A prefabricated panel structure and a method of installing the prefabricated panel structure

Abstract

Disclosed is a prefabricated panel structure (100a, 100b, 200a, 200b, 400) for a building surface (102, 202), comprising two or more connectable panels and panel engagement means (150, 250). Each panel comprises a main frame with a bottom beam (112, 212, 312, 412), a top beam (114, 214, 314, 414), and structural elements (116, 216, 416) in between; an interior layer assembly (117, 217) on the building-facing side; and an outer envelope system (118, 218). Engagement means comprise positioners (152, 252, 352a, 352b, 452) and alignment sockets (154, 254, 354a, 354b, 454) to enable vertical assembly. The bottom beam of the first panel attaches to a supporting structure (104, 204), while the top beam of the end panel acts as a termination beam, each top beam being attachable to the building surface via attachment means (106, 206).

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to field of prefabricated façade construction, and more specifically, to prefabricated façade panels.BACKGROUND

[0002] In the field of prefabricated façade construction, current techniques primarily involve two methods of installing wall panels: individual attachment to the existing building structure and stacking panels using various connection systems. The individual attachment approach requires each panel to be separately supported and fixed to the building's wall or ceiling, often utilizing steel supports or brackets. This method is labor-intensive and time-consuming, necessitating precise on-site measurements, alignment, and the installation of supports for each panel. The extensive use of steel not only increases material costs but also adds complexity to the installation process due to the need for accurate placement and secure fastening.

[0003] Alternatively, panels are stacked on top of one another using mechanical fastening systems or interlocking mechanisms, such as wooden locking systems. These systems involve custom-sized wooden components that interlock to connect vertically adjacent panels. While stacking reduces the need for individual supports, it introduces challenges related to material usage and installation efficiency. The custom components increase material costs and require additional manufacturing steps to produce non-standard sizes. The assembly process is complicated, demanding careful alignment and adjustment during installation, which prolongs the overall construction timeline. Additionally, on-site sealing and finishing are often necessary to ensure weatherproofing and structural integrity, further increasing labor costs, installation complexity and time.

[0004] Both methods face significant shortcomings in achieving fast and cost-efficient installation of façade elements without extensive on-site work. The reliance on precise on-site adjustments makes the installation process susceptible to delays and errors. Material inefficiencies arise from the use of heavy steel supports or custom wooden components, leading to higher costs and complicated logistics. The need for on-site finishing, such as sealing joints and installing flashings, extends the project duration and requires skilled labor, contributing to increased expenses.

[0005] These problems are due to the lack of a standard, efficient means of connecting panels that allows for quick assembly with minimal on-site adjustments. Existing systems do not address the need for precise alignment and secure connection between panels while simplifying the installation process. The absence of integrated connection mechanisms results in longer installation times and higher labor costs. Therefore, there is a need for a prefabricated panel structure that enables fast and efficient installation through improved means of connecting panels, reducing on-site work, and optimizing material usage.SUMMARY

[0006] The aim of the present disclosure is to provide a solution to enable fast and cost-efficient installation of façade elements without the need for extensive on-site work.

[0007] The aim of the disclosure is achieved by a prefabricated panel structure and a method of installing the prefabricated panel structure as defined in the appended independent claims to which reference is made to. Advantageous features are set out in the appended dependent claims.

[0008] The advantage of the present prefabricated panel structure and the installation method is that it enables fast and cost-efficient installation of façade elements without extensive on-site work by using integrated panel engagement means that allow precise alignment and secure stacking of panels, thereby reducing material costs and labor time by minimizing the need for on-site adjustments, additional support structures, and finishing work.

[0009] Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments construed in conjunction with the appended claims that follow.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The summary above, and the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the embodiments of the disclosure are shown in the drawings, with references to the following figures wherein: Figure FIG. 1a is a side view of an example of a prefabricated panel structure according to an embodiment of the present disclosure; Figure FIG. 1b is a side view of an example of a prefabricated panel structure according to another embodiment of the present disclosure; Figure FIG. 1c is a front view of the intermediate panels illustrating the vertical stacking of the panels; Figure FIG. 1d illustrates an alternative embodiment of a panel engagement means; Figure FIG. 1e illustrates a cross-sectional view of an embodiment of a prefabricated panel structure; Figures FIG. 1f and FIG. 1g illustrate different embodiments of the panel engagement means; Figure FIG. 2a is a side view of another example of a prefabricated panel structure; Figure FIG. 2b is a front view of another example of the prefabricated panel structure; Figure FIG. 2c illustrates a front view of another embodiment of a panel engagement means; Figures FIG. 2d - FIG. 2f show top views of the prefabricated panel structure; Figure FIG. 2g shows an example of prefabricated panel structures installed to the building surface; Figure FIG. 3 is a front view an example of intermediate panels; Figures FIG. 4a-FIG. 4c illustrate installation of the panels of a prefabricated panel structure. DETAILED DESCRIPTION OF EMBODIMENTS

[0011] The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. The present disclosure provides a prefabricated panel structure and a method of installing the prefabricated panel structure, which significantly improves the efficiency and cost-effectiveness of installing prefabricated façade panels by integrated panel engagement means. This design enables precise alignment and secure vertical stacking of panels into a continuous column, reducing the need for extensive on-site adjustments, additional support structures, and finishing work, thereby minimizing material usage and labor time while enhancing the structural integrity and airtightness of the prefabricated panel structure.

[0012] According to the present disclosure the prefabricated panel structure for a building surface comprises two or more panels connectable to each other, and one or more panel engagement means; the two or more panels comprising at least a first panel and an end panel and each panel of the two or more panels having a main frame formed of a bottom beam at a bottom edge of the panel, a top beam opposite to the bottom beam at a top edge of the panel, and structural elements positioned between the bottom beam and the top beam; an interior layer assembly attached to the building surface side of the main frame, and an envelope system attached to an outer side of the main frame; wherein the one or more panel engagement means comprises one or more positioners configured for placement along the length of one edge of one panel of the two or more panels, and one or more alignment sockets, each having a first end and a second end, and the first end is configured to receive the one or more positioners, and the one or more alignment sockets are spaced along the length of one edge of the other panel of the two or more panels, such that the one or more positioners of the one panel are arranged to fit into the one or more alignment sockets of the other panel; the two or more panels are connectable to each other in series, one on top of another, along the building surface, wherein each preceding panel of the two or more panels is connectable to a subsequent panel of the two or more panels via the one or more panel engagement means, forming a continuous vertical column of connected panels; the bottom beam of the first panel of the two or more panels is configured for attachment to a supporting structure on the building surface; the top beam of the end panel of the two or more panels is a termination beam of the continuous vertical column of the connected two or more panels; and the top beam of each panel of the two or more panels is configured for attachment to the building surface by an attachment means.

[0013] The prefabricated panel structure for a building surface enables fast and cost-efficient installation of façade elements without the need for extensive on-site work. More specifically, it enables to reduce the amount of work on the construction site, to reduce or disperse the effects on wall panels due to wind loads, and enables the detachability of wall panels. I.e., the panels of the prefabricated panel structure and thus the entire prefabricated panel structure is detachable, meaning the panels can be removed in reverse order of installation. This is important from the perspective of material reuse.

[0014] Prefabrication of panels with integrated interior and exterior layers minimizes the need for on-site finishing. The use of positioners and alignment sockets simplifies assembly, reducing labor time and errors. The ability to stack panels vertically using panel engagement means allows for rapid construction without the need for individual support or complex connection systems. The main frame and attachment means distributing loads effectively, including wind loads, reducing the need for additional support structures and enhancing safety. The design allows panels to be detached if necessary, facilitating maintenance, adaptability, or future modifications without significant deconstruction.

[0015] The prefabricated panel structure is arranged for both the renovation of existing buildings (e.g., in industrial renovation) and new constructions. The building surface may be any external wall of the building at any angle. Thus, it can be applied to any external wall of the building at any angle, making it adaptable to various building types like schools, hotels, shopping centers, and apartment buildings.

[0016] The integration of panel engagement means allows for precise alignment and secure stacking of panels without extensive adjustments or custom fitting on-site. The one or more panel engagement means, comprising positioners and alignment sockets, is a mechanism that ensures the panels align correctly and securely engage with one another. It facilitates precise alignment of the panels during installation, reducing the need for on-site adjustments and ensuring structural integrity.

[0017] The positioners of the panel engagement means are configured for placement along the length of one edge of a panel, ensure precise alignment and secure engagement between the panels and help to guide the panels into the correct position during assembly, reducing the need for manual adjustments, extensive on-site work and installation time. Once the panels are engaged, the positioners also contribute to the structural integrity of the connection, helping to lock the panels together securely. The positioners are thus primarily alignment tools that physically guide the panels into the correct position during assembly. The positioners help to ensure that the panels are properly aligned with each other along the connection points, such as at the top and bottom beams of adjacent panels. Thus, the positioners help to facilitate accurate placement and structural alignment of the panels, making the assembly process easier and more precise.

[0018] The alignment sockets of the panel engagement means are designed to receive the positioners from the adjacent panel. The alignment sockets provide a receptacle for the positioners, allowing the positioners to engage properly and ensuring that the panels align correctly. The configuration of the alignment sockets aids in quick assembly and secure connections of the panels by facilitating smooth insertion of positioners, securing panels together and helping to make the installation process quick and straightforward by reducing the need for manual adjustments. Alignment sockets may be openings or slots designed to receive positioners from an adjacent panel, ensuring proper alignment and secure connection during the assembly process.

[0019] The depth of the one or more alignment sockets may correspond to the length of the one or more positioner. The depth of the one or more alignment sockets may also be formed partially of the height of the panel or through the panel in a vertical direction, connecting the bottom edge of the panel and the top edge of the panel.

[0020] The two or more panels connectable to each other allow for modular construction, enabling panels to be assembled quickly on-site by stacking them vertically, which reduces installation time and labor. The first panel is the initial panel that is installed to the building's supporting structure. The end panel is the final panel in the sequence, completing the assembly at the top of the building surface and serves as the termination point of the vertical column. The first panel and the end panel define starting and ending points for installation, simplifying planning and assembly.

[0021] The main frame formed of the bottom beam, top beam, and structural elements ensures effective load distribution, reducing the need for additional support structures and dispersing wind loads. Each panel has a main frame with a bottom beam at the bottom edge, a top beam at the top edge, and structural elements in between. The main frame provides structural strength and rigidity, enabling the panels to bear loads effectively, including wind loads, and reducing the need for additional support structures.

[0022] The bottom beam of the first panel is designed to attach directly to a supporting structure on the building surface and provides a stable and secure base for the panel assembly, reducing the need for extensive groundwork or adjustments. The top beam of the last panel in the series of panels serves as the termination point and ensures structural completeness and stability at the top of the panel assembly.

[0023] The attachment means for top beam of each panel are structural fasteners (e.g., wind brackets) for securing the top beam of each panel to the building surface. This connection ensures that the panel is firmly attached and stabilized, particularly against lateral forces such as wind. The structural fastener, such as wind brackets or other suitable fasteners, helps to keep the panel securely in place and contributes to the overall integrity of the wall assembly. The attachment means may be in one or two pieces, and help to stabilize the panels against lateral forces such as wind, enhancing structural integrity and safety, and distributing wind loads effectively. In an embodiment, wherein the attachment means comprises a bottom piece and a top piece connected to each other, the bottom piece of the attachment means is pre-fixed fixed to the upper part of the panel and top piece of the attachment means is arranged to be fixed to the building surface. Both pieces of the attachment means can be screwed together with self-drilling screws from the top.

[0024] The structural elements positioned between the bottom beam and the top beam are integral components of the main frame of each panel. These elements provide vertical support, enhance rigidity, and contribute to the overall structural integrity of the panel. The structural elements may be e.g., vertical studs to provide primary vertical support, resist loads, and maintain the spacing between the beams; reinforcement members for increasing load-bearing capacity, custom-designed elements for specific structural requirements. The structural elements provide additional support and rigidity, contributing to the overall strength of the panel and its ability to withstand wind loads. These elements ensure that the panel can bear vertical and lateral loads effectively, including wind loads, thereby reducing the need for additional on-site support structures. Integrating these structural elements into the prefabricated panels reduces on-site labor and construction time.

[0025] The interior layer assembly attached to the building surface side of the panel of the prefabricated panel structure may comprise in one embodiment a vapor barrier layer (PE, etc.), an internal battens with insulation between battens and one or more internal boards, such as plasterboard, OSB, veneer, chipboard, fiber board, wooden paneling, etc. In another embodiment the interior layer assembly may comprise a vapor barrier and a compensation insulation (e.g., soft mineral wool). The interior layer assembly enhances thermal insulation and moisture resistance from the building surface side, eliminating the need for extensive interior finishing work on-site. Each panel may be finished with an external envelope system attached to the outer side of the panel of the prefabricated panel structure.

[0026] The envelope system may comprise one or more layers of the following: a façade covering, an air gap, and a wind barrier. These layers provide thermal insulation, weather resistance and aesthetic finish, reducing the need for exterior finishing work on-site. The façade or surface covering layer is selected from the group consisting of wooden paneling, fiber cement boards, metal sheeting, tiles, or any material compliant with industry standards for weather resistance and aesthetic finishing in construction. The wind barrier layer is selected from the group consisting of plasterboard, oriented strand board (OSB), wool plate, cement board, or fiberboard, or any material meeting the industry standard for wind resistance and thermal insulation in building applications.

[0027] Panels connectable in series, one on top of another refers to that the construction of the panels allows the panels to be stacked vertically along the building surface, forming a continuous column. This simplifies the assembly process, enabling quick vertical construction and reducing labor requirements.

[0028] According to an embodiment, the prefabricated panel structure further comprises one or more intermediate panels between the first panel and the end panel. The one or more intermediate panels are panels installed between the first panel and the end panel. These intermediate panels are used when more than two panels are required to cover the desired area of the building surface. The inclusion of intermediate panels into the prefabricated panel structure allows it to cover the building surfaces of various heights, enhancing the scalability and adaptability of the façade installation process. The inclusion of intermediate panels allows for the vertical extension of modular construction of the façade using standardized components, reducing the need for custom fabrication or on-site modifications. The use of panel engagement means across all panels enables seamless connection between all panels, simplifies the stacking process, enabling rapid installation, by ensuring that each panel securely connects to the panel below and above it, forming a continuous vertical column. This further reduces complexity and potential errors. Such vertical stacking of the panels of the prefabricated panel structure reduces the need for additional support structures or extensive alignment efforts. Secure connections distribute loads effectively, including wind and seismic forces. Additionally, it ensures a uniform appearance without visible gaps or misalignments.

[0029] The main frame formed of the bottom beam, the top beam, and structural elements positioned between the bottom beam and the top beam of each intermediate panel provides a structural design that is consistent across all panels, ensuring uniform load-bearing capacity and that the loads are effectively distributed. Such consistent framing allows for effective transfer of loads through the vertical column of panels. The top beam of each intermediate panel is configured for attachment to the building surface using attachment means, which provides lateral stability and secures each panel to the existing building structure. Such secure attachments resist lateral forces like wind, reducing the risk of panel displacement. It also eliminates the need for extensive scaffolding or temporary support during installation.

[0030] According to the embodiments, the one or more alignment sockets are formed in the top beam, in the bottom beam, or in the top beam and in the bottom beam. When the alignment sockets are in the top beam of the lower panel, the upper panel's positioners align into them as it is lowered, utilizing gravity for smooth alignment. If the alignment sockets are in the bottom beam of the upper panel, the alignment sockets receive the positioners from the lower panel as the upper panel is lowered, aiding precise placement. When the alignment sockets are in both beams, it allows for the use of longer positioners or different alignment strategies, enhancing flexibility and efficiency. Different options of the placement of alignment sockets allow to adapt the prefabricated panel structure to various installation requirements and building designs. It enhances installation flexibility considering the project specifics, such as building geometry and site conditions. Depending on the configuration, gravity can be utilized to aid alignment, or panels can be installed in challenging orientations. The ability to place alignment sockets in different locations makes the system suitable for vertical, angled, or complex façades. Efficient alignment methods minimize manual adjustments and on-site work. The prefabricated alignment sockets eliminate the need for drilling or modifications during installation. Optimal placement of alignment sockets ensures secure connections, improves structural integrity, enhances the façade's ability to resist loads, including wind forces.

[0031] In an embodiment, wherein the alignment sockets are integrated into the top beam of the panel during prefabrication, when installing panels, the positioners on the bottom beam of the upper panel fit into the alignment sockets on the top beam of the lower panel. As the upper panel is lowered, the positioners are naturally guided into the alignment sockets. This simplifies the alignment process, reducing installation time, and eliminates the need for on-site adjustments or drilling. This enables faster panel placement due to gravity-assisted alignment.

[0032] In another embodiment, wherein the alignment sockets are integrated into the bottom beam of the panel during prefabrication, the positioners are located on the top beam of the preceding panel, and as the subsequent panel is lowered, its bottom beam's alignment sockets receive the positioners. The alignment sockets in the bottom beam of the upper panel guide it onto the positioners of the lower panel. Installers can focus on guiding the panel downward, with the positioners ensuring correct placement. This eliminates the need for on-site modifications and provides better control during installation. Such secure connections also improve load transfer between panels.

[0033] An embodiment, wherein the alignment sockets are formed in both the top beam and the bottom beam, allows for the use of double-ended positioners and provides flexibility in the placement of positioners and sockets. Installers can choose the most effective method for alignment based on site conditions or personal preference. This improves overall stability, reduces complexity and inventory requirements, speeds up the installation process, enhances the façade's ability to withstand environmental forces, reduces the need for multiple panel designs, simplifies logistics and manufacturing.

[0034] According to the embodiments, the one or more panel engagement means thus comprises the one or more positioners being positioned on the top beam of the preceding panel of the two or more panels and the one or more alignment sockets being positioned on the bottom beam of the subsequent panel of the two or more panels, or the one or more alignment sockets being positioned on the top beam of the preceding panel of the two or more panels and the one or more positioners being positioned on the bottom beam of the subsequent panel of the two or more panels. In these embodiments, two configurations of the prefabricated panel structure for the arrangement of the panel engagement means are specified. These configurations provide flexibility in how the panels are connected during installation, allowing for efficient assembly based on practical considerations and installer preferences. By specifying the arrangement of positioners and alignment sockets, the panels can be designed for ease of assembly, reducing installation time and labor costs, and enhancing the efficiency of installation, structural integrity, and adaptability to various construction scenarios.

[0035] In one configuration, wherein the one or more positioners are installed to the top beam of the preceding panel and the one or more alignment sockets are integrated into the bottom beam of the subsequent panel to be installed next, the subsequent panel can be easily lowered onto the pre-installed positioners, allowing gravity to assist in precise alignment, which simplifies the installation process, reduces installation time and on-site labor by minimizing manual handling and the need for installing alignment elements during assembly. This enhances safety by reducing potential installation errors, and improves alignment accuracy by naturally guiding the panel into place, leading to a higher-quality installation with fewer adjustments.

[0036] In the second configuration, wherein the one or more alignment sockets are integrated into the top beam of the preceding panel and the one or more positioners are affixed to the bottom beam of the subsequent panel, as the subsequent panel is lowered, its positioners engage with the alignment sockets on the preceding panel. This is facilitating precise alignment and guided installation, which provides flexibility to adapt to site conditions or installer preferences, enhances installation quality by minimizing errors, reduces on-site labor and installation time by streamlining the process, and overall makes the installation faster and more cost-effective.

[0037] By providing the option to place positioners and alignment sockets either on the top beam of the preceding panel or the bottom beam of the subsequent panel, it allows installers to choose the most efficient method for specific circumstances, reducing installation time and labor costs while enhancing versatility to adapt to different building designs and preferences. Factory pre-installation of these components ensures precision and consistent quality, minimizing misalignment, on-site corrections, and delays, which leads to quicker installation, improved structural stability against environmental loads like wind forces, and a higher-quality façade with enhanced safety. The secure yet detachable engagement between panels facilitates maintenance and future modifications, contributing to sustainability and making the prefabricated panel structure suitable for a wide range of building types and installation scenarios, including both new constructions and renovations.

[0038] According to the embodiments, a cross-section of the one or more alignment sockets is round, oval, or polygonal (e.g., square, rectangle, hexagonal). The variations in the shape of the alignment socket cross-section allows for adjustments during installation of the panels and improves cost-efficient installation of the panels without extensive on-site work. Different shapes enable to compensate for minor misalignments or dimensional variations due to production tolerances.

[0039] Round alignment sockets provide precise alignment for structural connections by allowing positioners of matching round shape to fit precisely, enhancing the overall stability of the façade. Such alignment sockets simplify installation due to their ease of manufacturing and reduce potential errors, as round sockets are straightforward to produce and install. The use of round alignment sockets ensures structural integrity without the need for additional testing. This reliability guarantees that connections meet safety standards without additional costs, enhancing safety and reducing engineering expenses. Overall, round alignment sockets contribute to secure connections that improve the façade's ability to withstand environmental loads, including wind forces, thereby effectively enabling achieving a fast, cost-efficient, and structurally correct installation.

[0040] Oval, more specifically elongated, alignment sockets allow for slight lateral movement of panels during installation, accommodating production tolerances and ensuring visually equal gaps and proper alignment with adjacent panels. This adjustability enhances installation efficiency by enabling installers to make fine lateral adjustments quickly, reducing installation time and minimizing the need for on-site modifications or rework. By ensuring uniform gaps between panels, oval sockets contribute to a high-quality visual finish and improve the overall aesthetic appeal of the building. Oval alignment sockets thus provide adjustability and flexibility while facilitating a fast, cost-efficient, and aesthetically pleasing installation.

[0041] Polygonal alignment sockets, such as square, rectangular, or hexagonal shapes, allow positioners with matching profiles to fit into them, preventing rotational movement between panels and enhancing structural stability. By locking panels against rotation, these sockets improve the façade's resistance to twisting or torsional forces, addressing critical structural needs where rotational stability is essential. Such alignment sockets provide increased structural control and design flexibility, without the need for on-site modifications or adjustments. The adaptability of polygonal alignment sockets allows for customization to meet specific structural or design requirements, enhancing resistance to specific loads or environmental forces. Overall, polygonal alignment sockets enhance stability and facilitate a fast, cost-efficient installation process by ensuring precise alignment and structural integrity.

[0042] According to the embodiments, the one or more positioners is selected from a group comprising positioning pins, a dowel, a rod, at least partially threaded rod, a tubular positioning means. The tubular positioning means may be rigid or flexible tubular positioning means. These different forms of positioners provide options for mechanical alignment and secure connection between panels during installation. By providing a range of positioners, flexibility, efficiency, and precision in the assembly process is enhanced. These positioners facilitate accurate alignment and secure connections between panels, reducing installation time, labor costs, and the need for specialized equipment or adjustments on-site. Pre-installing these positioners in the factory simplifies the on-site assembly process. Installers can quickly connect panels without extensive measurements or adjustments, accelerating installation and reducing labor expenses. Simplifying the installation process with pre-installed positioners reduces manual handling and the potential for accidents on-site, enhancing overall safety. The variety of positioners allows installers to choose the most suitable type for specific project requirements or site conditions. E.g., positioning pins and dowels provide straightforward alignment. Tubular positioning means, whether rigid or flexible, can accommodate integrated infrastructure systems like ventilation ducts or cabling, streamlining the installation process. Positioners such as pins or rods ensure precise alignment between panels by guiding them into the correct position during assembly. This reduces misalignment errors, leading to a higher-quality installation and minimizing the need for on-site adjustments. Using positioners like dowels or threaded rods enhances the mechanical connection between panels, improving structural integrity and the façade's ability to withstand environmental loads, such as wind forces. This contributes to the overall stability and durability of the building façade. Tubular positioning means can serve dual purposes by acting as alignment tools and accommodating infrastructure systems like ventilation ducts or electrical conduits. This integration reduces the need for additional installations on-site, further streamlining construction. Positioners, such as dowels or removable pins, allow panels to be detached if necessary for maintenance or future modifications. This contributes to the sustainability and adaptability of the prefabricated panel structure.

[0043] By incorporating positioners selected from positioning pins, dowels, rods, threaded rods, or tubular positioning means (rigid or flexible), the prefabricated panel structure enables fast and cost-efficient installation without extensive on-site work. These positioners contribute to precise alignment, secure connections, and flexibility in installation, leading to reduced installation time, lower labor costs, and enhanced structural integrity. The adaptability of the positioners to accommodate integrated infrastructure systems further streamlines the construction process. Overall, such positioners enhance efficiency, quality, and versatility in façade installation, fulfilling the objectives of the present disclosure.

[0044] The positioners are crucial in ensuring precise alignment and secure connections between panels in the prefabricated panel structure. The positioners can be installed either at the factory during the prefabrication process or on the construction site. Attaching the positioners to the beams on the construction site before lifting the panels into place enables to avoid complications during transportation, such as the panel's weight pushing the positioners into the element if they were attached at the factory.

[0045] Installing the positioners on the upper panel, with alignment sockets in the top beam of the lower panel, facilitates easier installation. The hanging positioners are more visible and can be easily guided into the alignment sockets. The alignment sockets must be appropriately sized, with minimal tolerance, so that the positioners fit securely and do not fall out.

[0046] The second end of the alignment socket may be an opened end, a closed end or closable with a closing means, such as a plug or plywood board. If holes or sockets for holding the positioning pins are formed through the beam, then to prevent the positioning pins from falling through, the holes in both beams on the opposite side are sealed with a piece of plywood board or similar material.

[0047] Positioners can take various forms, such as pins, rods, or dowels, which may be smooth, threaded, or partially threaded (where a portion of the thread engages with the wood, and the smooth part extends to fit into the socket of the adjacent panel). The primary function of the positioners is to ensure the immobility of the lower and upper panels perpendicular to each other, eliminating any slack. However, an installation tolerance is required in the lateral direction of the lower and upper panels to allow for minor adjustments during installation.

[0048] The openings of the alignment sockets match the diameter of the positioners in the transverse direction but provide more tolerance in the lateral (width) direction. E.g., with a 16 mm metal positioning pin, a 16 mm diameter hole can be drilled in the top beam for pin installation, and an oval alignment socket can be created in the bottom beam to allow for lateral adjustment. This design accommodates minor production tolerances and ensures visually equal gaps between panels.

[0049] The most critical property of the positioning pins and other rod-shaped positioners is the strength. Such positioners are arranged to withstand wind loads without breaking and be durable over time (resistant to rust, rot, etc.). The length and diameter of the positioners are determined based on structural calculations, considering factors such as wind loads. The positioners are essential for transferring wind loads from one panel to another. The lower panel is supported by brackets attached to the building structure, and each panel is also fixed to the façade using wind brackets to absorb wind loads. When the upper panel is lifted onto the positioners of the lower panel, the positioners transfer the wind load from the bottom edge of the upper panel, through the top edge of the lower panel, and to the brackets fixed to the building structure.

[0050] The spacing and diameter of the positioners depend on structural calculations related to wind loads. The diameter of the positioner, e.g., positioning pin and similar positioners, can be approximately 10 - 40 mm. The diameter of the positioning pin may range from 10, 15, 20, 25, 30, or 35 mm up to 15, 20, 25, 30, 35, or 40 mm. Each panel comprises at least two positioners to ensure stability, with spacing determined by factors such as panel height and wind load. The spacing of the positioners, regardless of shape, may be in the range of 500-3000 mm. As an example, the spacing of the positioners may range from 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, 2500, 2600, 2700, 2800 or 2900 mm up to 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, 2500, 2600, 2700, 2800, 2900, or 3000 mm.

[0051] E.g., the panel height can vary from 0.5-6.0 meters. The panel height can thus vary from 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0 or 5.5 meters up to 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5 or 6.0 meters. Alternatively, the panel height may be up to 12 meters, wherein it is necessary that one panel has to cover more than one floor. I.e., one panel may cover 2 or three floors. In such embodiments, each panel may comprise additional attachment means between the bottom beam and the top beam. In the case of such a taller panels, additional intermediate attachment means are added to the panels according to the necessary statics calculations.

[0052] Wind load values can range significantly based on geographic location and building height. The typical wind load may vary from 0.3 kN / m 2< with minimal wind exposure up to 1.5 kN / m 2< in areas prone to high winds. The spacing between positioning pins can vary in a range of 0.5 - 3.0 meters. E.g., using smaller diameter positioning pins (10-16 mm) may require closer spacing (0.5-1.5 meters) to ensure that the load capacity is not exceeded, which is suitable for lower wind loads and smaller panel heights. Conversely, larger diameter pins (16-40 mm) can be spaced further apart (1.5-3.0 meters) as these can handle greater loads, necessary for higher wind loads and taller panels. E.g., with a panel height of 2.8 meters and a wind load gk=0.68kN / m 2< calculations determine that the spacing for a 16 mm positioning pin should be approximately 2.2 meters. By increasing the diameter of the positioning pin, it is possible to increase the spacing; however, if the spacing becomes too large, the load-bearing capacity of the top or bottom beam may become a limiting factor. E.g., a tall panel of 4.0 meters in a high wind load area (1.5 kN / m 2< ) may need positioning pins with a diameter of 40 mm spaced at 1.0 meter intervals to ensure structural safety.

[0053] E.g., for integrated infrastructure system (e.g., ventilation, cables, etc.), flexible tubes as positioners may be used and have lengths of 150-1500 mm and diameters of 19.99-299.99 mm, fitting into alignment sockets (e.g., rigid tubes) with slightly smaller diameters of 20-300 mm. Flexible tubes as positioners may thus have lengths ranging from 150, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, or 1450 mm up to 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, or 1450 mm, and diameters ranging from 19.99, 25, 30, 50, 100, 150, 200, or 250 mm up to 25, 30, 50, 100, 150, 200, 250 or 299.99 mm. This ensures airtight connections and facilitates the integration of building systems without additional on-site work. E.g., an oval ventilation tube 51x137mm. The range may be from 20x30 to 200x400 mm.

[0054] The ability to adjust parameters allows the system to accommodate specific project requirements, whether it is a low-rise building in a sheltered area or a high-rise structure in a windy location. Integration with other systems is also facilitated by these dimensional ranges, ensuring seamless incorporation without compromising structural integrity. These theoretical ranges provide a framework for designing prefabricated panel structures that effectively address the technical challenges of ensuring structural integrity, efficient installation, and adaptability to various project requirements.

[0055] The spacing of the alignment sockets along the beams may be determined according to structural requirements or set at regular intervals. Spaced at regular intervals refers to evenly distributed alignment sockets without specifying exact distances, allowing for flexibility. Spaced according to structural requirements means the spacing is based on the specific needs of the structure, which can vary between applications. Spaced along the length of the beam indicates distribution along the beam without defining precise spacing.

[0056] An essential aspect of the prefabricated panel structure is the combination of panel engagement means with attachment means to distribute wind loads evenly and reduce the effects of wind-induced pressures, shifts, vibrations, and deformations. It is crucial that the panel engagement means with attachment means can withstand these forces to maintain structural integrity. The load-bearing capacity of the wood-to-wood positioners joint is calculated based on the wind load surface acting on the connection. Increasing the diameter of the positioners allows for increased spacing, but structural calculations must ensure that the beams can handle the loads.

[0057] To simplify installation, the rod-shaped positioners may be chamfered, meaning their outer 90-degree edges are smoothed. This design facilitates easier insertion of the positioners into the alignment sockets during assembly, reducing potential installation issues and enhancing overall efficiency.

[0058] By carefully considering the installation methods, sizing, and structural requirements of the positioners and alignment sockets, the prefabricated panel structure ensures a fast, efficient, and secure installation process. The positioners not only align the panels precisely but also play a vital role in transferring wind loads and maintaining the structural integrity of the façade, effectively addressing the technical challenges outlined in the disclosure.

[0059] According to the embodiments, a length of the one or more positioners is 30-1500 mm and a diameter of the one or more positioners is 10 - 300 mm. As an example, the length of the positioners may range from 30, 40, 50, 60, 70, 80, 90, 100, 120, 140, 160, 180, 200, 220, 240, 260, 280, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, 1000, 1050, 1100, 1150, 1200, 1250, 1300, 1350, 1400, or 1450 mm up to 40, 50, 60, 70, 80, 90, 100, 120, 140, 160, 180, 200, 220, 240, 260, 280, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, 1000, 1050, 1100, 1150, 1200, 1250, 1300, 1350, 1400, 1450, or 1500 mm, and the diameter of the positioners may range from 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, or 290 mm up to 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, or 300 mm. These ranges for the length and diameter of the positioners are critical to meet various structural and installation requirements, which enable fast and cost-efficient installation of façade elements without extensive on-site work.

[0060] More specifically, such ranges allow the positioners to be tailored to the specific structural needs of each project. The dimensions of the beams and the number and size of the positioners are calculated based on static data and structural calculations, such as wind loads and panel heights. This ensures that the positioners are strong enough to transfer loads between panels, maintaining the structural integrity of the façade without the need for additional on-site reinforcements or modifications on-site, allowing for quick and accurate assembly. Installers can rely on the predefined sizes to fit the positioners into the alignment sockets smoothly, speeding up the installation process and reducing labor costs.

[0061] The length and diameter of the positioners are critical for ensuring that panels align correctly during installation. Proper alignment eliminates horizontal assembly gaps that would otherwise need to be closed between wall panels. Positioners according to these dimensions transfer the wind loads and other forces from one panel to another most effectively. E.g., a positioning pin with a diameter of 16 mm and a length suitable for the panel's beam thickness transfers wind loads from the upper panel through the positioning pin to the lower panel and to the brackets fixed to the building structure.

[0062] The ability to select positioner dimensions within a broad range (length of 30-1500 mm and diameter of 10-300 mm) allows engineers to design the connection based on precise structural calculations. This ensures that the positioning pins have the necessary strength without over-engineering, which would increase costs and complexity unnecessarily. By determining the dimensions during the design phase and incorporating them into the prefabricated panels, on-site adjustments are minimized. Installers do not need to cut or modify positioners or alignment sockets on-site, which reduces installation time and potential errors.

[0063] The positioners that are within manageable size ranges facilitate easier transportation and handling. E.g., the positioners can be installed on-site rather than at the factory if the size would complicate transportation, such as long or protruding elements that could be damaged during transportation.

[0064] These dimensions also align with the requirements of integrated infrastructure system like ventilation ducts. E.g., rigid tubes (i.e., the alignment sockets) with diameters of 20-300 mm and lengths of 150-1500 mm can accommodate flexible tubes (i.e., the positioners) with slightly smaller diameters, ensuring a precise fit and effective sealing. An example of the positioners is a smooth steel pin measuring 16 mm in diameter and 120 mm in length. This size provides sufficient strength and ease of installation.

[0065] By ensuring proper alignment and eliminating gaps between the panels, the prefabricated panel structure presents a uniform appearance without distinguishable joints. This enhances the building's aesthetic appeal and eliminates the need for additional finishing work on-site.

[0066] The length of the positioning pin depends on the combined thickness of the bottom beam of the upper panel and the top beam of the lower panel. It is important that the pin does not fall through the alignment socket in the lower panel. I.e., the alignment socket is preferably not fully through the beam or there is a stopper added below the beam to prevent the positioner from falling through the alignment socket. The positioning pin with a shape that prevents it from falling through (such as a wider collar in the middle) may be used alternatively. A plywood board may be placed on the bottom beam of the upper panel. This is necessary when the positioning pin is inserted into the beam of the upper panel before connecting the panels.

[0067] In renovation projects, existing structures often impose constraints on the size of components. Therefore, narrower ranges are selected to accommodate these limitations while ensuring structural integrity. In renovation project the positioners may be e.g., positioning pins having a diameter 10-20 mm and length 20-200 mm and corresponding alignment sockets matching the cross-sectional shape of the positioning pins with a diameter 10-20 mm and depth 10-100 mm. E.g., in an embodiment, a 16 mm diameter positioning pin with a length of 120 mm may be used, wherein the alignment socket has a matching diameter of 16 mm and a depth of 60 mm. This configuration provides sufficient structural support and precise panel alignment, thereby ensuring efficient installation.

[0068] New constructions offer more flexibility, allowing for larger components to enhance load-bearing capacity and accommodate design requirements. In renovation project the positioners may be e.g., positioning pins having a diameter 20-40 mm and length 150-400 mm and corresponding alignment sockets matching the cross-sectional shape of the positioning pins with a diameter 20-40 mm and depth 75-200 mm. E.g., a 30 mm diameter positioning pin with a length of 300 mm provides enhanced structural support suitable for larger panels and higher wind loads in new constructions. The alignment socket depth of 150 mm ensures a strong connection while accommodating the design of the new building.

[0069] In renovation projects, the integration of infrastructure systems must consider existing building constraints. Smaller diameters and lengths are preferred to minimize alterations. Thus, in an example of the renovation project, the positioners are e.g., flexible tubes having a diameter 50-150 mm and overhang length 200-500 mm and corresponding alignment sockets are rigid tubes matching the cross-sectional shape of the flexible tubes with a diameter approximately 51-151 mm and length 200-500 mm. E.g., flexible tubes may have a diameter of 100 mm and overhang length 300 mm and the rigid tubes may have the diameter 101 mm and length 300 mm. This allows the flexible tube to slide into the rigid tube smoothly, forming an airtight connection ideal for ventilation ducts or utility conduits in renovation projects where space is limited.

[0070] New buildings can accommodate larger infrastructure components, facilitating the integration of extensive systems. E.g., in an embodiment, the positioners are flexible tubes with a diameter 150-250 mm and overhang length 500-1000 mm and corresponding alignment sockets are rigid tubes matching the cross-sectional shape of the flexible tubes with a diameter approximately 151-251 mm and a length 500-1000 mm. This larger diameter is suitable for substantial ventilation systems or utility channels in new constructions, where design parameters allow for larger dimensions.

[0071] Optionally, the two or more panels of the prefabricated panel structure according to the present disclosure may comprise an integrated infrastructure system in a form of tubular means connected to the second end of the tubular positioning means or wherein the two or more panels comprise integrated infrastructure system formed partially of the height of the panel or formed through the panel in a vertical direction connecting the bottom edge of the panel and the top edge of the panel. By incorporating infrastructure systems within the one or more panels of the prefabricated panel structure enables fast and cost-efficient installation of façade elements without extensive on-site work. Pre-installing infrastructure components e.g., like ventilation ducts, electrical conduits, communication cables, plumbing, or water supply lines reduces the need for additional on-site installation and coordination among different trades. This speeds up the construction process, minimizes labor costs, and reduces potential installation errors. By integrating infrastructure systems within the prefabricated panels, this embodiment significantly enhances the efficiency and cost-effectiveness of façade installation. It minimizes the need for extensive on-site work, reduces labor costs, and accelerates the construction schedule. The automatic alignment and connection of the integrated infrastructure system ensures functionality and compliance with building regulations. This not only streamlines the installation process but also improves the overall quality and performance of the building.

[0072] By pre-installing tubular elements of the infrastructure systems within the panels during the manufacturing process, the overall construction time is shortened, and labor costs are reduced. Installers no longer need to allocate additional time and resources to install these systems separately on-site, which also minimizes the potential for errors or misalignments that can occur during manual installation.

[0073] This provides improved efficiency and precision in aligning infrastructure systems across panels. The tubular means ensure that connections between panels are automatically aligned and securely connected during assembly, providing continuous pathways for ventilation, electrical wiring, or other utilities. This ensures airtight connections, which is crucial for the performance of ventilation systems and energy efficiency of the building.

[0074] Additionally, integrating these systems within the panels enhances the overall quality and consistency of the construction. It reduces the likelihood of damage to infrastructure components during installation and protects them from environmental exposure before the building envelope is sealed.

[0075] In an embodiment, wherein the one or more panels comprise e.g., ventilation ducting, these are assembled fully or partially in the insulation. Ventilation ducts may be placed inside wool, cut away from cold external environment. The ventilation ducting is designed in upright position as the ventilation unit is located on the roof (or alternatively in the basement in some cases) and all ducts are directed there. Ventilation ducts are arranged to enter the building through the wall, to window opening, etc. Such an integrated infrastructure system may additionally comprise fire dampers and ventilation cover mounted into pre-assembled ventilation ducts. The ventilation ducts may be formed vertically either partially or completely through the panel. The pre-integrated and aligned ventilation duct connections are configured to automatically connect when the two or more panels are joined, eliminating the need for on-site ducting work. Alternatively, the integrated infrastructure system may comprise slide-in telescopic duct connectors equipped with gaskets for airtight connections between adjacent panels, wherein the ducting may be embedded within the insulation layer and isolated from external environmental conditions.

[0076] The integrated infrastructure systems may be selected from the group consisting of electrical conduits, communication cables, plumbing, or water supply lines, configured for seamless connection during the assembly process. In addition to ventilation ducting, other technical systems can also be integrated into the elements of the integrated infrastructure system and connected in a similar manner.

[0077] If the panel is meant to include a ventilation duct that is arranged to run inside the panel, it has a corresponding set of slide-in tubing elements in the upper and lower parts of the panels to facilitate airtight connections when the panel is lowered in place.

[0078] The tubes of the integrated infrastructure system may be either round or flat. In the embodiment, wherein the tube of the integrated infrastructure system is flat, the slide-in tube is also flat. The portion of the tube that is inserted can range from 200-1000mm in length. The insertion length of the tube may thus range from 200, 300, 400, 500, 600, 700, 800, or 900 mm up to 200, 300, 400, 500, 600, 700, 800, 900, or 1000 mm. The slide-in tube may be made of sheet metal or plastic. One or more gaskets can be added to the inserted plastic tube to ensure an airtight connection. The slide-in tube is attached to the frame of the panel in a way that allows lateral movement.

[0079] Additionally, the tubular integrated infrastructure system may further comprise pre-installed cable routing channels for electrical and communication systems, designed to automatically align and connect with corresponding channels in adjacent panels or ventilation ducts configured to automatically align and connect with adjacent panels, providing a continuous airflow pathway.

[0080] According to some embodiments, the one or more alignment sockets are formed at least partially in the interior layer assembly. The one or more alignment sockets can be positioned inside the panel, within the wooden frame, or partially or entirely within the frame plane. The embodiment, wherein one or more alignment sockets are positioned inside the panel, eliminates the need to cut through the wooden frame. It is important that the ductwork does not end up in a so-called "cold zone" and is covered with insulation from the outside. By forming alignment sockets at least partially within the interior layer assembly, it enhances the efficiency and cost-effectiveness of the prefabricated panel structure. It simplifies manufacturing and installation processes, maintains structural integrity, improves thermal performance, and reduces on-site labor. Thus, it enables fast and cost-efficient installation of façade elements without the need for extensive on-site work, while also improving the building's overall quality and performance.

[0081] The alignment sockets can be positioned inside the panel, within the wooden frame, or partially or entirely within the frame plane. By positioning the alignment sockets inside the panel rather than cutting through the wooden frame, this design eliminates the need to modify the structural frame, preserving its integrity and simplifying the manufacturing process.

[0082] By integrating the alignment sockets within the interior layers of the panel, it enables to eliminate the need to cut through the wooden frame and maintains the strength and stability of the panel's main structural components. This avoids compromising the structural integrity, which could otherwise necessitate additional reinforcement or complex engineering solutions. I.e., avoiding cuts through the wooden frame preserves the panel's load-bearing capacity, ensuring the façade remains strong and durable without additional reinforcement. Forming alignment sockets within the interior layers streamlines production by reducing the complexity of cutting precise openings in the frame. This decreases manufacturing time and potential errors. During installation, panels can be aligned and connected more easily, as the alignment sockets are integrated into the panel layers, reducing on-site labor.

[0083] Positioning alignment sockets and any associated ductwork within the insulated interior layers ensures they are not exposed to the cold zone. By covering these components with insulation from the outside, thermal bridges are minimized, preventing heat loss and condensation issues. Keeping alignment sockets and ductwork within the insulated interior layers maintains a continuous thermal barrier, improving the building's overall energy performance and reducing heating or cooling costs. This enhances the building's energy efficiency.

[0084] Pre-integrating alignment sockets within the panels minimize the need for on-site adjustments or modifications. Installers do not need to cut or alter the wooden frame or insulation during assembly, accelerating the installation process and reducing labor costs. Integrated alignment sockets simplify the panel alignment process on-site. Installers can assemble panels more quickly without needing specialized tools or making precise cuts during installation.

[0085] In different embodiments, the two or more panels further comprise one or more of a sealing system for the joints between the two or more panels; a pre-integrated load-bearing support system; at least one pre-formed opening configured to accommodate a window or a door. These features enhance installation efficiency and reduce on-site work as follows. The embodiment, wherein the two or more panels comprise the sealing system for the joints between the panels reduces on-site work, minimizes installation time, and ensures that the prefabricated panel structure performs effectively in terms of energy efficiency and weather resistance. The sealing system comprises a sealant applied during the installation process for horizontal joints; or a self-expanding gasket applied to vertical joints, ensures windproof and airtight connections. By sealing the horizontal and vertical joints directly during installation, the façade achieves a continuous barrier against air and moisture infiltration. This eliminates the need for later sealing and thereby reduces the on-site work.

[0086] The embodiment, wherein the two or more panels comprise the pre-integrated load-bearing support system within the panels, such as a load-bearing beam attached to the bottom beam, the pre-integrated load-bearing support system enhances structural stability and simplifies the assembly process, enabling the panels to support additional loads without requiring extra structural elements on-site and thereby facilitating fast and cost-efficient installation of façade elements without extensive on-site work. The pre-integrated load-bearing support system may be used only in the first panel or in any panel as needed. By allowing the panels to be connected in series without the need for separate load-bearing structures for each panel, the embodiment thus reduces installation time and material costs. The pre-integrated support system can include reinforced internal frames, interlocking load-bearing joints, post-tensioning cables, or composite beam integration.

[0087] The embodiment, wherein the two or more panels comprise at least one pre-formed opening configured to accommodate a window or a door enables completing the panels from the outside entirely in the factory and thereby reducing additional work on-site and accelerating the construction schedule. The at least one pre-formed opening may comprise perimeter reinforcement elements integrated into the panel structure around the opening to provide structural support and stability; sealing systems positioned around the perimeter of the opening, including windproof and vapor-proof barriers, to ensure airtight and weatherproof integration of the window or door; finish elements applied to the edges of the opening, configured to align with the external envelope system of the panel, ensuring a seamless transition between the panel surface and the installed window or door.

[0088] Optionally, the bottom beam of each subsequent panel may be equipped with a pre-integrated connection mechanism configured to engage with the one or more alignment sockets in the top beam of the preceding panel. The pre-integrated connection mechanism ensures that the panels are easily aligned, securely connected, and locked together during installation. The pre-integrated connection mechanism is for self-locking and sealing the panels, configured to securely connect and seal the panels in place, forming a secure and airtight connection without requiring additional on-site labor or materials. The pre-integrated connection mechanism is a system that not only aligns the panels (like positioners do) but also locks them in place and creates a seal to ensure a secure and possibly airtight and watertight connection. That ensures that once the panels are in place, the panels remain securely connected without the need for additional fasteners or manual locking. This aspect ensures that the connection is protected against environmental factors, such as moisture, air leakage, or dust.

[0089] In an embodiment, the pre-integrated connection mechanism may comprise positioning pins, particularly if the positioning pins are designed to engage with the alignment sockets that provides both alignment and a secure lock. However, pre-integrated connection mechanism may comprise additional components other than positioning pins, e.g., such as gaskets, clamps, or other elements that lock the panels together and create a seal.

[0090] E.g., the pre-integrated connection mechanism may comprise a hook-and-latch mechanism. In such embodiment, the first beam of the subsequent panel may be equipped with hooks that slide into the alignment sockets of the preceding panel. Once in position, a latch mechanism may automatically engage, securing the panels together. As the panels are aligned, the hooks enter the apertures, and a latch on the hook engages within the aperture, preventing the panels from separating. This may additionally comprise a manual release feature for disassembly.

[0091] In an embodiment, the pre-integrated connection mechanism may comprise positioning pins, particularly if the positioning pins are designed to engage with the alignment sockets that provides both alignment and a secure lock. However, pre-integrated connection mechanism may comprise additional components other than positioning pins, e.g., such as gaskets, clamps, or other elements that lock the panels together and create a seal.

[0092] E.g., the pre-integrated connection mechanism may comprise a hook-and-latch mechanism. In such embodiment, the first beam of the subsequent panel may be equipped with hooks that slide into the alignment sockets of the preceding panel. Once in position, a latch mechanism may automatically engage, securing the panels together. As the panels are aligned, the hooks enter the apertures, and a latch on the hook engages within the aperture, preventing the panels from separating. This may additionally comprise a manual release feature for disassembly.

[0093] In another example the pre-integrated connection mechanism may comprise sliding bolt mechanism, wherein the first beam of the subsequent panel includes sliding bolts that are pre-installed and aligned with the corresponding alignment sockets of the preceding panel. When the panels are brought together, the bolts slide into the apertures and lock in place. As the panels are aligned, the bolts are pushed into the alignment sockets and a spring mechanism inside the beam automatically locks the bolts in place, securing the connection.

[0094] In another example the pre-integrated connection mechanism may comprise expandable dowels integrated to the first beam of the subsequent panel that fit into the alignment sockets. When inserted, the dowels expand, filling the alignment socket and locking the panels together. As the panels are brought together, the dowels are pushed into the alignment sockets, where they expand, locking the panels in place.

[0095] According to the embodiments, the envelope system of two or more panels is formed of one or more layers selected from a group comprising façade covering, air gap, or wind barrier or the envelope system of two or more panels comprises a pre-integrated horizontal joint flashing configured to align automatically with adjacent panels during installation. By incorporating these layers into the panels, the system enhances protection against environmental factors such as wind, moisture, and air infiltration. These layers can differ depending on the specific project, client demands, architectural concept or state regulations. The pre-integration of the envelope system components within the panels reduces installation time and labor costs, while improving the quality and consistency of the construction. It ensures that the building envelope is effectively sealed and protected against environmental factors, enhancing energy efficiency and durability. By streamlining the installation process and minimizing on-site adjustments, this design facilitates a more efficient and reliable construction for building façades.

[0096] The façade covering serves as the outermost protective layer, providing both durability and aesthetic appeal. The façade covering layer may be selected from the group consisting of wooden paneling, fiber cement boards, metal sheeting, tiles, or any material compliant with industry standards for weather resistance and aesthetic finishing in construction. The inclusion of an air gap allows for ventilation behind the façade covering, which prevents moisture buildup and promotes drying of any infiltrated water, thereby extending the lifespan of the building envelope. The wind barrier layer minimizes air infiltration, improving the building's energy efficiency by reducing heat loss due to drafts. The wind barrier layer may be selected from the group consisting of plasterboard, oriented strand board (OSB), wool plate, cement board, or fiberboard, or any material meeting the industry standard for wind resistance and thermal insulation in building applications.

[0097] The integration of prefabricated horizontal joint flashings that align automatically during installation simplifies the assembly process and ensures effective sealing between panels. This enables to direct water away from the facade to prevent water damage and eliminates the need for additional on-site sealing work and reduces the potential for installation errors. By providing a continuous barrier against water ingress and air leakage, the joint flashings enhance the overall performance of the façade.

[0098] Optionally, the prefabricated panel structure may further comprise one or more of a building surface specific adjustment; or a sill positioned between the bottom beam of the first panel and the supporting structure. These additional features further enhance the prefabricated panel structure's adaptability and efficiency.

[0099] In an embodiment, wherein the prefabricated panel structure comprises one or more building surface specific adjustments, the adjustments are modifications made to the one or more panels to accommodate the unique characteristics of the building surface to which they will be attached. Such adjustments may be related to the variations in the building's geometry, uneven surfaces, or the presence of existing structural elements that the panels must interface with. The building surface specific adjustments may also be for additional lateral stability, such as reinforced corner connections, lateral bracing systems, wind brackets as enhanced anchoring points in one piece or in two-piece, wind-resistant overlapping joints, integrated rigid backing layers. By incorporating building surface specific adjustments into the prefabricated panels, the installation process becomes more efficient and adaptable to different building conditions without requiring extensive on-site modifications. This reduces the time and labor associated with customizing panels on-site to fit irregularities or unique features of the building surface. The panels arrive at the construction site ready to install, tailored to the specific requirements of the building, which accelerates the installation process and minimizes potential errors. This enhances the precision of the installation, ensures a better fit between the panels and the building structure, and leads to cost savings by reducing on-site adjustments and labor.

[0100] In an embodiment, wherein the prefabricated panel structure comprises the sill positioned between the bottom beam of the first panel and the supporting structure, the sill serves as an intermediary element that facilitates a secure and stable connection between the panel and the building's supporting framework. It compensates for any irregularities in the supporting structure, provides a level surface for the first panel, and is arranged to function as a barrier against moisture ingress from the ground. The sill can be with leveling blocks or without leveling blocks. The sill may be arranged to provide a level surface for the bottom beam of the first panel, ensuring proper alignment and distribution of loads across the support brackets; accommodate adjustments in height or level through the use of shims or leveling elements positioned between the sill and the support brackets; distribute the load from the bottom beam of the first panel evenly across the support brackets, enhancing the stability and structural integrity of the panel assembly; protect the bottom beam of the first panel from direct contact with the support brackets, thereby reducing wear and extending the lifespan of the panel structure. This simplifies the installation process, enhances the structural integrity of the prefabricated panel structure, and reduces the need for extensive on-site adjustments or custom fitting. It further ensures that the first panel is correctly aligned and securely attached, which is critical for the subsequent installation of additional panels. Additionally, the sill may comprise features such as moisture barriers or insulation, enhancing the building's overall performance in terms of energy efficiency and durability. This streamlines the installation process, reduces labor costs, and ensures a high-quality, durable connection between the façade panels and the building structure, thereby enabling fast and cost-efficient installation without extensive on-site work.

[0101] According to the embodiments, the one or more positioners may be surrounded by one or more gaskets, positioned between the positioner and the alignment socket. Adding the one or more gaskets ensures airtight and watertight seals between panels. This effectively prevents air and moisture infiltration through the panel engagement means, enhancing thermal performance and weatherproofing of the prefabricated panel structure. Integrating gaskets around the positioners between the positioners and the alignment socket reduces the need for additional sealing work on-site, thereby accelerating the installation process and minimizing labor costs. The gaskets also accommodate minor manufacturing tolerances and movements caused by thermal expansion or building settlement, maintaining the integrity and alignment of the panels over time. This facilitates fast and cost-efficient installation of prefabricated panel structure without extensive on-site work.

[0102] According to another aspect, the present disclosure provides a method of installing a prefabricated panel structure on a building surface, the method comprises the steps of: fixing a bottom beam of a first panel of two or more panels to a supporting structure on the building surface; fixing a top beam of the first panel of the two or more panels to the building surface; assembling one or more subsequent panels of the two or more panels by aligning one or more positioners of the subsequent panel with one or more alignment sockets in a preceding panel. The method enables fast and cost-efficient assembly of the prefabricated panel structure without extensive on-site work. By utilizing the prefabricated panels equipped with integrated features such as positioners and alignment sockets of the panel engagement means, the method ensures precise alignment, structural integrity, and minimizes labor requirements.

[0103] The step of fixing the bottom beam of the first panel to the supporting structure, such as a plinth or steel supports fixed to the plinth establishes a strong and level foundation for the prefabricated panel structure. By directly transferring all loads to the plinth or supporting structure, it ensures structural stability. The use of prefabricated supports and sills reduces the need for on-site adjustments and complex foundation work, thereby saving time and labor costs. It also simplifies the alignment process for the subsequent installation of panels. After securing the bottom of the first panel, the top beam is fixed to the building using adjustable brackets. These brackets allow for horizontal adjustments, enabling precise alignment of the panel along the vertical axis. This ensures that the panel is vertical and correctly positioned, which is crucial for the installation of additional panels above. The adjustable brackets facilitate fine-tuning of the panel's position without extensive on-site modifications. This ensures accurate vertical alignment, enhancing the façade's aesthetic appearance and structural performance. By allowing adjustments during installation, it reduces potential errors and rework, contributing to a faster and more efficient construction process.

[0104] With the first panel securely in place, subsequent panels are installed by aligning their positioners with the alignment sockets of the preceding panel. The positioners, such as positioning pins or dowels, are inserted into pre-formed alignment sockets in the beams of the panels. As each panel is lowered into place, the positioners fit into the alignment sockets, ensuring precise alignment and secure connection between panels. This step streamlines the assembly process by utilizing panel engagement means. The precise alignment facilitated by the positioners and alignment sockets reduces installation time and minimizes the need for skilled labor. It enhances structural integrity by ensuring secure connections that effectively transfer loads between panels, including wind and other environmental forces. By eliminating the need for on-site drilling or adjustments, it further reduces costs and potential installation errors.

[0105] Prefabricated components and the elimination of extensive on-site adjustments accelerate the installation process. By assembling panels from the ground up using standardized procedures, construction timelines are shortened. Integrated positioners and alignment sockets ensure accurate alignment between panels, reducing errors and ensuring a high-quality finish. Adjustable brackets allow for fine-tuning during installation, maintaining the prefabricated panel structure 's vertical alignment. By securely fixing panels to both the supporting structure and to each other, the method ensures that loads are properly transferred through the prefabricated panel structure to the foundation. This enhances the building's ability to withstand environmental forces such as wind loads.

[0106] The panel assembly process always moves upwards, starting from the ground floor. In renovation projects, steel supports are attached to the plinth, and a timber sill is placed on top, leveled with blocks for accuracy. The first panel is then positioned on the timber sill and secured. This panel includes a custom-sized top beam with pre-formed alignment sockets to accommodate positioners from the subsequent upper panel. Once the ground floor panel, i.e., the first panel of two or more panels, is installed and adjusted using brackets, the second panel is assembled on top. The upper panel's bottom beam contains the positioners, which align with the pre-formed alignment sockets in the top beam of the lower panel. This facilitates quick and accurate assembly without the need for on-site modifications. By ensuring that all load transfers and alignments are handled within the prefabricated elements, the method minimizes the complexity of on-site work. The panels are designed to accommodate necessary adjustments, and the integration of features like brackets and positioners simplifies the installation process. The present method thus significantly improves a fast, efficient, and cost-effective installation of façade elements. Each step is designed to reduce on-site labor, enhance precision, and maintain structural integrity. By utilizing prefabricated panels with integrated alignment and support systems, the method streamlines construction, reduces potential for errors, and ensures a high-quality, durable façade that meets both aesthetic and structural requirements.DETAILED DESCRIPTION OF THE DRAWINGS

[0107] Figure FIG. 1a is a side view of an example of a prefabricated panel structure according to an embodiment of the present disclosure, wherein the prefabricated panel structure 100a for a building surface 102 comprise a first panel 120 and an end panel 140 connectable to each other by panel engagement means. Each panel of the two panels has a main frame formed of a bottom beam 112 at a bottom edge of the panel, a top beam 114 opposite to the bottom beam at a top edge of the panel, and structural elements 116 positioned between the bottom beam and the top beam. Each panel of the two panels further comprises an interior layer assembly 117 attached to the building surface side of the main frame, and an envelope system 118 attached to an outer side of the main frame. The panel engagement means comprises positioners 152 configured for placement along the length of one edge of one panel of the two or more panels, and alignment sockets 154 , each having a first end and a second end. The first end is configured to receive the positioners. The alignment sockets are spaced along the length of one edge of the other panel of the two panels, such that the positioners of the one panel are arranged to fit into the alignment sockets of the other panel; the two panels are connectable to each other in series, one on top of another, along the building surface, wherein the preceding panel of the two panels, i.e., the first panel 120 , is connectable to a subsequent panel of the two panels, i.e., the end panel 140 , via the panel engagement means, forming a continuous vertical column of connected panels. The bottom beam 112 of the first panel 120 is configured for attachment to a supporting structure 104 on the building surface 102 . The top beam 114 of the end panel 140 of the two panels is a termination beam of the continuous vertical column of the connected two panels; and the top beam 114 of each panel of the two panels is configured for attachment to the building surface by an attachment means 106 .

[0108] Figure FIG. 1b is a side view of an example of a prefabricated panel structure according to another embodiment of the present disclosure, wherein the prefabricated panel structure 100b for a building surface 102 comprises three panels connectable to each other and wherein the third panel is an intermediate panel 130 between the first panel 120 and the end panel 140 . Each panel of the three panels comprises a main frame formed of a bottom beam 112 at a bottom edge of the panel, a top beam 114 opposite to the bottom beam at a top edge of the panel, and structural elements 116 positioned between the bottom beam and the top beam; an interior layer assembly 117 attached to the building surface side of the main frame, and an envelope system 118 attached to an outer side of the main frame. In this embodiment, the panel engagement means are formed in the top beam 114 of the first panel 120 and in the bottom beam 112 of the intermediate panel 130 arranged to engage the intermediate panel to the first panel and in the top beam 114 of the intermediate panel and in the bottom beam 112 of the end panel 140 arranged to engage the end panel to the intermediate panel. The panel engagement means comprises positioners 152 configured for placement along the length of bottom beam 112 of the intermediate panel 130 and the bottom beam 112 of the end panel 140 , and alignment sockets 154 , spaced along the length of the top beam 114 of the first panel 120 and the top beam 114 of the intermediate panel 130 . Thereby enabling the three panels to be connectable to each other in series, one on top of another, along the building surface, wherein each preceding panel of the three panels is connectable to a subsequent panel of the three panels via the panel engagement means, forming a continuous vertical column of connected panels. The bottom beam 112 of the first panel 120 of the three panels is configured for attachment to a supporting structure 104 on the building surface 102 . The top beam 114 of the end panel 140 of the three panels is a termination beam of the continuous vertical column of the connected three panels. The top beam 114 of each panel of the three panels is configured for attachment to the building surface by an attachment means 106 .

[0109] Figure FIG. 1c is a front view of the intermediate panels 130 illustrating the vertical stacking of the panels, wherein a subsequent intermediate panel 130 is installed on top of the preceding intermediate panel 130 , so that the alignment sockets 154 in the upper beam 114 of the preceding intermediate panel 130 are arranged to receive the positioners 152 in the bottom beam 112 of the subsequent intermediate panel 130 . Figure FIG. 1c further illustrates the embodiments, wherein the panels of the integrated infrastructure system comprise pre-formed openings 160 configured to accommodate a window or a door. The alignment sockets 154 shown in figures FIG. 1a-FIG. 1c are formed in the corresponding beams so that the second ends of the alignment sockets are closed ends. The positioners 152 used in the embodiments shown in figures FIG. 1a-FIG. 1c are attached to the corresponding beams so that the positioners do not fall off the beams.

[0110] Figure FIG. 1d illustrates an alternative embodiment of a panel engagement means 150 to the panel engagement means 150 shown in figures FIG. 1a-FIG. 1c, wherein the panel engagement means 150 is formed of the positioners 152 configured for placement along the length of the bottom beam 112 of the subsequent panel of the two or more panels, and alignment sockets 154 spaced along the length of the top beam 114 of the preceding panel of the two or more panels and formed through the corresponding beam 114 so that the second ends 157 of the alignment sockets 154 are opened. In such embodiments the second ends 157 may be closable with a closing means 158 .

[0111] Figure FIG. 1e illustrates a cross-sectional view of an embodiment of a prefabricated panel structure mounted on the building surface 102 , wherein a bottom beam 112 of a subsequent panel is installed on top of the top beam 114 of the first panel 120 . The bottom beam of the first panel is attached to a supporting structure 104 and the top beam of the 114 of the first panel is attached to the building surface 102 by an attachment means 106 . The subsequent panel may be the end panel or the intermediate panel. The panels of the prefabricated panel structure comprise the envelope system 118 layer and the interior layer assembly 117 layer. The bottom beam 114 of the subsequent panel and the top beam 114 of the first panel are engaged by the positioners 152 fitted into the alignment sockets. The first panel 120 further comprises a pre-integrated load-bearing support system 109 attached along the bottom beam 112 and a sill 107 , wherein the bottom beam 112 is supported on top of the sill 107 . The height of the first panel is adjusted by the leveling elements 108 between the supporting structure 104 and the sill 107 .

[0112] Figures FIG. 1f and FIG. 1g illustrate embodiments of the panel engagement means 150 with different geometric configurations of the alignment sockets 154 . In figure FIG. 1f, the alignment sockets are oval alignment sockets 154a . In figure FIG. 1g, the alignment sockets are polygonal alignment sockets 154b . These different geometric designs of the alignment sockets accommodate corresponding positioners 152 . The figures illustrate how the alignment sockets allow for slight lateral adjustments during installation.

[0113] Figure FIG. 2a is a side view of another example of a prefabricated panel structure 200a for a building surface 202 , wherein the prefabricated panel structure 200 comprises an integrated infrastructure system 280 formed partially of the height of the panel. According to this example, the integrated infrastructure system 280 is a ventilation system. As shown in FIG. 2a, the prefabricated panel structure 200 comprises a first panel 220 and an end panel 240 connectable to each other by panel engagement means. Each panel of the two panels has a main frame formed of a bottom beam 212 at a bottom edge of the panel, a top beam 214 opposite to the bottom beam at a top edge of the panel, and structural elements 216 positioned between the bottom beam and the top beam. Each panel of the two panels further comprises an interior layer assembly 217 attached to the building surface side of the main frame, and an envelope system 218 attached to an outer side of the main frame. The panel engagement means comprises positioners 252 configured for placement along the length of one edge of one panel of the two or more panels, and alignment sockets 254 , each having a first end 256 and a second end 257 . Each of the first ends 256 of the alignment sockets 254 is configured to receive the positioner 252 . The alignment sockets 254 are spaced along the length of one edge of the other panel of the two panels, such that the positioners 252 of the one panel are arranged to fit into the alignment sockets 254 of the other panel. The alignment sockets 254 are rigid slide-in tubes, the positioners 252 are flexible tubes, the flexible tubes are slid into the rigid slide-in tube. For connecting the flexible tubular positioners 252 with the integrated infrastructure system 280 , an extension sleeve 207 is used. The two panels are connectable to each other in series, one on top of another, along the building surface, wherein the preceding panel of the two panels, i.e., the first panel 220 , is connectable to a subsequent panel of the two panels, i.e., the end panel 240 , via the panel engagement means, forming a continuous vertical column of connected panels. The bottom beam 212 of the first panel 220 is configured for attachment to a supporting structure 204 on the building surface 202 . The top beam 214 of the end panel 240 of the two panels is a termination beam of the continuous vertical column of the connected two panels. The top beam 214 of each panel of the two panels is configured for attachment to the building surface by an attachment means 206 .

[0114] Figure FIG. 2b is a front view of another example of the prefabricated panel structure 200b for a building surface, wherein the prefabricated panel structure 200b comprises a first panel 220 , an end panel 240 and an intermediate panel 230 between the first panel 220 and the end panel 240 connectable to each other and an integrated infrastructure system 280 . Each panel comprises a main frame formed of a bottom beam 212 at a bottom edge of the panel, a top beam 214 opposite to the bottom beam at a top edge of the panel, and structural elements 216 positioned between the bottom beam and the top beam. The top beam 214 of the end panel 240 of the three panels is a termination beam of the continuous vertical column of the connected three panels. The integrated infrastructure system 280 is formed partially of the height of the first panel 220 , through the intermediate panel 230 in a vertical direction connecting the bottom edge of the intermediate panel 230 and the top edge of the intermediate panel 230 and partially of the height of the end panel 240 . In this embodiment, the panel engagement means are formed in the top beam 214 of the first panel 220 and in the bottom beam 212 of the intermediate panel 230 arranged to engage the intermediate panel to the first panel and in the top beam 214 of the intermediate panel and in the bottom beam 212 of the end panel 240 arranged to engage the end panel to the intermediate panel. The panel engagement means comprises positioners 252 configured for placement along the length of bottom beam 212 of the intermediate panel 230 and the bottom beam 212 of the end panel 240 , and alignment sockets 254 , spaced along the length of the top beam 214 of the first panel 220 and the top beam 214 of the intermediate panel 230 . The alignment sockets 254 are rigid slide-in tubes, the positioners 252 are flexible tubes, the flexible tubes 252 are slid into the rigid slide-in tube 254 . Thereby enabling the panels to be connectable to each other in series, one on top of another, along the building surface, wherein each preceding panel of the three panels is connectable to a subsequent panel of the three panels via the panel engagement means, forming a continuous vertical column of connected panels.

[0115] Figure FIG. 2c illustrates a front view of another embodiment of a panel engagement means 250 , which is formed of tubular positioners 252 configured for placement along the length of the top beam 214 of the preceding panel of the two or more panels, and tubular alignment sockets 254 spaced along the length of the bottom beam 212 of the subsequent panel of the two or more panels. The tubular alignment sockets 254 are rigid slide-in tubes and formed through the corresponding beam 214 so that the second ends 257 of the alignment sockets 254 are opened. Tubular positioners 252 are flexible tubes, which can be slid into the rigid slide-in tubes 254 when the subsequent panel is installed to the preceding panel. The panel engagement means 250 further comprises gaskets 270 positioned around the positioners so, when the positioners are slid into the alignment sockets, the gaskets 270 form airtight and watertight seal between the positioners and the alignment sockets.

[0116] Figures FIG. 2d - FIG. 2f show top views of the prefabricated panel structure illustrating different positions of the alignment sockets 254 in relation to an interior layer assembly 217 . The prefabricated panel structure shown in figures FIG. 2d - FIG. 2f is installed on the building surface 202 and comprises the interior layer assembly 217 on the building surface side of the prefabricated panel structure, the envelope system 218 on the outer side of the prefabricated panel structure, the top beam 214 between the interior layer assembly 217 and the envelope system 218 and the alignment sockets 254 formed into the prefabricated panel structure. In figure FIG. 2d the alignment sockets 254 are formed in the interior layer assembly 217 . In figure FIG. 2e the alignment sockets 254 are formed at least partially in the interior layer assembly 217 . In figure FIG. 2d the alignment sockets 254 are formed in the top beam 214 or through the top beam 214 .

[0117] Figure FIG. 2g shows prefabricated panel structures with integrated infrastructure system 280 installed to the building surface 202 of a five-story building. A prefabricated panel structure installed to the building surface 202 comprises a first panel 220 , three intermediate panels 230 and an end panel 240 , wherein the panels are stacked on top of another panel forming a continuous vertical column of connected panels. The panels are connected via the panel engagement means, wherein the panel engagement means of the first panel 220 and each panel of the intermediate panels 230 comprise three positioners 252 placed to the top beam 214 and the panel engagement means of each panel of the three intermediate panels 230 and the end panel 240 comprise three corresponding alignment sockets 254 placed to the bottom beam 212 . During the installation process, the positioners 252 are slid into the corresponding alignment sockets 254 . The building surface 202 is covered by three vertical columns of panels of the prefabricated panel structures side by side. The intermediate panels 230 and the end panel 240 comprise pre-formed openings 260 . The integrated infrastructure system 280 is formed through panel engagement means of all panels of the vertical columns of panels of the prefabricated panel structures starting from the first panel.

[0118] Figure FIG. 3 is a front view an example of intermediate panels 330 of the prefabricated panel structure, wherein the intermediate panels 330 comprising alignment sockets 354a at least partially formed into the top beams 314 of the intermediate panels 330 and corresponding positioners 352a, such as positioning pins, placed to the bottom beams 312 of the intermediate panels 330 . According to the embodiment, the intermediate panels 330 further comprise alignment sockets 354b , such as rigid slide-in tubes, formed through the bottom beams 312 and positioners 352b , such as flexible tubes, placed to the top beams 314 . When the panels are connected to each other, the flexible tubes 352b , fitted into the rigid slide-in tubes 354b form a continuous pathway for the integrated infrastructure systems 380 .

[0119] Figures FIG. 4a-FIG. 4c illustrate installation of the panels of a prefabricated panel structure 400 comprising a first panel 420 having structural elements 416 and an end panel 440 having structural elements 416 , positioners 452 , such as flexible tubes, attached to a bottom beam 412 of the end panel 440 and alignment sockets 454 , such as slide-in tubes, formed through the top beam 414 of the first panel 420 . Figure FIG. 4a illustrates that when the end panel 440 is lifted above the first panel 420 and the positioners 452 are placed along the length of the bottom beam 412 of the end panel 440 , the positioners 452 are in the hanging positions. In figure FIG. 4b it is shown that when the end panel 440 is lowered closer to the alignment sockets 454 in the top beam 414 of the first panel 420 , the positioners 452 are guided by the installer into the alignment sockets 454 . In figure FIG. 4c it is shown that the end panel 440 is lifted into place on top of the first panel 420 and the positioners 452 are fully moved into the alignment sockets 454 .

Examples

Embodiment Construction

[0011]The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. The present disclosure provides a prefabricated panel structure and a method of installing the prefabricated panel structure, which significantly improves the efficiency and cost-effectiveness of installing prefabricated façade panels by integrated panel engagement means. This design enables precise alignment and secure vertical stacking of panels into a continuous column, reducing the need for extensive on-site adjustments, additional support structures, and finishing work, thereby minimizing material usage and labor time while enhancing the structural integrity and airtightness of the prefabricated panel structure.

[0012]According to the present disclosure the prefabricated panel structure for a building surface comprises two or more panels connectable to each other, and one or more panel engagement means; the two or more panels comprising at least a...

TECHNICAL FIELD

[0001] The present disclosure relates generally to field of prefabricated façade construction, and more specifically, to prefabricated façade panels.BACKGROUND

[0002] In the field of prefabricated façade construction, current techniques primarily involve two methods of installing wall panels: individual attachment to the existing building structure and stacking panels using various connection systems. The individual attachment approach requires each panel to be separately supported and fixed to the building's wall or ceiling, often utilizing steel supports or brackets. This method is labor-intensive and time-consuming, necessitating precise on-site measurements, alignment, and the installation of supports for each panel. The extensive use of steel not only increases material costs but also adds complexity to the installation process due to the need for accurate placement and secure fastening.

[0003] Alternatively, panels are stacked on top of one another using mechanical fastening systems or interlocking mechanisms, such as wooden locking systems. These systems involve custom-sized wooden components that interlock to connect vertically adjacent panels. While stacking reduces the need for individual supports, it introduces challenges related to material usage and installation efficiency. The custom components increase material costs and require additional manufacturing steps to produce non-standard sizes. The assembly process is complicated, demanding careful alignment and adjustment during installation, which prolongs the overall construction timeline. Additionally, on-site sealing and finishing are often necessary to ensure weatherproofing and structural integrity, further increasing labor costs, installation complexity and time.

[0004] Both methods face significant shortcomings in achieving fast and cost-efficient installation of façade elements without extensive on-site work. The reliance on precise on-site adjustments makes the installation process susceptible to delays and errors. Material inefficiencies arise from the use of heavy steel supports or custom wooden components, leading to higher costs and complicated logistics. The need for on-site finishing, such as sealing joints and installing flashings, extends the project duration and requires skilled labor, contributing to increased expenses.

[0005] These problems are due to the lack of a standard, efficient means of connecting panels that allows for quick assembly with minimal on-site adjustments. Existing systems do not address the need for precise alignment and secure connection between panels while simplifying the installation process. The absence of integrated connection mechanisms results in longer installation times and higher labor costs. Therefore, there is a need for a prefabricated panel structure that enables fast and efficient installation through improved means of connecting panels, reducing on-site work, and optimizing material usage.SUMMARY

[0006] The aim of the present disclosure is to provide a solution to enable fast and cost-efficient installation of façade elements without the need for extensive on-site work.

[0007] The aim of the disclosure is achieved by a prefabricated panel structure and a method of installing the prefabricated panel structure as defined in the appended independent claims to which reference is made to. Advantageous features are set out in the appended dependent claims.

[0008] The advantage of the present prefabricated panel structure and the installation method is that it enables fast and cost-efficient installation of façade elements without extensive on-site work by using integrated panel engagement means that allow precise alignment and secure stacking of panels, thereby reducing material costs and labor time by minimizing the need for on-site adjustments, additional support structures, and finishing work.

[0009] Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments construed in conjunction with the appended claims that follow.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The summary above, and the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the embodiments of the disclosure are shown in the drawings, with references to the following figures wherein: Figure FIG. 1a is a side view of an example of a prefabricated panel structure according to an embodiment of the present disclosure; Figure FIG. 1b is a side view of an example of a prefabricated panel structure according to another embodiment of the present disclosure; Figure FIG. 1c is a front view of the intermediate panels illustrating the vertical stacking of the panels; Figure FIG. 1d illustrates an alternative embodiment of a panel engagement means; Figure FIG. 1e illustrates a cross-sectional view of an embodiment of a prefabricated panel structure; Figures FIG. 1f and FIG. 1g illustrate different embodiments of the panel engagement means; Figure FIG. 2a is a side view of another example of a prefabricated panel structure; Figure FIG. 2b is a front view of another example of the prefabricated panel structure; Figure FIG. 2c illustrates a front view of another embodiment of a panel engagement means; Figures FIG. 2d - FIG. 2f show top views of the prefabricated panel structure; Figure FIG. 2g shows an example of prefabricated panel structures installed to the building surface; Figure FIG. 3 is a front view an example of intermediate panels; Figures FIG. 4a-FIG. 4c illustrate installation of the panels of a prefabricated panel structure. DETAILED DESCRIPTION OF EMBODIMENTS

[0011] The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. The present disclosure provides a prefabricated panel structure and a method of installing the prefabricated panel structure, which significantly improves the efficiency and cost-effectiveness of installing prefabricated façade panels by integrated panel engagement means. This design enables precise alignment and secure vertical stacking of panels into a continuous column, reducing the need for extensive on-site adjustments, additional support structures, and finishing work, thereby minimizing material usage and labor time while enhancing the structural integrity and airtightness of the prefabricated panel structure.

[0012] According to the present disclosure the prefabricated panel structure for a building surface comprises two or more panels connectable to each other, and one or more panel engagement means; the two or more panels comprising at least a first panel and an end panel and each panel of the two or more panels having a main frame formed of a bottom beam at a bottom edge of the panel, a top beam opposite to the bottom beam at a top edge of the panel, and structural elements positioned between the bottom beam and the top beam; an interior layer assembly attached to the building surface side of the main frame, and an envelope system attached to an outer side of the main frame; wherein the one or more panel engagement means comprises one or more positioners configured for placement along the length of one edge of one panel of the two or more panels, and one or more alignment sockets, each having a first end and a second end, and the first end is configured to receive the one or more positioners, and the one or more alignment sockets are spaced along the length of one edge of the other panel of the two or more panels, such that the one or more positioners of the one panel are arranged to fit into the one or more alignment sockets of the other panel; the two or more panels are connectable to each other in series, one on top of another, along the building surface, wherein each preceding panel of the two or more panels is connectable to a subsequent panel of the two or more panels via the one or more panel engagement means, forming a continuous vertical column of connected panels; the bottom beam of the first panel of the two or more panels is configured for attachment to a supporting structure on the building surface; the top beam of the end panel of the two or more panels is a termination beam of the continuous vertical column of the connected two or more panels; and the top beam of each panel of the two or more panels is configured for attachment to the building surface by an attachment means.

[0013] The prefabricated panel structure for a building surface enables fast and cost-efficient installation of façade elements without the need for extensive on-site work. More specifically, it enables to reduce the amount of work on the construction site, to reduce or disperse the effects on wall panels due to wind loads, and enables the detachability of wall panels. I.e., the panels of the prefabricated panel structure and thus the entire prefabricated panel structure is detachable, meaning the panels can be removed in reverse order of installation. This is important from the perspective of material reuse.

[0014] Prefabrication of panels with integrated interior and exterior layers minimizes the need for on-site finishing. The use of positioners and alignment sockets simplifies assembly, reducing labor time and errors. The ability to stack panels vertically using panel engagement means allows for rapid construction without the need for individual support or complex connection systems. The main frame and attachment means distributing loads effectively, including wind loads, reducing the need for additional support structures and enhancing safety. The design allows panels to be detached if necessary, facilitating maintenance, adaptability, or future modifications without significant deconstruction.

[0015] The prefabricated panel structure is arranged for both the renovation of existing buildings (e.g., in industrial renovation) and new constructions. The building surface may be any external wall of the building at any angle. Thus, it can be applied to any external wall of the building at any angle, making it adaptable to various building types like schools, hotels, shopping centers, and apartment buildings.

[0016] The integration of panel engagement means allows for precise alignment and secure stacking of panels without extensive adjustments or custom fitting on-site. The one or more panel engagement means, comprising positioners and alignment sockets, is a mechanism that ensures the panels align correctly and securely engage with one another. It facilitates precise alignment of the panels during installation, reducing the need for on-site adjustments and ensuring structural integrity.

[0017] The positioners of the panel engagement means are configured for placement along the length of one edge of a panel, ensure precise alignment and secure engagement between the panels and help to guide the panels into the correct position during assembly, reducing the need for manual adjustments, extensive on-site work and installation time. Once the panels are engaged, the positioners also contribute to the structural integrity of the connection, helping to lock the panels together securely. The positioners are thus primarily alignment tools that physically guide the panels into the correct position during assembly. The positioners help to ensure that the panels are properly aligned with each other along the connection points, such as at the top and bottom beams of adjacent panels. Thus, the positioners help to facilitate accurate placement and structural alignment of the panels, making the assembly process easier and more precise.

[0018] The alignment sockets of the panel engagement means are designed to receive the positioners from the adjacent panel. The alignment sockets provide a receptacle for the positioners, allowing the positioners to engage properly and ensuring that the panels align correctly. The configuration of the alignment sockets aids in quick assembly and secure connections of the panels by facilitating smooth insertion of positioners, securing panels together and helping to make the installation process quick and straightforward by reducing the need for manual adjustments. Alignment sockets may be openings or slots designed to receive positioners from an adjacent panel, ensuring proper alignment and secure connection during the assembly process.

[0019] The depth of the one or more alignment sockets may correspond to the length of the one or more positioner. The depth of the one or more alignment sockets may also be formed partially of the height of the panel or through the panel in a vertical direction, connecting the bottom edge of the panel and the top edge of the panel.

[0020] The two or more panels connectable to each other allow for modular construction, enabling panels to be assembled quickly on-site by stacking them vertically, which reduces installation time and labor. The first panel is the initial panel that is installed to the building's supporting structure. The end panel is the final panel in the sequence, completing the assembly at the top of the building surface and serves as the termination point of the vertical column. The first panel and the end panel define starting and ending points for installation, simplifying planning and assembly.

[0021] The main frame formed of the bottom beam, top beam, and structural elements ensures effective load distribution, reducing the need for additional support structures and dispersing wind loads. Each panel has a main frame with a bottom beam at the bottom edge, a top beam at the top edge, and structural elements in between. The main frame provides structural strength and rigidity, enabling the panels to bear loads effectively, including wind loads, and reducing the need for additional support structures.

[0022] The bottom beam of the first panel is designed to attach directly to a supporting structure on the building surface and provides a stable and secure base for the panel assembly, reducing the need for extensive groundwork or adjustments. The top beam of the last panel in the series of panels serves as the termination point and ensures structural completeness and stability at the top of the panel assembly.

[0023] The attachment means for top beam of each panel are structural fasteners (e.g., wind brackets) for securing the top beam of each panel to the building surface. This connection ensures that the panel is firmly attached and stabilized, particularly against lateral forces such as wind. The structural fastener, such as wind brackets or other suitable fasteners, helps to keep the panel securely in place and contributes to the overall integrity of the wall assembly. The attachment means may be in one or two pieces, and help to stabilize the panels against lateral forces such as wind, enhancing structural integrity and safety, and distributing wind loads effectively. In an embodiment, wherein the attachment means comprises a bottom piece and a top piece connected to each other, the bottom piece of the attachment means is pre-fixed fixed to the upper part of the panel and top piece of the attachment means is arranged to be fixed to the building surface. Both pieces of the attachment means can be screwed together with self-drilling screws from the top.

[0024] The structural elements positioned between the bottom beam and the top beam are integral components of the main frame of each panel. These elements provide vertical support, enhance rigidity, and contribute to the overall structural integrity of the panel. The structural elements may be e.g., vertical studs to provide primary vertical support, resist loads, and maintain the spacing between the beams; reinforcement members for increasing load-bearing capacity, custom-designed elements for specific structural requirements. The structural elements provide additional support and rigidity, contributing to the overall strength of the panel and its ability to withstand wind loads. These elements ensure that the panel can bear vertical and lateral loads effectively, including wind loads, thereby reducing the need for additional on-site support structures. Integrating these structural elements into the prefabricated panels reduces on-site labor and construction time.

[0025] The interior layer assembly attached to the building surface side of the panel of the prefabricated panel structure may comprise in one embodiment a vapor barrier layer (PE, etc.), an internal battens with insulation between battens and one or more internal boards, such as plasterboard, OSB, veneer, chipboard, fiber board, wooden paneling, etc. In another embodiment the interior layer assembly may comprise a vapor barrier and a compensation insulation (e.g., soft mineral wool). The interior layer assembly enhances thermal insulation and moisture resistance from the building surface side, eliminating the need for extensive interior finishing work on-site. Each panel may be finished with an external envelope system attached to the outer side of the panel of the prefabricated panel structure.

[0026] The envelope system may comprise one or more layers of the following: a façade covering, an air gap, and a wind barrier. These layers provide thermal insulation, weather resistance and aesthetic finish, reducing the need for exterior finishing work on-site. The façade or surface covering layer is selected from the group consisting of wooden paneling, fiber cement boards, metal sheeting, tiles, or any material compliant with industry standards for weather resistance and aesthetic finishing in construction. The wind barrier layer is selected from the group consisting of plasterboard, oriented strand board (OSB), wool plate, cement board, or fiberboard, or any material meeting the industry standard for wind resistance and thermal insulation in building applications.

[0027] Panels connectable in series, one on top of another refers to that the construction of the panels allows the panels to be stacked vertically along the building surface, forming a continuous column. This simplifies the assembly process, enabling quick vertical construction and reducing labor requirements.

[0028] According to an embodiment, the prefabricated panel structure further comprises one or more intermediate panels between the first panel and the end panel. The one or more intermediate panels are panels installed between the first panel and the end panel. These intermediate panels are used when more than two panels are required to cover the desired area of the building surface. The inclusion of intermediate panels into the prefabricated panel structure allows it to cover the building surfaces of various heights, enhancing the scalability and adaptability of the façade installation process. The inclusion of intermediate panels allows for the vertical extension of modular construction of the façade using standardized components, reducing the need for custom fabrication or on-site modifications. The use of panel engagement means across all panels enables seamless connection between all panels, simplifies the stacking process, enabling rapid installation, by ensuring that each panel securely connects to the panel below and above it, forming a continuous vertical column. This further reduces complexity and potential errors. Such vertical stacking of the panels of the prefabricated panel structure reduces the need for additional support structures or extensive alignment efforts. Secure connections distribute loads effectively, including wind and seismic forces. Additionally, it ensures a uniform appearance without visible gaps or misalignments.

[0029] The main frame formed of the bottom beam, the top beam, and structural elements positioned between the bottom beam and the top beam of each intermediate panel provides a structural design that is consistent across all panels, ensuring uniform load-bearing capacity and that the loads are effectively distributed. Such consistent framing allows for effective transfer of loads through the vertical column of panels. The top beam of each intermediate panel is configured for attachment to the building surface using attachment means, which provides lateral stability and secures each panel to the existing building structure. Such secure attachments resist lateral forces like wind, reducing the risk of panel displacement. It also eliminates the need for extensive scaffolding or temporary support during installation.

[0030] According to the embodiments, the one or more alignment sockets are formed in the top beam, in the bottom beam, or in the top beam and in the bottom beam. When the alignment sockets are in the top beam of the lower panel, the upper panel's positioners align into them as it is lowered, utilizing gravity for smooth alignment. If the alignment sockets are in the bottom beam of the upper panel, the alignment sockets receive the positioners from the lower panel as the upper panel is lowered, aiding precise placement. When the alignment sockets are in both beams, it allows for the use of longer positioners or different alignment strategies, enhancing flexibility and efficiency. Different options of the placement of alignment sockets allow to adapt the prefabricated panel structure to various installation requirements and building designs. It enhances installation flexibility considering the project specifics, such as building geometry and site conditions. Depending on the configuration, gravity can be utilized to aid alignment, or panels can be installed in challenging orientations. The ability to place alignment sockets in different locations makes the system suitable for vertical, angled, or complex façades. Efficient alignment methods minimize manual adjustments and on-site work. The prefabricated alignment sockets eliminate the need for drilling or modifications during installation. Optimal placement of alignment sockets ensures secure connections, improves structural integrity, enhances the façade's ability to resist loads, including wind forces.

[0031] In an embodiment, wherein the alignment sockets are integrated into the top beam of the panel during prefabrication, when installing panels, the positioners on the bottom beam of the upper panel fit into the alignment sockets on the top beam of the lower panel. As the upper panel is lowered, the positioners are naturally guided into the alignment sockets. This simplifies the alignment process, reducing installation time, and eliminates the need for on-site adjustments or drilling. This enables faster panel placement due to gravity-assisted alignment.

[0032] In another embodiment, wherein the alignment sockets are integrated into the bottom beam of the panel during prefabrication, the positioners are located on the top beam of the preceding panel, and as the subsequent panel is lowered, its bottom beam's alignment sockets receive the positioners. The alignment sockets in the bottom beam of the upper panel guide it onto the positioners of the lower panel. Installers can focus on guiding the panel downward, with the positioners ensuring correct placement. This eliminates the need for on-site modifications and provides better control during installation. Such secure connections also improve load transfer between panels.

[0033] An embodiment, wherein the alignment sockets are formed in both the top beam and the bottom beam, allows for the use of double-ended positioners and provides flexibility in the placement of positioners and sockets. Installers can choose the most effective method for alignment based on site conditions or personal preference. This improves overall stability, reduces complexity and inventory requirements, speeds up the installation process, enhances the façade's ability to withstand environmental forces, reduces the need for multiple panel designs, simplifies logistics and manufacturing.

[0034] According to the embodiments, the one or more panel engagement means thus comprises the one or more positioners being positioned on the top beam of the preceding panel of the two or more panels and the one or more alignment sockets being positioned on the bottom beam of the subsequent panel of the two or more panels, or the one or more alignment sockets being positioned on the top beam of the preceding panel of the two or more panels and the one or more positioners being positioned on the bottom beam of the subsequent panel of the two or more panels. In these embodiments, two configurations of the prefabricated panel structure for the arrangement of the panel engagement means are specified. These configurations provide flexibility in how the panels are connected during installation, allowing for efficient assembly based on practical considerations and installer preferences. By specifying the arrangement of positioners and alignment sockets, the panels can be designed for ease of assembly, reducing installation time and labor costs, and enhancing the efficiency of installation, structural integrity, and adaptability to various construction scenarios.

[0035] In one configuration, wherein the one or more positioners are installed to the top beam of the preceding panel and the one or more alignment sockets are integrated into the bottom beam of the subsequent panel to be installed next, the subsequent panel can be easily lowered onto the pre-installed positioners, allowing gravity to assist in precise alignment, which simplifies the installation process, reduces installation time and on-site labor by minimizing manual handling and the need for installing alignment elements during assembly. This enhances safety by reducing potential installation errors, and improves alignment accuracy by naturally guiding the panel into place, leading to a higher-quality installation with fewer adjustments.

[0036] In the second configuration, wherein the one or more alignment sockets are integrated into the top beam of the preceding panel and the one or more positioners are affixed to the bottom beam of the subsequent panel, as the subsequent panel is lowered, its positioners engage with the alignment sockets on the preceding panel. This is facilitating precise alignment and guided installation, which provides flexibility to adapt to site conditions or installer preferences, enhances installation quality by minimizing errors, reduces on-site labor and installation time by streamlining the process, and overall makes the installation faster and more cost-effective.

[0037] By providing the option to place positioners and alignment sockets either on the top beam of the preceding panel or the bottom beam of the subsequent panel, it allows installers to choose the most efficient method for specific circumstances, reducing installation time and labor costs while enhancing versatility to adapt to different building designs and preferences. Factory pre-installation of these components ensures precision and consistent quality, minimizing misalignment, on-site corrections, and delays, which leads to quicker installation, improved structural stability against environmental loads like wind forces, and a higher-quality façade with enhanced safety. The secure yet detachable engagement between panels facilitates maintenance and future modifications, contributing to sustainability and making the prefabricated panel structure suitable for a wide range of building types and installation scenarios, including both new constructions and renovations.

[0038] According to the embodiments, a cross-section of the one or more alignment sockets is round, oval, or polygonal (e.g., square, rectangle, hexagonal). The variations in the shape of the alignment socket cross-section allows for adjustments during installation of the panels and improves cost-efficient installation of the panels without extensive on-site work. Different shapes enable to compensate for minor misalignments or dimensional variations due to production tolerances.

[0039] Round alignment sockets provide precise alignment for structural connections by allowing positioners of matching round shape to fit precisely, enhancing the overall stability of the façade. Such alignment sockets simplify installation due to their ease of manufacturing and reduce potential errors, as round sockets are straightforward to produce and install. The use of round alignment sockets ensures structural integrity without the need for additional testing. This reliability guarantees that connections meet safety standards without additional costs, enhancing safety and reducing engineering expenses. Overall, round alignment sockets contribute to secure connections that improve the façade's ability to withstand environmental loads, including wind forces, thereby effectively enabling achieving a fast, cost-efficient, and structurally correct installation.

[0040] Oval, more specifically elongated, alignment sockets allow for slight lateral movement of panels during installation, accommodating production tolerances and ensuring visually equal gaps and proper alignment with adjacent panels. This adjustability enhances installation efficiency by enabling installers to make fine lateral adjustments quickly, reducing installation time and minimizing the need for on-site modifications or rework. By ensuring uniform gaps between panels, oval sockets contribute to a high-quality visual finish and improve the overall aesthetic appeal of the building. Oval alignment sockets thus provide adjustability and flexibility while facilitating a fast, cost-efficient, and aesthetically pleasing installation.

[0041] Polygonal alignment sockets, such as square, rectangular, or hexagonal shapes, allow positioners with matching profiles to fit into them, preventing rotational movement between panels and enhancing structural stability. By locking panels against rotation, these sockets improve the façade's resistance to twisting or torsional forces, addressing critical structural needs where rotational stability is essential. Such alignment sockets provide increased structural control and design flexibility, without the need for on-site modifications or adjustments. The adaptability of polygonal alignment sockets allows for customization to meet specific structural or design requirements, enhancing resistance to specific loads or environmental forces. Overall, polygonal alignment sockets enhance stability and facilitate a fast, cost-efficient installation process by ensuring precise alignment and structural integrity.

[0042] According to the embodiments, the one or more positioners is selected from a group comprising positioning pins, a dowel, a rod, at least partially threaded rod, a tubular positioning means. The tubular positioning means may be rigid or flexible tubular positioning means. These different forms of positioners provide options for mechanical alignment and secure connection between panels during installation. By providing a range of positioners, flexibility, efficiency, and precision in the assembly process is enhanced. These positioners facilitate accurate alignment and secure connections between panels, reducing installation time, labor costs, and the need for specialized equipment or adjustments on-site. Pre-installing these positioners in the factory simplifies the on-site assembly process. Installers can quickly connect panels without extensive measurements or adjustments, accelerating installation and reducing labor expenses. Simplifying the installation process with pre-installed positioners reduces manual handling and the potential for accidents on-site, enhancing overall safety. The variety of positioners allows installers to choose the most suitable type for specific project requirements or site conditions. E.g., positioning pins and dowels provide straightforward alignment. Tubular positioning means, whether rigid or flexible, can accommodate integrated infrastructure systems like ventilation ducts or cabling, streamlining the installation process. Positioners such as pins or rods ensure precise alignment between panels by guiding them into the correct position during assembly. This reduces misalignment errors, leading to a higher-quality installation and minimizing the need for on-site adjustments. Using positioners like dowels or threaded rods enhances the mechanical connection between panels, improving structural integrity and the façade's ability to withstand environmental loads, such as wind forces. This contributes to the overall stability and durability of the building façade. Tubular positioning means can serve dual purposes by acting as alignment tools and accommodating infrastructure systems like ventilation ducts or electrical conduits. This integration reduces the need for additional installations on-site, further streamlining construction. Positioners, such as dowels or removable pins, allow panels to be detached if necessary for maintenance or future modifications. This contributes to the sustainability and adaptability of the prefabricated panel structure.

[0043] By incorporating positioners selected from positioning pins, dowels, rods, threaded rods, or tubular positioning means (rigid or flexible), the prefabricated panel structure enables fast and cost-efficient installation without extensive on-site work. These positioners contribute to precise alignment, secure connections, and flexibility in installation, leading to reduced installation time, lower labor costs, and enhanced structural integrity. The adaptability of the positioners to accommodate integrated infrastructure systems further streamlines the construction process. Overall, such positioners enhance efficiency, quality, and versatility in façade installation, fulfilling the objectives of the present disclosure.

[0044] The positioners are crucial in ensuring precise alignment and secure connections between panels in the prefabricated panel structure. The positioners can be installed either at the factory during the prefabrication process or on the construction site. Attaching the positioners to the beams on the construction site before lifting the panels into place enables to avoid complications during transportation, such as the panel's weight pushing the positioners into the element if they were attached at the factory.

[0045] Installing the positioners on the upper panel, with alignment sockets in the top beam of the lower panel, facilitates easier installation. The hanging positioners are more visible and can be easily guided into the alignment sockets. The alignment sockets must be appropriately sized, with minimal tolerance, so that the positioners fit securely and do not fall out.

[0046] The second end of the alignment socket may be an opened end, a closed end or closable with a closing means, such as a plug or plywood board. If holes or sockets for holding the positioning pins are formed through the beam, then to prevent the positioning pins from falling through, the holes in both beams on the opposite side are sealed with a piece of plywood board or similar material.

[0047] Positioners can take various forms, such as pins, rods, or dowels, which may be smooth, threaded, or partially threaded (where a portion of the thread engages with the wood, and the smooth part extends to fit into the socket of the adjacent panel). The primary function of the positioners is to ensure the immobility of the lower and upper panels perpendicular to each other, eliminating any slack. However, an installation tolerance is required in the lateral direction of the lower and upper panels to allow for minor adjustments during installation.

[0048] The openings of the alignment sockets match the diameter of the positioners in the transverse direction but provide more tolerance in the lateral (width) direction. E.g., with a 16 mm metal positioning pin, a 16 mm diameter hole can be drilled in the top beam for pin installation, and an oval alignment socket can be created in the bottom beam to allow for lateral adjustment. This design accommodates minor production tolerances and ensures visually equal gaps between panels.

[0049] The most critical property of the positioning pins and other rod-shaped positioners is the strength. Such positioners are arranged to withstand wind loads without breaking and be durable over time (resistant to rust, rot, etc.). The length and diameter of the positioners are determined based on structural calculations, considering factors such as wind loads. The positioners are essential for transferring wind loads from one panel to another. The lower panel is supported by brackets attached to the building structure, and each panel is also fixed to the façade using wind brackets to absorb wind loads. When the upper panel is lifted onto the positioners of the lower panel, the positioners transfer the wind load from the bottom edge of the upper panel, through the top edge of the lower panel, and to the brackets fixed to the building structure.

[0050] The spacing and diameter of the positioners depend on structural calculations related to wind loads. The diameter of the positioner, e.g., positioning pin and similar positioners, can be approximately 10 - 40 mm. The diameter of the positioning pin may range from 10, 15, 20, 25, 30, or 35 mm up to 15, 20, 25, 30, 35, or 40 mm. Each panel comprises at least two positioners to ensure stability, with spacing determined by factors such as panel height and wind load. The spacing of the positioners, regardless of shape, may be in the range of 500-3000 mm. As an example, the spacing of the positioners may range from 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, 2500, 2600, 2700, 2800 or 2900 mm up to 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, 2500, 2600, 2700, 2800, 2900, or 3000 mm.

[0051] E.g., the panel height can vary from 0.5-6.0 meters. The panel height can thus vary from 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0 or 5.5 meters up to 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5 or 6.0 meters. Alternatively, the panel height may be up to 12 meters, wherein it is necessary that one panel has to cover more than one floor. I.e., one panel may cover 2 or three floors. In such embodiments, each panel may comprise additional attachment means between the bottom beam and the top beam. In the case of such a taller panels, additional intermediate attachment means are added to the panels according to the necessary statics calculations.

[0052] Wind load values can range significantly based on geographic location and building height. The typical wind load may vary from 0.3 kN / m 2< with minimal wind exposure up to 1.5 kN / m 2< in areas prone to high winds. The spacing between positioning pins can vary in a range of 0.5 - 3.0 meters. E.g., using smaller diameter positioning pins (10-16 mm) may require closer spacing (0.5-1.5 meters) to ensure that the load capacity is not exceeded, which is suitable for lower wind loads and smaller panel heights. Conversely, larger diameter pins (16-40 mm) can be spaced further apart (1.5-3.0 meters) as these can handle greater loads, necessary for higher wind loads and taller panels. E.g., with a panel height of 2.8 meters and a wind load gk=0.68kN / m 2< calculations determine that the spacing for a 16 mm positioning pin should be approximately 2.2 meters. By increasing the diameter of the positioning pin, it is possible to increase the spacing; however, if the spacing becomes too large, the load-bearing capacity of the top or bottom beam may become a limiting factor. E.g., a tall panel of 4.0 meters in a high wind load area (1.5 kN / m 2< ) may need positioning pins with a diameter of 40 mm spaced at 1.0 meter intervals to ensure structural safety.

[0053] E.g., for integrated infrastructure system (e.g., ventilation, cables, etc.), flexible tubes as positioners may be used and have lengths of 150-1500 mm and diameters of 19.99-299.99 mm, fitting into alignment sockets (e.g., rigid tubes) with slightly smaller diameters of 20-300 mm. Flexible tubes as positioners may thus have lengths ranging from 150, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, or 1450 mm up to 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, or 1450 mm, and diameters ranging from 19.99, 25, 30, 50, 100, 150, 200, or 250 mm up to 25, 30, 50, 100, 150, 200, 250 or 299.99 mm. This ensures airtight connections and facilitates the integration of building systems without additional on-site work. E.g., an oval ventilation tube 51x137mm. The range may be from 20x30 to 200x400 mm.

[0054] The ability to adjust parameters allows the system to accommodate specific project requirements, whether it is a low-rise building in a sheltered area or a high-rise structure in a windy location. Integration with other systems is also facilitated by these dimensional ranges, ensuring seamless incorporation without compromising structural integrity. These theoretical ranges provide a framework for designing prefabricated panel structures that effectively address the technical challenges of ensuring structural integrity, efficient installation, and adaptability to various project requirements.

[0055] The spacing of the alignment sockets along the beams may be determined according to structural requirements or set at regular intervals. Spaced at regular intervals refers to evenly distributed alignment sockets without specifying exact distances, allowing for flexibility. Spaced according to structural requirements means the spacing is based on the specific needs of the structure, which can vary between applications. Spaced along the length of the beam indicates distribution along the beam without defining precise spacing.

[0056] An essential aspect of the prefabricated panel structure is the combination of panel engagement means with attachment means to distribute wind loads evenly and reduce the effects of wind-induced pressures, shifts, vibrations, and deformations. It is crucial that the panel engagement means with attachment means can withstand these forces to maintain structural integrity. The load-bearing capacity of the wood-to-wood positioners joint is calculated based on the wind load surface acting on the connection. Increasing the diameter of the positioners allows for increased spacing, but structural calculations must ensure that the beams can handle the loads.

[0057] To simplify installation, the rod-shaped positioners may be chamfered, meaning their outer 90-degree edges are smoothed. This design facilitates easier insertion of the positioners into the alignment sockets during assembly, reducing potential installation issues and enhancing overall efficiency.

[0058] By carefully considering the installation methods, sizing, and structural requirements of the positioners and alignment sockets, the prefabricated panel structure ensures a fast, efficient, and secure installation process. The positioners not only align the panels precisely but also play a vital role in transferring wind loads and maintaining the structural integrity of the façade, effectively addressing the technical challenges outlined in the disclosure.

[0059] According to the embodiments, a length of the one or more positioners is 30-1500 mm and a diameter of the one or more positioners is 10 - 300 mm. As an example, the length of the positioners may range from 30, 40, 50, 60, 70, 80, 90, 100, 120, 140, 160, 180, 200, 220, 240, 260, 280, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, 1000, 1050, 1100, 1150, 1200, 1250, 1300, 1350, 1400, or 1450 mm up to 40, 50, 60, 70, 80, 90, 100, 120, 140, 160, 180, 200, 220, 240, 260, 280, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, 1000, 1050, 1100, 1150, 1200, 1250, 1300, 1350, 1400, 1450, or 1500 mm, and the diameter of the positioners may range from 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, or 290 mm up to 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, or 300 mm. These ranges for the length and diameter of the positioners are critical to meet various structural and installation requirements, which enable fast and cost-efficient installation of façade elements without extensive on-site work.

[0060] More specifically, such ranges allow the positioners to be tailored to the specific structural needs of each project. The dimensions of the beams and the number and size of the positioners are calculated based on static data and structural calculations, such as wind loads and panel heights. This ensures that the positioners are strong enough to transfer loads between panels, maintaining the structural integrity of the façade without the need for additional on-site reinforcements or modifications on-site, allowing for quick and accurate assembly. Installers can rely on the predefined sizes to fit the positioners into the alignment sockets smoothly, speeding up the installation process and reducing labor costs.

[0061] The length and diameter of the positioners are critical for ensuring that panels align correctly during installation. Proper alignment eliminates horizontal assembly gaps that would otherwise need to be closed between wall panels. Positioners according to these dimensions transfer the wind loads and other forces from one panel to another most effectively. E.g., a positioning pin with a diameter of 16 mm and a length suitable for the panel's beam thickness transfers wind loads from the upper panel through the positioning pin to the lower panel and to the brackets fixed to the building structure.

[0062] The ability to select positioner dimensions within a broad range (length of 30-1500 mm and diameter of 10-300 mm) allows engineers to design the connection based on precise structural calculations. This ensures that the positioning pins have the necessary strength without over-engineering, which would increase costs and complexity unnecessarily. By determining the dimensions during the design phase and incorporating them into the prefabricated panels, on-site adjustments are minimized. Installers do not need to cut or modify positioners or alignment sockets on-site, which reduces installation time and potential errors.

[0063] The positioners that are within manageable size ranges facilitate easier transportation and handling. E.g., the positioners can be installed on-site rather than at the factory if the size would complicate transportation, such as long or protruding elements that could be damaged during transportation.

[0064] These dimensions also align with the requirements of integrated infrastructure system like ventilation ducts. E.g., rigid tubes (i.e., the alignment sockets) with diameters of 20-300 mm and lengths of 150-1500 mm can accommodate flexible tubes (i.e., the positioners) with slightly smaller diameters, ensuring a precise fit and effective sealing. An example of the positioners is a smooth steel pin measuring 16 mm in diameter and 120 mm in length. This size provides sufficient strength and ease of installation.

[0065] By ensuring proper alignment and eliminating gaps between the panels, the prefabricated panel structure presents a uniform appearance without distinguishable joints. This enhances the building's aesthetic appeal and eliminates the need for additional finishing work on-site.

[0066] The length of the positioning pin depends on the combined thickness of the bottom beam of the upper panel and the top beam of the lower panel. It is important that the pin does not fall through the alignment socket in the lower panel. I.e., the alignment socket is preferably not fully through the beam or there is a stopper added below the beam to prevent the positioner from falling through the alignment socket. The positioning pin with a shape that prevents it from falling through (such as a wider collar in the middle) may be used alternatively. A plywood board may be placed on the bottom beam of the upper panel. This is necessary when the positioning pin is inserted into the beam of the upper panel before connecting the panels.

[0067] In renovation projects, existing structures often impose constraints on the size of components. Therefore, narrower ranges are selected to accommodate these limitations while ensuring structural integrity. In renovation project the positioners may be e.g., positioning pins having a diameter 10-20 mm and length 20-200 mm and corresponding alignment sockets matching the cross-sectional shape of the positioning pins with a diameter 10-20 mm and depth 10-100 mm. E.g., in an embodiment, a 16 mm diameter positioning pin with a length of 120 mm may be used, wherein the alignment socket has a matching diameter of 16 mm and a depth of 60 mm. This configuration provides sufficient structural support and precise panel alignment, thereby ensuring efficient installation.

[0068] New constructions offer more flexibility, allowing for larger components to enhance load-bearing capacity and accommodate design requirements. In renovation project the positioners may be e.g., positioning pins having a diameter 20-40 mm and length 150-400 mm and corresponding alignment sockets matching the cross-sectional shape of the positioning pins with a diameter 20-40 mm and depth 75-200 mm. E.g., a 30 mm diameter positioning pin with a length of 300 mm provides enhanced structural support suitable for larger panels and higher wind loads in new constructions. The alignment socket depth of 150 mm ensures a strong connection while accommodating the design of the new building.

[0069] In renovation projects, the integration of infrastructure systems must consider existing building constraints. Smaller diameters and lengths are preferred to minimize alterations. Thus, in an example of the renovation project, the positioners are e.g., flexible tubes having a diameter 50-150 mm and overhang length 200-500 mm and corresponding alignment sockets are rigid tubes matching the cross-sectional shape of the flexible tubes with a diameter approximately 51-151 mm and length 200-500 mm. E.g., flexible tubes may have a diameter of 100 mm and overhang length 300 mm and the rigid tubes may have the diameter 101 mm and length 300 mm. This allows the flexible tube to slide into the rigid tube smoothly, forming an airtight connection ideal for ventilation ducts or utility conduits in renovation projects where space is limited.

[0070] New buildings can accommodate larger infrastructure components, facilitating the integration of extensive systems. E.g., in an embodiment, the positioners are flexible tubes with a diameter 150-250 mm and overhang length 500-1000 mm and corresponding alignment sockets are rigid tubes matching the cross-sectional shape of the flexible tubes with a diameter approximately 151-251 mm and a length 500-1000 mm. This larger diameter is suitable for substantial ventilation systems or utility channels in new constructions, where design parameters allow for larger dimensions.

[0071] Optionally, the two or more panels of the prefabricated panel structure according to the present disclosure may comprise an integrated infrastructure system in a form of tubular means connected to the second end of the tubular positioning means or wherein the two or more panels comprise integrated infrastructure system formed partially of the height of the panel or formed through the panel in a vertical direction connecting the bottom edge of the panel and the top edge of the panel. By incorporating infrastructure systems within the one or more panels of the prefabricated panel structure enables fast and cost-efficient installation of façade elements without extensive on-site work. Pre-installing infrastructure components e.g., like ventilation ducts, electrical conduits, communication cables, plumbing, or water supply lines reduces the need for additional on-site installation and coordination among different trades. This speeds up the construction process, minimizes labor costs, and reduces potential installation errors. By integrating infrastructure systems within the prefabricated panels, this embodiment significantly enhances the efficiency and cost-effectiveness of façade installation. It minimizes the need for extensive on-site work, reduces labor costs, and accelerates the construction schedule. The automatic alignment and connection of the integrated infrastructure system ensures functionality and compliance with building regulations. This not only streamlines the installation process but also improves the overall quality and performance of the building.

[0072] By pre-installing tubular elements of the infrastructure systems within the panels during the manufacturing process, the overall construction time is shortened, and labor costs are reduced. Installers no longer need to allocate additional time and resources to install these systems separately on-site, which also minimizes the potential for errors or misalignments that can occur during manual installation.

[0073] This provides improved efficiency and precision in aligning infrastructure systems across panels. The tubular means ensure that connections between panels are automatically aligned and securely connected during assembly, providing continuous pathways for ventilation, electrical wiring, or other utilities. This ensures airtight connections, which is crucial for the performance of ventilation systems and energy efficiency of the building.

[0074] Additionally, integrating these systems within the panels enhances the overall quality and consistency of the construction. It reduces the likelihood of damage to infrastructure components during installation and protects them from environmental exposure before the building envelope is sealed.

[0075] In an embodiment, wherein the one or more panels comprise e.g., ventilation ducting, these are assembled fully or partially in the insulation. Ventilation ducts may be placed inside wool, cut away from cold external environment. The ventilation ducting is designed in upright position as the ventilation unit is located on the roof (or alternatively in the basement in some cases) and all ducts are directed there. Ventilation ducts are arranged to enter the building through the wall, to window opening, etc. Such an integrated infrastructure system may additionally comprise fire dampers and ventilation cover mounted into pre-assembled ventilation ducts. The ventilation ducts may be formed vertically either partially or completely through the panel. The pre-integrated and aligned ventilation duct connections are configured to automatically connect when the two or more panels are joined, eliminating the need for on-site ducting work. Alternatively, the integrated infrastructure system may comprise slide-in telescopic duct connectors equipped with gaskets for airtight connections between adjacent panels, wherein the ducting may be embedded within the insulation layer and isolated from external environmental conditions.

[0076] The integrated infrastructure systems may be selected from the group consisting of electrical conduits, communication cables, plumbing, or water supply lines, configured for seamless connection during the assembly process. In addition to ventilation ducting, other technical systems can also be integrated into the elements of the integrated infrastructure system and connected in a similar manner.

[0077] If the panel is meant to include a ventilation duct that is arranged to run inside the panel, it has a corresponding set of slide-in tubing elements in the upper and lower parts of the panels to facilitate airtight connections when the panel is lowered in place.

[0078] The tubes of the integrated infrastructure system may be either round or flat. In the embodiment, wherein the tube of the integrated infrastructure system is flat, the slide-in tube is also flat. The portion of the tube that is inserted can range from 200-1000mm in length. The insertion length of the tube may thus range from 200, 300, 400, 500, 600, 700, 800, or 900 mm up to 200, 300, 400, 500, 600, 700, 800, 900, or 1000 mm. The slide-in tube may be made of sheet metal or plastic. One or more gaskets can be added to the inserted plastic tube to ensure an airtight connection. The slide-in tube is attached to the frame of the panel in a way that allows lateral movement.

[0079] Additionally, the tubular integrated infrastructure system may further comprise pre-installed cable routing channels for electrical and communication systems, designed to automatically align and connect with corresponding channels in adjacent panels or ventilation ducts configured to automatically align and connect with adjacent panels, providing a continuous airflow pathway.

[0080] According to some embodiments, the one or more alignment sockets are formed at least partially in the interior layer assembly. The one or more alignment sockets can be positioned inside the panel, within the wooden frame, or partially or entirely within the frame plane. The embodiment, wherein one or more alignment sockets are positioned inside the panel, eliminates the need to cut through the wooden frame. It is important that the ductwork does not end up in a so-called "cold zone" and is covered with insulation from the outside. By forming alignment sockets at least partially within the interior layer assembly, it enhances the efficiency and cost-effectiveness of the prefabricated panel structure. It simplifies manufacturing and installation processes, maintains structural integrity, improves thermal performance, and reduces on-site labor. Thus, it enables fast and cost-efficient installation of façade elements without the need for extensive on-site work, while also improving the building's overall quality and performance.

[0081] The alignment sockets can be positioned inside the panel, within the wooden frame, or partially or entirely within the frame plane. By positioning the alignment sockets inside the panel rather than cutting through the wooden frame, this design eliminates the need to modify the structural frame, preserving its integrity and simplifying the manufacturing process.

[0082] By integrating the alignment sockets within the interior layers of the panel, it enables to eliminate the need to cut through the wooden frame and maintains the strength and stability of the panel's main structural components. This avoids compromising the structural integrity, which could otherwise necessitate additional reinforcement or complex engineering solutions. I.e., avoiding cuts through the wooden frame preserves the panel's load-bearing capacity, ensuring the façade remains strong and durable without additional reinforcement. Forming alignment sockets within the interior layers streamlines production by reducing the complexity of cutting precise openings in the frame. This decreases manufacturing time and potential errors. During installation, panels can be aligned and connected more easily, as the alignment sockets are integrated into the panel layers, reducing on-site labor.

[0083] Positioning alignment sockets and any associated ductwork within the insulated interior layers ensures they are not exposed to the cold zone. By covering these components with insulation from the outside, thermal bridges are minimized, preventing heat loss and condensation issues. Keeping alignment sockets and ductwork within the insulated interior layers maintains a continuous thermal barrier, improving the building's overall energy performance and reducing heating or cooling costs. This enhances the building's energy efficiency.

[0084] Pre-integrating alignment sockets within the panels minimize the need for on-site adjustments or modifications. Installers do not need to cut or alter the wooden frame or insulation during assembly, accelerating the installation process and reducing labor costs. Integrated alignment sockets simplify the panel alignment process on-site. Installers can assemble panels more quickly without needing specialized tools or making precise cuts during installation.

[0085] In different embodiments, the two or more panels further comprise one or more of a sealing system for the joints between the two or more panels; a pre-integrated load-bearing support system; at least one pre-formed opening configured to accommodate a window or a door. These features enhance installation efficiency and reduce on-site work as follows. The embodiment, wherein the two or more panels comprise the sealing system for the joints between the panels reduces on-site work, minimizes installation time, and ensures that the prefabricated panel structure performs effectively in terms of energy efficiency and weather resistance. The sealing system comprises a sealant applied during the installation process for horizontal joints; or a self-expanding gasket applied to vertical joints, ensures windproof and airtight connections. By sealing the horizontal and vertical joints directly during installation, the façade achieves a continuous barrier against air and moisture infiltration. This eliminates the need for later sealing and thereby reduces the on-site work.

[0086] The embodiment, wherein the two or more panels comprise the pre-integrated load-bearing support system within the panels, such as a load-bearing beam attached to the bottom beam, the pre-integrated load-bearing support system enhances structural stability and simplifies the assembly process, enabling the panels to support additional loads without requiring extra structural elements on-site and thereby facilitating fast and cost-efficient installation of façade elements without extensive on-site work. The pre-integrated load-bearing support system may be used only in the first panel or in any panel as needed. By allowing the panels to be connected in series without the need for separate load-bearing structures for each panel, the embodiment thus reduces installation time and material costs. The pre-integrated support system can include reinforced internal frames, interlocking load-bearing joints, post-tensioning cables, or composite beam integration.

[0087] The embodiment, wherein the two or more panels comprise at least one pre-formed opening configured to accommodate a window or a door enables completing the panels from the outside entirely in the factory and thereby reducing additional work on-site and accelerating the construction schedule. The at least one pre-formed opening may comprise perimeter reinforcement elements integrated into the panel structure around the opening to provide structural support and stability; sealing systems positioned around the perimeter of the opening, including windproof and vapor-proof barriers, to ensure airtight and weatherproof integration of the window or door; finish elements applied to the edges of the opening, configured to align with the external envelope system of the panel, ensuring a seamless transition between the panel surface and the installed window or door.

[0088] Optionally, the bottom beam of each subsequent panel may be equipped with a pre-integrated connection mechanism configured to engage with the one or more alignment sockets in the top beam of the preceding panel. The pre-integrated connection mechanism ensures that the panels are easily aligned, securely connected, and locked together during installation. The pre-integrated connection mechanism is for self-locking and sealing the panels, configured to securely connect and seal the panels in place, forming a secure and airtight connection without requiring additional on-site labor or materials. The pre-integrated connection mechanism is a system that not only aligns the panels (like positioners do) but also locks them in place and creates a seal to ensure a secure and possibly airtight and watertight connection. That ensures that once the panels are in place, the panels remain securely connected without the need for additional fasteners or manual locking. This aspect ensures that the connection is protected against environmental factors, such as moisture, air leakage, or dust.

[0089] In an embodiment, the pre-integrated connection mechanism may comprise positioning pins, particularly if the positioning pins are designed to engage with the alignment sockets that provides both alignment and a secure lock. However, pre-integrated connection mechanism may comprise additional components other than positioning pins, e.g., such as gaskets, clamps, or other elements that lock the panels together and create a seal.

[0090] E.g., the pre-integrated connection mechanism may comprise a hook-and-latch mechanism. In such embodiment, the first beam of the subsequent panel may be equipped with hooks that slide into the alignment sockets of the preceding panel. Once in position, a latch mechanism may automatically engage, securing the panels together. As the panels are aligned, the hooks enter the apertures, and a latch on the hook engages within the aperture, preventing the panels from separating. This may additionally comprise a manual release feature for disassembly.

[0091] In an embodiment, the pre-integrated connection mechanism may comprise positioning pins, particularly if the positioning pins are designed to engage with the alignment sockets that provides both alignment and a secure lock. However, pre-integrated connection mechanism may comprise additional components other than positioning pins, e.g., such as gaskets, clamps, or other elements that lock the panels together and create a seal.

[0092] E.g., the pre-integrated connection mechanism may comprise a hook-and-latch mechanism. In such embodiment, the first beam of the subsequent panel may be equipped with hooks that slide into the alignment sockets of the preceding panel. Once in position, a latch mechanism may automatically engage, securing the panels together. As the panels are aligned, the hooks enter the apertures, and a latch on the hook engages within the aperture, preventing the panels from separating. This may additionally comprise a manual release feature for disassembly.

[0093] In another example the pre-integrated connection mechanism may comprise sliding bolt mechanism, wherein the first beam of the subsequent panel includes sliding bolts that are pre-installed and aligned with the corresponding alignment sockets of the preceding panel. When the panels are brought together, the bolts slide into the apertures and lock in place. As the panels are aligned, the bolts are pushed into the alignment sockets and a spring mechanism inside the beam automatically locks the bolts in place, securing the connection.

[0094] In another example the pre-integrated connection mechanism may comprise expandable dowels integrated to the first beam of the subsequent panel that fit into the alignment sockets. When inserted, the dowels expand, filling the alignment socket and locking the panels together. As the panels are brought together, the dowels are pushed into the alignment sockets, where they expand, locking the panels in place.

[0095] According to the embodiments, the envelope system of two or more panels is formed of one or more layers selected from a group comprising façade covering, air gap, or wind barrier or the envelope system of two or more panels comprises a pre-integrated horizontal joint flashing configured to align automatically with adjacent panels during installation. By incorporating these layers into the panels, the system enhances protection against environmental factors such as wind, moisture, and air infiltration. These layers can differ depending on the specific project, client demands, architectural concept or state regulations. The pre-integration of the envelope system components within the panels reduces installation time and labor costs, while improving the quality and consistency of the construction. It ensures that the building envelope is effectively sealed and protected against environmental factors, enhancing energy efficiency and durability. By streamlining the installation process and minimizing on-site adjustments, this design facilitates a more efficient and reliable construction for building façades.

[0096] The façade covering serves as the outermost protective layer, providing both durability and aesthetic appeal. The façade covering layer may be selected from the group consisting of wooden paneling, fiber cement boards, metal sheeting, tiles, or any material compliant with industry standards for weather resistance and aesthetic finishing in construction. The inclusion of an air gap allows for ventilation behind the façade covering, which prevents moisture buildup and promotes drying of any infiltrated water, thereby extending the lifespan of the building envelope. The wind barrier layer minimizes air infiltration, improving the building's energy efficiency by reducing heat loss due to drafts. The wind barrier layer may be selected from the group consisting of plasterboard, oriented strand board (OSB), wool plate, cement board, or fiberboard, or any material meeting the industry standard for wind resistance and thermal insulation in building applications.

[0097] The integration of prefabricated horizontal joint flashings that align automatically during installation simplifies the assembly process and ensures effective sealing between panels. This enables to direct water away from the facade to prevent water damage and eliminates the need for additional on-site sealing work and reduces the potential for installation errors. By providing a continuous barrier against water ingress and air leakage, the joint flashings enhance the overall performance of the façade.

[0098] Optionally, the prefabricated panel structure may further comprise one or more of a building surface specific adjustment; or a sill positioned between the bottom beam of the first panel and the supporting structure. These additional features further enhance the prefabricated panel structure's adaptability and efficiency.

[0099] In an embodiment, wherein the prefabricated panel structure comprises one or more building surface specific adjustments, the adjustments are modifications made to the one or more panels to accommodate the unique characteristics of the building surface to which they will be attached. Such adjustments may be related to the variations in the building's geometry, uneven surfaces, or the presence of existing structural elements that the panels must interface with. The building surface specific adjustments may also be for additional lateral stability, such as reinforced corner connections, lateral bracing systems, wind brackets as enhanced anchoring points in one piece or in two-piece, wind-resistant overlapping joints, integrated rigid backing layers. By incorporating building surface specific adjustments into the prefabricated panels, the installation process becomes more efficient and adaptable to different building conditions without requiring extensive on-site modifications. This reduces the time and labor associated with customizing panels on-site to fit irregularities or unique features of the building surface. The panels arrive at the construction site ready to install, tailored to the specific requirements of the building, which accelerates the installation process and minimizes potential errors. This enhances the precision of the installation, ensures a better fit between the panels and the building structure, and leads to cost savings by reducing on-site adjustments and labor.

[0100] In an embodiment, wherein the prefabricated panel structure comprises the sill positioned between the bottom beam of the first panel and the supporting structure, the sill serves as an intermediary element that facilitates a secure and stable connection between the panel and the building's supporting framework. It compensates for any irregularities in the supporting structure, provides a level surface for the first panel, and is arranged to function as a barrier against moisture ingress from the ground. The sill can be with leveling blocks or without leveling blocks. The sill may be arranged to provide a level surface for the bottom beam of the first panel, ensuring proper alignment and distribution of loads across the support brackets; accommodate adjustments in height or level through the use of shims or leveling elements positioned between the sill and the support brackets; distribute the load from the bottom beam of the first panel evenly across the support brackets, enhancing the stability and structural integrity of the panel assembly; protect the bottom beam of the first panel from direct contact with the support brackets, thereby reducing wear and extending the lifespan of the panel structure. This simplifies the installation process, enhances the structural integrity of the prefabricated panel structure, and reduces the need for extensive on-site adjustments or custom fitting. It further ensures that the first panel is correctly aligned and securely attached, which is critical for the subsequent installation of additional panels. Additionally, the sill may comprise features such as moisture barriers or insulation, enhancing the building's overall performance in terms of energy efficiency and durability. This streamlines the installation process, reduces labor costs, and ensures a high-quality, durable connection between the façade panels and the building structure, thereby enabling fast and cost-efficient installation without extensive on-site work.

[0101] According to the embodiments, the one or more positioners may be surrounded by one or more gaskets, positioned between the positioner and the alignment socket. Adding the one or more gaskets ensures airtight and watertight seals between panels. This effectively prevents air and moisture infiltration through the panel engagement means, enhancing thermal performance and weatherproofing of the prefabricated panel structure. Integrating gaskets around the positioners between the positioners and the alignment socket reduces the need for additional sealing work on-site, thereby accelerating the installation process and minimizing labor costs. The gaskets also accommodate minor manufacturing tolerances and movements caused by thermal expansion or building settlement, maintaining the integrity and alignment of the panels over time. This facilitates fast and cost-efficient installation of prefabricated panel structure without extensive on-site work.

[0102] According to another aspect, the present disclosure provides a method of installing a prefabricated panel structure on a building surface, the method comprises the steps of: fixing a bottom beam of a first panel of two or more panels to a supporting structure on the building surface; fixing a top beam of the first panel of the two or more panels to the building surface; assembling one or more subsequent panels of the two or more panels by aligning one or more positioners of the subsequent panel with one or more alignment sockets in a preceding panel. The method enables fast and cost-efficient assembly of the prefabricated panel structure without extensive on-site work. By utilizing the prefabricated panels equipped with integrated features such as positioners and alignment sockets of the panel engagement means, the method ensures precise alignment, structural integrity, and minimizes labor requirements.

[0103] The step of fixing the bottom beam of the first panel to the supporting structure, such as a plinth or steel supports fixed to the plinth establishes a strong and level foundation for the prefabricated panel structure. By directly transferring all loads to the plinth or supporting structure, it ensures structural stability. The use of prefabricated supports and sills reduces the need for on-site adjustments and complex foundation work, thereby saving time and labor costs. It also simplifies the alignment process for the subsequent installation of panels. After securing the bottom of the first panel, the top beam is fixed to the building using adjustable brackets. These brackets allow for horizontal adjustments, enabling precise alignment of the panel along the vertical axis. This ensures that the panel is vertical and correctly positioned, which is crucial for the installation of additional panels above. The adjustable brackets facilitate fine-tuning of the panel's position without extensive on-site modifications. This ensures accurate vertical alignment, enhancing the façade's aesthetic appearance and structural performance. By allowing adjustments during installation, it reduces potential errors and rework, contributing to a faster and more efficient construction process.

[0104] With the first panel securely in place, subsequent panels are installed by aligning their positioners with the alignment sockets of the preceding panel. The positioners, such as positioning pins or dowels, are inserted into pre-formed alignment sockets in the beams of the panels. As each panel is lowered into place, the positioners fit into the alignment sockets, ensuring precise alignment and secure connection between panels. This step streamlines the assembly process by utilizing panel engagement means. The precise alignment facilitated by the positioners and alignment sockets reduces installation time and minimizes the need for skilled labor. It enhances structural integrity by ensuring secure connections that effectively transfer loads between panels, including wind and other environmental forces. By eliminating the need for on-site drilling or adjustments, it further reduces costs and potential installation errors.

[0105] Prefabricated components and the elimination of extensive on-site adjustments accelerate the installation process. By assembling panels from the ground up using standardized procedures, construction timelines are shortened. Integrated positioners and alignment sockets ensure accurate alignment between panels, reducing errors and ensuring a high-quality finish. Adjustable brackets allow for fine-tuning during installation, maintaining the prefabricated panel structure 's vertical alignment. By securely fixing panels to both the supporting structure and to each other, the method ensures that loads are properly transferred through the prefabricated panel structure to the foundation. This enhances the building's ability to withstand environmental forces such as wind loads.

[0106] The panel assembly process always moves upwards, starting from the ground floor. In renovation projects, steel supports are attached to the plinth, and a timber sill is placed on top, leveled with blocks for accuracy. The first panel is then positioned on the timber sill and secured. This panel includes a custom-sized top beam with pre-formed alignment sockets to accommodate positioners from the subsequent upper panel. Once the ground floor panel, i.e., the first panel of two or more panels, is installed and adjusted using brackets, the second panel is assembled on top. The upper panel's bottom beam contains the positioners, which align with the pre-formed alignment sockets in the top beam of the lower panel. This facilitates quick and accurate assembly without the need for on-site modifications. By ensuring that all load transfers and alignments are handled within the prefabricated elements, the method minimizes the complexity of on-site work. The panels are designed to accommodate necessary adjustments, and the integration of features like brackets and positioners simplifies the installation process. The present method thus significantly improves a fast, efficient, and cost-effective installation of façade elements. Each step is designed to reduce on-site labor, enhance precision, and maintain structural integrity. By utilizing prefabricated panels with integrated alignment and support systems, the method streamlines construction, reduces potential for errors, and ensures a high-quality, durable façade that meets both aesthetic and structural requirements.DETAILED DESCRIPTION OF THE DRAWINGS

[0107] Figure FIG. 1a is a side view of an example of a prefabricated panel structure according to an embodiment of the present disclosure, wherein the prefabricated panel structure 100a for a building surface 102 comprise a first panel 120 and an end panel 140 connectable to each other by panel engagement means. Each panel of the two panels has a main frame formed of a bottom beam 112 at a bottom edge of the panel, a top beam 114 opposite to the bottom beam at a top edge of the panel, and structural elements 116 positioned between the bottom beam and the top beam. Each panel of the two panels further comprises an interior layer assembly 117 attached to the building surface side of the main frame, and an envelope system 118 attached to an outer side of the main frame. The panel engagement means comprises positioners 152 configured for placement along the length of one edge of one panel of the two or more panels, and alignment sockets 154 , each having a first end and a second end. The first end is configured to receive the positioners. The alignment sockets are spaced along the length of one edge of the other panel of the two panels, such that the positioners of the one panel are arranged to fit into the alignment sockets of the other panel; the two panels are connectable to each other in series, one on top of another, along the building surface, wherein the preceding panel of the two panels, i.e., the first panel 120 , is connectable to a subsequent panel of the two panels, i.e., the end panel 140 , via the panel engagement means, forming a continuous vertical column of connected panels. The bottom beam 112 of the first panel 120 is configured for attachment to a supporting structure 104 on the building surface 102 . The top beam 114 of the end panel 140 of the two panels is a termination beam of the continuous vertical column of the connected two panels; and the top beam 114 of each panel of the two panels is configured for attachment to the building surface by an attachment means 106 .

[0108] Figure FIG. 1b is a side view of an example of a prefabricated panel structure according to another embodiment of the present disclosure, wherein the prefabricated panel structure 100b for a building surface 102 comprises three panels connectable to each other and wherein the third panel is an intermediate panel 130 between the first panel 120 and the end panel 140 . Each panel of the three panels comprises a main frame formed of a bottom beam 112 at a bottom edge of the panel, a top beam 114 opposite to the bottom beam at a top edge of the panel, and structural elements 116 positioned between the bottom beam and the top beam; an interior layer assembly 117 attached to the building surface side of the main frame, and an envelope system 118 attached to an outer side of the main frame. In this embodiment, the panel engagement means are formed in the top beam 114 of the first panel 120 and in the bottom beam 112 of the intermediate panel 130 arranged to engage the intermediate panel to the first panel and in the top beam 114 of the intermediate panel and in the bottom beam 112 of the end panel 140 arranged to engage the end panel to the intermediate panel. The panel engagement means comprises positioners 152 configured for placement along the length of bottom beam 112 of the intermediate panel 130 and the bottom beam 112 of the end panel 140 , and alignment sockets 154 , spaced along the length of the top beam 114 of the first panel 120 and the top beam 114 of the intermediate panel 130 . Thereby enabling the three panels to be connectable to each other in series, one on top of another, along the building surface, wherein each preceding panel of the three panels is connectable to a subsequent panel of the three panels via the panel engagement means, forming a continuous vertical column of connected panels. The bottom beam 112 of the first panel 120 of the three panels is configured for attachment to a supporting structure 104 on the building surface 102 . The top beam 114 of the end panel 140 of the three panels is a termination beam of the continuous vertical column of the connected three panels. The top beam 114 of each panel of the three panels is configured for attachment to the building surface by an attachment means 106 .

[0109] Figure FIG. 1c is a front view of the intermediate panels 130 illustrating the vertical stacking of the panels, wherein a subsequent intermediate panel 130 is installed on top of the preceding intermediate panel 130 , so that the alignment sockets 154 in the upper beam 114 of the preceding intermediate panel 130 are arranged to receive the positioners 152 in the bottom beam 112 of the subsequent intermediate panel 130 . Figure FIG. 1c further illustrates the embodiments, wherein the panels of the integrated infrastructure system comprise pre-formed openings 160 configured to accommodate a window or a door. The alignment sockets 154 shown in figures FIG. 1a-FIG. 1c are formed in the corresponding beams so that the second ends of the alignment sockets are closed ends. The positioners 152 used in the embodiments shown in figures FIG. 1a-FIG. 1c are attached to the corresponding beams so that the positioners do not fall off the beams.

[0110] Figure FIG. 1d illustrates an alternative embodiment of a panel engagement means 150 to the panel engagement means 150 shown in figures FIG. 1a-FIG. 1c, wherein the panel engagement means 150 is formed of the positioners 152 configured for placement along the length of the bottom beam 112 of the subsequent panel of the two or more panels, and alignment sockets 154 spaced along the length of the top beam 114 of the preceding panel of the two or more panels and formed through the corresponding beam 114 so that the second ends 157 of the alignment sockets 154 are opened. In such embodiments the second ends 157 may be closable with a closing means 158 .

[0111] Figure FIG. 1e illustrates a cross-sectional view of an embodiment of a prefabricated panel structure mounted on the building surface 102 , wherein a bottom beam 112 of a subsequent panel is installed on top of the top beam 114 of the first panel 120 . The bottom beam of the first panel is attached to a supporting structure 104 and the top beam of the 114 of the first panel is attached to the building surface 102 by an attachment means 106 . The subsequent panel may be the end panel or the intermediate panel. The panels of the prefabricated panel structure comprise the envelope system 118 layer and the interior layer assembly 117 layer. The bottom beam 114 of the subsequent panel and the top beam 114 of the first panel are engaged by the positioners 152 fitted into the alignment sockets. The first panel 120 further comprises a pre-integrated load-bearing support system 109 attached along the bottom beam 112 and a sill 107 , wherein the bottom beam 112 is supported on top of the sill 107 . The height of the first panel is adjusted by the leveling elements 108 between the supporting structure 104 and the sill 107 .

[0112] Figures FIG. 1f and FIG. 1g illustrate embodiments of the panel engagement means 150 with different geometric configurations of the alignment sockets 154 . In figure FIG. 1f, the alignment sockets are oval alignment sockets 154a . In figure FIG. 1g, the alignment sockets are polygonal alignment sockets 154b . These different geometric designs of the alignment sockets accommodate corresponding positioners 152 . The figures illustrate how the alignment sockets allow for slight lateral adjustments during installation.

[0113] Figure FIG. 2a is a side view of another example of a prefabricated panel structure 200a for a building surface 202 , wherein the prefabricated panel structure 200 comprises an integrated infrastructure system 280 formed partially of the height of the panel. According to this example, the integrated infrastructure system 280 is a ventilation system. As shown in FIG. 2a, the prefabricated panel structure 200 comprises a first panel 220 and an end panel 240 connectable to each other by panel engagement means. Each panel of the two panels has a main frame formed of a bottom beam 212 at a bottom edge of the panel, a top beam 214 opposite to the bottom beam at a top edge of the panel, and structural elements 216 positioned between the bottom beam and the top beam. Each panel of the two panels further comprises an interior layer assembly 217 attached to the building surface side of the main frame, and an envelope system 218 attached to an outer side of the main frame. The panel engagement means comprises positioners 252 configured for placement along the length of one edge of one panel of the two or more panels, and alignment sockets 254 , each having a first end 256 and a second end 257 . Each of the first ends 256 of the alignment sockets 254 is configured to receive the positioner 252 . The alignment sockets 254 are spaced along the length of one edge of the other panel of the two panels, such that the positioners 252 of the one panel are arranged to fit into the alignment sockets 254 of the other panel. The alignment sockets 254 are rigid slide-in tubes, the positioners 252 are flexible tubes, the flexible tubes are slid into the rigid slide-in tube. For connecting the flexible tubular positioners 252 with the integrated infrastructure system 280 , an extension sleeve 207 is used. The two panels are connectable to each other in series, one on top of another, along the building surface, wherein the preceding panel of the two panels, i.e., the first panel 220 , is connectable to a subsequent panel of the two panels, i.e., the end panel 240 , via the panel engagement means, forming a continuous vertical column of connected panels. The bottom beam 212 of the first panel 220 is configured for attachment to a supporting structure 204 on the building surface 202 . The top beam 214 of the end panel 240 of the two panels is a termination beam of the continuous vertical column of the connected two panels. The top beam 214 of each panel of the two panels is configured for attachment to the building surface by an attachment means 206 .

[0114] Figure FIG. 2b is a front view of another example of the prefabricated panel structure 200b for a building surface, wherein the prefabricated panel structure 200b comprises a first panel 220 , an end panel 240 and an intermediate panel 230 between the first panel 220 and the end panel 240 connectable to each other and an integrated infrastructure system 280 . Each panel comprises a main frame formed of a bottom beam 212 at a bottom edge of the panel, a top beam 214 opposite to the bottom beam at a top edge of the panel, and structural elements 216 positioned between the bottom beam and the top beam. The top beam 214 of the end panel 240 of the three panels is a termination beam of the continuous vertical column of the connected three panels. The integrated infrastructure system 280 is formed partially of the height of the first panel 220 , through the intermediate panel 230 in a vertical direction connecting the bottom edge of the intermediate panel 230 and the top edge of the intermediate panel 230 and partially of the height of the end panel 240 . In this embodiment, the panel engagement means are formed in the top beam 214 of the first panel 220 and in the bottom beam 212 of the intermediate panel 230 arranged to engage the intermediate panel to the first panel and in the top beam 214 of the intermediate panel and in the bottom beam 212 of the end panel 240 arranged to engage the end panel to the intermediate panel. The panel engagement means comprises positioners 252 configured for placement along the length of bottom beam 212 of the intermediate panel 230 and the bottom beam 212 of the end panel 240 , and alignment sockets 254 , spaced along the length of the top beam 214 of the first panel 220 and the top beam 214 of the intermediate panel 230 . The alignment sockets 254 are rigid slide-in tubes, the positioners 252 are flexible tubes, the flexible tubes 252 are slid into the rigid slide-in tube 254 . Thereby enabling the panels to be connectable to each other in series, one on top of another, along the building surface, wherein each preceding panel of the three panels is connectable to a subsequent panel of the three panels via the panel engagement means, forming a continuous vertical column of connected panels.

[0115] Figure FIG. 2c illustrates a front view of another embodiment of a panel engagement means 250 , which is formed of tubular positioners 252 configured for placement along the length of the top beam 214 of the preceding panel of the two or more panels, and tubular alignment sockets 254 spaced along the length of the bottom beam 212 of the subsequent panel of the two or more panels. The tubular alignment sockets 254 are rigid slide-in tubes and formed through the corresponding beam 214 so that the second ends 257 of the alignment sockets 254 are opened. Tubular positioners 252 are flexible tubes, which can be slid into the rigid slide-in tubes 254 when the subsequent panel is installed to the preceding panel. The panel engagement means 250 further comprises gaskets 270 positioned around the positioners so, when the positioners are slid into the alignment sockets, the gaskets 270 form airtight and watertight seal between the positioners and the alignment sockets.

[0116] Figures FIG. 2d - FIG. 2f show top views of the prefabricated panel structure illustrating different positions of the alignment sockets 254 in relation to an interior layer assembly 217 . The prefabricated panel structure shown in figures FIG. 2d - FIG. 2f is installed on the building surface 202 and comprises the interior layer assembly 217 on the building surface side of the prefabricated panel structure, the envelope system 218 on the outer side of the prefabricated panel structure, the top beam 214 between the interior layer assembly 217 and the envelope system 218 and the alignment sockets 254 formed into the prefabricated panel structure. In figure FIG. 2d the alignment sockets 254 are formed in the interior layer assembly 217 . In figure FIG. 2e the alignment sockets 254 are formed at least partially in the interior layer assembly 217 . In figure FIG. 2d the alignment sockets 254 are formed in the top beam 214 or through the top beam 214 .

[0117] Figure FIG. 2g shows prefabricated panel structures with integrated infrastructure system 280 installed to the building surface 202 of a five-story building. A prefabricated panel structure installed to the building surface 202 comprises a first panel 220 , three intermediate panels 230 and an end panel 240 , wherein the panels are stacked on top of another panel forming a continuous vertical column of connected panels. The panels are connected via the panel engagement means, wherein the panel engagement means of the first panel 220 and each panel of the intermediate panels 230 comprise three positioners 252 placed to the top beam 214 and the panel engagement means of each panel of the three intermediate panels 230 and the end panel 240 comprise three corresponding alignment sockets 254 placed to the bottom beam 212 . During the installation process, the positioners 252 are slid into the corresponding alignment sockets 254 . The building surface 202 is covered by three vertical columns of panels of the prefabricated panel structures side by side. The intermediate panels 230 and the end panel 240 comprise pre-formed openings 260 . The integrated infrastructure system 280 is formed through panel engagement means of all panels of the vertical columns of panels of the prefabricated panel structures starting from the first panel.

[0118] Figure FIG. 3 is a front view an example of intermediate panels 330 of the prefabricated panel structure, wherein the intermediate panels 330 comprising alignment sockets 354a at least partially formed into the top beams 314 of the intermediate panels 330 and corresponding positioners 352a, such as positioning pins, placed to the bottom beams 312 of the intermediate panels 330 . According to the embodiment, the intermediate panels 330 further comprise alignment sockets 354b , such as rigid slide-in tubes, formed through the bottom beams 312 and positioners 352b , such as flexible tubes, placed to the top beams 314 . When the panels are connected to each other, the flexible tubes 352b , fitted into the rigid slide-in tubes 354b form a continuous pathway for the integrated infrastructure systems 380 .

[0119] Figures FIG. 4a-FIG. 4c illustrate installation of the panels of a prefabricated panel structure 400 comprising a first panel 420 having structural elements 416 and an end panel 440 having structural elements 416 , positioners 452 , such as flexible tubes, attached to a bottom beam 412 of the end panel 440 and alignment sockets 454 , such as slide-in tubes, formed through the top beam 414 of the first panel 420 . Figure FIG. 4a illustrates that when the end panel 440 is lifted above the first panel 420 and the positioners 452 are placed along the length of the bottom beam 412 of the end panel 440 , the positioners 452 are in the hanging positions. In figure FIG. 4b it is shown that when the end panel 440 is lowered closer to the alignment sockets 454 in the top beam 414 of the first panel 420 , the positioners 452 are guided by the installer into the alignment sockets 454 . In figure FIG. 4c it is shown that the end panel 440 is lifted into place on top of the first panel 420 and the positioners 452 are fully moved into the alignment sockets 454 .

Examples

Embodiment Construction

[0011]The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. The present disclosure provides a prefabricated panel structure and a method of installing the prefabricated panel structure, which significantly improves the efficiency and cost-effectiveness of installing prefabricated façade panels by integrated panel engagement means. This design enables precise alignment and secure vertical stacking of panels into a continuous column, reducing the need for extensive on-site adjustments, additional support structures, and finishing work, thereby minimizing material usage and labor time while enhancing the structural integrity and airtightness of the prefabricated panel structure.

[0012]According to the present disclosure the prefabricated panel structure for a building surface comprises two or more panels connectable to each other, and one or more panel engagement means; the two or more panels comprising at least a...

Claims

1. A prefabricated panel structure (100a, 100b, 200a, 200b, 400) for a building surface (102, 202), the prefabricated panel structure comprises: - two or more panels connectable to each other, and - one or more panel engagement means (150, 250); - the two or more panels comprising at least a first panel (120, 220, 420) and an end panel (140, 240, 440) and - each panel of the two or more panels having a main frame formed of a bottom beam (112, 212, 312, 412) at a bottom edge of the panel, a top beam (114, 214, 314, 414) opposite to the bottom beam at a top edge of the panel, and structural elements (116, 216, 416) positioned between the bottom beam and the top beam; an interior layer assembly (117, 217) attached to the building surface side of the main frame, and an envelope system (118, 218) attached to an outer side of the main frame; wherein: - the one or more panel engagement means comprises one or more positioners (152, 252, 352a, 352b, 452) configured for placement along the length of one edge of one panel of the two or more panels, and one or more alignment sockets (154, 254, 354a, 354b, 454), each having a first end (256) and a second end (157, 257), and the first end is configured to receive the one or more positioners, and the one or more alignment sockets are spaced along the length of one edge of other panel of the two or more panels, such that the one or more positioners of the one panel are arranged to fit into the one or more alignment sockets of the other panel; - the two or more panels are connectable to each other in series, one on top of another, along the building surface, wherein each preceding panel of the two or more panels is connectable to a subsequent panel of the two or more panels via the one or more panel engagement means, forming a continuous vertical column of connected panels; - the bottom beam of the first panel of the two or more panels is configured for attachment to a supporting structure (104, 204) on the building surface; - the top beam of the end panel of the two or more panels is a termination beam of the continuous vertical column of the connected two or more panels; and - the top beam of each panel of the two or more panels is configured for attachment to the building surface by an attachment means (106, 206).

2. The prefabricated panel structure according to claim 1, wherein the prefabricated panel structure further comprises one or more intermediate panels (130, 230, 330) between the first panel and the end panel.

3. The prefabricated panel structure according to claim 1 or 2, wherein the one or more alignment sockets are formed in the top beam, in the bottom beam, or in the top beam and in the bottom beam.

4. The prefabricated panel structure according to any of the preceding claims, wherein the one or more panel engagement means comprises - the one or more positioners being positioned on the top beam of the preceding panel of the two or more panels and the one or more alignment sockets being positioned on the bottom beam of the subsequent panel of the two or more panels, or - the one or more alignment sockets being positioned on the top beam of the preceding panel of the two or more panels and the one or more positioners being positioned on the bottom beam of the subsequent panel of the two or more panels.

5. The prefabricated panel structure according to any of the preceding claims, wherein a cross-section of the one or more alignment sockets is round, oval (154a), or polygonal (154b).

6. The prefabricated panel structure according to any of the preceding claims, wherein the one or more positioners is selected from a group comprising positioning pins, a dowel, a rod, at least partially threaded rod, a tubular positioning means.

7. The prefabricated panel structure according to any of the preceding claims, wherein the one or more alignment sockets (254) are formed at least partially in the interior layer assembly (217).

8. The prefabricated panel structure according to any of the preceding claims, wherein, wherein a length of the one or more positioners is 30-1500 mm and a diameter of the one or more positioners is 10 - 300 mm.

9. The prefabricated panel structure according to any of the preceding claims, wherein the two or more panels comprise an integrated infrastructure system (280, 380) in a form of tubular means connected to the second end of the tubular positioning means or wherein the two or more panels comprise integrated infrastructure system formed partially of the height of the panel or formed through the panel in a vertical direction connecting the bottom edge of the panel and the top edge of the panel.

10. The prefabricated panel structure according to any of the preceding claims, wherein the two or more panels further comprise one or more of a sealing system for the joints between the two or more panels; a pre-integrated load-bearing support system (109); at least one pre-formed opening (160, 260) configured to accommodate a window or a door.

11. The prefabricated panel structure according to any of the preceding claims, wherein the bottom beam of each subsequent panel is equipped with a pre-integrated connection mechanism configured to engage with the one or more alignment sockets in the top beam of the preceding panel.

12. The prefabricated panel structure according to any of the preceding claims, wherein the envelope system of two or more panels is formed of one or more layers selected from a group comprising façade covering, air gap, or wind barrier or the envelope system of two or more panels comprises a pre-integrated horizontal joint flashing configured to align automatically with adjacent panels during installation.

13. The prefabricated panel structure according to any of the preceding claims, wherein the prefabricated panel structure further comprises one or more of a building surface specific adjustments; or a sill (107) positioned between the bottom beam of the first panel and the supporting structure.

14. The prefabricated panel structure according to any of the preceding claims, wherein the one or more positioners are surrounded by one or more gaskets (270), positioned between the positioner and the alignment socket.

15. A method of installing a prefabricated panel structure, as defined in any of the preceding claims, on a building surface, the method comprises the steps of: - fixing a bottom beam of a first panel of two or more panels to a supporting structure on the building surface; - fixing a top beam of the first panel of the two or more panels to the building surface; - assembling one or more subsequent panels of the two or more panels by aligning one or more positioners of the subsequent panel with one or more alignment sockets in a preceding panel.

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