section lie in end-side rail recesses (24) of the timber-beam studs (4.1 - 4.z), adjacent to the remaining end tongues (25a, b).

2. Wall panel according to claim 1, characterised in that - the thickness (d) of the rails (6a, b) is at most 30%, preferably at most 25%, at most 20% of the thickness (D) of the stud layer (4) and / or - the thickness (d) of the rails (6a, b) is at most 45 mm, in particular at most 35 mm, in particular at most 25 mm and / or - the thickness (d) of the end tongues (25a, b) is at least 55 mm, in particular at least 60 mm, in particular at least 65 mm.

3. Wall panel according to any of the preceding claims, characterised in that - along the rails (6a, b), positioning recesses (23) having the width (b) of a timber-beam stud (4.1) are present at defined intervals and at corresponding, mutually opposite positions, between which there are studs whose rail recess (24a, b) and end tongue (25a, b) are then shorter than in studs away from the positioning recesses (23).

4. Wall panel according to any of the preceding claims, characterised in that - the rails (6a, b) do not project in the longitudinal direction (10) beyond the ends of the timber-beam studs (4.1 - 4z), in particular end flush with them, and where appropriate are set back relative to them.

5. Wall panel according to any of the preceding claims, characterised in that - the timber-beam studs (4.1 - 4z) consist of solid (sawn) timber with the grain direction (9) primarily in the longitudinal direction (10) of the timber-beam studs (4.1 - 4z), - the transverse rails (6a, b) consist of laminated wood, in particular plywood, in particular veneer plywood, with in particular at least five layers (8) and preferably with crossing fibre orientation in the individual layers (8).

6. Wall panel according to any of the preceding claims, characterised in that - the sheathing panel (5) consists of material effective for fire protection, in particular flame-retardant material, - in particular a plasterboard, - preferably a gypsum fibreboard stabilised with fibres, in particular non-combustible fibres.

7. Wall panel according to any of the preceding claims, characterised in that - each timber-beam stud (4.1 - 4z) is connected to each of the rails (6a, b) by two screws (13) or nails (13) or staples (13).

8. Wall panel according to claim 7, characterised in that - the screws (13) or nails (13), in particular screw nails, or staples are inserted from the side (4b) facing away from the rail (6a, b) through the stud layer (4) into the rail (6a, b), and / or - the screws (13) or nails (13) or staples are inserted through the sheathing panel (5) and where appropriate the rail (6a, b) into the timber-beam studs (4.1 - 4.z).

9. Wall panel according to any of the preceding claims, characterised in that - where there are several sheathing or facing panels (5), these abut, in the transverse direction (11) to the longitudinal direction (10) of the timber-beam studs (4.1 - 4.z), on one of the timber-beam studs (4.1 - 4.z).

10. Wall panel according to any of the preceding claims, characterised in that the timber-beam studs (4.1 - 4p) arranged close to one another define at least one stud package (4P) and that the wall panel comprises a special package, in particular - a door package (4PT) which contains a door opening (T), optionally enclosed by reveal timbers, or - a window package (4PF) which contains a window opening (F), optionally enclosed by reveal timbers, wherein the special package has in particular a width (B) equal to the simple or an integral multiple of the width (b) of a timber-beam stud (4.1).

11. Method for producing a wall panel (1) according to any of the preceding claims, wherein the stud layer (4) is produced in a continuous process by a) arranging two rails (6a, b) at the correct stud longitudinal spacing and with free space between them, with their end faces facing downwards in a defined position, in particular against an end stop (31), b) inserting a first stud (4.1) between them by placing the end tongues (25a, b) of the stud (4.1) on the two rails (6a, b), so that the rails lie in the rail recesses (24a, b), c) fixing, in particular screwing, stapling or nailing, this stud through its end tongues (25a, b) to the two transverse rails (6a, b), d) inserting the next stud (4.2) between the rails (6a, b) behind the last stud, in particular already fixed to the rails (6a, b), (4.1), e) fixing, in particular screwing or nailing or stapling, this stud through its end tongues opposite to the two rails (6a, b), f) repeating steps d) and e) until, over the entire length of the transverse rails (6a, b), their stud longitudinal spacing is filled with timber-beam studs (4.1 - 4.z). characterised in that - in steps d) and e), instead of one or more individual studs (4.2), an installation package (4PInst) having a width equal to the simple or an integral multiple of the width (b) of a single stud is inserted.

12. Method according to claim 11, characterised in that - between steps b) and c) the next stud (4.2) or the next special package (4P) is pushed up to the preceding stud (4.1).

13. Method according to one of the preceding method claims, characterised in that after fixing each stud or a defined number of studs (4.1, 4.2, 4.3) between the rails (6a, b), the resulting stud layer (4) and / or the at least one end stop (31) - either is moved forwards by the width of a timber-beam stud or of a special package, - in particular after deactivating the end stop (31).

14. Method according to one of the preceding method claims, characterised in that to move the resulting stud layer forwards, the first timber-beam stud (4.1), with the rails (6a, b) fastened thereto, is grasped by a gripper and moved forwards in defined steps in the transport direction (10).

15. Method according to any of the preceding method claims, wherein - the two rails (6a, b) have, on the narrow longitudinal sides facing one another and at corresponding longitudinal positions, positioning recesses (23) with a length corresponding to the width (b) of a stud (4.1), characterised in that - in the regions away from the positioning recesses (23), studs of a type A which have short end tongues (25a, b) are inserted, - between two positioning recesses (23), studs of a type B which have short end tongues (25a, b) are inserted.

16. Method according to any of the preceding method claims, characterised in that after completing the stud layer (4), its sheathing is carried out by g) placing at least one layer of sheathing panels (5) on the upper side of the finished stud layer (4), h) fixing, in particular screwing or nailing or stapling, these sheathing panels (5) opposite to the stud layer (4), i) turning the stud layer (4) so that the sheathing panels (5) fastened thereto face downwards and the rails (6a, b) face upwards, k) repeating steps g) and h) on the side of the stud layer (4) that now faces upwards.

Images